Vol. IV (A)

UNILEVER FACTORY
6th OF OCTOBER - EGYPT
RENOVATION AND REFURNISHING UNILEVER FACTORY
VOLUME IV (A)
TECHNICAL SPECIFICATIONS
PROJECT No. 2039
APRIL 2015
TECHNICAL SPECIFICATION COVER SHEET REVISED SHEETS
THIS PAGE IS A RECORD OF ALL SPECIFICATION REVISIONS. NORMALLY, REVISED SHEETS ONLY ATTACHED
EACH TIME THE SPECIFICATION IS CHANGED ONLY THE NEW OR ENTIRE SPECIFICATION RE-ISSUED
REVISED PAGES ARE ISSUED. ENTIRE SPECIFICATION REVISED
THE NATURE OF THE REVISION IS BRIEFLY NOTED UNDER REMARKS BUT

ISSUED FOR
THESE REMARKS ARE NOT A PART OF THE SPECIFICATION. THE REVISED
PAGES BECOME PART OF THE ORIGINAL SPECIFICATION AND SHALL BE REVIEW/COMMENTS
COMPLETED WITHIN THEIR ENTIRELY. TENDER/QUOTATION X
PURCHASE
CONSTRUCTION
REV. DATE PREPARED REVIEWED APPROVED PAGES REMARKS

NO. BY BY BY
A Apr. 2015 R.E. 4 ISSUED FOR CLIENT REVIEW
0 Apr. 2015 R.E. 4 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. TABLE OF CONTENTS
CAIRO - EGYPT 00010-2039 0
ECG Form No. E409 Rev. 5/03 Sheet 0 of 4

RENOVATION AND REFURNISHING UNILEVER FACTORY 6TH OCTOBER ,
EGYPT PHASE 1&2 (COST REDUCTION)
CONTENTS
VOLUME I
GENERAL REQUIREMENTS
(Not Included)
VOLUME II
MEASUREMENT AND PAYMENT,

BILL OF QUANTITIES &
LIST OF MANUFACTURERS
DIVISION 0: INFORMATION
00010 Table of Contents

00015 List Of Drawing
DIVISION 1: GENERAL REQUIREMENTS
01270 Measurement and Payment

01275 Bill of Quantities
01295 List of Manufacturers
VOLUME III
SCHEDULES
DIVISION 0: INFORMATION
00160 Finishing Schedules

00161 Doors, Windows, and Elevations Schedules
00162 Architectural Standard Details
VOLUME IV
TECHNICAL SPECIFICATIONS - PART A
DIVISION 1: GENERAL REQUIREMENTS
01732 Selective Demolition
DIVISION 2: SITE CONSTRUCTION
02300 Earthwork
DIVISION 3: CONCRETE
03300 Cast-In-Place Concrete
Table of Contents Section 00010

Renovation and Refurnishing Unilever Factory 6th October , Page 1 of 4
Egypt Phase 1&2 (Cost Reduction) (Prj. 2039)
03360 CONCRETE FINISHES
03544 Cement-Based Screeds
03940 Structural Element Repairs and Strengthening
DIVISION 4: MASONRY
04810 Unit Masonry Assemblies
DIVISION 5: METALS
05120 Structural Steel

05500 Metal Fabrications
05521 Pipe and Tube Railings
DIVISION 6: WOOD AND PLASTIC
06420 Paneling
DIVISION 7: THERMAL AND MOISTURE PROTECTION
07115 Bituminous Damp-Proofing

07134 Polyethylene Sheet
07411 Metal Roof Panels
07412 Metal Wall Panels
07531 EPDM Single-Ply Membrane Roofing
07552 SBS-MODIFIED BITUMINOUS MEMBRANE
07620 Sheet Metal Flashing
07841 Through-Penetration Firestop Systems
07920 Joint Sealants
DIVISION 8: DOORS AND WINDOWS
08114 Steel Doors and Frames

08331 OVERHEAD COILING DOORS
08340 Special Function Doors
08520 Aluminum Windows
08710 Door Hardware
08800 GLAZING
DIVISION 9: FINISHES
09220 Portland Cement Plaster

09260 Gypsum Board
09310 Ceramic Tile
09561 Gypsum Units Ceilings
09638 Stone Paving and Flooring
09651 Resilient Floor Tile
09671 Resinous Flooring
09911 Painting

DIVISION 10: SPECIALTIES
10200 Louvers and Vents

10445 Signage
10801 Toilet and Bath Accessories
DIVISION 13: SPECIAL CONSTRUCTION
13916 Fire Protection

13967 Clean Agent Fire Extinguishing System
13968 Carbon Dioxide Extinguishing Systems
DIVISION 14: CONVEYING SYSTEMS
14210 Electric Traction Elevators
VOLUME IV
TECHNICAL SPECIFICATIONS - PART B
DIVISION 15: MECHANICAL WORKS
15030 Electrical Requirements for Mechanical Equipment

15050 Basic Mechanical Materials and Methods
15064 Ductile Iron Pipes and Fittings
15069 UPVC Pipes and Fittings for Drainage
15071 Polypropylene Pipes and Fittings
15100 Valves
15145 Hangers and Supports
15250 Mechanical Insulation
15400 Plumbing Works
15411 Cast Iron Pipes and Fittings
15417 Steel Pipe and Fittings for Fire Protection System
15430 Plumbing Specialties
15454 Domestic Water Booster Pump Set
15501 General Provisions for Heating, Ventilation and Air-Conditioning
15510 Pipes and Pipe Fittings
15516 Refrigerant Piping for Split Systems
15547 Mounting and Isolating of Mechanical Systems
15549 Thermal Insulation
15782 Air Conditioning Units
15784 Split Units
15792 Acoustic Treatment
15860 Exhaust and Ventilating Fans
15880 Sheet Metal Ductwork
15932 Air Distribution Equipment
15950 Automatic Control
15970 Electric Motors and Controllers
15990 Testing, Adjusting and Balancing
15995 Painting

DIVISION 16: ELECTRICAL
16050 Basic Electrical Materials And Methods

16060 Grounding And Bonding For Electrical Systems
16120 Low-Voltage Electrical Power Conductors And Cables
16124 Medium Voltage Cable
16130 Raceways, boxes and cabinets
16139 Cable Trays
16140 Wiring Devices
16145 LIGHTING CONTROL DEVICES
16195 Electrical Identification
16264 Uninterruptible Power System
16280 LOW VOLTAGE POWER FACTOR CORRECTION EQUIPMENT
16343 Ring Main Unit
16425 Low Voltage Switchboards
16450 Enclosed Bus Assemblies
16461 medium voltage dry distribution transformer
16500 Lighting
16670 Lightning Protection Systems
16721 Fire Alarm System
16750 Structured Cabling Network
Appendix
Bms Point Schedule


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
A Apr. 2015 E.F. 7 ISSUED FOR CLIENT REVIEW
0 Apr. 2015 E.F. 7 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. SELECTIVE DEMOLITION
CAIRO - EGYPT 01732 - 2039 0

CONTENTS
SECTION 01732
SELECTIVE DEMOLITION
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Definitions 2
1.4 Submittals 2
1.5 Quality Assurance 3
1.6 Project Conditions 3
1.7 Warranty 4
PART 2 PRODUCTS 4
(Not Used) 4
PART 3 EXECUTION 4
3.1 Examination 4
3.2 Utility Services and Mechanical/Electrical Systems 4
3.3 Preparation 5
3.4 Selective Demolition, General 5
3.5 Selective Demolition Procedures for Specific Materials 6
3.6 Disposal Of Demolished Materials 7
3.7 Cleaning 7
Selective Demolition Section 01732

SECTION 01732
SELECTIVE DEMOLITION
PART 1 GENERAL
1.1 RELATED DOCUMENTS
1.1.1 Drawings and general provisions of the Contract, including General and
Supplementary Conditions and other Division 01 Specification Sections, apply to
this Section.
1.2 SUMMARY
1.2.1 This Section Includes the Following:
 Demolition and removal of selected site elements.

 Salvage of existing items to be reused or recycled.
1.3 DEFINITIONS
1.3.1 Remove: Detach items from existing construction and legally dispose of them
off-site, unless indicated to be removed and salvaged or removed and reinstalled.
1.3.2 Remove and Salvage: Detach items from existing construction and deliver them
to Owner ready for reuse.
1.3.3 Remove and Reinstall: Detach items from existing construction, prepare them
for reuse, and reinstall them where indicated.
1.3.4 Existing to Remain: Existing items of construction that are not to be removed
and that are not otherwise indicated to be removed, removed and salvaged, or
removed and reinstalled.
1.4 SUBMITTALS
1.4.1 Qualification Data: For demolition firm.
1.4.2 Schedule of Selective Demolition Activities: Indicate the following:
 Detailed sequence of selective demolition and removal work, with starting and
ending dates for each activity. Ensure Owner's building manager's and other
tenants' on-site operations are uninterrupted.
 Interruption of utility services. Indicate how long utility services will be
interrupted.
 Coordination for shutoff, capping, and continuation of utility services.
 Use of elevator and stairs.
 Locations of proposed dust- and noise-control temporary partitions and means

of egress, including for other tenants affected by selective demolition
operations.
 Coordination of Owner's continuing occupancy of portions of existing building
and of Owner's partial occupancy of completed Work.
 Means of protection for items to remain and items in path of waste removal
from building.
1.4.3 Inventory: After selective demolition is complete, submit a list of items that have
been removed and salvaged.
1.4.4 Predemolition Photographs and Videotapes: Show existing conditions of

adjoining construction and site improvements, including finish surfaces, that
might be misconstrued as damage caused by selective demolition operations.
Comply with Division 01 Section "Photographic Documentation." Submit before
Work begins.
1.4.5 Landfill Records: Indicate receipt and acceptance of hazardous wastes by a

landfill facility licensed to accept hazardous wastes.
1.5 QUALITY ASSURANCE
1.5.1 Demolition Firm Qualifications: An experienced firm that has specialized in

demolition work similar in material and extent to that indicated for this Project.
1.5.2 Regulatory Requirements: Comply with hauling and disposal regulations of

authorities having jurisdiction.
1.5.3 Standards: Comply with ANSI A10.6 and NFPA 241.
1.5.4 Predemolition Conference: Conduct conference at Project site.
1.6 PROJECT CONDITIONS
1.6.1 Employer will occupy portions of building immediately adjacent to selective

demolition area. Conduct selective demolition so Owner's operations will not be
disrupted.
1.6.2 Conditions existing at time of inspection for bidding purpose will be maintained
by Owner as far as practical.
1.6.3 Notify Engineer of discrepancies between existing conditions and Drawings

before proceeding with selective demolition.
1.6.4 Hazardous Materials: It is not expected that hazardous materials will be

encountered in the Work.
 If materials suspected of containing hazardous materials are encountered, do

not disturb; immediately notify Engineer and Owner.
1.6.5 Storage or sale of removed items or materials on-site is not permitted.

1.6.6 Utility Service: Maintain existing utilities indicated to remain in service and
protect them against damage during selective demolition operations.
 Maintain fire-protection facilities in service during selective demolition

operations.
1.7 WARRANTY
1.7.1 Existing Warranties: Remove, replace, patch, and repair materials and surfaces
cut or damaged during selective demolition, by methods and with materials so as
not to void existing warranties.
PART 2 PRODUCTS
(Not Used)
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Verify that utilities have been disconnected and capped.
3.1.2 Survey existing conditions and correlate with requirements indicated to

determine extent of selective demolition required.
3.1.3 Inventory and record the condition of items to be removed and reinstalled and
items to be removed and salvaged.
3.1.4 When unanticipated mechanical, electrical, or structural elements that conflict

with intended function or design are encountered, investigate and measure the
nature and extent of conflict. Promptly submit a written report to Engineer.
3.1.5 Engage a professional structural engineer to survey condition of building to

determine whether removing any element might result in structural deficiency or
unplanned collapse of any portion of structure or adjacent structures during
selective demolition operations.
3.1.6 Survey of Existing Conditions: Record existing conditions by use of

preconstruction photographs and preconstruction videotapes.
3.1.7 Perform surveys as the Work progresses to detect hazards resulting from
selective demolition activities.
3.2 UTILITY SERVICES AND MECHANICAL/ELECTRICAL SYSTEMS
3.2.1 Existing Services/Systems: Maintain services/systems indicated to remain and

protect them against damage during selective demolition operations.
3.2.2 Service/System Requirements: Locate, identify, disconnect, and seal or cap off

indicated utility services and mechanical/electrical systems serving areas to be
selectively demolished.
 Arrange to shut off indicated utilities with utility companies.

 If services/systems are required to be removed, relocated, or abandoned,
before proceeding with selective demolition provide temporary
services/systems that bypass area of selective demolition and that maintain
continuity of services/systems to other parts of building.
 Cut off pipe or conduit in walls or partitions to be removed. Cap, valve, or plug
and seal remaining portion of pipe or conduit after bypassing.
 Where entire wall is to be removed, existing services/systems may be

removed with removal of the wall.
3.3 PREPARATION
3.3.1 Site Access and Temporary Controls: Conduct selective demolition and debris-
removal operations to ensure minimum interference with roads, streets, walks,
walkways, and other adjacent occupied and used facilities.
3.3.2 Temporary Facilities: Provide temporary barricades and other protection

required to prevent injury to people and damage to adjacent buildings and
facilities to remain.
 Provide protection to ensure safe passage of people around selective

demolition area and to and from occupied portions of building.
 Provide temporary weather protection, during interval between selective
demolition of existing construction on exterior surfaces and new construction,
to prevent water leakage and damage to structure and interior areas.
 Protect walls, ceilings, floors, and other existing finish work that are to remain
or that are exposed during selective demolition operations.
 Cover and protect furniture, furnishings, and equipment that have not been
removed.
 Comply with requirements for temporary enclosures, dust control, heating,
and cooling.
3.3.3 Temporary Shoring: Provide and maintain shoring, bracing, and structural
supports as required to preserve stability and prevent movement, settlement, or
collapse of construction and finishes to remain, and to prevent unexpected or
uncontrolled movement or collapse of construction being demolished.
3.4 SELECTIVE DEMOLITION, GENERAL
3.4.1 General: Demolish and remove existing construction only to the extent required
by new construction and as indicated. Use methods required to complete the
Work within limitations of governing regulations and as follows:
 Neatly cut openings and holes plumb, square, and true to dimensions

required. Use cutting methods least likely to damage construction to remain
or adjoining construction. Use hand tools or small power tools designed for
sawing or grinding, not hammering and chopping, to minimize disturbance of
adjacent surfaces. Temporarily cover openings to remain.
 Cut or drill from the exposed or finished side into concealed surfaces to avoid
marring existing finished surfaces.
 Do not use cutting torches until work area is cleared of flammable materials.
At concealed spaces, such as duct and pipe interiors, verify condition and
contents of hidden space before starting flame-cutting operations.
Maintain fire watch and portable fire-suppression devices during flame-cutting
operations.
 Locate selective demolition equipment and remove debris and materials so as
not to impose excessive loads on supporting walls, floors, or framing.
 Dispose of demolished items and materials promptly.
3.4.2 Removed and Salvaged Items:
 Clean salvaged items.

 Pack or crate items after cleaning. Identify contents of containers.
 Store items in a secure area until delivery to Employer.
 Transport items to Owner's storage area as designated by Employer.
 Protect items from damage during transport and storage.
3.4.3 Removed and Reinstalled Items:
 Clean and repair items to functional condition adequate for intended reuse.
Paint equipment to match new equipment.
 Pack or crate items after cleaning and repairing. Identify contents of
containers.
 Protect items from damage during transport and storage.
 Reinstall items in locations indicated. Comply with installation requirements
for new materials and equipment. Provide connections, supports, and
miscellaneous materials necessary to make item functional for use indicated.
3.4.4 Existing Items to Remain: Protect construction indicated to remain against

damage and soiling during selective demolition. When permitted by Engineer,
items may be removed to a suitable, protected storage location during selective
demolition and cleaned and reinstalled in their original locations after selective
demolition operations are complete.
3.5 SELECTIVE DEMOLITION PROCEDURES FOR SPECIFIC MATERIALS
3.5.1 Masonry: Demolish in small sections. Cut masonry at junctures with

construction to remain, using power-driven saw, then remove masonry between
saw cuts.

3.5.2 Air-Conditioning Equipment: Remove equipment without releasing refrigerants.
3.6 DISPOSAL OF DEMOLISHED MATERIALS
3.6.1 General: Except for items or materials indicated to be reused, salvaged,

reinstalled, or otherwise indicated to remain Owner's property, remove
demolished materials from Project site and legally dispose of them in an
approved landfill.
 Do not allow demolished materials to accumulate on-site.

 Remove and transport debris in a manner that will prevent spillage on
adjacent surfaces and areas.
 Remove debris from elevated portions of building by chute, hoist, or other
device that will convey debris to grade level in a controlled descent.
3.6.2 Burning: Do not burn demolished materials.
3.6.3 Disposal: Transport demolished materials off Employer's property and legally
dispose of them.
3.7 CLEANING
3.7.1 Clean adjacent structures and improvements of dust, dirt, and debris caused by
selective demolition operations. Return adjacent areas to condition existing
before selective demolition operations began.
END OF SECTION


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
A Apr.2015 E.F. 16 ISSUED FOR CLIENT REVIEW
0 Apr.2015 E.F. 16 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. EARTHWORK
CAIRO - EGYPT 02300 - 2039 0

CONTENTS
SECTION 02300
EARTHWORK
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Reference Standards 2
1.4 Related Sections 3
1.5 Submittals 3
1.6 Definitions 4
1.8 Use of Explosives 5
1.9 Contractor's Responsibility 5
1.10 Testing and Inspection 6
PART 2 PRODUCTS 7
2.1 Soil Materials 7
2.2 Warning Tape 8
2.3 Water 9
2.4 Equipment 9
PART 3 EXECUTION 9
3.1 Open-Cut Excavation, General 9
3.2 Excavation for Structures 11
3.3 Approval of Subgrade Bottom 11
3.4 Footing Subgrade 13
3.5 Backfilling Around Foundations 13
3.6 Soil Replacement Under Foundations 13
3.7 Slab-on-Grade 14
3.8 Field Quality Control 14
3.9 Auxiliary Works 14
3.10 Tolerance Limits 15
3.11 Surface Finish 15
3.12 Disposal 16
Earthwork Section 02300

Renovation and Refurnishing Unilever Factory 6th October, Page 1 of 16
SECTION 02300
EARTHWORK
PART 1 GENERAL
Drawings and general provisions of the Contract, including Contract Conditions

and Division 1 Specification Sections, apply to work of this section.
1.2 SUMMARY
This section covers:
- Procurement and supply of materials, delivery, transportation, handling and

storing at site
- Survey of the site
- Cleaning and garbing
- Stockpiling and disposal of excavated material
- All necessary safety measures
- Testing
- Excavation and backfilling for building and structures to subgrade elevations.
- Preparing subgrades for slab-on-grade, walkways, pavement, etc... to final
grade and levels
Extent of excavation, backfilling shall be as indicated on the Drawings.
1.3 REFERENCE STANDARDS
Excavation, backfilling and grading for structures, roads and utilities shall be
performed in compliance with Drawings, tests and with the requirements of the
Roads and Bridges Authority (R.B.A.), the specifications of the American
Association of State Highway and Transportation Officials (AASHTO), the Egyptian
Code of Practice for Soil Mechanics and Design and Execution of Foundations, and
the specifications of the American Society of Testing and Materials (ASTM) as
noted below:
American Society of Testing and Materials
ASTM No.
C 136 Sieve Analysis of Fine and Coarse Aggregates
C 142 Clay Lumps and Friable Particles in Aggregates
D 421 Practice for Dry Preparation of Soil Samples for Particle Size Analysis
and Determination of Soil Constants

D 422 Particle Size Analysis of Soils
D 427 Shrinkage Factors of Soils
D 698 Moisture Density Relation of Soils and Soil Aggregate Mixtures
D 854 Specific Gravity of Soils
D 1556 Density of Soil in Place by the Sand-Cone Method
D 1557 Moisture Density Relations of Soils and Soil Aggregate Mixtures Using
10 lb (4.54 kg) Hammer and 18 in (457 mm) Drop
D 1586 Penetration Test and Split-Barrel Sampling of Soils
D 2167 Density and Unit Weight of Soil In-Place by the Rubber Balloon
Method
D 2487 Classification of Soils for Engineering Purposes
The American Association of State Highway and Transportation Officials
AASHTO No.
T-180 Method of Test of Resistance R-Value and Expansion Pressure of

Compacted Soils
T-191 Sand Cone Method
The Egyptian Code of Practice for Soil Mechanics and Design and Execution of
Foundations
Part 1: Site investigation, pp. 72 plate load test.
1.4 RELATED SECTIONS
The following sections include requirements which relate to this section:
03300 Cast-in-Place Concrete
1.5 SUBMITTALS
Submit the following in accordance with Conditions of the Contract and Division-1
Specification Sections:
1.5.1 Samples: Submit for verification purposes:
- 2 kg samples sealed in airtight containers, of each proposed fill and backfill soil
material from on-site or borrow sources
- 300 mm long of each type of plastic warning tape
- 300 x 300 mm samples of drainage fabric

1.5.2 Detailed design of temporary side slopes and side support system (if any) for
approval.
1.5.3 Stockpiling of excavated materials for approval.
1.6 DEFINITIONS
1.6.1 Backfill: Soil materials used to fill an excavation.
1.6.2 Borrow Soil: Satisfactory soil imported from off-site for use as fill or backfill.
1.6.3 Excavation: Removal of materials encountered to subgrade elevations.
1.6.4 Additional excavation: Excavation below subgrade elevation as directed by

Engineer.
1.6.5 Bulk Excavation: Excavation more than 3.00 m in width and pits more than 9 m
in length.
1.6.6 Unauthorized Excavation: Excavation below subgrade elevation or beyond

indicated dimensions without direction by Engineer. Unauthorized excavation, as
well as remedial work directed by Engineer, shall be without additional
compensation.
1.6.7 Fill: Soil materials used to raise existing grades.
1.7.1 Project Site Information:
A geotechnical report has been prepared for this project and is available. The
opinions expressed in this report, the design and drawings are those of the
geotechnical engineer and represent interpretations of the subsoil conditions,
tests, and results of analyses conducted by the geotechnical engineer.
The Contractor shall carry out his own site investigations and shall inform and
satisfy himself as to the character, quality and distribution of all material to be
excavated, filled, spoiled and borrowed. The Contractor shall be fully responsible
for asserting necessary information concerning permanent water-table, period of
rainfall and all matters affecting the excavation and foundation work.
The contractor is responsible to verify the required different levels before starting
construction works.
Before starting any construction works, re-compact the top surface to assure the
quality of compaction.
1.7.2 Topographic Survey: Do not assume accuracy of the existing benchmark, and run
a closing survey of the existing project area and take cross-sectional elevations
and levels of the works on the Site and submit the result to the Engineer for
approval, as quantities of excavation, earthwork etc., shall be measured from
these levels as agreed and signed by the Engineer.

Locate datum level used to establish benchmarks sufficiently distant so as not to
be affected by movement resulting from excavation operations.
Employ a qualified professional engineer or surveyor; establish exact elevations at

fixed points, construct and protect benchmarks during the period of construction.
Such benchmarks shall be checked periodically and whenever required by
Engineer.
1.7.3 Existing Utilities: Do not interrupt utilities, if any, serving facilities occupied by
Employer or others unless permitted in writing by Engineer and then only after
arranging to provide temporary utility services according to requirements
indicated.
1.8 USE OF EXPLOSIVES
Blasting and use of explosives is prohibited. Do not bring explosives onto Site or
use in work.
1.9 CONTRACTOR'S RESPONSIBILITY
The methods of excavation which the Contractor desires to use shall be at the
sole discretion of the Contractor.
The Contractor shall perform all excavation and backfilling as required for all
works under this Contract. Excavations shall be carried out in all materials, by
whatever means necessary and shall be performed accurately to the lines, levels
and grades shown on Drawings.
Except where indicated on the Drawings to remain undisturbed, the Contractor

shall remove all unaccepted topsoil, plants, roots, vegetations, rubbish, rock, etc.,
from areas lying within limits of structures and from area to receive fill,
embankment, surfacing, road construction, concrete or other constructions.
1.9.1 Safety of Excavations: It is the Contractor's responsibility to provide and maintain

safe excavations for all phases of construction. In no case shall any be made in
such a manner to endanger or damage workmen, adjacent utilities, paving or
structures. The Contractor shall be responsible for providing safe construction
slopes and he shall adequately shore and sheet the side of excavations to ensure
complete safety against collapse of soil at these areas.
In the event of a fall occurring in any excavation the Contractor shall carry out at
his own expense and to the satisfaction of the Engineer any re-excavation
reinstatement or repairs which may become necessary as the result of such fall.
Any voids caused by a fall shall be filled and consolidated as directed by the
Engineer.
1.9.2 Protection of Persons and Properties: The Contractor shall erect temporary
fencing or barricade open excavations occurring as part of this work and post with
warning lamps and take all necessary steps to prevent any entry of public to the
vicinity of open excavation. The Contractor shall protect structures and utilities

from damage caused by settlement, lateral movement, undermining, washout
and other hazards created by earthwork operations.
The Contractor shall restore and repair any damage or defects caused to adjacent
structures, utilities or properties without responsibilities or extra charge to the
Employer.
1.9.3 Protection of Utilities and Services: Any cable, pipeline or other services exposed
by Contractor shall be protected and supported by him to prevent damage to the
service. Supports shall be maintained throughout the whole period of the
exposure of services and it shall be the Contractor's responsibility to ensure that,
on and after backfilling or building in, the said services are adequately supported
by any satisfactory means so that no damage shall be caused to them on or after
such backfilling or building in.
1.10 TESTING AND INSPECTION
1.10.1 Testing: Samples of all fill material shall be tested before placement and
classification according to ASTM D 2487 of each on site or borrow soil material
proposed for fill and backfill shall be submitted to the Engineer. Soil compaction
test for fill under the structure shall be according to ASTM D 698 for each on site
or borrow soil material. Soil compaction test for roads and parking areas shall be
performed to determine the maximum dry density and optimum moisture
content of soil as per AASHTO T-180. Field quality control testing shall be as
specified in Clause 3.8 of this section. The Contractor shall perform all such tests
at his own expense by a testing laboratory approved by the Engineer in
accordance with the following AASHTO Specifications:
Amount of Materials Finer than 0.075 Sieve No. 200 in Aggregates T - 1 1

Sieve Analysis T- 27
Soil Preparation (Dry Method) T- 87
Mechanical Analysis of Soil T- 88
Liquid Limit T- 89
Plastic Limit T- 90
Soil Preparation (Wet Method) T-146
Moisture-Density Relationship T-180
Density of Soil in Place T-191
The California Bearing Ratio for Soils T-193
Coarse Particle Correction T-224
1.10.2 Site Testing Laboratory: Allow a testing agency approved by Engineer for work
inspection in an independent testing laboratory to be qualified according to ASTM
E329 to conduct soil materials and rock definition testing, as documented
according to ASTM D3740 and ASTM E548 or provide a complete site laboratory
with the necessary qualified persons to perform the required inspections and
tests (cost of these services are to be included in the Contract Price).

1.10.3 Inspections: The following inspections shall be performed after the completion of
the work:
- Visual inspection after clearing, grubbing and stripping

- Level check for the areas excavated, backfilled or cut and filled
PART 2 PRODUCTS
2.1 SOIL MATERIALS
General: Provide borrow soil materials when sufficient satisfactory soil materials
are not available from excavations.
2.1.1 Ordinary Backfill Materials: Satisfactory backfill or fill materials shall be selected
materials complying with ASTM D 2487 (soil classification groups GW, GP, GM,
SW, SP and SM or a combination of these group symbols) and free from clay, rock
or gravel larger than 50 mm in any dimension, debris, waste, vegetation, organic
matters, other deleterious matter and the percentage of fine materials passing
ASTM sieve No. 200 shall not exceed 15%.
Chemical salts including sulphates (SO4) and chlorides (Cl) must not exceed 0.35%.
The Engineer shall have complete control over the excavation, moving, filling and
disposition of all material and shall determine the suitability of material to be
placed in fill areas.
The excavated material declared by the Engineer to be suitable for fill is to be

used as filling.
All surplus excavated material, or materials determined unsuitable shall be as

soon as practicable loaded and spoiled out of the work area and all other filling
materials shall be imported materials obtained from borrow areas at locations
approved by Engineer.
2.1.2 Unsatisfactory Soils: Shall be ASTM D2487 soil classification groups GC, SC, ML,
MH, CL, CH, OL, OH and PT or a combination of these group symbols.
Unsatisfactory soils include satisfactory soils not maintained within 2% of

optimum moisture content at time of compaction.
2.1.3 Backfill and Fill: Shall be by using satisfactory soil materials only.
Engineering Fill: Naturally or artificially graded mixture of natural or crushed

gravel, crushed stone and natural or crushed sand/gravel mixture; to ASTM
D2940, with at least 90 percent passing a 38 mm (1½ inch) sieve and not more
than 12 percent passing Sieve No. 200
Borrow Areas: Imported fill material shall be one from sources approved by the
engineer. Borrow area shall be delineated and suitably demonstrated by
laboratory testing which shall also determine standard proctor density and

optimum moisture content. A minimum of one set of tests shall be carried out
per 10 000 m3 of material proven suitable for use and/or when a change in the
characteristics of the material becomes evident, or at any other time required by
the Contractor. The limit and extent of suitable material shall be established for
each borrow area and material shall not be brought from outside these limits
without approval from the engineer.
2.1.4 Soil Replacement Materials: Structural backfill shall be on any ground where fills
are to be placed. Structural backfilling materials shall be sandy materials, well
graded with a suitable amount of binders, compatible, free of harmful water-
soluble substances, and such as the strength and bearing capacity of the
structural backfill (soil) shall not be significantly affected by the presence of
water.
The materials shall comply with the following requirements:
- For structural Fill beneath roads, the used materials shall conform to AASHTO
Classification A-1-a for flexible pavement, and A-3 for rigid pavement.
- Maximum size of materials shall not exceed 50 mm
- Percentage of fine materials passing ASTM Sieve No. 200 must not exceed 10%
- Percentage of sulphates (SO3) and chlorides (Cl) shall not exceed 0.35%
- Grading of materials shall satisfy the following:
D60 / D10 > 6

(D30)2 / (D10 x D60) = 1 to 3
Where D10, D30 and D60 correspond to 10%, 30% and 60% finer of the typical
grain size of materials, respectively.
2.1.5 Unsuitable Materials: Unsuitable material shall be defined as all materials not
complying with the description of suitable materials and shall include particles in
excess of 50 mm size and that which is clay, coral, oil contaminated, organic,
combustible or materials not capable of complying with compaction requirement
of this specification. Excavated material contaminated with subgrade material
shall be deemed unsuitable. All unsuitable material shall be removed from site.
2.2 WARNING TAPE
Acid and alkali-resistant polyethylene film warning tape for marking and
identifying underground utilities 150 mm wide and 4 mils thick continuously
inscribed with a description of the utility; colored as follows:
- Red: Electric
- Yellow: Gas, oil, steam and dangerous materials
- Orange: Telephone and other communications
- Blue: Water systems
- Green: Sewer system

2.3 WATER
Water used for soil compaction shall be clean and free from unusual proportions
of dissolved salt, organic matters and industrial contamination oils, acids or other
deleterious matter.
Water shall not contain chemical salts including sulphates (SO4) and chlorides (Cl)
in a percentage that shall increase the overall salts percentage for filling materials
more than 0.35%.
2.4 EQUIPMENT
Use types of equipment that are most suitable for the work and of numbers, sizes
and capacities that can perform earthwork as specified within the time schedule.
Equipment for earthwork shall be operated in strict accordance to manufacturer's
instructions and recommendations and shall be always maintained by the
Contractor in such condition that they shall deliver manufacturer's rated
capacities.
PART 3 EXECUTION
The Contractor should through negligence or other fault excavate or fill beyond
the designated lines, and replace/remove such excavation/fill in an approved
manner and condition at his own expense with satisfactory soil materials and
thoroughly compact to a density equal to adjacent original ground.
Do not neglect to check for underground services which may not initially appear
to be of interest. Protect utilities, structures, improvements, pavement from
damage caused by settlement due to lateral movement created by earthwork
operations.
No compensation shall be paid to the Contractor in respect to excavation or

backfilling for the extra width.
3.1 OPEN-CUT EXCAVATION, GENERAL
Excavation shall be performed as indicated on Drawings and in the Specifications

to the lines, grades and elevations shown or as directed by the Engineer.
Survey points, bench marks, boundary stones and the like shall be removed only
with the engineer’s written consent.
Removed boundary stones and marking shall be stored according to the engineer
instructions.
Extra temporary bench marks to be provided by the Contractor shall be furnished

with a plate, approximately 250 x 250 mm in size painted in black letters on a
light background with clearly legible weather proof oil paint.

For all fill and cut over 1.0 m in height, sturdy stakes shall be placed at any
changes of direction of the ground but in all cases at intervals not greater than 30
m as directed by the engineer.
Permanent slope (if any) to be kept in the sand shall be stabilized by one of the
following means:
- Mass concrete blinding

- Cement/sand mixture
- Bituminous/cement mixture.
The quantity, type and capacity of the equipment provided, the work method
envisaged transportation and distribution of the excavated materials, location of
stockpiles, main storage areas as well as the approximate number of laborers,
and the working schedule and any amendment to it during the construction
period shall require the engineer’s prior approval.
Bottom and slopes of open-cut elevations on which concrete is to be placed shall

be finished exactly according to the established levels and slopes.
Regardless of the methods of excavation adopted, the basis of payment shall be

as assumed in Section 01270 “Measurement and Payment”.
Excavation shall consist of removal of all earth, rocks, boulders, remains of

buildings, services not to be used and all material encountered within the limits
indicated to subgrade elevations indicated on Drawings and subsequent
stockpiling of materials needed for backfilling or disposal of material determined
unsuitable.
Excavation shall be unclassified and shall be completed regardless of the type of

material and obstruction encountered together with soil, boulders and other
materials.
The Contractor shall make his own estimate of the kind and extent of the various
materials and presence or absence of water which shall be encountered in the
excavation.
Where rock or other hard material is encountered it shall be removed by line

drilling or ripping.
All stones or rock fragments larger than 100 mm in their greatest dimension shall
not be permitted in the top 150 mm of the subgrade.
The final 150 mm depth of all excavations shall be taken out manually or
otherwise if accepted by the Engineer and the bottom leveled and rammed
immediately prior to placing structures.
Footings, foundations and pipes shall rest on firm undisturbed soil free from loose
materials.

Stockpile soil materials suitable for backfill at sufficient distance away from edge
of excavation and neatly pile in stock piles in a manner that shall not overload or
cause collapse of excavation sides. All unsuitable and surplus excavated materials
shall be immediately removed from site, loaded and transported to dumps
approved by local authorities.
Extend excavations a sufficient distance from structures for placing and removing
concrete formwork, for installing services and other construction, for inspection.
Excavate to indicated elevations and dimensions within a tolerance of ± 25 mm.
No back-throwing whatever shall be allowed and all materials shall be brought to

the surface and formed in heaps clear of excavation.
Over Excavation: If somewhere and for any reason excavations are executed
beyond the established lines and without the engineer’s previous approval, the
Contractor shall backfill with lean concrete or other approved materials, the
volume corresponding to the over excavation.
3.1.1 Drainage of Excavated Areas: Grading in the vicinity of excavations shall be

controlled to prevent surface water from flowing into excavated areas.
Protect subgrades from softening and damage by rain or water accumulation.
The excavation shall at all times be well drained, kept free from storm water,
percolating water or subsoil water.
The Contractor shall repair at his own expense any damage that may result from
his failure to keep the excavation free from water.
3.2 EXCAVATION FOR STRUCTURES
3.2.1 Excavation Limits for Structures: Banks shall be either shored or sloped at a safe
angle according to conditions and to the approval of the Engineer. If necessary
extend a reasonable sufficient distance from footing and foundations to permit
placing and removal of concrete form work, shoring, installation of services and
other constructions, for performing all works in the excavation and for inspection.
No compensation shall be paid to the Contractor in respect to excavation or
backfilling of extended distances.
If any part of an excavated area is in error or excavated wider than required, the
excess excavated distance shall be backfilled as directed by the Engineer and
compacted at the Contractor's charge.
3.3 APPROVAL OF SUBGRADE BOTTOM
When excavation has reached required subgrade elevations, the Engineer shall
inspect soil materials at these elevations for suitability as a foundation level for
the related construction, and he may instruct the Contractor to test the bearing
capacity of the soil at this level. If the bottoms of excavation found to be
unsuitable as bearing surfaces, as a result of such tests, the Engineer may decide
to continue excavation until suitable bearing materials are encountered and

replaced with compact backfill. Additional excavation and replacement material
shall be paid for, according to the Contract.
Excavated materials shall not be piled-up along sides of excavations in a manner

that will overload or cause collapse of excavation sides.
Sub-soil from the excavation shall be selected for suitability for backfilling and
compaction, and shall be free from any organic materials and shall not have big
lumps. It shall be placed directly in its final position or stacked on site as directed
by the Engineer in the vicinity of the work and those unsuitable for fill shall be
removed from site to a tip provided by the Contractor. All other filling materials
shall be imported.
Cleaning and removal of trash and debris from excavation shall be done before
backfilling works.
Contractor shall make corrections and adjustments in methods or moisture

content in order to achieve the correct fill density.
Compaction areas shall be kept separate and no layer shall be covered by another
until the proper density is obtained.
Roads' banks, if any, shall be sloped at a safe angle of repose.
Materials shall be as specified in Part 2 of this section and compaction

requirements shall be based on relative density.
The soil used in backfilling shall be mixed with sufficient water to provide
moisture content within a range of 2% from the optimum value. The mixing
process shall be completed out of backfill area then soil shall be spread in loose
lifts and compacted at designated locations. The moisture content shall be
uniform throughout the compacted layer. If the field quality testing as specified in
Clause 3.8 revealed moisture content out of the previously specified range, the
soil shall be removed, remixed and compacted again.
Effective spreading equipment shall be used on each layer to obtain uniform

thickness prior to compacting. As the compaction of each layer progresses,
continuous leveling and manipulating shall be required to assure uniform density.
Water shall be added in order to obtain the correct water content and the
required density on stocked soil outside the excavation. Construction equipment
shall be routed uniformly over the entire surface both in width and longitudinal
extent of each layer before the next lift is started. At the start of the work a field
2
test shall be performed in the Site over an adequate area not less than 100 m to
determine the allowable thickness of layers that can be compacted to the
required density by means of the compaction equipment provided by the
Contractor.
Pipes and reinforced concrete foundation members such as tie-beams laid on

natural ground shall be protected with a minimum of 1000 mm of tamped fill
over the top surface or according to Drawings before heavy equipment is allowed
to pass over.

Backfill excavations shall start as promptly as work permits, but not until
completion of the following:
- Acceptance of layers below finish grade including, where applicable, damp-

proofing, waterproofing and perimeter insulation.
- Inspection, testing, approval and recording locations of underground utilities
have been performed and recorded. Do not backfill trenches until tests and
inspections have been made and backfilling is authorized by the Engineer. Use
care in backfilling to avoid damage or displacement of pipe systems.
- Removal of concrete formwork.
- Removal of temporary shoring and bracing, backfilling of voids with
satisfactory materials. Cut off temporary sheeting, piling driven below bottom
of structures and remove in a manner to prevent settlement of the structure
or utilities or leave in place if required. External surfaces of wood sheeting
instructed to be left in place shall be painted with suitable protective material.
- After installation of pipes and cables according to specifications and all related
tests are performed and approved by Engineer.
- Removal of trash and debris from excavation.
3.4 FOOTING SUBGRADE
Unless otherwise indicated on Drawings, the subgrade under footings and tie-
beams shall be prepared in the following sequence:
- Excavate under footing and tie-beams down to the required depth from
existing ground surface.
- Flood bottom of excavation with water for a minimum period of 72 hours.
- Clean bottom of excavation from the loose surface soil skin and compact the
soil using suitable compaction equipment.
3.5 BACKFILLING AROUND FOUNDATIONS
Use selected materials as specified in Clause 2.1 and compact mechanically or by

manual tamping to 90% of maximum dry density according to ASTM D 1556 at
optimum moisture content during excavation.
3.6 SOIL REPLACEMENT UNDER FOUNDATIONS
Satisfactory soil replacement materials shall be selected material free from clay,
rock or gravel larger than 50 mm and in any dimensions debris, waste, vegetation.
The maximum dry density of the material shall be not less than 1900 kg/m3.
Percentage of fine materials passing ASTM Sieve No. 200 must not exceed 10%,
and the percentage of sulphates (SO3) and chlorides (Cl), shall not exceed 0.35%.
Percentage of absorbed water by weight shall be 10% maximum. Percentage of

dissolution in water of coarse and fine aggregates shall be 5% maximum.

Compaction shall be executed in 250 mm-thick layers (loose thickness) uniformly
spread, compacted mechanically using vibratory rollers. Manual tamping can be
used in narrow areas according to available space. Replacement shall be
compacted to a minimum of 95% of maximum dry density in modified Proctor
test.
3.7 SLAB-ON-GRADE
Unless otherwise indicated on Drawings, when depth of fill required is up to

about 100 cm, soil replacement under slab on grade shall be executed in the
following sequence:
- Flood bottom of excavation with water for a minimum period of 72 hours.

- Clean bottom of excavation from the loose surface skin and compact to 90%
of maximum dry density (according to ASTM D 1556) using suitable compactor
as directed by the Engineer.
- Backfill with selected suitable good quality materials up to bottom elevations
of slabs in 250 mm thick loose lifts and compact to 95% of maximum dry
density at optimum moisture content during excavation by the use of suitable
compactor as directed by the Engineer.
- Grade area to a smooth surface, free from irregular surface changes.
3.8 FIELD QUALITY CONTROL
: Allow testing agency to inspect and test each subgrade and each fill layer.
Compaction and field density tests of in-place soil or the fill shall be made at each
location directed by the Engineer at the rate of one (1) test every 250 m2 for each
compacted layer according to ASTM D1556.
Field density tests shall be performed in accordance with AASHTO T-191 (sand
cone method). The Contractor shall perform the following tests at locations as
directed by the Engineer:
- Laboratory test for Maximum Dry Density (MDD), Optimum moisture content,
for each layer.
- Field density and California Bearing Ratio (CBR), for each layer as required by
the Engineer.
- The areas shall be rejected if the resulting test results do not satisfy specified
requirements.
- The Contractor shall be responsible for making good all settlement of filling
that may occur at/to the end of the Defect Liability Period.
3.9 AUXILIARY WORKS
Unless otherwise specified, all and any kind of works, materials, services, safety
measures, etc. as well as, and if so requested by the Engineer, all tests and
samples required for the completion of the work shall be for the responsibility of
the Contractor. The auxiliary works comprises, but not limited to the following:

- Removing and storing of boundary stones, bench marks, etc., protection of
surveying points/designations by means of boards, and protection of all
secondary survey points, profiles, etc.
- Difficulties to be overcome where excavation may have to be carried out in
layers.
- Keeping off or diversion of water if any, including any pump required, difficult
work caused by water, etc.
- Removal of any buried pipes, fascines and the like that might interfere with
excavation profiles, irrespective of whether or not such structures are
specified.
- Difficulties resulting from the specification relating to filling, eliminating
unsuitable material from filling and if necessary, mixing of different soil
materials.
- Transport of excavated materials to fill or deposit, placing and spreading in
layers according to conditions and drawings and careful compaction.
- Difficulties in transport due to existing ground condition.
- Sorting of excavated materials which if necessary, are to be used for special
purposes.
- Providing, maintaining and later removing access way maintaining existing
ways and roads providing, placing, maintaining and later removing, conveying
and dumping materials and/or equipment that might be required.
3.10 TOLERANCE LIMITS
The tolerance limits for the permanent finished earthworks will be as follows:
- Horizontal dimensions will be within +75 mm and –75 mm of the true

dimensions shown on the approved drawings.
- For slopes to embankments or cutting the horizontal deviation between the
top and the bottom of the slope will be within +5% and –5% of the true
horizontal component of the slope shown or calculated from the approved
drawings.
- Formation levels shall be within 0 mm and –25 mm of the true levels shown
on drawings.
- Other earth work levels shall be within +50 and –50 mm of the true levels
shown on the approved drawings.
3.11 SURFACE FINISH
The top surface area shall be of dense and level without any protruding rock
fragments in excess of 50 mm, recesses of soft spots to the satisfaction of the
engineer.

3.12 DISPOSAL
Remove surplus satisfactory soil and waste materials including unsatisfactory soil,
trash, and debris, and legally dispose it off to the public disposal areas.
END OF SECTION 02300


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. CAST-IN-PLACE CONCRETE
CAIRO - EGYPT 03300 -2039 0

CONTENTS
SECTION 03300
CAST-IN-PLACE CONCRETE
Page
PART 1 GENERAL 3
1.2 Summary 3
1.5 Submittals 4
1.7 Delivery, Storage and Handling 6
PART 2 PRODUCTS 6
2.1 Cement 6
2.2 Aggregates 7
2.3 Mixing Water 9
2.4 Steel Reinforcing Bars 9
2.5 Tie Wire 10
2.6 Welded Wire Fabric 10
2.7 Form Release Agent 10
2.8 Curing Materials 10
2.9 Supports For Reinforcement 10
2.10 Formwork 10
2.11 Steel Fibers Reinforced Concrete (SFRC) 10
2.12 Admixtures 11
2.13 Concrete Mixes 11
2.14 Designed Mixes 11
2.15 Quality Control 13
2.16 Standard Mixes 15
2.17 Construction Joint Sealants 16
PART 3 EXECUTION 16
3.1 Concrete 16
3.2 Steel Reinforcement 19
3.3 Formwork 20
3.4 Testing and Inspection 23
3.5 Tolerances of Reinforced Concrete 24
3.6 Fair-Face Concrete 25
Cast-in-Place Concrete Section 03300

LIST OF TABLES
Page
Table 1: Grading Requirements for Coarse Aggregate 8
Table 2: Grading Requirements for Fine Aggregate 9
Table 3: Lower Limits for standard tensile test of steel 10
Table 4: Non air entrained concrete grades 14
Table 5: Slump values 16
Table 6: Standard concrete mixes 16
Table 7: Crushing strength of plain concrete mix (slump 75 mm) 16
Table 8: minimum age of concrete for safe removal of forms 20

SECTION 03300
CAST-IN-PLACE CONCRETE
PART 1 GENERAL
1.1.1 Drawings and General Provisions of the Contract, including Contract Conditions
and Division-1 Specification Sections, apply to work of this Section.
1.2 SUMMARY
1.2.1 This section covers the specifications for cast-in-situ structural concrete work
required by the Contract including formwork, reinforcement, mix design,
placement procedures and finishes.
1.3.1 Concrete works shall be performed in strict accordance with the Specifications,
Drawings and the stipulations of the latest editions of the Egyptian Standard
Specifications (ES), the British Standard Specifications (BS), the specifications of
the American Society for Testing and Materials (ASTM) and the designations of
the American Association of State Highway and Transportation Officials (AASHTO)
as referenced to throughout the section.
1.3.2 Egyptian Code of Practice
 Egyptian Code of Practice for Design and Construction of Reinforced Concrete,

ECCS 203-2007.
1.3.3 Egyptian Standard Specifications ES No.
257 Electrical Arc-Welding of Structural Steel

262 Steel Bars for Concrete Reinforcement
534 Metal Scaffolding
583 Sulphate Resisting Portland Cement
917 Standard Tests for Approval of Welds
1109 Concrete Aggregates from Natural Sources
1618 Fabric of Welded Steel Bars for Reinforced Concrete
1658 Methods of Testing Concrete
1899 Part 1: Accelerating Admixtures, Retarding Admixtures and Water
Reducing Admixtures
4756 Portland Cement (Ordinary and Rapid-Hardening)

1.3.4 American Concrete Institute ACI NO
304 Recommended Practice for Measuring Mixing, Transporting

and Placing Concrete
318 Building Code Requirements for Reinforced-Concrete
350R Concrete Sanitary Engineering Structures.
1.3.5 American Society for Testing and Materials
ASTM No.
A 497 Specifications for Welded Deformed Steel Wire Fabric for Concrete
Reinforcement
C 31 Practice for Making and Curing Concrete Test Specimens in the Field
C 40 Test Method for Organic Impurities in Fine Aggregates for Concrete
C 94 Specification for Ready Mixed Concrete
C 171 Specification for Sheet Materials for Curing Concrete
C 172 Practice for Sampling Freshly Mixed Concrete
C 309 Liquid Membrane-Forming Compounds for Curing Concrete
C 494 Specification for Chemical Admixtures for Concrete
C 1059 Specification for Latex Agents for Bonding Fresh to Hardened

Concrete
1.3.6 American Association of State Highway and Transportation Officials AASHTO No.
M-182 Burlap Cloth Made from Jute or Kenaf

T-96 Standard Method of Test for Abrasion
1.3.7 In the event of conflict between various codes and standards, the most stringent
shall apply.
1.4.1 The following specification sections includes requirements which relate to this
section:
 Section 07920 Joint Sealants
1.5 SUBMITTALS
1.5.1 Submit the following in accordance with Conditions of the Contract and Division-1

 Product Data: For proprietary materials and items, including reinforcement
and forming accessories, waterstops, admixtures, patching compounds, joint
systems, curing compounds, dryshake finish materials, joint sealants and oth-
ers as requested by the Engineer.
 Shop Drawings: For fabrication, bending and placement of concrete reinforce-
ment. Details for reinforced concrete shall show, stirrup spacing, diagrams of
bent bars, arrangement of concrete reinforcement, special reinforcement re-
quired for openings through concrete structures, etc.
 Shop drawings for formwork, prepared by an approved structural consulting
engineer for fabrication and erection of forms for specific finished concrete
surfaces as indicated. Show general construction of forms including jointing,
special form joint or reveals, location and pattern of form, tie placement and
other items which affect exposed concrete visually.
 Engineer's review is for general structural and architectural applications and
features only. Design of formwork for structural stability and efficiency is the
Contractor's responsibility.
 Concrete Mix: mixing, transporting, and placing equipment and procedures.
 Shop Drawing: For concrete construction joint locations, sequence of pouring
and method of curing.
 Samples: Of all materials to be used in the Works as specified and as otherwise
requested by the Engineer including names, sources and descriptions.
 Laboratory Test Reports: For concrete materials, mix and mix design tests as
specified.
 Material Certificates: In lieu of or in addition to material laboratory test re-
ports when permitted or requested by the Engineer. Material certificates shall
indicate the date of manufacture and shall be signed by the manufacturer and
Contractor, certifying that each material item complies with, or exceeds, speci-
fied requirements.
 Daily Reports: Indicating all information related to concrete and reinforced
concrete work.
1.6.1 Materials and installed work may require testing and retesting at any time during
the progress of the Works. Tests, including retesting of rejected materials or
installed work, shall be done at the Contractor's expense.
1.6.2 Concrete Testing Services: A testing laboratory to perform material evaluation

tests, design concrete mixes and progress concrete testing shall be founded on
Site by the Contractor.
1.6.3 Pre-execution Conference: At least 15 days prior to submittal of design mixes,

conduct a meeting to review detailed requirements for preparing concrete design
mixes and to determine procedures for satisfactory concrete operations. Review
requirements for submittals, status of coordinating work and availability of
materials. Establish preliminary work progress schedule and procedures for
materials inspection, testing and certifications. Request that representatives of

each entity directly concerned with all concrete and reinforced concrete attend
this conference including, but not be limited to, the following:
 Contractor’s superintendent.
 Laboratory responsible for concrete design mixes.
 Laboratory responsible for field quality control.
 Ready-mix concrete producer.
 Concrete subcontractor.
 Primary admixture manufacturers.
1.7 DELIVERY, STORAGE AND HANDLING
1.7.1 Cement shall be delivered to Site in sealed bags bearing the manufacturer's name
and the type of cement. Bulk cement delivered directly from factory in special
container trucks and stored in steel, elevated weather-tight silos is acceptable.
1.7.2 Cement shall be fully protected during handling and transport from adverse
weather conditions, moisture and over stacking.
1.7.3 Cement shall be stored in piles not more than ten bags high in perfectly dry
weatherproof sheds, clear from the ground on planks or other damp-proofing
supports. Free passages, minimum one meter wide, shall be left between stored
bags and sidewalls of buildings (if any) so that each bag shall be visible.
1.7.4 Each consignment of cement shall be stored apart from earlier ones, and
consignments shall be used in the order they were delivered. Any consignment
which has become lumped caked or otherwise adversely affected shall be
removed from Site immediately.
1.7.5 Steel Reinforcement: Deliver and handle steel reinforcement in a manner to

prevent bending and damage. Store according to grade, length, and diameter.
PART 2 PRODUCTS
2.1 CEMENT
2.1.1 Unless otherwise indicated on Drawings, type of cement used shall be ordinary
Portland cement to ES No. 4756 for above-grade castings and below-grade
castings.
2.1.2 Use one brand of cement throughout the project. The source of supply of cement
shall be subject to the Engineer's approval. The date of manufacture must be
recorded. Follow-up tests shall be performed by an approved testing laboratory
and the Contractor shall at all times furnish test certificates and proof that the
required standard specification has been complied with.
2.1.3 Cement used in concrete work shall be less than six months old from date of
manufacture.

2.2 AGGREGATES
2.2.1 Aggregates shall not contain harmful materials which may reduce the strength or
durability of concrete nor materials which may attack the reinforcement. Mixed
coarse and fine aggregates together shall not contain more than 0.05% (by
weight) chloride ions.
2.2.2 Coarse aggregate shall be gravel or crushed stone or a combination thereof.
2.2.3 Gravel or crushed stone shall be durable particles of uniform quality throughout.
Each of the materials shall have a wear of not more than 40% when tested
according to AASHTO Method T-96 Standard Method of Test for Abrasion.
2.2.4 Coarse aggregates shall not contain more than 0.04% (by weight) chloride ions.
2.2.5 Coarse aggregate shall be free from salt, mica, alkali, organic matter or other
deleterious material either free or as adherent coating on particles. It shall not
contain more than 0.25% by weight of clay lumps, not more than 1.0% by weight
of shale, not more than 5.0% by weight laminated, friable, flat, chip-like, thin or
elongated particles. The loss by decantation when tested by approved methods
shall not exceed 1%.
2.2.6 The nominal maximum size of aggregate shall be governed by the type of
structure element in which concrete to be cast. Grading requirements of coarse
aggregate shall be as shown in Table 1.
2.2.7 Fine Aggregate: Furnish natural siliceous sands from approved pits, free from
Opaline, Felspar, mica, fool's gold, siliceous magnesium, limestone or other
deleterious or reactive substances. Fine aggregate shall be clean, hard, durable,
and well graded.
2.2.8 Fine aggregates shall not contain more than 0.06% (by weight) of chloride ions.
2.2.9 Fine aggregate shall also be free from salt or alkali and shall not contain more
than 0.5% by weight of clay lumps. When subjected to the color test for organic
impurities (ASTM C 40), it shall not show a color darker than the standard. When
tested by approved methods, it shall conform to the grading and percentage
passing each sieve by weight as shown in Table 2. The material removed by the
Standard Test of Decantation shall not exceed 4%.
2.2.10 Coarse and Fine Aggregate: Shall comply with ES No. 1109, having absorption as
measured in accordance with BS 812 not greater than 2%.
2.2.11 Fine, Coarse and All-in Aggregates: Used for concrete shall comply with the
requirements of their corresponding Egyptian Standard Specifications.
2.2.12 The Grading of Aggregates: Shall be such as to produce concrete of the specified
proportions that will work readily into position without segregation and without
the use of excessive water content. The grading limits for sand, gravel, or all-in
aggregates given in Table 1 and Table 2 may serve as a guide for this purpose. It
shall be the Contractor's responsibility to design and work out concrete mixes to
attain the specified strengths.

Table 1
Grading Requirements for Coarse Aggregate
Percentage by mass passing BS Sieves for Nominal Sizes

Sieve Size Graded Ag- Single-sized
mm gregate Aggregate
40 mm 20 mm 14 mm 40 mm 20 mm 14 mm 10
to 5 mm to 5 mm to 5 mm mm
50.0 100 - - 100 - - -
37.5 90-100 100 - 85-100 100 - -
20.0 35-70 90-100 - 0-25 85-100 100 -
14.0 - - 90-100 - - 85-100 100
10.0 10-40 30-60 50-85 0-5 0-25 0-50 85-
100
5.0 0-5 0-10 0-10 - 0-5 0-10 0-25
2.36 - - - - - - 0-5
Table 2
Grading Requirements for Fine Aggregate
Percentage by Mass Passing BS Sieve

Sieve Size Additional Limits for Grading
Overall Limits
C M F
10.00 mm 100 - - -
5.00 mm 80-100 - - -
2.36 mm 60-100 60-100 65-100 80-100
1.18 mm 30-100 30-90 45-100 70-100
600 microns 15-100 15-54 25-80 55-100
300 microns 5-70 5-40 15-18 5-70
150 microns 0-15* - - -
* Increased to 20% for crushed stone fines except when they are used for heavy
floors.
Note: Fine aggregate not complying with Table 2 may also be used provided that
such materials produce concrete of the required quality.
2.2.13 Maximum Nominal Size of Coarse Aggregate: The maximum nominal size of
coarse aggregate shall be as large as possible within the limits specified in the
code of practice or as shown on Drawings but in no case greater than 1/5 of the
narrowest dimension of the member, and shall be less than 1/3 of the depth of
slab, provided that concrete can be placed without difficulty so as to surround all

reinforcement thoroughly and to fill corners of forms.
2.2.14 The grading of aggregates shall be controlled by furnishing coarse aggregate in

one size for 10 mm maximum size and in two sizes for aggregate of 25 mm
maximum size.
2.2.15 In no case shall maximum size of coarse aggregate exceed 3/4 of the minimum
clear spacing between bars or between reinforcing bars and forms.
2.2.16 For general purpose, a maximum size of 25 mm shall be satisfactory.
2.3 MIXING WATER
2.3.1 Mixing water for concrete shall be drinking water (potable water) or water of
chemical composition acceptable for drinking (except for bacteriological limits)
and be clean and free from organic impurities, industrial, contamination oils, salts
and any other substances that may be harmful to cement or steel reinforcement.
2.3.2 For plain concrete and mud slabs without reinforcement sea water may be used
for mixing concrete only after approval of the Engineer, and increasing the
cement to obtain same compressive strength required.
2.4 STEEL REINFORCING BARS
2.4.1 Reinforcement shall be as shown on Drawings and shall comply with the
requirements of the Egyptian Standard Specifications No. 262 for:
 Normal Mild Steel (Grade 24/35 bars)

 High Tensile Steel (Grade 40/60 bars)
2.4.2 Grade 60 bars shall be deformed and contain notches to sustain better bond with
concrete. The area of the non-continuous notches and deformations shall not be
taken into consideration.
2.4.3 Table 3 gives the lower limit for the results of the Standard Tensile Test as
described in ES No. 262.
Table 3
Lower Limits for Standard Tensile Test of Steel
Kind of Steel Yield Stress Proof Stress Tensile Strength Minimum

MPa MPa MPa Elongation
%
Normal Mild Steel 240 0 350 20
(Grade 24/35)
High Tensile Steel - 400 600 10
(Grade 40/60)
2.4.4 Mill certificates shall be submitted for each consignment of reinforcing steel. This
mill certificates shall state the place of manufacture, details of composition,

manufacture, strength, and mill analysis and test reports. Follow-up tests shall be
performed by an approved testing laboratory. Specimens shall be selected by the
representative of testing laboratory under the supervision of the Engineer from
batches received on Site.
2.5 TIE WIRE
2.5.1 Tie wire shall be annealed steel. Except where otherwise required, tie wire shall
be minimum 1.2 mm diameter.
2.6 WELDED WIRE FABRIC
2.6.1 Shall be deformed-steel, welded steel wire fabric to ES No. 1618.
2.7 FORM RELEASE AGENT
2.7.1 Commercially formulated form release agent that shall not bond with stains or
adversely affect concrete surface. Formulate form release agent with rust
inhibitor for steel form facing materials.
2.8 CURING MATERIALS
2.8.1 Water: Shall be as specified in Clause 2.3.
2.8.2 Liquid Membrane-Forming Curing Compound: Clear liquid membrane-forming

curing compound complying with ASTM C 309, Type 1, Class B. Moisture loss shall
not be more than 0.55 kg/m2 when applied at a rate of 0.210 liter/m2.
2.8.3 Use membrane-curing compounds that will not affect surfaces to be covered with
finish materials applied directly to concrete.
2.9 SUPPORTS FOR REINFORCEMENT
2.9.1 Bolsters chairs, spacers and other devices for spacing, supporting and fastening
reinforcing bars in place and which may be in contact with forms, plain concrete
footings or mud slabs, shall be the same grade as the main reinforcing rebars.
2.10 FORMWORK
2.10.1 Form for concrete work can be of timber, plywood or metal, lumber or wrought
formwork shall be used where shown on Drawings or directed by Engineer.
2.10.2 Furnish form in largest practicable size to minimize number of joints. Lumbers
shall be dressed on two edges for tight fit. Provide forms with sufficient wall
thickness to resist plastic cement loads without deformation.
2.11 STEEL FIBERS REINFORCED CONCRETE (SFRC)
2.11.1 Steel fibers reinforced concrete is a concrete containing Steel fibrous materials
which increase its structural integrity and strength. It contains short disconnected
fibers that are uniformly distributed and randomly oriented in the concrete mix

2.11.2 Steel fibers are made of cold drawn steel wire with low content of carbon (C) and
should be delivered in paper bags or cardboard boxes of 20-25kg
2.11.3 According to manufacturer data sheet and design mix
2.11.4 Steel fibers used in the mix shall be complying with ASTM 820/96, ASTM C
1116/95.
2.12 ADMIXTURES
2.12.1 Admixtures may be used, with the written approval of the Engineer, in concrete
for special reasons such as waterproofing, retarding initial setting time, improve
workability, reduce amount of water, etc. Use admixtures strictly in accordance
with manufacturer's instructions.
2.12.2 Admixtures shall be of no harmful effect with regard to concrete or steel. The
maximum limit shall be given as a ratio of the weight of cement. Concrete
containing admixtures shall at least resist 90% of the compression, bending and
bond between steel and concrete stresses of the corresponding value for concrete
prepared without admixtures provided that such concrete shall satisfy the
specified characteristic concrete strength as specified in Table 4.
2.12.3 Use admixtures that contain not more than 2% chloride ions of the admixture
weight or 0.03% of the cement weight complying to BS No. 8110 and compatible
with other admixtures and cementitious materials, do not use admixture
containing calcium chloride.
2.12.4 Water-Reducing Admixture: Shall comply with ASTM C 494, Type A.
 High-Range Water-Reducing Admixture (Super Plasticizer): Shall comply with

ASTM C 494, Type F or Type G.
 Water Reducing and Retarding Admixture: Shall comply with ASTM C 494, Type
D.
2.12.5 Bonding Agents: Work as adhesive or sealing agent, can be based on polyvinyl
acetate copolymer or viscous and shall produce 2 components product based on
modified epoxy resin, according to manufacturer and shall be applied directly to
wet surface to bond fresh to old concrete or to repair crack in concrete.
2.13 CONCRETE MIXES
2.13.1 Designed mixes shall be used throughout the Works, unless otherwise shown on
Drawings and Bill of Quantities. Standard concrete mixes can be used, if
specifically called for and noted on Drawings.
2.14 DESIGNED MIXES
2.14.1 The Contractor shall design concrete mixes to satisfy the strength requirements of
various classes of concrete to be used in the Works.
2.14.2 Concrete mix design shall start as soon as practical after the award of the
Contract, and well in advance of any scheduled concreting work to allow adequate

time for the design and testing of concrete cubes as defined hereinafter. No
concreting shall be commenced before the satisfactory completion of design and
testing of the designed mix samples.
2.14.3 Quantities of cement, fine and coarse aggregate shall be measured by weight.
2.14.4 Approved designed mixes shall be maintained throughout the duration of the
Contract.
2.14.5 Mix designs shall satisfy the specified characteristic concrete strength
requirements given in Table 4. In order to allow for unavoidable variations, the
mix shall be designed to have a mean strength equal to or exceeding 125% of the
specified works characteristic strength.
2.14.6 Concrete mix may be provisionally accepted on basis of 7-day results, when these
satisfy the requirements for 28-day results, and strengths shall not be less than
eighty percent of those required at 28-days.
2.14.7 Concrete grades required for this project shall be as shown in Table 4.
2.14.8 Trial Mixes: Before commencement of work, trial mixes shall be prepared under
full-scale conditions and tested in accordance with ES 1658, Methods of Testing
Concrete.
2.14.9 Representative samples of materials to be used shall be taken and a trial mix using
the proposed proportions shall be made on each of three different days produced
by the same plant and under the same supervision. The workability of each of
these three trial mixes shall be determined. The proposed mix proportions shall
be accepted if the average strength of the three trial mixes is not less than the
characteristic strength plus 30 kg/cm2. Further trial mixes shall be made if any of
the cube results in any set is less than the specified characteristic concrete
strength or if the difference between the highest result and the lowest result in
any of the sets exceeds 20% of the overall average of the set.
2.14.10 Cube Tests for Control Purposes: Works cube tests shall be made on concrete
samples during the progress of the works. Concrete for test specimens shall be
taken at the point of deposit. A minimum of nine (9) cubes 150 mm shall be taken
for each day's pour or each 100 m3 of concrete poured whichever is smaller.
Separate samples shall be taken for each structural element if poured separately.
From each sample three (3) cubes shall be tested after 7 days, three (3) after 28
days and three (3) kept as spares.
2.14.11 If the number of cubes test is less than 20 cubes, the result of any cube test shall
not be less than the required characteristic strength, and the difference between
the highest and the lowest results shall not exceed 25% of the average of all
results.
2.14.12 If the number of cubes test is more than 20 cubes, the number of results less than
the required characteristic strength shall not exceed one (1) for every 20 results,
and the difference between the highest and the lowest results shall not exceed
25% of the average of all the results.

Table 4
Non-Air Entrained Concrete Grades
Maxi- Minimum Maximum Characteristic Target

Grade mum Cement Water Ce- Strength after Slump Uses
Aggre- Content ment Ratio 28 Days (mm)
gate Size (kg/m3) (weight) (kg/cm2)
(mm)
A 25 400 0.43 350 50 Cast in situ Reinforced
Concrete
B 38 250 0.50 250 75 Slab on Grade and Plain
Concrete Footings
C 38 250 0.50 180 75 Plain Concrete Blinding
2.14.13 When the result of the 7-day test is unsatisfactory, the Contractor may elect to
remove and replace the defective concrete without waiting for the 28-day test. If
the result of the 28-day test is unsatisfactory, all concreting shall be stopped. The
Contractor shall then; test concrete of the suspected portions of the structure in
such a manner as may be appropriate to the particular conditions or parts of the
works.
2.14.14 Should tests prove that concrete is unsatisfactory then the condemned concrete
shall be cut out, removed and replaced by the Contractor.
2.14.15 When works cube tests show concrete strengths consistently higher than those
specified, the contractor may reduce the number of tests to be made to the
minimum required by the Referenced Standards.
2.15 QUALITY CONTROL
2.15.1 Supervision: Employ a competent person and permanently keep him on Site until
the completion of concreting work. His first duty shall be to supervise all stages in
preparation and placing of concrete. He shall be responsible for supervising all
tests of materials, molding and testing of concrete cubes and maintaining and
calibrating all mixing and measuring plant.
2.15.2 Aggregates: Separate storage bins with adequate provision for drainage shall be
provided for each size of aggregate used (40-20 mm, 30-20 mm, 25-20 mm, 20-10
mm, 10-5 mm, and 5 mm down).
2.15.3 The grading of coarse and fine aggregates shall be determined at least once a
week to check whether the grading are similar to those of the samples used in
trial mixes.
2.15.4 Batching and Mixing Plant: Concrete shall be machine mixed by appropriate
drum-type batch machine mixer.
2.15.5 If centralized batching plant is planned for use by the Contractor, concrete shall

be mixed dry, transported in transit mixers to place of work where water is to be
added and final mixing is to be carried. If haulage distances are very short, mixing
can take place at the batching plant and concrete transported in agitators or
transit mixers.
2.15.6 About 10% of water required for the batch shall enter the drum in advance of
cement and aggregates. Remainder of water shall be added gradually while the
drum is in action so that required quantity is in the drum by the end of the first
quarter of mixing time. Concrete shall be mixed until a mixture of uniform color
and consistency is obtained and mixing shall continue for at least 1.5 minutes
after all water has been added. In no circumstances shall mixing time be less than
that recommended by the manufacturer of the mixer. Should mixing be
determined by a certain number of revolutions of the drum, then adequate
means and meters shall be provided to check number of revolutions before the
discharge of each batch mix.
2.15.7 The amount of concrete mixed in any one batch shall not exceed the rated
capacity of the mixer. The whole of the batch is to be evacuated before loading
the drum with a fresh batch. On cessation of work, including all delays exceeding
20 minutes, the mixers and all handling plant shall be washed with clean water
and any deposits of old concrete in drums shall be cleaned out by rotating clean
aggregate and water in the drum, or by other appropriate means, before any
fresh concrete is mixed. Mixers shall be properly maintained and all worn out
blades shall be replaced with new ones or built-up by welding.
2.15.8 Concrete shall not be remixed if mixing water has been added to it for more than
twenty (20) minutes. No additions to concrete shall be permitted once mixed.
2.15.9 If concreting work is done by using ready mixed concrete it shall conform to ASTM
C 94 and concrete shall be mixed dry, transported in transit mixers to place of
work where water is to be added and final mixing is to be carried. If haulage
distances are very short, mixing can take place at the batching plant and concrete
transported in agitators or transit mixers.
2.15.10 When air temperature is between 30°C and 32°C reduce mixing and delivery time
to 60 minutes. When air temperature is above 32°C reduce mixing time and
delivery to 45 minutes.
2.15.11 Provide batch ticket for each batch discharged and used in the work, indicating
project identification, name and number, date, time, mix type, mix quantity, and
amount of water added.
2.15.12 In special cases for concrete-work of non-important items concrete may be mixed
at each place of work with a batch mixer of an approved type fitted with a water-
measuring device.
2.15.13 Control of Water Content: Water/cement ratio shall be controlled at values

determined in trial mixes. Appropriate allowances shall be made for water
contained by the aggregates. Provisions shall be made to determine the moisture
content of aggregates. Tests shall be performed at least once a day for fine
aggregate but less frequently for coarse aggregate. Further tests shall be made

whenever there is a noticeable difference in moisture content of any of the
aggregates.
2.15.14 Workability: Workability shall be controlled by direct measurement of water

content, making allowance for water contained by fine and coarse aggregates.
Slump test shall be used as a guide for workability.
2.15.15 Table 5 indicates the acceptable slump in mm for the corresponding type of
structure.
Table 5
Slump Values
Type of Structure Type of Compaction Slump in mm (max.)

Concrete Foundation Mechanical -
Reinforced Concrete Work Mechanical 50
R.C. Structures of Heavy Rein- Mechanical 100
forcement and Tin Walls
Tremie Concrete Mechanical 150-230
Plain Concrete Works Manual 75
Slab on Grade Mechanical 75
2.16 STANDARD MIXES
2.16.1 For concreting work of non-important items where characteristic strength is less
than 200 kg/cm2, standard mixes may be used where fine and coarse aggregates
are measured by weight. Standard mixes shall be as shown in Table 6, and 7.
Table 6
Standard Concrete Mixes
Ratio of Mix by Concrete Consistency Characteristic

Kind Strength of Concrete
Weight & Max. Slump mm
After 28 days kg/cm2
Ordinary Cement:Sand:Gravel Plastic Concrete with 150
Mix a. 1:2:4 (300 kg ce- slump from 50 to 80
ment/m3 of finished mm
concrete)
b. 1:1¾:3½ (350 kg ce- Plastic concrete with 175
ment/m3 of finished slump from 50 to 80
concrete) mm

Table 7
Crushing Strength of Plain Concrete Mix
(Slump 75 mm)
Cube Strength Characteristic Cube

Mix Proportions by Weight Strength after 28 Days
after 7 Days
kg/cm2 kg/cm2
1:2:4 (250 kg cement/m3 finished con- 135 180

crete)
Mechanical Mixing
1:1¾:3½ (300 kg cement/m3 finished con- 190 250
crete)
Mechanical Mixing
2.17 CONSTRUCTION JOINT SEALANTS
2.17.1 Shall conform to Division 7, Section 07920 "Joint Sealants".
PART 3 EXECUTION
3.1 CONCRETE
3.1.1 Measuring and Mixing: Measuring and mixing shall be carried out as specified
under Clause 2.12.
3.1.2 Transporting: Concrete shall be handled from the place of mixing to the place of
final deposit as rapidly as practicable by methods that will prevent segregation or
contamination of the ingredients all as specified under Clause 2.12.3.
3.1.3 It shall be deposited as nearly as practicable in its final position to avoid re-
handling or flowing.
3.1.4 Placing
 Advance Notice: Give sufficient advance notice to the Engineer and anyone
who has the right to attend the casting of concrete before starting to place
concrete in any unit to permit the inspection of forms, reinforcing steel place-
ment, and preparation for casting. No concrete shall be placed in any unit,
prior to the proper completion of formwork and placement of reinforcing steel
and the Engineer's written acceptance of such works.
 Daylight: Unless the getting all necessary permits for working at dark, concrete
mixing, placing and finishing shall be done in daylight hours only. Placement
shall not commence when it is evident that the work cannot be completed be-
fore dark unless adequate provisions are made to lighten the entire site of all
operations.
 Weather Conditions: Concrete placement shall not be permitted when im-
pending weather conditions may result in rainfall or low temperature which
will impair the quality of finished work. In case rainfall should occur after plac-

ing operations have started, the Contractor shall provide ample covering to
protect the work.
 Placing: Before placing concrete, inspect and complete form-work installation,
reinforcing steel, etc... Notify other crafts to permit installation of their work
and cooperate with other trades in setting such work. Forms shall be thor-
oughly cleaned of all dirt, shavings, loose stones etc., and shall be well soaked
with water. No standing water shall be present inside forms when concreting.
 Concrete shall be placed in its final position before setting has commenced and
shall not be subsequently disturbed. Concrete shall be placed in layers not ex-
ceeding 500 mm depth to ensure proper compaction and vibration, or in layers
of such thickness that no concrete shall be placed on concrete that has hard-
ened sufficiently to cause the formation of seams of weakness. Place each lay-
er while underlying one is still plastic. Concrete shall not be freely dropped
more than 1.5 m without the use of tremies.
 Concreting shall be carried out continuously up to construction joints desig-
nated by the approved shop drawings. A detailed record shall be kept by the
Contractor for all concreting operations reflecting date, time, shade, air tem-
perature, relative humidity, and weather conditions for every part of the
Works.
 Construction Joints: Locate and install construction joints as indicated in shop
drawings. Contact surfaces of hardened concrete shall be thoroughly hacked,
swept clean, wetted, and covered with a coat of neat cement mortar grout
freshly mixed and placed immediately before receiving fresh concrete. Con-
struction joints shall be at right angles to the general direction of the member
and provided with joggles where possible. Additional reinforcement shall be
placed at construction joints as shown on Drawings.
 All construction joints incorporating waterstops as indicated on Drawings or
joints of water-retaining structures shall incorporate rubber waterstops as
specified hereinbefore. Jointing of waterstops other than by heat welding shall
not be permitted. Waterstops shall be installed so that they are securely held
in their correct positions whilst concrete is placed. Secure flanges of water-
stops to reinforcing bars with 1.2 mm diameter tie wire spaced at a maximum
of 450 mm. Use only approved tool recommended by manufacturer to perfo-
rate the flanges of waterstops. Concrete shall be fully and properly compacted
around waterstops to ensure that no voids or porous areas remain. Where re-
inforcement is present, adequate clearances shall be left between it and all
waterstops to permit proper compaction of concrete. No holes shall be made
through any waterstops to pass reinforcing steel.
 Joints at concrete surfaces shall have 20 mm wide by 20 mm deep grooves for
the full length of construction joints on both exposed sides. All joints shall be
formed to the correct dimensions as specified and shown on Drawings and
sealed with a sealing compound applied after the concrete has cured. Sealant
shall be applied in accordance with the printed instructions of the manufactur-
er and as specified in Division 7 Section 07920 "Joint Sealants".
 Shear Keyways and Control Joints: Unless otherwise shown on Drawings, all
construction joints of water-retaining structures shall be provided with shear
keyways. Form keyways to details shown on Drawings.

 Control joints shall be groove formed with hand tool finishing, at intervals as
directed by the Engineer. Minimum depth of joint shall be equal to 1/4 of the
slab depth.
 Compaction: Concrete shall be thoroughly compacted during placing operation
and carefully worked around reinforcement, around embedded fixtures and in-
to corners of forms so that it will be in close contact with reinforcement and
free of honeycombs. Concrete shall be compacted by approved immersion-
type mechanical or electromechanical vibrators of proper sizes and diameters
best suited for the cast element. Over vibration causing segregation shall be
avoided and transportation of concrete through forms by vibrators shall not be
permitted.
3.1.5 Curing: Protect freshly placed concrete from premature drying. Concrete shall be
kept constantly wet for seven days. This period may be reduced to five days for
rapid hardening cement. Water if used for curing concrete shall be same as that
for concrete mixing. As climate is hot, dry or windy, concrete shall be covered by
a layer of waterproof material immediately after placing, to be protected from
rapid moisture loss before and during finishing operation. Maintain cover in
contact with concrete for seven days.
3.1.6 Proper precautions and measures shall be taken to ensure proper curing of
concrete by either setting up a mechanical water fog-spray system covering the
total concreted surface, this system shall operate continuously during the curing
period, or by covering the concreted surfaces with burlap weighing not less than
300 gm/m2 or absorptive cover and thoroughly saturate cover with water so that
they shall be kept moist continuously during the curing period.
3.1.7 Curing shall start immediately after the disappearance of free surface water. For
special purposes additional extra test cubes of each portion or member, if
requested by the Engineer, shall be cured in the same place and exactly in the
same manner as the portions or members they represent. After seven days, they
shall be transported to the laboratory where they shall be kept in water until
tested.
3.1.8 Curing compound as specified in Clause 2.8.2 may be used for curing concrete in
lieu of water. Curing compound shall be applied to all exposed concrete surfaces
as soon as the surface of the freshly placed concrete becomes dull, (within 2
hours after surface water has disappeared) or immediately after form stripping of
columns, vertical surfaces of walls and beam sides. Curing compound shall be
applied by means of sprayers or rollers and shall result in a continuous whitish
film. Rate of spraying shall be in strict conformance to the manufacturer's
recommendations.
3.1.9 Work in Hot Weather: When shade air temperature is 36°C and rising, the coarse
aggregate shall be sprayed with water or cooled by appropriate measures. Special
precautions shall be taken during all concreting operations so that temperature of
concrete does not exceed 32°C when placed.
3.1.10 Fresh concrete placed at these temperatures shall be carefully shaded from
sunrays and wind.

3.2 STEEL REINFORCEMENT
3.2.1 Cleaning: Before placing reinforcement into forms, all steel for reinforcement
shall be cleaned and freed from loose mill scale, loose rust, oil and grease or other
harmful matter that may destroy or reduce bond strength.
3.2.2 Placing: Concrete cover to reinforcing steel shall be as indicated on Drawings and
shall be measured from the outer surface of steel reinforcement and outer
surfaces of stirrups in case of beams and columns. All reinforcement shall be
placed and rigidly maintained in positions shown on Drawings and secured against
displacement. This shall be ensured by tying, welding, using spacing blocks,
hangers, bolsters, metal clips or supports. Accurately place reinforcement and
securely wire tie with pincers in precise position at all points where bars cross. Tie
stirrups to bars at both top and bottom. No supports or metal clips shall be
placed in contact with forms unless plastic-coated, galvanized or rust-proofed.
The ends of binding tie wire shall be bent inward and trimmed allowing no
encroachment on the concrete cover trimmed with exercising special care for
surfaces to remain exposed and unpainted. Placing of reinforcement shall be
checked by the Engineer and in no case shall concrete be poured around any steel
that has not been approved by the Engineer.
3.2.3 Bending: All bars shall be bent cold and in accordance with bending schedules.
3.2.4 All bending and scheduling of bars for the reinforcement of concrete shall comply
with BS EN No. 4066.
3.2.5 Bending by heat may be allowed for large diameter bars only after receiving a
written permission from the Engineer.
3.2.6 If heating is permitted, provisions shall be made so that bending temperature

does not exceed 800°C and steel is left to cool gradually. Sudden cooling by water
is strictly prohibited.
3.2.7 For rods of cold twisted bars such as "Tor Steel" which have their strength
increased by cold working, bending by heat shall not be permitted.
3.2.8 Reinforcement shall not be bent or straightened in a manner that will injure the
material.
3.2.9 Where reinforcement bars are bent aside at construction joints and afterwards
bent back into approximately their original positions, care shall be taken to ensure
that at no time shall the radius of the bend be less than 4 bar diameters for
normal mild steel and 6 bar diameters for high-yield steel. Care shall also be
taken when bending back bars to ensure that concrete around bars is not
damaged.
3.2.10 Splicing of reinforcing bars shall not be permitted except where shown on
Drawings. All splices and overlaps shall comply with the requirements of the
Egyptian Code of Practice for design and construction of reinforced concrete and
the notes written on Drawings.
3.2.11 Spacing Blocks: Where concrete blocks are used to ensure the specified cover to

the reinforcement, they shall be made of mortar not leaner than 1 part cement to
2 parts sand. Steel tie wire shall be embedded in spacing blocks to securely tie
them to the reinforcement.
3.2.12 Plastic spacers and chairs may be used; they shall be according to steel diameter
and required cover.
3.2.13 Spacers and chairs shall be placed at a maximum spacing of 1.0 meters.
3.2.14 The contractor shall provide all necessary distance pieces, chairs, and spacer bars
at his own expense.
3.3 FORMWORK
3.3.1 General: Design, erect, support, brace and maintain formwork to support vertical
and lateral, static and dynamic loads that might be applied until concrete
structure can support such loads. It shall be constructed to the correct size, and
shape, to remain sufficiently tight to prevent loss of grout or mortar of concrete.
Forms for concrete surfaces can be of timber, plywood, or metal. Wrought
formwork shall be used where shown on Drawings or directed by the Engineer.
3.3.2 Provide top forms for inclined surfaces where slope is too steep to place concrete
with bottom forms only.
3.3.3 Bolts and rods shall be used for internal ties. They shall be so arranged that when
the forms are removed no metal shall exist within 30 mm of any surface. All holes
shall be filled with mortar after the removal of the bolts and all external parts of
the metal ties.
3.3.4 All exposed corners and edges of concrete shall be chamfered by using wood,
metal, and PVC or rubber 25 x 25 mm triangular fillets inside the forms.
Chamfered fillets shall also be used at horizontal construction joints in concrete
walls to produce uniform smooth lines
3.3.5 Forms in contact with concrete shall be cleaned and treated with approved
composition or form oil. Care shall be taken not to spatter reinforcement with
such composition.
3.3.6 Metal Formwork: Metal forms shall be selected for their surface flatness and
smoothness. Where metal forms are selected for use, provide metal forms of
standard manufactured units with a system to function easily and properly, to
comply with the dimension, design loads of the project and of sufficient strength
to withstand pressure of concrete placing operations.
3.3.7 Metal forms shall be fabricated by a specialized professional manufacturer having

a minimum of 5 years’ experience in successful fabrication of metal form and
similar units required for this project.
3.3.8 Submit manufacturer's instruction, catalogues, detailed information concerning

system, installation instruction, handling, jointing, connections, details at
openings and supplemental steel framing, fasteners and accessories. Metal sheets
shall be of sufficient thickness and reinforced with concealed stiffeners or backing

materials or both as required producing required concrete smooth finish surface.
3.3.9 Provide forms easy to remove without hammering or prying against concrete
surface.
3.3.10 Rust-stained steel formwork shall not be acceptable.
3.3.11 Reuse of Formwork: Clean surfaces of forms to be reused in work, remove fins
and laitance. Apply form coating as specified in Sub-Clause 3.3.6 for reused forms.
3.3.12 Delaminated or otherwise damaged form-facing material shall not be acceptable

for exposed surface.
3.3.13 Strutting: The design and erection of the formwork together with the adequacy of
all bracing and strutting shall be the responsibility of the Contractor. The
Contractor shall ensure that there shall be no deformations or failure of the
shuttering during concreting and shall include in his rates for all necessary
scaffolding or staging, boxing out for fittings and all other works incidental to the
shuttering to be erected.
3.3.14 The Contractor shall submit to the Engineer detailed drawings and calculation of
special strutting-work, if so requested, for his approval. Said approval shall not
relieve the Contractor from his responsibilities in case of failure and his obligation
to repair all defects at his own expense.
3.3.15 Provision for Embedded Articles: Provide openings in concrete formwork to

accommodate work of other trades. Determine size and location of openings
accurately. All pipes passing through concrete walls, beams, or slabs shall pass
through sleeves fixed into position before concreting. All pipes and sleeves
passing through concrete shall have steel flanges welded to them as specified and
as shown on Drawings.
3.3.16 Embedded articles shall be built-in as the work proceeds. Where impractical, steel
inserts shall be built-in or holes and box-outs shall be left for fixation after
removal of forms.
3.3.17 If anchor bolts are cast into concrete during construction, they shall be held
accurately and rigidly in the correct position by means of metal-sheet templates
or otherwise approved method, the deviation must not exceed the following:
Bolt Diameter Deviation
Up to 12 mm 5 mm
From 13 mm to 32 mm 7 mm
33 mm and over 10 mm
3.3.18 Threads of bolts shall be protected with a cold applied petroleum-based anti-
corrosion coat and sealing tape or similar material approved by the Engineer,
during delivery, storage and concreting.
3.3.19 After concreting, the threaded bolt projections, with attached nuts and washers
shall be protected against corrosion with similar sealing tape and protected

against mechanical change with a timber shield or otherwise approved method
until the erection of the steel works.
3.3.20 Formwork Coating: Coat contact surface of formwork before reinforcement is

placed with an approved non-residual, rust preventative form coating compound
that will not bond with, stain or adversely affect concrete surfaces and shall not
impair subsequent treatment of concrete surfaces. Do not allow form-coating
materials to accumulate in forms or to contact with hardened concrete surfaces
against which fresh concrete shall be placed.
3.3.21 Form coating shall be applied to provide a thin uniform coating without
contaminating the reinforcement.
3.3.22 Cleaning: All rubbish, particularly chippings, shavings, tie wire trim, and sawdust
shall be removed from interior of forms before concrete is placed. Provide
temporary openings in wall forms for cleaning. Prior to pouring, clean interior of
walls as specified hereinbefore and patch openings.
3.3.23 Removal of Forms: In any case, forms shall not be removed until the concrete has
attained sufficient strength to ensure structural stability and to carry both dead
load and any construction loads that may be imposed on it. Concrete shall be hard
enough so that surfaces will not be injured in any way when reasonable care is
used in removing forms.
3.3.24 The minimum period of time that shall elapse between pouring concrete and
removal of forms shall be in no case less than the age shown in Table 8.
Table 8
Minimum Age of Concrete for

Safe Removal of Forms
Type of Formwork Minimum Age of Concrete

Vertical formwork to columns and walls 24 hours
Soffit formwork to slabs 14 days
Soffit formwork to beams and props to slabs 14 days
Props to beams 14 days
3.3.25 In no circumstances shall forms of structural elements that support weight of

concrete be removed and struck until concrete reaches a cube strength of at least
seventy five percent (75%) of the concrete characteristic strength.
3.3.26 Forms shall be removed with due care and attention avoiding all shock or
vibration that would damage concrete.
3.3.27 The Contractor shall make good all concrete surfaces after removal of forms.
3.3.28 Shores and Supports: Before removal of forms temporary shore and brace
suspended slabs with suitable members of sufficient strength to withstand

imposed loads.
3.3.29 After removal of forms, shore the produced slab so that, the employed supports
are concentric on the shores supporting the underlying slab.
3.3.30 Keep shores in place until concrete has attained its required strength and heavy
loads due to construction operation have been removed.
3.3.31 Surface Finish: Brushed or rough-tamped finish shall be applied on top surfaces of
all cast in-situ slabs.
3.4 TESTING AND INSPECTION
3.4.1 Testing of Concrete: Testing for compressive strength of concrete sampled during
the progress of the work shall be as follows:
3.4.2 Sampling Concrete: Concrete for the test specimens shall be taken at point of
deposit to ensure that specimens are representing concrete cast into structure
members, a number of concrete samples shall be taken from different points.
3.4.3 The quantity of each concrete sample shall be enough to mould the number of
test specimens required and shall be taken from one work point. The location
from which each sample is taken shall be noted.
3.4.4 Test Specimens: Test specimens shall be prepared as specified in ES 1658.
3.4.5 Storage of Test Specimens: Test specimens shall be stored on Site at temperature
15-20°C and humidity not less than 90%. Twenty-four hours after making
specimens, they shall be released from moulds, marked, stored and cured by
immersing them in water temperature (15-20°C). Specimens to be sent to a
laboratory for testing, shall be packed for transit in damp sand or other suitable
damp material and shall reach the laboratory at least 24 hours before test time.
On arrival at the laboratory, they shall be similarly immersed in water until test
date.
3.4.6 Method of Testing: Tests shall be made at age of concrete corresponding to that
of the specified strength. Tests shall be made as specified in ES 1658.
3.4.7 Testing of Steel Reinforcement: Reinforcement steel used in concrete shall be

tested before use for each consignment on Site. Tests shall be carried on three
specimens for each different diameter, the results of which shall comply with the
characteristic strength given by ES 262 for tested grade.
3.4.8 Core Testing of In Place Concrete: When strength tests of cube specimens have
failed to meet the specified acceptance criteria, perform core testing and take
samples of in-place concrete as required. Results of in-place concrete core testing
shall be evaluated in accordance with ACI 318.
3.4.9 Load Testing of Structures: Should the Engineer have any doubts as to the
workmanship and quality of the concrete of floor systems based on his evaluation
for results of testing of concrete specimens and results of concrete core samples,
then he may order the load testing of parts or whole sections of the structures,

such testing shall be performed in full compliance with the requirements of the
Egyptian Code of Practice for Design and Construction of Reinforced Concrete as
amended herein.
3.4.10 This test shall be made after the expiry of 6 weeks of effective hardening of
concrete. In such tests, the structure shall be subjected in 4 approximately equal
stages to a superimposed load equal to one and half times the specified
superimposed live load used for design plus a load equivalent to the final dead
load (floors, partitions, etc..) and this load shall be maintained for a period of 24
hours, the reading of the deflection and width of the cracks shall be taken before
removal of load. The value of deflection shall not be more than the limiting value
as per the above mentioned code.
3.4.11 During the test, struts strong enough to sustain the whole load shall be placed in
position leaving a gap under members to allow for the expected deflection. If
deflection value is more than the above mentioned limit and if within 24 hours of
the removal of the load, the structure does not show a recovery of at least 75% of
the maximum deflection shown during the 24 hours under load and the crack
width is within allowable limits the test loading shall be repeated. The part of
structure shall be considered rejected if the recovery after the second test is not
at least 75% of the maximum deflection shown during the second test. If during
the test, or upon removal of the load, the structure shows signs of weakness,
undue deflection or faulty construction, it shall be reconstructed or strengthened
as necessary and instructed by the Engineer at the Contractor's own expense.
3.4.12 All such load testing shall be performed by the Contractor and at his own expense.
3.4.13 Repairs: No repairs or patching are to start before obtaining the approval of the
Engineer as to the techniques to be followed and the extent of the work. The
Engineer shall have the right to stop any or all work of repairs even after his
approval of same if in his opinion the Contractor is not carrying the work properly
or that there may exist a hazard or danger to the structure. All repairs, if
approved, shall be made by the Contractor at no extra cost to the Employer.
3.5 TOLERANCES OF REINFORCED CONCRETE
3.5.1 The following are the allowable tolerances in Reinforced Concrete which shall be
applicable as mentioned in the Egyptian Code of Practice for design and
construction of reinforced concrete, ministerial Decree No. 203-2001.
 Variation in cross sectional dimensions of different elements (columns, beams,

thickness of walls and slabs) = + 10 mm or - 5 mm for dimensions equal or less
than 400 mm and + 15 mm or - 10 mm for dimensions more than 400 mm.
 Variation in plan from specified location of the building = + 25 mm in any loca-
tion.
 Deviation in plan for any horizontal dimension (axes of columns, beams, walls):
+5 mm in (any bay or 6 m in any direction) and not more than + 25 mm in the
overall dimension of the structure.
 Deviation from plumb 5 mm for 6 m height with a maximum of 25 mm for the
full building height (maximum 30 m).

 Deviation in concrete cover shall be - 6 mm for depth equal or less than 250
mm and - 8 mm for depth more than 250 mm.
 Variation in distance between reinforcing bars for slabs, walls and between
stirrups + 20 mm provided that total number of bars in meter is as specified.
 Variation from specified joint width = + 5 mm.
 Deviation of underside level (before stripping forms) of beams and slabs
+ 5 mm for each 3.00 m length.
3.6 FAIR-FACE CONCRETE
3.6.1 The finished faces of concrete shall be sound, solid, and free from defects arising
from faulty formwork or other causes.
3.6.2 The surface of fair-face concrete shall be free from honeycombing.
3.6.3 All shuttering to exposed faces shall be made of polyethane faced plywood, or
metal shuttering.
3.6.4 Prior to placing the reinforcement, the internal surface of all formwork shall be
treated with an adequate approved mould-oil, which shall not stain on concrete
surfaces.
3.6.5 Curing with water is recommended, no curing materials shall be used.

EACH TIME THE SPECIFICATION IS CHANGED ONLY THE NEW OR REVISED ENTIRE SPECIFICATION RE-ISSUED
PAGES ARE ISSUED. ENTIRE SPECIFICATION REVISED

ISSUED FOR
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CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. CONCRETE FINISHES
CAIRO - EGYPT 03360 – 2039 0

CONTENTS
SECTION 03360
CONCRETE FINISHES
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Delivery, Storage, and Handling 2
PART 2 PRODUCTS 3
2.1 High Abrasion Floor Topping 3
PART 3 EXECUTION 3
3.1 Preparation 3
3.2 Application 3
3.3 Cleaning and Protecting 3
Concrete Finishes Section 03360

SECTION 03360
CONCRETE FINISHES
PART 1 GENERAL
Supplementary Conditions and Division 1 Specification Sections, apply to this
Section.
1.2 SUMMARY
1.2.1 This Section includes dry shake hardener applied to fresh concrete surfaces.
1.2.2 Related Sections include the following:
 Division 3 Section "Can-In Place Concrete".
1.3 SUBMITTALS
1.3.1 Product Data: For each type of product indicated. Include manufacturer's
technical data, application instructions, and recommendations.
1.3.2 Samples: Submit three samples of 100 mm square mm each of concrete covered
with the dry shake hardener.
1.3.3 Material Certificates: For flooring system, signed by manufacturer.
1.3.4 Maintenance Data.
1.4.1 Source Limitations: Obtain materials through one source from a single
manufacturer.
1.4.2 Mockups:
 Apply mockups on 1200-mm-square floor area selected by Engineer.

 Approved mockups may become part of the completed Work if undisturbed at time
of Substantial Completion.
1.5 DELIVERY, STORAGE, AND HANDLING
1.5.1 Deliver materials in original packages and containers, with seals unbroken,
bearing manufacturer's labels indicating brand name and directions for storage
and mixing with other components.
1.5.2 Store materials to prevent deterioration from moisture, heat, cold, direct sunlight,
or other detrimental effects.
1.6.1 Environmental Limitations: Comply with manufacturer's written instructions for

substrate temperature, ambient temperature, moisture, and other conditions
affecting flooring application.
PART 2 PRODUCTS
2.1 High Abrasion Floor Topping
2.1.1 Ready to-use blend of non-metallic synthetic mineral aggregate and cement to
apply as a dry shake to the surface of fresh cementitious surfaces to provide
continuous protection to cementitious surfaces against wear, impact and abrasion
and to provide also good resistance against fuel, oil, greases.
2.1.2 Coverage Rate: As recommended by manufacture, but not less than 7 kg/m2.
PART 3 EXECUTION
3.1 PREPARATION
3.1.1 General: Prepare substrates according to flooring manufacturer's written

instructions and the requirements as specified in Division 3 Section “Cast-In Place
Concrete”.
3.1.2 Concrete Substrates: Provide sound concrete surfaces free of laitance, glaze,
efflorescence, curing compounds, form-release agents, dust, dirt, grease, oil, and
other contaminants incompatible with flooring.
3.2 APPLICATION
3.2.1 General: Apply the hardener according to manufacturer's written instructions.
3.2.2 Cure flooring according to manufacturer's written instruction and requirements as

specified in Division 3 Section “Cast-In Place Concrete”. Prevent contamination
during application and curing processes.
3.3 CLEANING AND PROTECTING
3.3.1 Protect flooring from damage and wear during the remainder of construction
period. Use protective methods and materials, including temporary covering,
recommended in writing by manufacturer.


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NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. CEMENT-BASED SCREEDS
CAIRO - EGYPT 03544 – 2039 0

CONTENTS
SECTION 03544
CEMENT-BASED SCREEDS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Definition 2
1.4 Submittals 2
1.8 Coordination 3
PART 2 PRODUCTS 3
2.1 Products And Materials 3
2.2 Reinforcement 4
2.3 Curing Materials 4
2.4 Related Materials 4
2.5 Design Mixes 4
2.6 Mixing 5
PART 3 EXECUTION 5
3.1 Examination 5
3.2 Preparation 5
3.3 Screed Application 5
3.4 Protection and Curing 6
3.5 Repairs 6
Cement-Based Screeds Section 03544

SECTION 03544
CEMENT-BASED SCREEDS
PART 1 GENERAL
Section.
1.2 SUMMARY
1.2.1 This Section includes:
 Cement-based screeds for interior finish floorings.

 Cement-based screeds for roof.
 Division 5; Section "Architectural Joints Systems" for expansion joint

requirements in screeds.
 Division 7; Section "Joint Sealants".
1.3 DEFINITION
1.3.1 “Screed” means a layer of cement-sand laid on the structural floor or roof to
achieve correct level or to receive another thin thick finish or coating material.
1.4 SUBMITTALS
1.4.1 Product Data: For each type of product indicated. Include mixing and application
instructions.
1.4.2 Shop Drawings: Include plans, sections, and details showing slopes where
indicated, screed thicknesses, penetrations, perimeter terminations control and
expansion joints, reinforcement and sequence coating.
1.4.3 Design Mixes: For each screed mix specified.
1.4.4 Material Certificates: Signed by manufacturers certifying that each of the

following materials complies with requirements:
 cement
 Admixtures.
 control joint system

1.5.1 Installer Qualifications: An experienced installer (applicator) who has completed

cement-based screed applications similar in material and extent to that required
for this Project, and whose work has resulted in construction with a record of
successful in-service performance.
1.6.1 Deliver materials in original packages and containers, with seals unbroken,
bearing manufacturer's labels indicating brand name and directions for storage,
mixing with other components, and application.
1.6.2 Store materials to comply with manufacturer's written instructions to prevent

deterioration from moisture or other detrimental effects.
1.7.1 Close areas to traffic during screed application and for time period after
application recommended in writing by manufacturer.
1.8 COORDINATION
1.8.1 Coordinate cement-based screed with requirements of finish flooring products,

including leveling compounds, underlays and adhesives, specified in Division 9
Sections.
PART 2 PRODUCTS
2.1 PRODUCTS AND MATERIALS
2.1.1 Screed: Cement-sand mix with admixtures applied over concrete deck to receive
another finishing material.
 Portland cement: Egyptian Standard Specification (E.S.S.) No. 4756.

 Compressive Strength: As specified in Clause 2.5 of this Section.
 Slump: 200 mm maximum at point of placement for concrete containing high-
range water-reducing admixture (super-plasticizer) and 75 mm maximum for
other concrete.
 Screed Additive: Plasticizers and water-retaining agents formulated for use
with screed when applied to substrate and conditions indicated and to
approval.
 Air Entraining Admixture: ASTM C260.
 Water Reducing Admixture: ASTM C494, Type A.
 Water-Reducing and Accelerating Admixture: ASTM C 494, Type F.
2.1.2 Aggregate: Normal Weight Aggregate: E.S.S. No. 1109 and as follows:

 Fine aggregate, consisting of sand, clean, hard and free of deleterious matter.
Grading is to be according to mix design.
 Coarse aggregate for fine-mix concrete screeds: Maximum aggregate size is to
be 8 mm.
2.1.3 Water: Potable.
2.2 REINFORCEMENT
2.2.1 Fibrous Reinforcement: 100% virgin polypropylene, fibrillated fibers containing no

reprocessed olefin materials and specifically manufactured to an optimum
gradation for use as concrete secondary reinforcement. Proportion shall be 0.9 kg
per m³ of concrete:
 Specific Gravity: 0.91.

 Tensile strength: 345 - 758 N/mm².
2.3 CURING MATERIALS
2.3.1 Absorptive Cover: Class 2, burlap cloth made from jute weighing approximately
305 g/sq. m when dry.
2.4 RELATED MATERIALS
2.4.1 Joint-Filler Strips: ASTM D 1751, asphalt-saturated cellulosic fiber, or

ASTM D 1752. Use cork fillers for applications that may be subject to surface
water.
2.4.2 Acrylic-Bonding Agent: ASTM C1059, Type II, non-redispersible, acrylic emulsion
or styrene butadiene.
2.4.3 Control Joint Profiles: Comply with requirements specified in Division 5, Section
“Architectural Joint System”. Intermediate movement zone shall be 10-mm wide.
Height of profile shall be selected from manufacturer’s full range in coordination
with screed depth and finishing material that shall be installed above screed.
2.4.4 SBR agent (styrene-butadiene-rubber).
2.5 DESIGN MIXES
2.5.1 Prepare design mixes for mortar concrete screed by laboratory trial batch method
according to ACI 211.1 and ACI 301 for each type and strength.
2.5.2 Limit water-soluble chloride ions to the maximum percentage by weight of

cement permitted by the American Concrete Institute, ACI 301.
2.5.3 Minimum Compressive Strength after 28 days is to be as follows:
 250 kg/cm2 for fine-mix concrete screeds (coarse aggregate of maximum size

of 8 mm is used), when tested according to ASTM C39.
 200 kg/cm2 for cement-sand screeds, when tested according to ASTM C109.
2.6 MIXING
2.6.1 Bonding Slurry: Mix 1 part Portland cement and 2 parts sand, by volume, with
water and an acrylic-bonding agent according to manufacturer's written
instructions to a thick paint consistency.
2.6.2 Screed: Mix screed materials and water in appropriate drum-type batch machine
mixer.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine substrates, with Installer present, for conditions affecting performance
of screed. Proceed with application only after unsatisfactory conditions have
been corrected.
3.1.2 Verify that concrete base slabs meet finish and surface profile requirements in
Division 3, Section "Cast-in-Place Concrete".
3.2 PREPARATION
3.2.1 Concrete Substrates: Mechanically remove laitance, glaze, efflorescence, curing

compounds, form-release agents, dust, dirt, grease, oil, and other contaminants
that might impair screed bond.
3.2.2 Comply with CRSI’s “Manual of Standard Practice” for fabricating, placing and
supporting reinforcement.
3.2.3 Install joint-filler strips where screed abuts vertical surfaces, such as column
pedestals, foundation walls, grade beams, and other locations, as indicated.
 Extend joint-filler strips full width and depth of joint, terminating flush with
screed surface, unless otherwise indicated.
 Terminate full-width joint-filler strips 13 mm below screed surface where joint
sealants, specified in Division 7, Section "Joint Sealants," are indicated.
 Install joint-filler strips in lengths as long as practicable. Where more than one
length is required, lace or clip sections together.
3.3 SCREED APPLICATION
3.3.1 Mix and scrub bonding slurry into dampened concrete to a thickness of 1.5 to 3
mm, without puddling. Place screed while slurry is still tacky.
3.3.2 Place screed continuously in a single layer, tamping and consolidating to achieve
tight contact with bonding surface. Do not permit cold joints or seams to develop
within pour strip.

 Screed surface with a straightedge and strike off to correct elevations.
 Slope surfaces uniformly where indicated.
 Begin initial floating using bull floats to form a uniform and open-textured
surface plane free of humps or hollows.
3.3.3 Finishing: Consolidate surface with power-driven floats as soon as screed can
support equipment and operator. Restraighten, cut down high spots, and fill low
spots. Repeat float passes and restraightening until surface is left with a uniform,
smooth, and free from cracks, ridges or depressions. Finish screeds to a smooth
surface with sheen.
 Finish and measure surface so deviation from 3-m long straightedge, is +/-
3mm maximum as gradual irregularities. Sudden irregularities or low spots are
not permitted.
3.3.4 Construction Joints: Construct joints true to line with faces perpendicular to
surface plane of screed, at locations indicated or as approved by Engineer.
 Coat face of construction joint with SBR adhesive at locations where screed is
placed against hardened or partially hardened screed.
3.3.5 Expansion Joints: Provide expansion joints in screeds coinciding on expansion

joints in underlaying structural slabs. Comply with details indicated on Drawings
and requirements of Division 5 Section “Architectural Joint Systems”.
3.3.6 Control Joint Profiles: Control joint profiles for screeds shall be used under
movement joints required in finishing layers. Position profile in such a way that
they will be in direct alignment with the finishing layers movement joints.
3.3.7 Screed Mix: Use cement-sand screed for screeds less than 70 mm in thickness.
Use fine-mix concrete for screeds 70 mm thick and more.
3.4 PROTECTION AND CURING
3.4.1 General: Protect freshly placed screed from premature drying and excessive cold
or hot temperatures.
3.4.2 Begin curing immediately after finishing screed. Cure by one or a combination of
the following methods:
 Moisture Curing: Keep surfaces continuously moist for not less than seven
days with water or absorptive cover, water saturated and kept continuously
wet. Cover screed surfaces and edges with 300-mm lap over adjacent
absorptive covers.
3.5 REPAIRS
3.5.1 Defective Screed: Repair and patch defective screed areas, including areas that
have not bonded to concrete substrate.

3.6.1 Sample Sets: At point of placement, testing and inspecting agency engaged by
the Contractor shall take a set of 3 molded-cube samples from the screed mix for
the first 93 sq. m. plus 1 set of samples for each subsequent 100 sq. m. of screed,
or fraction thereof, but not less than 6 samples for each day's placement.
Samples shall be tested according to ASTM C 39 or ASTM C 109 for compliance
with compressive strength requirements.


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ECG ENGINEERING CONSULTANTS GROUP S.A. STRUCTURAL ELEMENT REPAIRS AND
CAIRO - EGYPT STRENGTHENING 03940 - 2039 0

CONTENTS
SECTION 03940
STRUCTURAL ELEMENT REPAIRS AND STRENGTHENING
Page
PART 1 GENERAL 2
1.2 Description of Work 2
1.4 Submittals 2
PART 2 PRODUCTS 3
2.1 General 3
2.2 Epoxy Resin Adhesive 3
2.3 Sand for Epoxy Adhesive 4
2.4 Bonding Agent And Anti-Corrosive Rebar Coating 4
2.5 Protective Coating 4
2.6 Admixtures 4
2.7 Cement 5
2.8 Concrete 5
2.9 Cold-Applied Bituminous Emulsion 5
PART 3 EXECUTION 6
3.1 General 6
3.2 Placing and Pouring 6
3.3 Backfilling and Compaction 9
Structural Element Repairs and Strengthening Section 03940

SECTION 03940
STRUCTURAL ELEMENT REPAIRS AND STRENGTHENING
PART 1 GENERAL
1.1.1 Drawings and general provisions of the Contract, including General Conditions,
Conditions of Particular Application and Division 01 Specification Sections, apply
to work of this section.
1.2 DESCRIPTION OF WORK
1.2.1 This section includes procedural requirements for strengthening and repairs of
reinforced concrete elements by:
 Enlarging or increasing the actual dimensions of various structural elements.

 Extent of (various - strengthening and repair) is shown on Drawings.
1.3.1 Structural repairs shall be performed in strict accordance with the corresponding
Codes, the stipulations of the American Society for Testing and Materials (ASTM),
as noted herein below, or other equivalent International Standards and Sound
Practice.
AMERICAN SOCIETY OF TESTING AND MATERIALS
ASTM NO.
C881 Specification for Epoxy-Resin-Base Bonding System for Concrete
C494 Specification for Chemical Admixtures for Concrete
C403 Test Method for Time of Setting of Concrete Mixtures by Penetration

Resistance
C260 Specification for Air-Entraining Admixtures for Concrete
1.4 SUBMITTALS
1.4.1 Product Data: For each type of admixture used, Contractor shall provide
manufacturer's technical information, label analysis, compliance with ASTM
requirements and application instructions for materials proposed for use.
1.4.2 Samples and Tests: Prior to beginning work, submit samples for Engineer's review
of appearance, color, texture, etc.
1.4.3 Engineer reserves the right to perform any or all of the tests indicated by ASTM.
Prior of using admixture, concrete trial mixes shall be made and tested in site.

1.4.4 Curing: Submit in details the method of curing which shall be employed to the
Engineer for approval.
1.4.5 Pouring: For each case submit the pouring procedure.
1.4.6 Shop Drawings: For each case the Contractor shall submit detailed drawings and
calculations for Engineer, to check stability of the nearest foundation to work.
1.4.7 Propping, supporting for the superstructure, shoring, bracing the excavation and
any other construction work to be carried near the existing foundations shall be
submitted for approval. This approval shall not relieve the Contractor from his
responsibility.
1.4.8 Proposed remedy if needed shall be submitted with detailed investigations for
approval.
PART 2 PRODUCTS
2.1 GENERAL
2.1.1 Materials used shall comply with Division 03 Section "Cast in Place Concrete" to
produce concrete with the specified proportions, consistency and shall work
readily into position without segregation, and use of an excessive water content
and can be compacted into a dense impervious mass.
2.2 EPOXY RESIN ADHESIVE
2.2.1 Shall be an epoxy resin, solvent free, 2 components, based on epoxy resin and
specially selected high strength filler complying with ASTM C 881 - Type V -
Grade 3 Class C.
 Density: 1.65 kg/L

 Compressive Strength: 50-60 N/mm2
 Flexural Strength: 30-40 N/mm2
 Tensile Strength: 15-20 N/mm2
 Bond Strength to Concrete: 3-3.5 N/mm2
 Bond Strength to Steel: 15 N/mm2
 Pot Life: 40 minutes
 Priming: Not required
 Capable of adhering to wet concrete and steel.

2.3 SAND FOR EPOXY ADHESIVE
2.3.1 The used sand shall meet the following gradation:
US SIEVES NO. PASSING %

No. 4 100 %
No. 16 90 - 100 %
No. 30 30 - 50 %
No. 50 0 - 10 %
No. 100 0- 5%
2.4 BONDING AGENT AND ANTI-CORROSIVE REBAR COATING
2.4.1 Cement based epoxy, solvent free, non-inflammable, of three components; epoxy,
anti-corrosive coating, and bonding agent.
 Pot Life: 90-180 minutes
 Density of mix:  2 kg/L

 Bonding Strength: 2-3 N/mm2
2.5 PROTECTIVE COATING
2.5.1 Two components solvent free coating materials, based on epoxy resin, cure
without shrinkage.
 Consumption rate shall be according to surface conditions.

 Density: Minimum 1.5 kg/L
2.6 ADMIXTURES
2.6.1 Admixtures shall meet the requirements of Type A, D or F as specified in ASTM C

494 modified as follows:
 The Water-Reducing Retarder: Shall retard to initial set of concrete a mini-

mum of 2 hours and maximum 4 hours, at a specified dosage rate and at an
ambient temperature of 90F.
2.6.2 The cement used in any series of test shall be type 5sulphate resistant cement
from one mill.
2.6.3 All concrete shall contain entrain-air, the air-entraining admixtures used in
concrete shall be neutralized vinzol resin.
2.6.4 High range water reducing admixtures when compared to a standard mix design
in accordance with ASTM C 494 shall produce the following:
 Reduce the required water by 20%

 Increase the 7 days compressive strength of concrete by a minimum of 10%
 Shall not retard the initial set of concrete by more than 1½ hours when tested
in accordance to ASTM C 403
 Shall not contain chloride air entraining agents or urea.
2.6.5 Air Entraining Admixtures: Shall meet the requirements of ASTM C 260 modified
as follows:
 The cement used shall be type 5 Sulphate resistant cement

 Minimum relative durability factor shall be 80
 Air entraining admixture shall be neutralized vinsol resin
2.6.6 Accelerating Admixtures: Shall meet the requirements of ASTM C 494 type C
modified as follows:
 Shall not contain chloride and shall be used in liquid form only.
 Shall be used only to meet special requirements and Engineer approval.
2.7 CEMENT
2.7.1 The cement used shall be ordinary Portland according to ASTM C 150
2.8 CONCRETE
2.8.1 Shall be according to concrete in Division 03Section " Cast In Place concrete ".
 Cement Content: 400 kg/m3

 Coarse aggregate: 18 mm or smaller
 Water Content 0.45
 Chloride: Free material shall be used
2.9 COLD-APPLIED BITUMINOUS EMULSION
2.9.1 Rubber-base, ready-to-use, cold-applied bituminous emulsion recommended for

the protection of concrete surfaces subject to attack from mild soil acids and salty
water. The employed emulsion shall be solvent-free, odorless, non-toxic and
suitable for application on both dry and damp surfaces.
2.9.2 The emulsion shall dry to form a rubber elaster membrane impervious to damp
and water and shall have high resistance to aggressive salts, chemicals.
2.9.3 Bituminous emulsion shall be of long term aging stability and shall resist
temperature varieties as specified for project site.

PART 3 EXECUTION
3.1 GENERAL
3.1.1 The strengthening and repair shall be by:
 Increasing the Section: Depth and width of the structural elements including
foundation by adding a new layer of concrete on top and around the existing
section of the structural element and bonding the two with an epoxy resin ad-
hesive.
 Enlarging the Total Reinforcement: Cross section by anchoring dowels for flex-
ural strength and even for shear strength and an additional cage of reinforce-
ment as required shall be placed in position.
3.2 PLACING AND POURING
3.2.1 Preparation of Old Concrete: The surface of old concrete shall required adequate
preparation, the defective concrete, and the surface of the structural element
shall be cut out till sound concrete is reached.
 Thickness of concrete to be removed shall not be less than the concrete cover
for the main reinforcement, all edges shall be tapered.
 Explosive shall not be used in the removal of any portion of the existing struc-
tural elements: footings or structure. Concrete shall be at the "break" line by
grinding or hammering and chiseling or other methods acceptable to Engineer.
 Roughening the concrete surface shall be done by sand blasting to receive the
new concrete.
 Carefully clean and remove all unsound, loose and foreign materials, pre moist
surface to saturation.
 Exposed reinforcement shall be thoroughly cleaned by wire brushing or sand
blasting and shall be free of rust, scalds, etc.
 Corroded reinforcement shall be removed and replaced by new reinforcement.
3.2.2 Formwork: Adequate form fabricated from appropriate materials: timber,

plywood, or steel shall be provided. Formwork shall be sufficiently rigid and
tightly fitted to the required dimensions, in a manner to minimize leakage of
cement slurry, and to support vertical and lateral static and dynamic loads that
might be applied without distortion and movement during pouring.
 All forms shall be shuttered to the existing concrete profile. Surface of forms
in contact with concrete shall be treated with suitable mould-oil, with a maxi-
mum of 350 g/l volatile organic compounds that will not bond with, or ad-
versely affect concrete surfaces.
3.2.3 Concrete Mix: New concrete for encasement shall have final properties that
match those of the old concrete as closely as possible (strength, modulus of
elasticity, creep coefficient, etc.).

 To avoid temperature and shrinkage cracks, especially in the transition areas,
the type of cement, cement content, and water content rates should be care-
fully evaluated. Low water cement ratio of 0.4 to 0.5 is advised.
 The use of concrete additions such as plasticizer, waterproofing and other shall
be used after Engineer approval.
 Slight re compaction, re vibration shall be required to improve the bond to the
old concrete.
3.2.4 Reinforcement: Additional reinforcement shall be installed in place, distance

between bars shall not be less than twice the bar diameters, to ensure that dense
concrete surround the bars.
 For protection of the reinforcement a cover of minimum 50 mm shall be pro-

vided.
 New reinforcing bars shall be installed as shown in drawings, new reinforcing
steel need not to be tied to old existing steel.
 Steel dowels shall be placed between old and new concrete, they shall be of:
13 mm diameter in a hole of 16 mm diameter with spacing as shown on Draw-
ing but not less than 200 mm for R.C and 300 mm for P.C., dowel depth in ex-
isting foundations shall be 150 mm for R.C. and 100 mm for P.C.
3.2.5 Pouring: During pouring care has to be taken to avoid sand pockets behind the
reinforcement.
 Pouring process shall be stopped during bad weather conditions, rain, wind or
hot weather (hot weather means that the ambient atmospheric temperature
at site in shade exceed 32°C).
 Pouring shall be from the lowest point of the new extension part.
 Sufficient hydrostatic head or pumping pressure shall be maintained to ensure
that the new extension part is filled completely.
3.2.6 Curing: Protect freshly placed concrete from premature drying by solar radiation
or wind. Concrete shall be kept constantly wet for 10 days, curing shall start
immediately after disappearance of free surface water.
 Curing shall be: either by setting up a mechanical water fog-spray system,

covering the total concrete surfaces, or by covering the concreted surfaces
with burlaps cloth made from jute weighing approximately 25 g/m2 so that
they shall be kept moist continuously during the curing period.
3.2.7 Excavation: The minimum trench size around the footing shall be excavated in
stage around the sides of the existing footing.
 Shuttering and bracing should be provided as necessary to prevent horizontal

movement of the surrounding ground. Attention shall be taken to did not dis-
turb the bedding strata and materials.
 Side supporting, lifting, showing and bracing shall be used for constructing new
encasement around the footings.

 Trench shall be excavated by using suitable protective system for side support-
ing. Shuttering with necessary wedging shall be accepted to join safe excava-
tion.
3.2.8 Encasement: Contractor shall verify the dimension of the existing structural
elements prior to or during material for the encasement.
 Portion of old footing shall be removed to the line and dimensions shown on
Drawings. Portion removed more than required shall be poured on the Con-
tractor expense.
 New encasement shall be in small sections in stages or side by side, by anchor-
ing tie bars, (dowels) and by placing reinforcement and concrete in the exca-
vated part.
 Preventive measures shall be taken to eliminate any potential side effects to
the existing superstructure structural elements. In order to do not damage the
existing structural elements above the footings, some disposition shall be tak-
en to support the existing elements in suspension during, doweling, concret-
ing.
 Careful examination of the existing superstructure structural elements and
footings shall be made before and during construction.
 Maximum reduction of the existing load shall be made before excavation.
 Holes for dowels shall be drilled larger than the dowel base maximum 3
mm. Grout the holes with thixotropic epoxy resin adhesive.
 Surface of concrete and rebars shall be coated with a bonding agent and
anti-corrosive rebar coating, of cement-based epoxy coating, before
pouring within 90 minutes.
 Concrete shall be of high quality with a minimum cement content of 400
kg/m3 concrete. The water cement ratio shall be to the minimum by using
high range water reducing concrete admixtures and super plasticize.
 For protection of concrete surface of each footing, a protective coating
shall be painted after 3 to 4 days by using two coat of rubber
bituminous coating. Minimum thickness of coats shall be 0.6 mm.
3.2.9 Admixtures: Prior of using an admixture in the work, trial mixes shall be made
and tested, using same materials and equipment to be used on site.
 Mix designs from previous or concurrent jobs may be used without trial mixes
if no substational change in any of the proposed ingredients has been made.
 For air-entraining admixtures the dosage utilized shall be the dosage approved
by tests. This dosage must be adjusted as necessary to produce the required
air content in concrete.
 All water reducing, water-reducing retarding, and high range water reducing
admixtures or accelerating admixtures dosage shall be based on trial mixes ap-
proved by Engineer.
 All admixtures used shall be in the liquid state with the exception of high,
range water reducers which may be in the powered form. All liquid admixtures

shall be dispensed separately but at the time as the mixing water, except that
liquid or powdered high-range water reducers shall be added to concrete on
site. No admixture shall be dispensed on dry aggregate.
 If during pouring of concrete an appreciable slump loss is noted conditional
high-range water reducing admixture shall be required to bring the concrete
back into the desired consistency. Addition of water other than in the water
reducer shall not be permitted on site.
 For concrete of 7 m3 volume or more or for ready mix concrete the admixture
shall be measured and dispressed by an adjustable dispenser.
 Completely automatic dispenser is not required except for use in automatic
batch plant.
 The dispenser shall be filled with the required amount and the operator will re-
lease the content without leakage into the mixing water.
 When high range water reducing are used with ready mix concrete the capaci-
ty of truck mixer shall be reduced for each batch by 25% of the rated capacity
to assure proper mixing of the admixture.
 The calibrated container shall be a measuring reservoir showing the level of
the admixture.
 A strip gauge of 10 grams air entraining admixture and ¼ kilograms of water
reducing or retarding shall be attached securely to the measuring apparatus.
 The strip shall be a material weather resistant. The accuracy of the equipment
shall be  3 %.
 For concrete of less than 7 m3 mixed on site the Engineer may waive the re-
quirements of mechanical dispensing equipment.
3.2.10 Cold-Applied Bituminous Emulsion Application: Apply a primer coat, emulsion

diluted with water at a percentage according to porosity and dampness of surface
and as recommended by manufacturer, and let to dry for two hours before
subsequent application.
 Apply 2 coasts of bitumen emulsion using brushes, rollers or sprayers at a rate

of about 2 kg/m2 to produce a uniform dry film thickness approved by the En-
gineer. Allow time for complete drying coats.
 Care shall be taken not to injure the vertical damp-proofing treatment either
during application or after completion.
3.3 BACKFILLING AND COMPACTION
3.3.1 Backfilling around the repaired foundations shall be done according to Division 02
Section "Earthwork".


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. UNIT MASONRY ASSEMBLIES
CAIRO - EGYPT 04810 – 2039 0

CONTENTS
SECTION 04810
UNIT MASONRY ASSEMBLIES
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Delivery, Storage, And Handling 4
1.7 Provsions For Other Work 5
PART 2 PRODUCTS 5
2.1 Concrete Masonry Units 5
2.2 Mortar And Grout Materials 6
2.3 Ties And Anchors, General 6
2.4 Reinforcement 7
2.5 Miscellaneous Masonry Accessories 7
2.6 Mortar And Grout Mixes 8
PART 3 EXECUTION 8
3.1 Examination 8
3.2 Installation, General 9
3.3 Construction Tolerances 9
3.4 Laying Masonry Walls 9
3.5 Mortar Bedding And Jointing 10
3.6 Masonry Joint Reinforcement 11
3.7 Vertical Reinforced Unit Masonry Installation 11
3.8 Anchoring Masonry To Concrete Columns And Walls 12
3.9 Control And Expansion Joints 12
3.10 Lintels 12
3.11 Fire Rated Masonry Walls 12
3.13 Repairing, Pointing, And Cleaning 13
3.14 Concrete Unit Masonry Schedule 13
Unit Masonry Assemblies Section 04810

SECTION 04810
UNIT MASONRY ASSEMBLIES
PART 1 GENERAL
Section.
1.2 SUMMARY
1.2.1 This Section includes unit masonry assemblies consisting of the following:
 Concrete masonry units.

 Mortar and grout.
 Autoclaved aerated concrete masonry
 Ties and anchors.
 Miscellaneous masonry accessories
 Joint reinforcement.
1.2.2 Related sections include the following:
 Division 3; Section "Cast-in Place Concrete" for concrete filled posts, beams for
reinforced concrete masonry.
 Division 5; Section "Metal Fabrications" for steel lintels.
 Division 7; Section "Sheet Metal Flashing and Trim" for sheet metal flashing
 Division 7; Section "Through-Penetration Fire Stop Systems" for smoke sealing and
fire stop material systems used for fire rated walls.
1.3 SUBMITTALS
1.3.1 Product Data: For each different masonry unit, accessory, and other
manufactured product specified.
1.3.2 Shop Drawings: Indicating details of lintels, horizontal and vertical reinforcement
of masonry, anchoring masonry to abutting concrete, movement joints, joints
between masonry and structure above, masonry intersections and junctions and
joint treatment.
1.3.3 Samples for Selection: For the following:
 Full-size units for each different exposed masonry unit required, showing the full
range of exposed colors, textures, and dimensions to be expected in the completed
construction.

 Accessories embedded in the masonry.
1.3.4 Qualification Data: For firms and persons specified in "Quality Assurance" Article.
1.3.5 Material Test Reports: From a qualified testing agency indicating and interpreting
test results of the following for compliance with requirements indicated:
 Each type of masonry unit required.
 Include size-variation data for block, verifying that actual range of sizes falls
within specified tolerances.
 Include test results, measurements, and calculations establishing net-area
compressive strength of masonry units.
 Mortar complying with property requirements of ASTM C 270.
 Grout mixes complying with compressive strength requirements of ASTM C 476.
Include description of type and proportions of grout ingredients.
 Each type and size of joint reinforcement
 Each type and size of anchor, tie, and metal accessory.
1.3.6 Document Conflict and Precedence:
 Notify Engineer prior to submitting proposal in the case of conflict among

Documents, including Drawings and Specifications.
 The strictest interpretation shall govern in the case of conflict between and/or
among Drawings and specifications, unless noted otherwise in writing by Engineer
1.4.1 Contractor shall perform a survey and inspection of foundations for compliance
with dimensional tolerances. Full comprehensive report shall be submitted to the
Engineer prior to commencing building masonry assemblies on foundations.
1.4.2 Engineering Responsibility: of reinforced concrete masonry to include the

following but not limited to:
 Determining the maximum unsupported height or length to thickness ratio, of all

interior and exterior walls prior to beginning construction according to the local
building code and the following codes:
 Building Code Requirements for Masonry Structures, according to ECP 204-
2005.
 Specifications for Concrete Masonry Structures, according to ECP 203-2007.
 Design of reinforced concrete masonry including concrete filled beams, post,
pilasters, lintels and soffits. Accessories include, but are not limited to ties, horizontal
and vertical reinforcement, anchors to the structure, and control joints.
 Design formwork, falsework, shoring, shoring and backshoring required to properly
execute work of this section, review of Drawings related to this Work, field review of
construction of this Work and submission written Site Review Reports.

1.4.3 Testing Agency Qualifications: An independent testing agency, acceptable to the
Engineer.
1.4.4 Source Limitations for Masonry Units: Obtain masonry units from a recognized
local manufacturer of a uniform texture and color, or a uniform blend within the
ranges accepted for these characteristics, through one source from a single
manufacturer for each product required.
1.4.5 Source Limitations for Mortar Materials: Obtain mortar ingredients of a uniform
quality, including color for exposed masonry, from a single manufacturer for each
cementitious component and from one source or producer for each aggregate.
1.4.6 Fire-resistance Ratings: Where indicated, provide materials and construction

identical to those of assemblies with fire-resistance ratings determined per ACI
216 by a testing and inspecting agency, by equivalent concrete masonry thickness,
or by other means, as acceptable to Engineer.
1.4.7 Mockups: Before installing unit masonry, build mockups to verify selections made
under sample Submittals and to demonstrate aesthetic effects and qualities of
materials and execution. Build mockups to comply with the following
requirements, using materials indicated for the completed Work:
 Locate mockups in the locations as directed by Engineer.

 Build mockups of reinforced assembly, double walls and single-wythe wall areas as
shown on Drawings.
 Notify Engineer seven days in advance of dates and times when mockups will be
constructed.
 Maintain mockups during construction in an undisturbed condition as a standard for
judging the completed Work.
 Approval of mockups does not constitute approval of deviations from the Contract
Documents contained in mockups, unless such deviations are specifically approved
by Engineer in writing.
 Approved mockups will become part of the completed Work if undisturbed at time
1.5.1 Store masonry units on elevated platforms in a dry location. If units are not
stored in an enclosed location, cover tops and sides of stacks with waterproof
sheeting, securely tied. If units become wet, do not install until they are dry.
1.5.2 Store cementitious materials on elevated platforms, under cover, and in a dry
location. Do not use cementitious materials that have become damp.
1.5.3 Store aggregates where grading and other required characteristics can be
maintained and contamination avoided.
1.5.4 Store masonry accessories, including metal items, to prevent corrosion and
accumulation of dirt and soil.

1.6.1 Protection of Masonry: During construction, cover tops of walls, projections, and
sills with waterproof sheeting at end of each day's work. Cover partially
completed masonry when construction is not in progress.
1.6.2 Extend cover a minimum of 600 mm down both sides and hold cover securely in
place.
1.6.3 Do not apply uniform floor or roof loads for at least 12 hours and concentrated
loads for at least 3 days after building masonry walls or columns.
1.6.4 Stain Prevention: Prevent grout, mortar, and soil from staining the face of
masonry to be left exposed or painted. Immediately remove grout, mortar, and
soil that come in contact with such masonry.
 Protect base of walls from rain-splashed mud and from mortar splatter by spreading
coverings on ground and over wall surface.
 Protect sills, ledges, and projections from mortar droppings.
 Protect surfaces of window and door frames, as well as similar products with
painted and integral finishes, from mortar droppings.
 Turn scaffold boards near the wall on edge at the end of each day to prevent rain
from splashing mortar and dirt onto completed masonry.
1.6.5 Hot-Weather Requirements: Comply with hot-weather construction

requirements contained in ACI 530.1/ASCE 6/TMS 602.
1.7 PROVSIONS FOR OTHER WORK
1.7.1 Coordinate installation of anchorages for metal fabrications.
1.7.2 Furnish setting drawings, templates, and directions for installing anchorages,
including sleeves, concrete inserts, anchor bolts, and items with integral anchors,
that are to be embedded in concrete or masonry
1.7.3 Protect adjacent finish materials against damage and spatter during installation of
masonry.
PART 2 PRODUCTS
2.1 CONCRETE MASONRY UNITS
2.1.1 General: Provide shapes indicated and as follows:
 Provide special shapes for lintels, corners, jambs, sash, control joints, headers,
bonding, and other special conditions.
 Provide bullnose units for outside corners, unless otherwise indicated.
2.1.2 Concrete Masonry Units: ASTM C90 or E.S.S. No. 1292, except for compressive

strength, and as follows:
 Unit Compressive Strength: Provide units, hollow or solid, with minimum

compressive strength of 6 MPa on net area.
 Weight Classification: Normal weight.
 Provide moisture-controlled units. All masonry units shall be factory cured.
 Size (Width): As indicated on Drawings.
2.1.3 Autoclaved aerated concrete masonry: Comply with ASTM C 1692 or E.S.S. No.
1401-2005, and as follows:
 Density: 550 Kg\m3

 Unit Compressive Strength: 20 Kg\cm2
 Thermal Conductivity: 0.132 w 1 m0c
 Size (Width): As indicated on Drawings
2.2 MORTAR AND GROUT MATERIALS
2.2.1 Portland cement: Ordinary Portland cement to E.S.S. No. 4756.
2.2.2 Hydrated Lime: Do not use Lime.
2.2.3 Aggregate for Mortar: E.S.S. No. 1108; except for joints less than 6.5 mm thick,
use aggregate graded with 100 percent passing the No. 26 (1.41-mm) sieve.
2.2.4 Aggregate for Grout: E.S.S. No. 1109, fine aggregate located in second grade
zone, with maximum size of aggregates of 5 mm passing the number 19 sieve.
2.2.5 Pre-Packaged Portland cement Mix: Pre-Packaged blend of Portland cement,

water, and aggregate complying with requirements specified in this Article
combined with set-controlling admixtures to produce a ready-mixed mortar
complying with ASTM C 1142. Compressive strength at 28 days shall not be less
than 5 MPa (minimum cement sand ratio 1:3-4 by volume).
2.3 TIES AND ANCHORS, GENERAL
2.3.1 General: Provide ties and anchors, specified in subsequent articles, made from
materials that comply with this Article, unless otherwise indicated.
2.3.2 Hot-Dip Galvanized Carbon-Steel Wire: ASTM A 82; with ASTM A 153, Class B-2
coating.
2.3.3 Steel Sheet, Galvanized after Fabrication: ASTM A 366/A 366M cold-rolled,
carbon-steel sheet hot-dip galvanized after fabrication to comply with
ASTM A 153.
2.3.4 Steel Plates, Shapes, and Bars: ASTM A 36/A 36M.

2.3.5 Post-installed Anchors: Provide chemical or torque-controlled expansion
anchors, with capability to sustain, without failure, a load equal to six times the
load imposed when installed in solid or grouted unit masonry and equal to four
times the load imposed when installed in concrete, as determined by testing per
ASTM E 488 conducted by a qualified independent testing agency.
 Corrosion Protection: Carbon-steel components zinc plated to comply with

ASTM B 633, Class Fe/Zn 5 (5 microns) for Class SC 1 service condition (mild).
 Anchor Type:
 Hollow Concrete Masonry: Anchors into or through hollow concrete

masonry units shall be of chemical type with galvanized or stainless steel
screen tube that allows the chemical adhesive to create a key within hollow
cell of unit
 Fully Grouted Concrete Masonry : Anchors into fully grouted masonry shall
be torque-controlled expansion
2.4 REINFORCEMENT
2.4.1 Masonry Joint Reinforcement:
 Expanded Steel mesh of suitable mesh size, galvanized.

 Minimum intensity is to be 1.1 Kg/m2. Metal lath shall be prefabricated in coil form,
to be install every 2 courses.
2.4.2 Vertical Reinforcement:
 Uncoated Steel Reinforcing Bars: ASTM A 615/A 615M or ASTM A 996/A 996M,
Grade 60 (Grade 420).
2.5 MISCELLANEOUS MASONRY ACCESSORIES
2.5.1 Compressible Filler: Non-Fire-Rated Assemblies, premolded filler strips complying

with ASTM D 1056, Grade 2A1; compressible up to 35 percent; of width and
thickness indicated; formulated from neoprene.
2.5.2 Preformed Control-Joint Gaskets: Material as indicated below, designed to fit

standard sash block and to maintain lateral stability in masonry wall; size and
configuration as indicated.
 Styrene-Butadiene-Rubber Compound: ASTM D 2000, Designation M2AA-805.
2.5.3 Bond-Breaker Strips: Asphalt-saturated, organic roofing felt complying with

ASTM D 226, Type I (No. 15 asphalt felt).
2.5.4 Reinforcing Bar Positioners: Wire units designed to fit into mortar bed joints
spanning masonry unit cells with loops for holding reinforcing bars in center of
cells. Units are formed from 3.6-mm steel wire, hot-dip galvanized after
fabrication. Provide units with either two loops or four loops as needed for
number of bars indicated.

2.6 MORTAR AND GROUT MIXES
2.6.1 General: Do not use admixtures, including pigments, air-entraining agents,

accelerators, retarders, water-repellent agents, compounds, or other admixtures,
unless otherwise indicated.
 Do not use calcium chloride in mortar or grout.

 Do not use lime in mortar. Use any approved liquid-type plasticizer that induces the
same effect of lime when used in mortar mix.
2.6.2 Pre-blended, Dry Mortar Mix: Furnish dry mortar ingredients in form of a pre-
blended mix. Measure quantities by weight to ensure accurate proportions, and
thoroughly blend ingredients before delivering to Project site.
2.6.3 Mortar for Unit Masonry: Cement-sand, lime-free mortar. Approved liquid-type
admixtures may be added to the mix to substitute the effect of lime. Compressive
strength shall be 5±1 N/mm2. Bending strength shall be 1 N/mm2 minimum.
Cement-sand mix shall be 1:3-4, by volume.
2.6.4 Grout for Unit Masonry: Comply with ASTM C 476. Unless otherwise specified,
use grout of consistency indicated or, if not otherwise indicated, of consistency
(fine or coarse) at time of placement that will completely fill spaces intended to
receive grout.
 Provide grout with a slump of 200 to 275 mm as measured according to

ASTM C 143.
 Use fine grout in grout spaces less than 50 mm in least horizontal dimension, unless
otherwise indicated.
 Use coarse grout in grout spaces 50 mm or more in least horizontal dimension,
 Concrete grout shall be used for filling hollow cells in bond beams, under concrete
lintels and bond beams, in window and door jambs, and other locations indicated on
Drawings or as specified. Grout shall be mechanically mixed in drum mixers in
volumetric proportions with only enough water shall be added to the mixture to
produce a mixture which is flowable, but which will not show an excess of water
when placed.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine conditions, for compliance with requirements for installation tolerances
and other conditions affecting performance.
 For the record, prepare written report, listing conditions detrimental to

performance.
 Proceed with installation only after unsatisfactory conditions have been corrected.
3.1.2 Before installation, examine rough-in and built-in construction to verify actual

locations of piping connections.
3.2 INSTALLATION, GENERAL
3.2.1 Thickness: Build composite walls and other masonry construction to the full
thickness shown. Build single-wythe walls to the actual widths of masonry units,
using units of widths indicated.
3.2.2 Build chases and recesses to accommodate items specified in this Section and in
other Sections of the Specifications.
3.2.3 Leave openings for equipment to be installed before completing masonry. After
installing equipment, complete masonry to match the construction immediately
adjacent to the opening.
3.2.4 Cut masonry units with motor-driven saws to provide clean, sharp, unchipped
edges. Cut units as required to provide a continuous pattern and to fit adjoining
construction. Where possible, use full-size units without cutting. Install cut units
with cut surfaces and, where possible, cut edges concealed.
3.2.5 Wetting of Brick: Wet brick before laying. Allow units to absorb water so they are
damp but not wet at the time of laying.
3.3 CONSTRUCTION TOLERANCES
3.3.1 Comply with tolerances in ACI 530.1/ASCE 6/TMS 602 and the following:
 For conspicuous vertical lines, such as external corners, door jambs, reveals, and
expansion and control joints, do not vary from plumb by more than 6 mm in 6 m,
nor 12 mm maximum.
 For vertical alignment of exposed head joints, do not vary from plumb by more than
6 mm in 3 m, nor 12 mm maximum.
 For conspicuous horizontal lines, such as exposed lintels, sills, parapets, and reveals,
do not vary from level by more than 6 mm in 6 m, nor 12 mm maximum.
 For exposed bed joints, do not vary from thickness indicated by more than plus or
minus 3 mm, with a maximum thickness limited to 12 mm. Do not vary from bed-
joint thickness of adjacent courses by more than 3 mm.
 For exposed head joints, do not vary from thickness indicated by more than plus or
minus 3 mm. Do not vary from adjacent bed-joint and head-joint thickness by more
than 3 mm.
3.4 LAYING MASONRY WALLS
3.4.1 Lay out walls in advance for accurate spacing of surface bond patterns with
uniform joint thickness and for accurate location of openings, movement-type
joints, returns, and offsets. Avoid using less-than-half-size units, particularly at
corners, jambs, and, where possible, at other locations.
3.4.2 Lay concealed masonry with all units in a wythe in running bond. Bond and
interlock each course of each wythe at corners. Do not use units with less than

nominal 100-mm horizontal face dimensions at corners or jambs.
3.4.3 Stopping and Resuming Work: In each course, rack back one-half-unit length for
one-half running bond or one-third-unit length for one-third running bond; do not
tooth. Clean exposed surfaces of set masonry, wet clay masonry units lightly if
required, and remove loose masonry units and mortar before laying fresh
masonry.
3.4.4 Fill space between hollow-metal frames and masonry solidly with mortar, unless
3.4.5 Where built-in items are to be embedded in cores of hollow masonry units, place
a layer of metal lath in the joint below and rod mortar or grout into core.
3.4.6 Fill cores in hollow concrete masonry units with grout 600 mm under bearing
plates, beams, lintels, posts, and similar items, unless otherwise indicated.
3.4.7 Build non-load-bearing interior non-fire rated walls or partitions full height of
story to underside of solid floor or roof structure above, unless otherwise
indicated.
3.4.8 Wedge non-load-bearing partitions against structure above with pieces of stone,
tiles or hand material.
3.4.9 Install compressible filler in joint between top of partition and underside of
structure above.
3.4.10 Fill joint with mortar after dead-load deflection of structure above approaches
final position.
3.4.11 Build fire rated interior walls and partitions full height to underside of solid floor
or structure above and provide an UL-tested system for filling joint between the
head of masonry wall and the underside of the Structure above. System is to be
rated for same fire rating as indicated for the masonry assembly (wall or partition)
and shall include mineral wool filler and fire-rated silicone-based sealant joint for
joint filling at both faces of the assembly.
3.5 MORTAR BEDDING AND JOINTING
3.5.1 Lay hollow masonry units as follows:
 With full mortar coverage on horizontal and vertical face shells.

 Bed webs in mortar in all courses of piers, columns, and pilasters, and where
adjacent to cells or cavities to be filled with grout.
3.5.2 Lay solid masonry units with completely filled bed and head joints; butter ends
with sufficient mortar to fill head joints and shove into place. Do not deeply
furrow bed joints or slush head joints.
3.5.3 Set stone trim units in full bed of mortar with full vertical joints. Fill dowel,
anchor, and similar holes.

 Clean soiled surfaces with fiber brush and soap powder and rinse thoroughly with
clear water.
 Allow cleaned surfaces to dry before setting.
 Wet joint surfaces thoroughly before applying mortar.
3.6 MASONRY JOINT REINFORCEMENT
3.6.1 General: Provide continuous masonry joint reinforcement as indicated. Install

entire length of reinforcement in mortar with a maximum cover of 25 mm from
face of masonry and finish mortar joint to normal thickness. Lap reinforcement a
minimum of 150 mm.
 Space reinforcement not more than 420 mm o.c. (each second course).
 Space reinforcement not more than 210 mm o.c. in foundation walls and parapet
walls.
 Provide reinforcement not more than 205 mm above and below wall openings and
extending 300 mm beyond openings.
 Reinforcement above is in addition to continuous reinforcement.
3.6.2 Cut or interrupt joint reinforcement at control and expansion joints, unless
3.6.3 Provide continuity at corners and wall intersections by using prefabricated "L" and
"T" sections. Cut and bend reinforcing units as directed by manufacturer for
continuity at returns, offsets, column fireproofing, pipe enclosures, and other
special conditions.
3.7 VERTICAL REINFORCED UNIT MASONRY INSTALLATION
3.7.1 Temporary Formwork and Shores: Construct formwork and shores to support
reinforced masonry elements during construction.
 Construct formwork to conform to shape, line, and dimensions shown. Make it

sufficiently tight to prevent leakage of mortar and grout. Brace, tie, and support
forms to maintain position and shape during construction and curing of reinforced
masonry.
 Do not remove forms and shores until reinforced masonry members have hardened
sufficiently to carry their own weight and other temporary loads that may be placed
on them during construction.
3.7.2 Placing Reinforcement: Comply with requirements of Division 3, Section “Cast-

In-place concrete”.
3.7.3 Grouting: Do not place grout until entire height of masonry to be grouted has
attained sufficient strength to resist grout pressure.
 Comply with requirements of ACI 530.1 or Section 2104.6 in the Uniform Building
Code (UBC) for cleanouts and for grout placement, including minimum grout space

and maximum pour height
3.8 ANCHORING MASONRY TO CONCRETE COLUMNS AND WALLS
3.8.1 Anchor masonry to concrete where masonry abuts or faces concrete columns or
walls, comply with the following:
 Anchor masonry to concrete with metal anchors embedded as specified in masonry

joints and attached to concrete.
 Space anchors as indicated, but not more than 420 mm o.c. vertically and 915 mm
o.c. horizontally.
3.9 CONTROL AND EXPANSION JOINTS
3.9.1 General: Install control and expansion joints in unit masonry where indicated on
approved shop drawings. Build-in related items as masonry progresses. Do not
form a continuous span through movement joints unless provisions are made to
prevent in-plane restraint of wall or partition movement.
3.9.2 Form control joints in concrete masonry as follows:
 Install preformed control-joint gaskets designed to fit standard sash block.
3.10 LINTELS
3.10.1 General: Provide lintels where shown and where openings of more than 610 mm
for block-size units are shown without structural steel or other supporting lintels.
3.10.2 Provide precast lintels made from concrete matching concrete masonry units in
color, texture, and compressive strength, unless otherwise specified elsewhere,
and with reinforcing bars indicated or required to support loads indicated. Cure
precast lintels by the same method used for concrete masonry units.
3.10.3 Provide minimum bearing of 200 mm at each jamb, unless otherwise indicated.
3.11 FIRE RATED MASONRY WALLS
3.11.1 Fire resistance rating of concrete masonry fire walls is to be as indicated on

Drawings.
3.11.2 Thickness indicated on Drawings is the minimum thickness.
3.11.3 Penetrations through fire rated masonry walls shall be sealed and treated with
material systems as specified in Division 7, Section “Through Penetration Fire Stop
Systems”.
3.11.4 Care shall be exercised to solidly fill all joints, vertical and horizontal, with mortar.
3.11.5 Control Joints: Use fire rated joint sealant to fill joints. Sealant rating shall match
rating of wall including joint.
3.11.6 Head of Wall of Partition Joint: Comply with requirements specified in Clause 3.4

of this Section.
3.11.7 Expansion Joints: Use UL-listed or tested joint assembly of same fire rating as fire
wall.
3.12.1 Engage a qualified independent testing agency approved by the Engineer to

perform field quality-control testing indicated below.
3.12.2 Payment for these services will be made by the Contractor.
3.12.3 Testing Frequency: Tests listed in this Article will be performed upon delivery of
materials to Site and at for each 250 m2 of masonry assemblies times during
construction.
3.12.4 Mortar properties will be tested per ASTM C 780.
3.13 REPAIRING, POINTING, AND CLEANING
3.13.1 Remove and replace masonry units that are loose, chipped, broken, stained, or
otherwise damaged or that do not match adjoining units. Install new units to
match adjoining units; install in fresh mortar, pointed to eliminate evidence of
replacement.
3.13.2 Pointing: During the tooling of joints, enlarge voids and holes, except weep holes,
and completely fill with mortar. Point up joints, including corners, openings, and
adjacent construction, to provide a neat, uniform appearance. Prepare joints for
sealant application.
3.13.3 In-Progress Cleaning: Clean unit masonry as work progresses by dry brushing to
remove mortar fins and smears before tooling joints.
3.14 CONCRETE UNIT MASONRY SCHEDULE
3.14.1 Use solid concrete blocks for building all bellow grade masonry, with sulphate
resistant cement, unless otherwise recommended by soil investigation report.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. STRUCTURAL STEEL
CAIRO - EGYPT 05120 – 2039 0

CONTENTS
SECTION 05120
STRUCTURAL STEEL
Page
PART 1 GENERAL 2
1.2 Summary 2
1.4 Submittals 4
PART 2 PRODUCTS 6
2.1 Materials 6
2.2 Fabrication 7
2.3 Anchorage of Masonry to Steel Structure 9
2.4 Shop Painting 9
2.5 Testing 9
PART 3 EXECUTION 10
3.1 Erection 10
3.2 Quality Control 12
3.3 Tolerances for Structural Steel Work 12
3.4 Cleaning and Touch-Up Painting 13
3.5 Painting System 13
Structural Steel
Renovation and Refurnishing Unilever Factory 6th October , Section 05120
Egypt Phase 1&2 (Cost Reduction) (Prj. 2039) Page 1 of 13
SECTION 05120
STRUCTURAL STEEL
PART 1 GENERAL
and Division-1 Specification Sections, apply to work of this section.
1.2 SUMMARY
1.2.1 Extent of structural steel work is shown on Drawings. Schedules, notes and
details are included to show size and location of members, typical connections
and type of steel required.
1.2.2 Check Drawings issued within these documents. Inform the Engineer, for his
decision, in case of any conflict, errors, etc.
1.2.3 Structural steel shall be fabricated according to the shop drawings prepared by
the Contractor, after Engineer’s approval, and based on the Drawings and
specifications.
1.3.1 All structural steel work shall be performed in strict accordance with the
specifications, drawings and the stipulations of the Egyptian Code of Practice, the
Egyptian Standard Specifications (ES) Latest Edition, the British Code of Practice,
British Standard Specifications (BS) and the specifications of the American Society
for Testing and Materials (ASTM) as noted herein below.
Egyptian Code of Practice
ECP No.
250-2004 Steel Constructions and Bridges
Egyptian Standard Specifications
ES No.
243 Mechanical Tests for Welded Joints
257 Metal Arc Welding of Structural Steel
260 Structural Steels
350 Steel Pipes Suitable for Screwing
427 Commercial Bolts
Structural Steel
428 Commercial Nuts
431 Plain Steel Washers for Special Purposes
435 Covered Carbon Steel for Arc Welding
715 Synthetic Priming Paints
917 Welder Qualifications
1058 Round Bars for Hot Rolled Steel Sections
1059 Hot rolled Steel Sections (Non-round Sections)
1060 Hot Rolled Steel Sections (Angles)
1061 Hot Rolled Steel Section (Beams)
1110 Mild Steel Sheets, Slips and Plates (Cold Rolled Steel Sheets)
1170 Hot Rolled Strip and Sheets
1171 Mild Steel Sheets Strips and Plates (Hot Rolled Plates by Continuous and
Non-continuous Process)
1423 General Technical Delivery Requirements (for Steel)
4756 Portland Cement (Ordinary and Rapid Hardening)
British Standard Specifications
BS No.
5135 Arc Welding of Carbon and Carbon Manganese Steel
5950 Structural Use of Steelworks in Buildings
American Society for Testing and Materials
ASTM No.
A 6M Specifications for General Requirements for Rolled Steel Plates, Shapes,

Sheet Piling, and Bars for Structural Use
A 36M Specification for Structural Steel
A 123 Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel
Products
A 325M Specification for High-Strength Bolts for Structural Steel Joints
A 490M Specification for High Strength Bolts, Classes 10.9 and 10.9.3, for Structural
Steel Joints
Structural Steel
E 94 Guide for Radiographic Testing
E 142 Method for Controlling Quality of Radiographic Testing
E 146 Practice for Ultrasonic Contact Examination of Weldments
E 165 Practice for Liquid Penetrant Inspection Method
F 959 Specification Compressible-Washer-Type Direct Tension Indicators for Use

with Structural Fasteners
Steel Structures Painting Council (SSPC)
American Welding Society (AWS)
1.3.2 In the event of conflict between various codes and standards the most stringent
conditions shall apply.
1.4 SUBMITTALS
1.4.1 Submit the following in accordance with Conditions of Contract and Division-1
 Product Data: Submit producer's or manufacturer's specifications and installa-

tion instructions for the following products:
 Structural steel (each type), including certified copies of mill reports
covering chemical and physical properties
 Ordinary bolts (each type), including nuts and washers
 High Strength bolts (each type)
 Structural steel primer and final paints
 Shrinkage-resistant grout
 Welding materials
 Include laboratory test reports and other data to show compliance with speci-
fications (including specified standards).
1.4.2 Shop Drawings: Submit final design and detailed shop drawings prepared under
supervision of a registered engineer, including calculation sheets, complete details
and schedules for fabrication and assembly of structural steel members
procedures and diagrams.
1.4.3 Submit for the approval of the Engineer, final designs and their calculation sheets
for the structural steel system under the same provisions and design criteria given
on the Drawings.
1.4.4 Include the following:
 Details of bracings, cuts, connections, cambers, holes and other pertinent data.
 Indicate welds by standard symbols and show size, length and type of each
weld, and materials involved.
Structural Steel
 Information on whatever splices are necessary as a result of rolling limitations.
 Qualities, diameters and distance between bolts with clear indication of the
different bolts.
 Design calculation sheets
1.4.5 Provide setting drawings, templates and directions for installation of anchor bolts
and other anchorages to be installed during concreting.
1.4.6 Test Reports: Provide certificate signed by the manufacturer giving the steel
grade. Submit copies of reports of tests conducted on shop and field bolted and
welded connections. Include data on type(s) of tests conducted and test results.
1.4.7 Surveys: Submit certified copies of each survey conducted by a professional

engineer, showing elevations and locations of base plates and anchor bolts to
receive structural steel and final elevations and locations for major members.
Indicate discrepancies between actual installation and drawings.
1.5.1 Allow for a qualified inspection agency to inspect and test materials at shop and
field. Such inspection and tests shall not relieve the Contractor of responsibility
for providing materials and fabrication procedure in compliance with specified
requirements. Promptly remove and replace materials or fabricated components,
which do not comply.
1.5.2 Tests, including retesting of rejected materials and fabricated work, shall be done
at the Contractor’s expense.
1.5.3 Qualifications for Welding Work: Qualify welding processes and welding
operators in accordance with ES 257 and ES 917. Provide certification that welders
to be employed in work have satisfactorily passed qualification tests. If
rectification of welders is required, retesting shall be the Contractor's
responsibility.
1.6.1 Deliver materials to Site at such intervals to ensure uninterrupted progress of

work.
1.6.2 Deliver anchor bolts and anchorage devices, which are to be embedded in cast-in-
place concrete or masonry, in ample time so as not to delay the work progress.
1.6.3 Store materials to permit easy access for inspection and identification. Keep steel
members off ground, using pallets, platforms or other supports. Protect steel
members and packaged materials from erosion and deterioration.
1.6.4 Do not store materials or structure in a manner that might cause distortion or
damage to members or supporting structures. Repair or replace damaged
materials or structures as directed.
Structural Steel
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Metal Surfaces: For fabrication of work which shall be exposed to view, use only
materials which are smooth and free of surface blemishes including pitting, seam
marks, roller marks, rolled trade names and roughness. Remove such blemishes
and minor defects by grinding or by welding and grinding, so that the thickness is
not reduced locally by more than 4% or 3 mm prior to cleaning, treating and
application of surface finishes.
2.1.2 The smoothing and straightening of plates and sections shall be carried out with a
press or a roll machine in cold conditions.
2.1.3 Materials used shall comply with ES No. 1423.
2.1.4 Structural Steel Shapes, Plates and Bars: All materials shall be sound and free
from such flaws, segregation, cracks lamination or surface flavors and must
comply with the corresponding Egyptian Standard Specifications. For high-
strength low-alloy steel, provide electrodes, welding rods and filler metals equal
in strength and compatible in appearance with parent metal joints.
2.1.5 Manufacturer’s test certificates for all steel used for fabrication or for bolts for the
works shall be supplied.
2.1.6 Rolling tolerance shall be  2 %.
2.1.7 Steel Pipe: Circular hollow shall comply to ASTM A 501, Type E Grade B, black,
made by the furnace butt fueling process.
2.1.8 Steel Sections: Shall comply with: ES No. 1060 Part I Equal Angles / Part II
Unequal Angles and ES No. 1061.
2.1.9 Checkered Plates: The thickness shall not be less than 6 mm. Raised lugs shall be
diamond shaped and shall have an angled and opposed pattern.
2.1.10 Steel sheets shall comply with ES No. 1171 mild steel sheets.
2.1.11 Anchor Bolts: ASTM A 307 carbon steel non-headed type unless otherwise
indicated.
2.1.12 Steel Bearing Plates: ASTM A 36M and ES No. 1110.
2.1.13 Carbon-Steel Bolts and Threaded Fasteners: ES No. 427-428 for carbon-steel,
hex-head bolts and threaded fasteners; carbon-steel nuts; and flat, unhardened
steel washers.
2.1.14 Finish: Hot dipped zinc coating, ASTM A 153 Class C.
2.1.15 High-Strength Bolts and Nuts: ASTM A 325, Type 1, heavy hex steel structural
bolts, heavy hex carbon-steel nuts, and hardened carbon-steel washers.
2.1.16 Nuts: Carbon Steel.

Structural Steel
2.1.17 Washers: Flat unhardened steel washers.
2.1.18 Finish: Hot-dip zinc coating, ASTM A 153M, Class C.
2.1.19 Welding Electrodes: Comply with AWS standards and ES No. 435.
2.1.20 Structural Steel Primer Paint: Fast curing, lead and chromate free, rust inhibiting
primer, compatible with substrates and with type of alkyd finish paint indicated,
with good resistance to normal atmospheric corrosion and with a volatile organic
compounds up to 420 g/l.
2.1.21 Grouting: Cement Grout: Portland cement conforming to ES 4756 and clean,
uniformly graded, natural sand. Mix at a ratio of 1.0 part cement to 3.0 parts
sand, by volume, with minimum water required for placement and hydration.
2.1.22 Non-metallic Shrinkage-Resistant Grout: Pre-mixed non-metallic, non-corrosive,

non-staining product, containing selected silica sands, Portland cement, shrinkage
compensating agents, plasticizing and water reducing agents.
2.1.23 Non-Shrink Epoxy Grouting: Shall be medium viscosity, solvent free, two
components product, with a high mechanical strength, chemical resistance and
adhesive properties, recommended adhesion for steel to concrete or concrete to
concrete and anchorage of bolts.
2.1.24 Welding Electrodes (Conforming to ES No. 435): All welding shall be metal-arc
welding of adequate capacity. The Contractor shall bear in mind the different
types of electrodes when choosing the welding machine to be used. He shall
select the type and diameter of electrodes according to the characteristics of the
base material and the position of the welding.
2.2 FABRICATION
2.2.1 Shop Fabrication and Assembly: Fabricate items of structural steel for locations
shown with dimensions, spacing, details and anchorages as indicated on
Drawings, in accordance with the Egyptian Code of Practice (ECP) Specifications
and other equivalent international standards as indicated on approved final shop
drawings.
2.2.2 Provide camber in structural members where indicated taking into account
deflection due to self-weight and applied loads.
2.2.3 Use new materials of size and thickness indicated, or if not indicated, as required
to produce strength and durability in finished product for use intended; use
proven details of fabrication and support.
2.2.4 All plates, bars and sections shall be flattened and straightened and made free
from twist before any work is done on them.
2.2.5 Allow for thermal movement resulting from a maximum change in ambient
temperature of 30°C in the design, fabrication and installation to prevent
buckling, and overstressing of welds and fasteners. Base design calculations on
actual temperature of metals and to both solar heat gain and nighttime sky heat
loss.
Structural Steel
2.2.6 Shear and punch metals clearly and accurately and remove burrs.
2.2.7 Form exposed work true to line and level with accurate angles and surfaces and
straight sharp edges. Ease exposed edges to a radius of approximately 0.8 mm
2.2.8 Remove sharp and rough areas on exposed traffic surfaces.
2.2.9 At exposed connections, grind exposed welds smooth and flash to match and
blend with adjoining surfaces.
2.2.10 Form exposed connections with hairline joints, using concealed fasteners
wherever possible.
2.2.11 Provide for anchorage of type shown, coordinate with supporting structure.
Fabricate and space anchorage devices to provide adequate support for intended
use.
2.2.12 Properly mark and match-mark materials for field assembly maintain marking
until steel has been erected. Fabricate for delivery sequence which shall expedite
erection and minimize field handling of materials.
2.2.13 Where finishing is required, complete assembly, including welding of units, before
start of finishing operations. Provide finish surfaces of members exposed in final
structure free of markings, burrs and other defects.
2.2.14 Bearing plates shall be machined to receive trusses.
2.2.15 Connections: Weld or bolt shop connections as indicated.
 Bolt field connections, except where welded connections or other connections

are indicated.
 Provide high strength threaded fasteners for principal bolted connections.
 Welded Construction: Comply with ES Code and ES No. 257 for procedures,
appearance and quality of welds and methods used in correcting welding work.
2.2.16 Specified weld length in shop drawings shall be effective length excluding end
craters.
2.2.17 For high-strength low-alloy steels, follow welding procedures as recommended by

steel producer for exposed and concealed connections.
2.2.18 All bevels or chamfers of edges indicated on Drawings shall be carried out before
welding and in strict accordance with the dimensions and indications specified.
2.2.19 Butt welds shall always be continuous and of complete penetration.
2.2.20 Weld shall be ground smooth and flush with adjacent surfaces.
2.2.21 Holes for other work: Provide holes required for securing other work to structural
steel framing and for passage of other work through steel framing members, as
shown on final shop drawings.
Structural Steel
2.2.22 Provide threaded nuts welded to framing and other specialty items as indicated to
receive other work.
2.2.23 Cutting: Cut, drill or punch holes perpendicular to metal surfaces. Do not flame
cut holes or enlarge holes by burning. Drill holes in bearing plates.
2.2.24 Perform cutting by machine to greatest extent possible or cutting shall be carried
out with saw, shears or flame cutting. Electric arc cutting is strictly forbidden.
2.2.25 Accurately mill ends of columns and other members transmitting loads in bearing.
2.3 ANCHORAGE OF MASONRY TO STEEL STRUCTURE
2.3.1 Provide and weld at surface against masonry works straps of metal strip 6 mm
thick, 40 mm wide and 250 mm long, capable to sustain without failure a load 6
times the loads imposed by masonry.
2.3.2 Straps shall be at a vertical distance of 500 mm o.c.
2.4 SHOP PAINTING
2.4.1 Shop paint structural steel, except those members or portions of members to be
embedded in concrete or mortar.
2.4.2 Do not paint surfaces, which shall be welded or high-strength, bolted with friction
type connection.
2.4.3 Paint on surfaces, which are scheduled to receive sprayed-on fireproofing and
shall be in accordance to fireproofing material manufacturer's recommendations.
2.4.4 Apply 2 coats of paint to surfaces, which are inaccessible after assembly or
erection or shall be embedded in other work.
2.4.5 Surface Preparation: All surfaces of steel shall be thoroughly cleaned by sand
blasting in the fabricating shop. After inspection and before transporting, clean
steel works to be painted. Remove loose rust, loose milscale and spatter, slag or
flux deposits and dust.
2.4.6 Dirt, burrs and other foreign matter shall be removed by grinding. All grease and
oil shall be removed by solvents. Surfaces shall be thoroughly dry before painting.
2.4.7 Painting: Immediately after surface preparation apply structural steel primer
paint, Anti Rust Synthetic Paint, at rate to provide dry film thickness of not less
than 1.5 mils.
2.5 TESTING
2.5.1 The Engineer shall perform shop inspections and tests and prepare test reports,
and shall state in each report whether the test specimen complies with or
deviates from requirements.
2.5.2 Correct deficiencies in, or remove and replace structural steel not complying with
requirements.
Structural Steel
2.5.3 Shop-bolted connections shall be tested and inspected in addition to visual
inspection, shop welded connections shall be tested.
PART 3 EXECUTION
3.1 ERECTION
3.1.1 Surveys: Employ a professional engineer or land surveyor for accurate erection of
structural steel. Check elevations of concrete and masonry bearing surfaces and
locations of anchor bolts and similar devices, before erection work proceeds and
report discrepancies to the Engineer. Do not proceed with erection until
corrections have been made, or until compensating adjustments to structural
steel work have been agreed upon by the Engineer.
3.1.2 Temporary Planking: Provide temporary planking shores, braces and working
platforms as necessary during erection to keep structural steel secure, plumb and
in alignment to effectively complete work.
3.1.3 Arrange that sufficient tack welds, bolts, braces or guy ropes are used to ensure
that work shall remain rigid until final bolting, riveting or welding is completed.
3.1.4 Anchor Bolts: Furnish anchor bolts and other connectors required for securing
structural steel to foundations and other in-place work.
3.1.5 Furnish templates and other devices as necessary for presetting bolts and other
anchors to accurate locations.
3.1.6 Remove temporary supports when permanent structural steel, connections, and
bearings are in place.
3.1.7 Setting Bases and Bearing Plates: Clean concrete and masonry bearing surfaces of
bond-reducing materials and roughen to improve bond to surfaces. Clean bottom
surface of base and bearing plates.
3.1.8 All bearing members, stanchion bases, beams and girders shall be securely
supported on suitable steel packs.
3.1.9 Packs shall not be larger than necessary, and shall not protrude unduly from
stanchion base. They shall be grouted in and the grout shall totally enclose them.
3.1.10 Set loose and attach base plates and bearing plates for structural members on
wedges, setting nuts or other adjusting devices.
3.1.11 Tighten anchor bolts after supported members have been positioned and
plumbed. Do not remove wedges or shims, but if protruding, cut off flush with
edge of base or bearing plate prior to packing with grout.
3.1.12 Bearing plates shall not be grouted until the steel work has been finally leveled
and plumbed.
3.1.13 Bearing plates shall be bedded in neat Portland cement grout to a thickness not
exceeding 25 mm.
Structural Steel
3.1.14 Pack grout solidly between bearing surfaces and bases or plates to ensure that no
voids remain. Finish exposed surfaces, protect installed materials and allow
curing.
3.1.15 For proprietary grout materials, comply with manufacturer's instructions.
3.1.16 Maintain erection tolerances of structural steel within the Egyptian Code.
3.1.17 Field Assembly: Set structural frames accurately to position, lines and elevations
indicated. Align and adjust various members forming a part of a complete frame
or structure before permanently fastening. Clean bearing surfaces and other
surfaces, which shall be in permanent contact before assembly. Perform
necessary adjustments to compensate for discrepancies in elevations and
alignment.
3.1.18 Level and plumb individual members of structure within specified tolerances.
3.1.19 Locate decking bundles to prevent over loading of supporting members.
3.1.20 Make allowance for difference between temperature at time of erection and
mean temperature at which structure shall be when completed.
3.1.21 Splice members only where indicated and accepted on shop drawings.
3.1.22 Erection Bolts: On exposed welded construction, remove erection bolts, fill holes
with plug welds and grind smooth at exposed surfaces.
3.1.23 Comply with specifications for bearing, adequacy of temporary connections,

alignment and removal of paint on surfaces adjacent to field welds.
3.1.24 When ordinary bolts are used, the matching of the holes shall be checked by
inverting a cylindrical gauge 1.5 mm smaller in rated diameter than the hole.
3.1.25 All holes shall be drilled not punched.
3.1.26 Do not enlarge unfair holes in members by burning or by use of drift pins, except
in secondary bracing members. Ream holes that must be enlarged to admit bolts.
3.1.27 Bolts shall be of sufficient length to show at least one full thread beyond the nut
after tightening.
3.1.28 When using high strength bolts a washer shall always be placed under the head
and under the nut. Nuts shall be tightened with ganged wrenches measuring the
applied torque.
3.1.29 Site connections generally shall be made with a minimum of two bolts to any
connections.
3.1.30 Gas Cutting: Do not use gas-cutting torches in field for correcting fabrication
errors in primary structural framing. Cutting shall be permitted only on secondary
members, which are not under stress, as acceptable to the Engineer. Finish gas-
cut sections equal to a sheared appearance when permitted.
Structural Steel
3.1.31 Cold sawn machine cut and flame cut edges shall be cleaned free of burns and
slag and left as smooth as regular as those produced by edge planning.
3.2 QUALITY CONTROL
3.2.1 Engage an independent testing and inspection agency to inspect high-strength

bolted connections and welded connections and to perform field inspections and
tests and prepare test reports.
3.2.2 Testing agency shall conduct and interpret tests and state in each report whether
tested work comply with requirements, and specifically state any deviations
therefrom.
3.2.3 Provide access for testing agency to places where structural steel work is being
fabricated or produced so that required inspection and testing can be
accomplished.
3.2.4 Correct deficiencies in or remove and replace structural steel work, which
inspections and test reports have indicated to be not in compliance with
requirements. Perform additional tests, at Contractor's expense, as may be
necessary to reconfirm any non-compliance of original work and as may be
necessary to show compliance of corrected work.
3.2.5 Field Bolted Connections: Shall be tested and inspected in accordance with BCP.
3.2.6 Field Welding: Remove paints from surfaces adjacent to field welds. All due
precautions shall be taken to protect the welding works against the wind.
3.2.7 It is forbidden to accelerate the cooling of welds by artificial means.
3.2.8 On exposed welded construction, remove erection bolts, fill holes with plug welds
and grind smooth at exposed surfaces.
3.2.9 Certify welders and conduct inspections and tests as required. Record types and
locations of defects found in work. Record work required and performed to
correct deficiencies.
3.2.10 Perform visual inspection of all welds. In addition to visual inspection field welded
connections shall be inspected and tested during fabrication according to
equipment as follows, at the Engineer’s option:
 Liquid Penetration Inspection ASTM E 165

 Magnetic Particle Inspection performed on root pass and on finished weld
 Radiographic Inspection ASTM E 94
 Ultrasonic Inspection ASTM E 164
3.3 TOLERANCES FOR STRUCTURAL STEEL WORK
3.3.1 No structural steel work member shall differ from the lines, level and plumb as
shown on Drawings by more than 3 mm and any such departure from the true line
or plumb shall not occur at a rate in excess of 1%. Any work laying outside the
above mentioned tolerances shall be dealt with as directed by the Engineer and at
Structural Steel
the Contractor’s expense.
3.4 CLEANING AND TOUCH-UP PAINTING
3.4.1 Immediately after erection clean field welds, bolted connections and abraded
area of shop paint. Necessary solvent cleaning shall be done before hand cleaning
or power tool cleaning.
3.4.2 Remove loose rust, mill scale, loose paint by hand chipping, scraping, sanding and
wire brushing, or by power tool cleaning.
3.4.3 Apply paint to exposed areas using same materials used for shop painting.
3.4.4 Apply by brush or spray to provide a minimum film thickness of 0.04 mm.
3.5 PAINTING SYSTEM
3.5.1 Comply with requirements of Division 09 Section “Painting”
Structural Steel

ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. METAL FABRICATIONS
CAIRO - EGYPT 05500 – 2039 0
ECG Form No. E409 Rev. 5/0 Sheet of 11

CONTENTS
SECTION 05500
METAL FABRICATIONS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.6 Coordination 3
PART 2 PRODUCTS 3
2.1 Metals, General 3
2.2 Ferrous Metals 3
2.3 Fasteners 4
2.4 Miscellaneous Materials 5
2.5 Grout 5
2.6 Fabrication, General 5
2.7 Miscellaneous Framing And Supports 6
2.8 Shelf Angles 7
2.9 Steel Ladders 7
2.10 Ladder Safety Cages 8
2.11 Gratings 8
2.12 Steel Pipe Bollards 8
2.13 Finishes, General 9
2.14 Steel And Iron Finishes 9
PART 3 EXECUTION 9
3.1 Preparation 9
3.3 Installing Miscellaneous Framing And Supports 10
3.4 Installing Pipe Bollards 11
3.5 Adjusting And Cleaning 11
Metal Fabrications Section 05500

SECTION 05500
METAL FABRICATIONS
PART 1 GENERAL
1.1.1 Drawings and general provisions of the Contract, including General and Supple-
mentary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
1.2.1 This Section includes, but is not limited to, the following metal fabrications, where
these fabrications are not specified in other Specifications Sections:
 Miscellaneous framing, supports and trims:
 Concealed applications where framing and supports are not indicated.

 Steel framing and supports for mechanical and electrical equipment.
 Steel framing and supports for engineering applications.
 Shelf angles.
 Steel ladder.
 Ladder safety cage.
 Grating.
 Steel bollards.
 Checkered-plate covers
 Division 4; Section "Unit Masonry Assemblies" for installing loose lintels, an-
chor bolts, and other items indicated to be built into unit masonry.
 Division 5; Section "Structural Steel" for structural-steel framing system com-
ponents.
 Division 9; Section “Painting” for surface preparation and applied finishes.
1.3 SUBMITTALS
1.3.1 Product Data: For Each product specified.
1.3.2 Shop Drawings: Detail fabrication and erection of each metal fabrication indicat-
ed. Include plans, elevations, sections, and details of metal fabrications and their
connections. Show anchorage and accessory items.
 Provide templates for anchors and bolts specified for installation under other

Sections.
1.3.3 Samples:
 Samples representative of materials and finished products as may be request-

ed by the Engineer.
1.3.4 Welding Certificates signed by the Contractor certifying that welders comply with
requirements specified under the "Quality Assurance" Article.
1.4.1 Fabricator Qualifications: Firms experienced in producing metal fabrications simi-

lar to those indicated for this Project and with a record of successful in-service
performance, as well as sufficient production capacity to produce required units,
without delaying the work.
1.4.2 Welding: Qualify procedures according to Egyptian Standards E.S.S. 921
1.5.1 Field Measurements: Where metal fabrications are indicated to fit walls and oth-
er construction, verify dimensions by field measurements before fabrication and
indicate measurements on Shop Drawings. Coordinate fabrication schedule with
construction progress to avoid delaying the Work.
1.5.2 Where field measurements cannot be made without delaying the Work, guaran-
tee dimensions and proceed with fabricating products without field measure-
ments. Coordinate construction to ensure that actual dimensions correspond to
guaranteed dimensions. Allow for trimming and fitting.
1.6 COORDINATION
1.6.1 Coordinate installation of anchorages for metal fabrications. Furnish setting

drawings, templates, and directions for installing anchorages, including sleeves,
concrete inserts, anchor bolts, and items with integral anchors, that are to be em-
bedded in concrete or masonry. Deliver such items to Project site in time for in-
stallation.
PART 2 PRODUCTS
2.1 METALS, GENERAL
2.1.1 Metal Surfaces, General: For metal fabrications exposed to view in the completed
Work, provide materials with smooth, flat surfaces without blemishes. Do not use
materials with exposed pitting, seam marks, roller marks, rolled trade names, or
roughness.
2.2 FERROUS METALS
2.2.1 Steel Plates, Shapes, and Bars: ASTM A 36/A 36M.

2.2.2 Rolled-Steel Floor Plate: ASTM A 786/A 786M, rolled from plate complying with
ASTM A 36/A 36M or ASTM A 283/A 283M, Grade C or D.
2.2.3 Abrasive-Surface Floor Plate: Steel plate with abrasive granules rolled into sur-
face.
2.2.4 Steel Tubing: ASTM A 500, cold-formed steel tubing.
2.2.5 Steel Pipe: ASTM A 53/A 53M, standard weight (Schedule 40), unless another
weight is indicated or required by structural loads.
2.2.6 Cast Iron: ASTM A 48/A 48M, Class 30, unless another class is indicated or re-
quired by structural loads.
2.2.7 Malleable-Iron Castings: ASTM A 47M, Grade 22010.
2.3 FASTENERS
2.3.1 Steel Bolts and Nuts: Regular hexagon-head bolts, ASTM A 307, Grade A
(ASTM F 568M, Property Class 4.6); with hex nuts, ASTM A 563 (ASTM A 563M);
and, where indicated, flat washers.
2.3.2 Anchor Bolts: ASTM F 1554, Grade 36.
 Provide hot-dip or mechanically deposited, zinc-coated anchor bolts where

item being fastened is indicated to be galvanized.
 Adhesive or cohesive failures.
 Eyebolts: ASTM A 489.
 Machine Screws: ASME B18.6.3 (ASME B18.6.7M).
 Lag Bolts: ASME B18.2.1 (ASME B18.2.3.8M).
 Wood Screws: Flat head, ASME B18.6.1.
 Plain Washers: Round, ASME B18.22.1 (ASME B18.22M).
 Lock Washers: Helical, spring type, ASME B18.21.1 (ASME B18.21.2M).
2.3.3 Cast-in-Place Anchors in Concrete: Anchors capable of sustaining, without failure,

a load equal to four times the load imposed, as determined by testing according
to ASTM E 488, conducted by a qualified independent testing agency.
 Threaded or wedge type; galvanized ferrous castings, either ASTM A 47/A 47

M malleable irons or ASTM A 27/A 27M cast steel. Provide bolts, washers, and
shims as needed, hot-dip galvanized per ASTM A 153/A 153M.
2.3.4 Expansion Anchors: Anchor bolt and sleeve assembly with capability to sustain,
without failure, a load equal to six times the load imposed when installed in unit
masonry and four times the load imposed when installed in concrete, as deter-
mined by testing according to ASTM E 488, conducted by a qualified independent
testing agency.

 Material for Anchors in Interior Locations: Carbon-steel components zinc-
plated to comply with ASTM B 633, Class Fe/Zn 5.
 Material for Anchors in Exterior Locations: Alloy Group 2 (A4) stainless-steel
bolts complying with ASTM F 593 (ASTM F 738M) and nuts complying with
ASTM F 594 (ASTM F 836M).
2.4 MISCELLANEOUS MATERIALS
2.4.1 Welding Rods and Bare Electrodes: Select according to E.S.S 921
2.4.2 Shop Primers: Provide primers that comply with Division 9 Section "Painting".
 Black steel: Use lead free, epoxy or polyurethane based primers compatible
with undercoats and finish top coats.
 Galvanized steel: Epoxy-polyamide cured primers compatible with undercoats
and finish top coats.
 Galvanized steel: Zinc-rich primer where
2.4.3 Galvanizing Repair Paint: High-zinc-dust-content paint for regalvanizing welds in

steel, complying with SSPC-Paint 20.
2.4.4 Bituminous Paint: Cold-applied asphalt emulsion complying with ASTM D 1187.
2.5 GROUT
2.5.1 No shrink, Nonmetallic Grout: Factory-packaged, nonstaining, noncorrosive, non-

gaseous grout complying with ASTM C 1107. Provide grout specifically recom-
mended by the manufacturer for interior and exterior applications.
2.6 FABRICATION, GENERAL
2.6.1 Shop Assembly: Preassemble items in shop to greatest extent possible to mini-
mize field splicing and assembly. Disassemble units only as necessary for shipping
and handling limitations. Use connections that maintain structural value of joined
pieces. Clearly mark units for reassembly and coordinated installation.
2.6.2 Shear and punch metals cleanly and accurately. Remove burrs.
2.6.3 Ease exposed edges to a radius of approximately 1 mm, unless otherwise indicat-
ed. Form bent-metal corners to smallest radius possible without causing grain
separation or otherwise impairing work.
2.6.4 Weld corners and seams continuously to comply with the following:
 Use materials and methods that minimize distortion and develop strength and
corrosion resistance of base metals.
 Obtain fusion without undercut or overlap.
 Remove welding flux immediately.

 At exposed connections, finish exposed welds and surfaces smooth and blend-
ed so that no roughness shows after finishing and contour of welded surface
matches that of adjacent surface.
2.6.5 Provide for anchorage of type indicated; coordinate with supporting structure.
Fabricate and space anchoring devices to secure metal fabrications rigidly in place
and to support indicated loads.
2.6.6 Cut, reinforce, drill, and tap metal fabrications as indicated to receive finish hard-
ware, screws, and similar items.
2.6.7 Fabricate joints that will be exposed to weather in a manner so as to exclude wa-
ter, or provide weep holes where water may accumulate.
2.6.8 Form exposed work true to line and level with accurate angles and surfaces and
straight sharp edges.
2.6.9 Remove sharp or rough areas on exposed traffic surfaces.
2.6.10 Form exposed connections with hairline joints, flush and smooth, using concealed
fasteners where possible. Use exposed fasteners of type indicated or, if not indi-
cated, Phillips flat-head (countersunk) screws or bolts. Locate joints where least
conspicuous.
2.6.11 Form metal fabrications from materials of size, thickness, and shapes indicated
but not less than that needed to comply with performance requirements indicat-
ed. Work to dimensions indicated or accepted on shop drawings, using proven
details of fabrication and support. Use type of materials indicated or specified for
various components of each metal fabrication.
2.7 MISCELLANEOUS FRAMING AND SUPPORTS
2.7.1 General: Provide steel framing and supports that are not a part of structural-steel
framework as necessary to complete the Work.
2.7.2 Fabricate units from structural-steel shapes, plates, and bars of welded construc-
tion, unless otherwise indicated. Fabricate to sizes, shapes, and profiles indicated
and as necessary to receive adjacent construction retained by framing and sup-
ports. Cut, drill, and tap units to receive hardware, hangers, and similar items.
 Fabricate units from slotted channel framing where indicated.

 Where units are indicated to be cast into concrete or built into masonry, equip
with integrally welded steel strap anchors 32 mm wide by 6 mm thick by 200
mm long at 600 mm o.c., unless otherwise indicated.
 Furnish inserts if units must be installed after concrete is placed.
2.7.3 Finish:
 Interior: Prime painted, minimum two coats, one in the shop and the second
field-applied after installation.

2.8 SHELF ANGLES
2.8.1 Fabricate shelf angles from steel angles of sizes indicated and for attachment to
concrete framing. Provide horizontally slotted holes to receive 19-mm bolts,
spaced not more than 150 mm from ends and 600 mm o.c., unless otherwise indi-
cated.
 Provide mitered and welded units at corners.

 Provide open joints in shelf angles at expansion and control joints. Make open
joint approximately 50 mm larger than expansion or control joint.
2.8.2 Galvanize shelf angles located in exterior walls.
2.8.3 Furnish wedge-type concrete inserts, complete with fasteners, to attach shelf an-
gles to cast-in-place concrete.
2.9 STEEL LADDERS
2.9.1 General: Fabricate ladders for locations shown, with dimensions, spacings, de-
tails, and anchorages as indicated.
 Comply with ANSI A14.3, unless otherwise indicated.

 For elevator pit ladders, comply with ASME A17.1.
2.9.2 Siderails: As indicated on Drawings
2.9.3 Bar Rungs: As indicated on Drawings.
2.9.4 Fit rungs in centerline of side rails; plug-weld and grind smooth on outer rail faces.
2.9.5 Support each ladder at top and bottom and not more than 1500 mm o.c. with
welded or bolted steel brackets.
 Size brackets to support design dead and live loads indicated and to hold cen-
terline of ladder rungs clear of the wall surface by not less than 180 mm.
 Extend side rails 1.1 m above top rung, and return rails to wall or structure un-
less other secure handholds are provided. If the adjacent structure does not
extend above the top rung, goose-neck the extended rails back to the structure
to provide secure ladder access
2.9.6 Provide nonslip surfaces on top of each rung, either by coating rung with alumi-
num-oxide granules set in epoxy-resin adhesive or by using a type of manufac-
tured rung filled with aluminum-oxide grout.
2.9.7 Galvanize ladders, including brackets and fasteners, in the following locations:
 Exterior.
 Interior, where indicated.
2.9.8 Finish is to be polyurethane-based coating system of color selected by the Engi-

neer. Comply with requirements of Division 9, Section "Painting".
2.10 LADDER SAFETY CAGES
2.10.1 General: Fabricate ladder safety cages to comply with ANSI A14.3. Assemble by
welding or riveting.
2.10.2 Primary Hoops: 12-by-64-mm steel flat bar hoops; and for cages longer than 6 m,
intermediate hoops spaced not more than 6 m o.c.
2.10.3 Provide at tops and bottoms of cages and spaced not more than 6 m o.c.
2.10.4 Secondary Intermediate Hoops: 8-by-50-mm steel flat bar hoops, spaced not
more than 1200 mm o.c. between primary hoops.
2.10.5 Vertical Bars: 8-by-50-mm steel flat bars secured to each hoop, spaced approxi-
mately 230 mm o.c.
2.10.6 Fasten assembled safety cage to ladder rails and adjacent construction by welding
or riveting, unless otherwise indicated.
2.10.7 Galvanize ladder safety cages, including fasteners, in the following locations:
 Exterior.
 Interior, where indicated.
2.10.8 Finish is to be polyurethane-based coating system of color selected by the Engi-

neer. Comply with requirements of Division 9, Section "Painting".
2.11 GRATINGS
2.11.1 Heavy duty non-rocking cast iron straight bar grating and angle frames to BS EN
124 with factory applied heavy duty epoxy-based finish coating system of black
color including primer and top coat and thickness to be as indicated on Drawings.
2.12 STEEL PIPE BOLLARDS
2.12.1 Fabricate steel pipe bollards from Schedule 80 steel pipe.
 Cap bollards with 6-mm- minimum steel plate.
2.12.2 Fabricate bollards with 10-mm thick steel baseplates for bolting to concrete slab.
Drill baseplates at all 4 corners for 19-mm anchor bolts.
 Where bollards are to be anchored to sloping concrete slabs, angle baseplates

for plumb alignment of bollards.
2.12.3 Fabricate sleeves for bollard anchorage from steel pipe or tubing with 6.4-mm
thick steel plate welded to bottom of sleeve. Make sleeves not less than 200 mm
deep and 19 mm larger than OD of bollard.

2.12.4 Finish is to be manufacture standard.
2.13 FINISHES, GENERAL
2.13.1 Finish metal fabrications after assembly.
2.14 STEEL AND IRON FINISHES
2.14.1 Galvanizing: For those items indicated for galvanizing after fabrication, apply zinc
coating by the hot-dip process complying with the following requirements:
 ASTM A 153 for galvanizing iron and steel hardware.

 ASTM A 123 for galvanizing both fabricated and unfabricated iron and steel
products made of uncoated rolled, pressed, and forged shapes, plates, bars,
and strip 0.76 mm thick or thicker.
2.14.2 Preparation for Shop Priming: Prepare uncoated ferrous-metal surfaces to com-
ply with minimum requirements indicated below for SSPC surface-preparation
specifications and environmental exposure conditions of installed metal fabrica-
tions:
 Exteriors (SSPC Zone 1B) and Items Indicated to Receive Zinc-Rich Primer:
SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning."
 Interiors (SSPC Zone 1A): SSPC-SP 3, "Power Tool Cleaning."
2.14.3 Apply shop primer to uncoated surfaces of metal fabrications, except those with
galvanized finishes and those to be embedded in concrete, sprayed-on fireproof-
ing, or masonry, unless otherwise indicated. Comply with SSPC-PA 1, "Paint Appli-
cation Specification No. 1," for shop painting.
 Stripe paint corners, crevices, bolts, welds, and sharp edges.
2.14.4 Factory-Applied Finishes: Comply with requirements as specified in Division 9

Section “Painting”
2.14.5 Galvanizing Repair Paint: High-zinc-dust-content paint for regalvanizing welds in

steel, complying with SSPC-Paint 20.
PART 3 EXECUTION
3.1 PREPARATION
3.1.1 Coordinate and furnish anchorages, setting drawings, diagrams, templates, in-
structions, and directions for installing anchorages, including concrete inserts,
sleeves, anchor bolts, and miscellaneous items having integral anchors that are to
be embedded in concrete or masonry construction. Coordinate delivery of such
items to Project site.

3.2.1 Fastening to In-Place Construction: Provide anchorage devices and fasteners

where necessary for securing metal fabrications to in-place construction. Include
threaded fasteners for concrete and masonry inserts, toggle bolts, through-bolts,
lag bolts, wood screws, and other connectors.
3.2.2 Cutting, Fitting, and Placement: Perform cutting, drilling, and fitting required for
installing metal fabrications. Set metal fabrications accurately in location, align-
ment, and elevation; with edges and surfaces level, plumb, true, and free of rack;
and measured from established lines and levels.
3.2.3 Provide temporary bracing or anchors in formwork for items that are to be built
into concrete, masonry, or similar construction.
3.2.4 Fit exposed connections accurately together to form hairline joints. Weld connec-
tions that are not to be left as exposed joints but cannot be shop welded because
of shipping size limitations. Do not weld, cut, or abrade surfaces of exterior units
that have been hot-dip galvanized after fabrication and are for bolted or screwed
field connections.
3.2.5 Field Welding: Comply with the following requirements:
 Use materials and methods that minimize distortion and develop strength and
corrosion resistance of base metals.
 Obtain fusion without undercut or overlap.
 Remove welding flux immediately.
 At exposed connections, finish exposed welds and surfaces smooth and blend-
ed so that no roughness shows after finishing and contour of welded surface
matches that of adjacent surface.
3.3 INSTALLING MISCELLANEOUS FRAMING AND SUPPORTS
3.3.1 General: Install framing and supports to comply with requirements of items being
supported, including manufacturers' written instructions and requirements indi-
cated on Shop Drawings, if any.
3.3.2 Anchor supports for operable partitions securely to and rigidly brace from building
structure.
3.3.3 Support steel girders on solid grouted masonry, concrete, or steel pipe columns.
Secure girders with anchor bolts embedded in grouted masonry or concrete or
with bolts through top plates of pipe columns.
 Where grout space under bearing plates is indicated at girders supported on

concrete or masonry, install as specified above for setting and grouting bearing
and leveling plates.

3.4 INSTALLING PIPE BOLLARDS
3.4.1 Anchor bollards to mounting substrate with expansion anchors. Provide four 19-
mm bolts at each bollard, unless otherwise indicated.
Embed anchor bolts at least 100 mm in concrete.
3.4.2 Anchor bollards in concrete with pipe sleeves preset and anchored into concrete.
Fill annular space around bollard solidly with nonshrink, nonmetallic grout; mixed
and placed to comply with grout manufacturer's written instructions. Slope grout
up approximately 3 mm toward bollard.
3.4.3 Anchor bollards in place with concrete footings. Center and align bollards in holes
75 mm above bottom of excavation. Place concrete and vibrate or tamp for con-
solidation. Support and brace bollards in position until concrete has cured.
3.4.4 Fill bollards solidly with concrete, mounding top surface to shed water.
3.5 ADJUSTING AND CLEANING
3.5.1 Touchup Painting: Immediately after erection, clean field welds, bolted connec-
tions, and abraded areas of shop paint, and paint exposed areas with the same
material as used for shop painting to comply with SSPC-PA 1 for touching up shop-
painted surfaces.
 Apply by brush or spray to provide a minimum 0.05 mm dry film thickness.
3.5.2 Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas
and repair galvanizing to comply with ASTM A 780.
3.5.3 Protect work as recommended by manufacturer to ensure that work is without

damage or deterioration at the time of Substantial Completion.

THIS PAGE IS A RECORD OF ALL SPECIFICATION REVISIONS. REVISED SHEETS ONLY ATTACHED
NORMALLY, EACH TIME THE SPECIFICATION IS CHANGED ONLY THE ENTIRE SPECIFICATION RE-ISSUED
NEW OR REVISED PAGES ARE ISSUED. ENTIRE SPECIFICATION REVISED
THE NATURE OF THE REVISION IS BRIEFLY NOTED UNDER REMARKS

ISSUED FOR
BUT THESE REMARKS ARE NOT A PART OF THE SPECIFICATION. THE
REVISED PAGES BECOME PART OF THE ORIGINAL SPECIFICATION AND REVIEW/COMMENTS
SHALL BE COMPLETED WITHIN THEIR ENTIRELY. TENDER/QUOTATION X
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. PIPE AND TUBE RAILINGS
CAIRO - EGYPT 05521 – 2039 0

CONTENTS
SECTION 05521
PIPE AND TUBE RAILINGS

Page
PART 1 GENERAL 2
1.1 Summary 2
1.2 Performance Requirements 2
1.3 Submittals 2
PART 2 PRODUCTS 3
2.1 Metals 3
2.3 Fabrication 4
PART 3 EXECUTION 5
Pipe and Tube Railings Section 05521

[
SECTION 05521
PIPE AND TUBE RAILINGS
PART 1 GENERAL
1.1 SUMMARY
1.1.1 This Section includes the following:
 Steel pipe railing.
 Steel handrail
1.2 PERFORMANCE REQUIREMENTS
1.2.1 Structural Performance: Provide railings capable of withstanding the effects of

gravity loads and the following loads and stresses within limits and under
conditions indicated:
 Handrails:
 Uniform load of 0.73 kN/m applied in any direction.

 Concentrated load of 0.89 KN applied in any direction.
 Uniform and concentrated loads need not be assumed to act concurrently.
 Top Rails of Guards:
 Uniform load of 0.73 kN/m applied in any direction.

 Concentrated load of 0.89 KN applied in any direction.
 Uniform and concentrated loads need not be assumed to act concurrently.
 Infill of Guards:
 Concentrated load of 0.22 KN applied horizontally on an area of 0.093 sq.

m.
 Uniform load of 1.2 kN/sq. m applied horizontally.
 Infill load and other loads need not be assumed to act concurrently.
1.3 SUBMITTALS
1.3.1 Product Data.
1.3.2 Samples: Short sections of railing or flat sheet metal Samples showing available
mechanical finishes.

[
1.4.1 Mockups: Build mockups to verify selections made under sample submittals and
to demonstrate aesthetic effects and set quality standards for fabrication and
installation.
 Build mockups as shown on Drawings.

 Build mockups for each form and finish of railing consisting of two posts, top
rail, infill area, and anchorage system components that are full height and are
not less than 600 mm in length.
1.5.1 Field Measurements: Verify handrail and railing dimensions by field

measurements before fabrication and indicate measurements on Shop Drawings.
Coordinate fabrication schedule with construction progress to avoid delaying the
Work.
 Established Dimensions: Where field measurements cannot be made without

delaying the Work, establish dimensions and proceed with fabricating
handrails and railings without field measurements. Coordinate construction to
ensure that actual dimensions correspond to established dimensions.
PART 2 PRODUCTS
2.1 METALS
2.1.1 General: Provide metal free from pitting, seam marks, roller marks, stains,
discolorations, and other imperfections where exposed to view on finished units.
2.1.2 Steel and Iron:
 Tubing: ASTM A 500 (cold formed) or ASTM A 513, Type 5 (mandrel drawn).
 Pipe: ASTM A 53M, Type F or Type S, Grade A, Standard Weight (Schedule 40),
unless another grade and weight are required by structural loads.
 Plates, Shapes, and Bars: ASTM A 36M.
 Castings: Either gray or malleable iron, unless otherwise indicated.
 Gray Iron: ASTM A 48M, Class 30, unless another class is indicated or
required by structural loads.
 Malleable Iron: ASTM A 47M.
2.1.3 Brackets, Flanges, and Anchors: Cast or formed metal of same type of material
and finish as supported rails, unless otherwise indicated.
2.2.1 Fasteners: Provide concealed fasteners, unless unavoidable or standard for

railings indicated.

[
 Steel Railings: Plated steel fasteners complying with ASTM B 633, Class Fe/Zn
25 for electrodeposited zinc coating.
2.2.2 Zinc-Rich Primer: Complying with SSPC-Paint 20 or SSPC-Paint 29 and compatible
with topcoat.
2.2.3 Anchors: Provide cast-in-place or torque-controlled expansion anchors, fabricated

from corrosion-resistant materials with capability to sustain, without failure, a
load equal to six times the load imposed when installed in unit masonry and equal
to four times the load imposed when installed in concrete, as determined by
testing per ASTM E 488.
2.2.4 Grout: Factory-packaged, nonshrink, nonmetallic grout complying with

ASTM C 1107; or water-resistant, nonshrink anchoring cement; recommended by
manufacturer for exterior use
2.2.5 Filler Metal and Electrodes: Provide type and alloy of filler metal and electrodes
as recommended by producer of metal to be welded or brazed and as required
for color match, strength, corrosion resistance, and compatibility in fabricated
items.
2.3 FABRICATION
2.3.1 General: Fabricate railings to comply with design, dimensions, and details
indicated, but not less than that required to support structural loads
2.3.2 Welded Connections: Cope components at connections to provide close fit, or

use fittings designed for this purpose. Weld all around at connections, including
at fittings
2.3.3 Form changes in direction by bending or by inserting prefabricated elbow fittings
2.3.4 Form curves by bending in jigs to produce uniform curvature; maintain cross
section of member throughout bend without cracking or otherwise deforming
exposed surfaces.
2.3.5 Close exposed ends of railing members with prefabricated end fittings.
2.3.6 Provide wall returns at ends of wall-mounted handrails, unless otherwise

indicated.
2.3.7 Brackets, Flanges, Fittings, and Anchors: Provide wall brackets, flanges,
miscellaneous fittings, and anchors to interconnect railing members to other
work, unless otherwise indicated
2.4.1 Steel and Iron:
 Galvanized Railings: Hot-dip galvanize exterior railings, after fabrication, to

comply with ASTM A 123/A 123M. Provide hot-dip galvanized fittings,
brackets, fasteners, sleeves, and other ferrous components.

[
 Field Applied Paint: Epoxy paint system with polyurethane top coat, comply
with requirements as sepecified in Division 9 Section “Painting”
PART 3 EXECUTION
3.1.1 General: Perform cutting, drilling, and fitting required for installing railings. Set
railings accurately in location, alignment, and elevation.
 Set posts plumb within a tolerance of 2 mm in 1 m.

 Align rails so variations from level for horizontal members and variations from
parallel with rake of steps and ramps for sloping members do not exceed 5
mm in 3 m.
3.1.2 Anchor posts in concrete by inserting into formed or core-drilled holes and
grouting annular space.
3.1.3 Attach handrails to wall with wall brackets.
3.1.4 Adjusting and Cleaning:
 Immediately after erection, clean field welds, bolted connections, and abraded
areas of shop paint, and paint exposed areas with the same material as used
for shop painting.
 Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas
and repair galvanizing to comply with ASTM A 780.

[

ISSUED FOR
PURCHASE
CONSTRUCTION
REV. PREPARED REVIEWED APPROVED

DATE PAGES REMARKS
NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. PANELING
CAIRO - EGYPT 06420 – 2039 0

CONTENTS
SECTION 06420
PANELING
Page
PART 1 GENERAL 2

1.2 Summary 2
1.3 Submittals 2
1.6 Coordination 3
PART 2 PRODUCTS 3
2.1 Materials 3
2.2 Installation Materials 4
2.4 Shop Finishing 5
2.5 Wall Panels 5
PART 3 EXECUTION 5
3.1 Preparation 5
3.2 Installation 5
Paneling Section 06420

SECTION 06420
PANELING
PART 1 GENERAL
Section.
1.2 SUMMARY
 Flush wood-veneered board paneling.
1.3 SUBMITTALS
1.3.1 Product Data: For panel products, adhesives, and finishing materials and
processes.
1.3.2 Shop Drawings: Show location of paneling, large-scale details, attachment

devices, and other components. Include dimensioned plans and elevations.
 Show details full size.

 Show locations and sizes of furring and blocking, including concealed blocking
specified in other Sections.
 For paneling produced from pre manufactured sets, show finished panel sizes,
set numbers, sequence numbers within sets, and method of cutting panels to
produce indicated sizes.
 For paneling veneered in fabrication shop, show veneer leaves with
dimensions, grain direction, exposed face, and identification numbers
indicating the flitch and sequence within the flitch for each leaf.
1.3.3 Samples for Initial Selection: Manufacturer's color charts consisting of units or
sections of units showing the full range of colors, textures, and patterns available
for each type of material indicated.
 Shop-applied transparent finishes.

 Shop-applied opaque finishes.
1.3.4 Samples for Verification: For the following:
 Veneer leaves representative of and selected from fitches to be used for

transparent-finished paneling.
 Wood-veneer-faced panel products with or for transparent finish, 300 by 600
mm, for each species and cut. Include at least one face-veneer seam and finish
as specified.
1.3.5 Qualification Data.
1.4.1 Fabricator Qualifications: A firm experienced in producing paneling similar to

that indicated for this Project and with a record of successful in-service
performance, as well as sufficient production capacity to produce required units.
1.4.2 Installer Qualifications: An experienced installer who has completed paneling

similar in material, design, and extent to that indicated for this Project and whose
work has resulted in construction with a record of successful in-service
performance.
1.4.3 Source Limitations: Engage a qualified woodworking firm to assume undivided

responsibility for production and installation of paneling with sequence-matched
wood veneers.
1.4.4 Quality Standard: Unless otherwise indicated, comply with AWI's "Architectural
Woodwork Quality Standards" for grades of paneling, construction, finishes, and
other requirements.
1.4.5 Mockups: Before fabricating and installing paneling, build mockups for each form
of construction and finish required to verify selections made under sample
Submittals and to demonstrate aesthetic effects and qualities of materials and
execution. Build mockups to comply with the following requirements, using
materials indicated for the completed Work:
 Build mockups in the location and of the size as directed by Engineer, but not
more than 10 m2 including one vertical joint.
 Demonstrate the proposed range of aesthetic effects and workmanship.
 Obtain Engineer's approval of mockups before starting paneling fabrication.
 Maintain mockups during construction in an undisturbed condition as a
standard for judging the completed Work.
 Approved mockups may become part of the completed Work if undisturbed at
time of Substantial Completion.
1.5.1 Do not deliver paneling until painting and similar operations that could damage
paneling have been completed in installation areas. If paneling must be stored in
other than installation areas, store only in areas where environmental conditions
comply with manufacture recommendations.
1.6 COORDINATION
1.6.1 Coordinate sizes and locations of framing, blocking, furring, reinforcements, and
other related units of Work specified in other Sections to ensure that paneling can
be installed as indicated.
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 General: Provide materials that comply with requirements of the AWI quality
standard for quality grade specified, unless otherwise indicated.
2.1.2 Wood Products: Comply with the following
 Medium-Density Fiberboard:
 Comply with ANSI A208.2, Grade MD-Exterior Glue.

 Density Rate: 785 kg/m³.
 Screw holding shall not be less than 1100 N for face and 900 N for edge.
 Use boards of highly smooth exposed surfaces to increase resistance to
fungal growth.
2.1.3 Adhesives:
 Do not use adhesives that contain urea formaldehyde.
2.2 INSTALLATION MATERIALS
2.2.1 Furring, Blocking, Shims, and Hanging Strips: Fire-retardant-treated preservative-

treat softwood lumber, kiln-dried to less than 15 percent moisture content.
2.2.2 Anchors: Select material, type, size, and finish required for each substrate for
secure anchorage. Provide nonferrous-metal or hot-dip galvanized anchors and
inserts for corrosion resistance. Provide toothed-steel or lead expansion sleeves
for drilled-in-place anchors.
2.3.1 Paneling Grade: Provide Premium grade paneling complying with the referenced
quality standard.
2.3.2 Wood Moisture Content: Comply with requirements of the referenced quality
standard for wood moisture content in relation to ambient relative humidity
during fabrication and in installation areas.
2.3.3 Arrange paneling in shop or other suitable space in proposed sequence for
examination by Engineer. Mark units with temporary sequence numbers to
indicate position in proposed layout.
 Lay out one elevation at a time if approved by Engineer.

 Notify Engineer seven days in advance of the date and time when layout will
be available for viewing.
 Provide lighting of similar type and level as that of final installation for viewing
layout, unless otherwise approved by Engineer.
 Rearrange paneling as directed by Engineer until layout is approved.
 Do not trim end units and other nonmodular size units to less than modular
size until after Engineer's approval of layout. Indicate trimming by masking
edges of units with nonmarking material.
 Obtain Engineer's approval of layout before start of assembly. Mark units and
Shop Drawings with assembly sequence numbers based on approved layout.

2.3.4 Shop cut openings, to maximum extent possible, to receive, appliances, electrical
work, and similar items. Locate openings accurately and use templates or
roughing-in diagrams to produce accurately sized and shaped openings. Sand
edges of cutouts to remove splinters and burrs.
2.4 SHOP FINISHING
2.4.1 Quality Standard: Comply with AWI Section 1500, unless otherwise indicated.
2.4.2 General: Finish paneling at fabrication shop as specified in this Section. Defer
only final touchup, cleaning, and polishing until after installation.
2.4.3 Preparations for Finishing: Comply with referenced quality standard for sanding,
filling countersunk fasteners, sealing concealed surfaces, and similar preparations
for finishing paneling, as applicable to each unit of work.
 Back priming: Apply two coats of sealer or primer, compatible with finish
coats, to concealed surfaces of paneling. Concealed surfaces of plastic-
laminate-clad paneling do not require backpriming when surfaced with plastic
laminate.
2.4.4 Transparent Finish:
 Grade: Premium.
 Finish: Polyurethane varnish, comply with requirements specified in Division 9
Section “Painting”.
 Staining: Match approved sample for color.
 Sheen: Match approved sample for color.
2.5 WALL PANELS
 Construction: MDF with white Oak hardwood veneer factory press-bonded

to face and edges.
 Thickness: 19 mm, unless otherwise indicated on Drawings.
 Dimensions: As indicated on Drawings
PART 3 EXECUTION
3.1 PREPARATION
3.1.1 Condition paneling to average prevailing humidity conditions in installation areas

before installation.
3.1.2 Before installing paneling, examine shop-fabricated work for completion and
complete work as required, including removal of packing and backpriming.
3.2 INSTALLATION
3.2.1 Quality Standard: Install paneling to comply with AWI Section 1700 for the same
grade specified in Part 2 of this Section for type of paneling involved.
3.2.2 Install paneling level, plumb, true, and straight with no distortions. Shim as
required with concealed shims. Install level and plumb to a tolerance of 3 mm in
2400 mm. Install with no more than 1.6 mm in 2400-mm vertical cup or bow and
3 mm in 2400-mm horizontal variation from a true plane.
3.2.3 Scribe and cut paneling to fit adjoining work, and refinish cut surfaces and repair
damaged finish at cuts.
3.2.4 Complete the finishing work specified in this Section to extent not completed at
shop or before installation of paneling. Fill nail holes with matching filler where
exposed. Apply specified finish coats, including stains and paste fillers if any, to
exposed surfaces where only sealer/prime coats were applied in shop.

3.3.1 Repair damaged and defective paneling, where possible, to eliminate functional
and visual defects; where not possible to repair, replace paneling. Adjust for
uniform appearance. Comply with requirements of Division 9, Section “Painting”
for final touch up of installed paneling.
3.3.2 Clean paneling on exposed surfaces. Touch up shop-applied finishes to restore

damaged or soiled areas.


ISSUED FOR
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CONSTRUCTION

NO. BY BY BY
A Apr.2015 E.F. 4 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. BITUMINOUS DAMP-PROOFING
CAIRO - EGYPT 07115 – 2039 0

CONTENTS
SECTION 07115
BITUMINOUS DAMP-PROOFING
Page
PART 1 GENERAL 2

1.2 Summary 2
1.3 Submittals 2
PART 2 PRODUCTS 3
2.1 Bituminous Damp-Proofing 3

PART 3 EXECUTION 3
3.1 Examination 3
3.2 Preparation 3
3.3 Application, General 4
3.4 Cold-Applied, Emulsified-Asphalt Damp-Proofing 4
3.5 Protection 4
3.6 Cleaning 4
Bituminous Damp-Proofing Section 07115

SECTION 07115
BITUMINOUS DAMP-PROOFING
PART 1 GENERAL
Section.
1.2 SUMMARY
1.2.1 This Section includes cold-applied, emulsified-asphalt damp-proofing applied as

indicated in Drawings.
1.3 SUBMITTALS
1.3.1 Product Data: For each type of product indicated including data substantiating
that materials comply with requirements for each damp-proofing material
specified. Include recommendations for method of application, primer, number
of coats, coverage or thickness, and protection course.
1.3.2 Material Certificates: For each product, signed by manufacturers,.
1.4.1 Source Limitations: Obtain primary damp-proofing materials and primers

through one source from a single manufacturer. Provide secondary materials
recommended by manufacturer of primary materials.
1.4.2 Single Source Responsibility: Obtain primary damp-proofing materials and

primers from one source and by a single manufacturer. Provide secondary
materials only as recommended by manufacturer of primary materials and as per
the Engineer’s approval.
1.5.1 Substrate: Proceed with damp-proofing only after substrate constructions curing
and penetrating works have been completed.
1.5.2 Weather Limitations: Proceed with installation only when existing and forecasted
weather conditions permit asphalt damp-proofing to be performed according to
manufacturers' written instructions.

PART 2 PRODUCTS
2.1 BITUMINOUS DAMP-PROOFING
2.1.1 Cold-Applied, Emulsified-Asphalt Damp-proofing:
 Brush and Spray Coats: This is an asphalt base, clay non-fibered, clay emulsion
under normal use it resists flow and sag. It conforms to ASTM D 1227, Type III,
Class 1.
2.2.1 Emulsified-Asphalt Primer: ASTM D 1227, Type III, Class 1, except diluted with
water as recommended by manufacturer.
2.2.2 Asphalt-Coated Glass Fabric: ASTM D 1668, Type I.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine substrates, with the Applicator present, for compliance with
requirements for surface smoothness and other conditions affecting performance
of work.
 Begin damp-proofing application only after substrate construction and

penetrating work have been completed and unsatisfactory conditions have
been corrected.
3.2 PREPARATION
3.2.1 Protection of Other Work: Mask or otherwise protect adjoining exposed surfaces
from being stained, spotted, or coated with damp-proofing. Prevent damp-
proofing materials from entering and clogging weepholes and drains.
3.2.2 Clean substrates of projections and substances detrimental to work; fill voids, seal
joints, and apply bond breakers if any, as recommended by prime materials
manufacturer.
3.2.3 Install cant strips and similar accessories as shown and as recommended by prime
materials manufacturer even though not shown.
3.2.4 Fill voids, seal joints, and apply bond breakers, if any, as recommended by prime
materials manufacturer, with particular attention at construction joints.

3.2.5 Install separate flashings and corner protection stripping, as recommended by
prime materials manufacturer, to precede application of damp-proofing. Comply
with manufacturer’s recommendations. Pay particular attention to requirements
at building expansion joints, if any.
3.2.6 If recommended by prime materials manufacturer, prime substrate in accordance

with manufacturer’s application instructions.
3.3 APPLICATION, GENERAL
3.3.1 Comply with manufacturer's written recommendations unless more stringent

requirements are indicated or required by Project conditions to ensure
satisfactory performance of damp-proofing.
 Apply additional coats if recommended by manufacturer or required to

achieve coverages indicated.
 Allow each coat of damp-proofing to cure 24 hours before applying
subsequent coats.
3.3.2 Apply damp-proofing to provide continuous plane of protection on exterior face

of concrete and masonry indicated to receive dimension stone cladding.
 Extend damp-proofing over outer face of structural members and concrete

slabs that interrupt concrete and masonry walls.
3.3.3 Reinforcement: At changes in plane install lapped course of glass fabric in first
coat of damp-proofing compound before it thickens.
3.4 COLD-APPLIED, EMULSIFIED-ASPHALT DAMP-PROOFING
3.4.1 On Concrete Backup for Dimension Stone Cladding: Apply one brush or spray
coat at not less than 0.4 L/sq. m.
3.4.2 On Masonry Backup for Dimension Stone Cladding: Apply primer and one brush
or spray coat at not less than 0.4 L/sq. m.
3.5 PROTECTION
3.5.1 Protect exterior, below grade damp-proofing membrane from damage until
backfill is completed. Remove overspray and spilt materials from surfaces not
intended to receive damp-proofing.
3.6 CLEANING
3.6.1 Remove damp-proofing materials from surfaces not intended to receive damp-
proofing.


ISSUED FOR
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NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. POLYETHYLENE SHEET
CAIRO - EGYPT 07134 – 2039 0

CONTENTS
SECTION 07134
POLYETHYLENE SHEET
Page
PART 1 GENERAL 2

1.2 Summary 2
1.4 Submittals 2
PART 2 PRODUCTS 3
2.1 General 3
2.2 Polyethylene Sheets 3
PART 3 EXECUTION 4
3.1 Preparation of Substrate 4

3.2 Application 5
3.4 ‎Protection and Clean-up 7
Polyethylene Sheet Section 07134

0
SECTION 07134
POLYETHYLENE SHEET
PART 1 GENERAL
and Division-1 Specification Sections, apply to work of this Section.
1.2 SUMMARY
1.2.1 This section covers the work of polyethylene sheet as shown on Drawings and
required by the Contract including the following:
 Below grade polyethylene sheet

 Under slab on grade.
1.2.2 Extent of polyethylene sheet work is indicated on Drawings.
1.3.1 Polyethylene sheet work shall be performed in strict accordance with the
stipulations of the specifications of the American Society for Testing and Materials
(ASTM), as referenced to throughout this section, or other approved international
standards and Sound Practice.
American Society for Testing and Materials
ASTM No.
D 2103 Specification of Polyethylene Film and Sheeting
E 154 Test Methods for Water Vapor Retarders Used in Contact with Earth
under Concrete Slabs, on Walls, or as Ground Cover
1.3.2 In the event of conflict between various codes and standards the most stringent
conditions apply.
1.4 SUBMITTALS
1.4.1 Submit the following in accordance with Conditions of the Contract and Division-1
Specification Section:
 Product Data: Include data substantiating that employed materials comply

with requirements specified in this section, and written instructions for
preparing, and treating substrate, and testing physical and performance
properties.

0
 Shop Drawings: Showing location and extent of polyethylene sheet including
details for substrate joints, sheet flashing, penetration, and termination
conditions.
 Samples: 100 x 150 mm minimum size of each material required for project.
 Product Test Reports: From a qualified independent testing agency indicating
and interpreting test results for compliance with requirements, based on
comprehensive testing.
1.5.1 Engage an experienced installer who has completed sheet work similar in
materials, design and extent to that indicated for project and that has resulted in
construction with a record of successful in-service performance.
1.5.2 Obtain materials and secondary materials from a single manufacturer.
1.6.1 Proceed with work only after substrate construction and penetrating work has
been completed.
1.6.2 Substrate shall be uniform well compacted soil, with surface graded and smooth.
1.6.3 Proceed with work only when existing and forecast weather conditions will permit
work to be performed in accordance with manufacturer's recommendations.
PART 2 PRODUCTS
2.1 GENERAL
2.1.1 Provide polyethylene sheet which comply with the specified requirements or
provide other similar alternative products which are certified in writing by
manufacturer to be superior in performance for application indicated
2.2 POLYETHYLENE SHEETS
2.2.1 Materials shall be uniform, flexible sheet consisting of unmodified high density
polyethylene (HDPE) containing no plasticizers, fillers, chemical additives,
reclaimed polymers or extenders. Not less than 2.5% carbon black shall be added
to the resin for ultraviolet resistance. The only other compound elements shall be
anti-oxidants and heat stabilizers, of which up to 1.5% total, as required for
manufacturing, may be added.
2.2.2 The membrane shall be supplied as a single-ply continuous sheet in a rolled form,
minimum width of sheets shall be 4.5 m. HDPE shall be hot-air weldable.
2.2.3 Polyethylene sheet shall be uniform, flexible, free of holes, blisters, undispersed
raw materials or any sign of contamination by foreign materials. Sheets shall also
be new, first-quality products designed and manufactured specifically for the
purpose of this work, as satisfactorily demonstrated by prior use to be suitable

0
and durable.
2.2.4 Polyethylene sheets shall meet the required following values:
Parameter Test Method Value

Thickness, microns ASTM D-2103 400 max.
Specific Gravity ASTM D-792, Method A-1 0.941 to 0.960
Weight, 1b/1000 ft2 ASTM D-2103 20 average
Tensile Properties ASTM D-882 32 min.
MD-1bf XD-1bf 28 min.
Elongation at Yield, % ASTM D-638 100 average
Tongue Tear ASTM D-1938 4 min.
MD-1bf XD-1bf 3.6 min.
Environmental Stress Crack-hours ASTM D-1693 Condition C 1500 min.
(100°C)
Hydrostatic Head Resistance ASTM D 5385 70 m
Dimensional Stability Each Direction,  2 max.
%
Puncture Resistance kg/mm FTMS 101C, Method 2065 2 min.
thickness
PART 3 EXECUTION
3.1 PREPARATION OF SUBSTRATE
3.1.1 Clean substrate of projections and substances detrimental to work; comply with
recommendations of materials manufacturer.
3.1.2 Fill voids, seal joints and apply bond breakers (if any) as recommended by
materials manufacturer, with particular attention to construction joints.
3.1.3 All vertical surfaces shall be firm, hard, smooth and dry and shall be thoroughly
chipped, wire brushed and washed with clean water to present a new fresh and
clean surface to which material shall bond.
3.1.4 Surfaces shall be even, smooth with any high spots knocked flat, clean, dry, free of
grease, loose materials, and foreign material which would interfere with sheet
application.
3.1.5 All vertical surfaces to which sheets shall be applied shall be thoroughly chipped
and wire brushed, and then washed with clean water to present a new fresh and
clean surface to which sheets shall bond.

0
3.2 APPLICATION
3.2.1 Comply with manufacturer's recommendations, except where more stringent

requirements are indicated or specified and where project conditions require
extra precautions or provisions to ensure satisfactory performance of work.
3.2.2 Polyethylene Sheet Installation:
 Apply Polyethylene sheet to the extent indicated on Drawings.

 Care shall be taken not to injure the Polyethylene sheet treatment either
during application or after completion.
 Seal penetration through sheets to provide watertight seal with penetration
seal patches.
 When laid under slab on grade verify that subgrade is compacted, dry, smooth,
sound and ready to receive HDPE.
 Before installation begins, inspect sheets for damage from transit. Sheets that
cannot be repaired, in the Engineer's judgment, shall be rejected and removed
from the work area and Site.
 During unwrapping of materials for use and placement, visually inspect
surfaces of sheets. Mark each imperfection for repair.
 Prior to start of installation, make necessary field measurements to provide
proper fit of sheets. Care shall be taken into consideration during handling the
polyethylene sheets.
 Accurately align sheet and maintain uniform side and end laps. Stagger and
laps HDPE sheets shall be placed in such a manner as to reduce field seaming
to a minimum. Polyethylene sheets shall be rolled-out side by side and
overlapped about 150 mm.
 Install loosely laid polyethylene sheet over entire area as shown on Drawings.
No material shall be placed when relative humidity is more than 80% or when
it is raining, unless the Contractor can demonstrate to the Engineer's
satisfaction that installation techniques compensate for these conditions.
 Maneuver sheets of HDPE into place in a manner which prevents wrinkles,
folds or similar distress which can cause damage to sheets or prevent their
satisfactory alignment or seaming. Factors such as expansion, contraction,
overlap at seams, seaming progress, wrapping around concrete element or any
other element and drainage shall be considered.
 Sandbags shall be used as necessary to temporarily anchor or hold the water-
proofing sheets in position during installation. Sandbag fabric shall be
sufficiently close knit to preclude fines from working through the bags.
 Protect sheets from equipment and other hazards and keep it clean and free of
all debris during placement. Protect sheets from uplift by wind and other
damage prior to seaming or attachment of edges.
 Seal sheet to structures in accordance with requirements of this section and
details shown on Drawings.

0
 Accurately align sheets and maintain uniform 150 mm minimum laps widths
and end lapper. Overlap and seal seams with adhesive stagger and tape end
laps to ensure watertight installation.
 Take extreme care during installation of sheets to be certain that no damage is
done to any part of sheet. Prohibit smoking at the Site by installation
personnel. No gasoline-driven generators or cans of flammable liquid shall be
placed on sheets. Under no circumstances shall the HDPE surfaces be used as
a work area for preparing patches, storing tools and supplies or other uses. If
needed, a protective cover shall be spread out as a work surface, to prevent
damage to sheets.
 Care shall be taken not to punch sheets either during installation or after
completion.
 Finished work of sheet shall be approved by the Engineer before construction
of subsequent permanent work.
3.2.3 Field Seams: Use lap joints to seal membrane sheets together in the field. Field
seams shall be made on a supporting smooth surface. Form seams by lapping
edges of sheets a minimum of 150 mm ensure completed laps lay flat and are free
of voids fish mouth or wrinkles. Wipe contact surfaces of sheets clean to remove
dirt, dust, moisture and other foreign materials and prepare in accordance with
the installer's seaming method approved by the Engineer. Extend seams to ends
of sheets.
 Seam sheets together, using adhesive or the fusion-extrusion welding system,

equipment and techniques. Insert copper wire for spark test, prior to welding,
at the extradite of weld at the edge of top sheet.
 When capping of a field seam is required, use pressure tape or a cover strip of
the same thickness as sheets (and from the same roll, if available) and of 100
mm minimum width. Position the strip over the center of field seam and weld
to sheets using a fillet weld each side with the insertion of copper wire as
described above for spark testing.
3.3.1 Observe the installation of the HDPE sheets, including making and testing of each
sheet seam and patch. Conform to practices specified hereinafter.
3.3.2 In-place Observation and Testing General: Visually inspect HDPE sheets, seams,
seals and repairs for defects as installation progresses and again on completion.
In addition, check all seams and repairs using a metal probe. Test each seam and
repair using a spark testing device. Defective and questionable areas shall be
clearly marked and repaired to the Engineer's satisfaction. Each area showing
injury due to scuffing, penetration by foreign objects or distress from rough
subsurface shall be replaced or covered by capping with an additional layer of
membrane material. Testing shall be performed in the presence of the Engineer.

0
3.4 ‎PROTECTION AND CLEAN-UP
3.4.1 Protect sheets after acceptance by the Engineer. Institute required procedures for
protection of completed membrane during installation of subsequent work.
3.4.2 The Contractor shall remove all equipment, rubbish, debris and clean the Site to
the satisfaction of the Engineer.

0

ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. METAL ROOF PANELS
CAIRO - EGYPT 07411 – 2039 0

CONTENTS
SECTION 07411
METAL ROOF PANELS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.4 Submittals 3
1.8 Coordination 6
1.9 Warranty 6
PART 2 PRODUCTS 7
2.1 Panel Materials 7
2.3 Foamed-Insulation-Core Metal Roof Panels 8
2.4 Miscellaneous Metal Framing 9
2.5 Accessories 10
2.6 Fabrication 10
2.7 Galvanized Corrugated Steel Sheet Roof Deck 11
PART 3 EXECUTION 12
3.1 Examination 12
3.2 Preparation 12
3.3 Steel Sheet Deck Installation 13
3.4 Metal Roof Panel Installation, General 14
3.5 Foamed Insulation Core Metal Roof Panel Installation 15
3.6 Accessory Installation 15
3.7 Erection Tolerances 16
3.9 Cleaning And Protection 16
Metal Roof Panels Section 07411

SECTION 07411
METAL ROOF PANELS
PART 1 GENERAL
Supplementary Conditions apply to this Section.
1.2 SUMMARY
1.2.1 This Section covers the work of metal roof system consisting of the following
components, but not limited to:
 Factory-formed and -assembled, foamed-insulation-core metal roof panels.

 Factory-formed and -assembled, foamed-insulation -core metal wall panels,
fire rated.
 Galvanized corrugated and smooth steel sheet roof deck.

 Rain water gutters of matching alloy and finish as roof panels.
1.2.2 Related Sections Accessory components include the following:
 Division 7 Section "Metal Wall Panels" for factory-formed metal soffit panels.
 Division 7 Section "Joint Sealants" for field-applied sealants not otherwise
specified in this Section and for general requirements for sealants applications.
1.3.1 Structural Performance: Provide metal roof panel assemblies capable of

withstanding the effects of gravity loads and the following loads and stresses
within limits and under conditions indicated, based on testing according to
ASTM E 1592 or ASTM E 330:
 Wind Loads: According to the Egyptian code of practice no. 201-2003, basic
wind speed (v) = 33.0 m/sec.
 Seismic Loads: Seismic Loads: Effects of earthquake motions calculated according to

requirements of Egyptian code of practice for calculating loads an forces in Structural
and building works, Ministerial Decree 367/2003; Zone two (2).
 Deflection Limits: Engineer metal panel assemblies to withstand design loads
with vertical deflections no greater than 1/180 of the span
1.3.2 Air Infiltration: Air leakage through assembly of not more than 0.3 L/s per sq. m
of roof area when tested according to ASTM E 283 at the following test-pressure

difference:
 Test-Pressure Difference: Negative 75 Pa
 Positive Preload Test-Pressure Difference: Greater than or equal to720 Pa and

the greater of 75% of building live load or 50% of building design positive
wind-pressure difference.
 Negative Preload Test-Pressure Difference: 50% of design wind-uplift-pressure

difference.
1.3.3 Water Penetration: Under site exposure conditions, moisture must not penetrate
onto internal surfaces, or into cavities not designed to be wetted.
1.3.4 Thermal Movements: Provide metal roof panel assemblies that allow for thermal
movements resulting from the following maximum change (range) in ambient and
surface temperatures by preventing buckling, opening of joints, overstressing of
components, failure of joint sealants, failure of connections, and other
detrimental effects. Base engineering calculation on surface temperatures of
materials due to both solar heat gain and nighttime-sky heat loss.
 Temperature Change (Range): 35 deg. C, ambient; 60 deg. C, material surfaces.
1.4 SUBMITTALS
1.4.1 Product Data: Include construction details, material descriptions, dimensions of

individual components and profiles, and finishes for each type of metal roof panel
and accessory.
1.4.2 Installer Certificates: Signed by product manufacturer certifying that the Installer
is approved, authorized, or licensed by the manufacturer to install his products.
1.4.3 Shop Drawings: Show fabrication and installation layouts of metal roof panels;
details of edge conditions, joints, panel profiles, corners, anchorages, trim,
flashings, closures, and accessories; and special details. Distinguish between
factory- and field-assembled works.
 Fixing details.
 Accessories: Include details of the following items, at a scale of not less than
1:10:
 Flashing and trim.
 Gutters.
 For installed products indicated to comply with design loads, include structural
analysis.
1.4.4 Coordination Drawings: Roof plans drawn to scale and coordinating penetrations
and roof-mounted items. Show the following:
 Roof panels and attachments.

 Purlins and rafters.
1.4.5 Samples for Initial Selection: For each type of metal roof panel indicated with
factory-applied color finishes.
 Include similar Samples of trim and accessories involving color selection.
1.4.6 Samples for Verification: For each type of exposed finish required, prepared on
Samples of size indicated below.
 Metal Roof and Soffit Panels: 300 mm long by actual panel width, in the
profile, style, color, and texture indicated. Include fasteners, clips, battens,
closures, and other metal roof panel accessories.
 Trim and Closures: 300 mm long. Include fasteners and other exposed
accessories.
 Accessories: 300 mm long Samples for each type of accessory.
1.4.7 Qualification Data: For firms and persons specified in the "Quality Assurance"
Article to demonstrate their capabilities and experience. Include lists of
completed projects with project names and addresses, names and addresses of
engineers and employers, and other information specified.
1.4.8 Material Certificates: Product certificates signed by manufacturers of the

following products certifying that sheet metal roofing and finishes comply with
specified requirements.
1.4.9 Product Test Reports: Based on evaluation of comprehensive tests performed by

a qualified testing agency.
1.4.10 Field quality-control inspection reports.
1.4.11 Maintenance Data: For metal roof panels to include in maintenance manuals.
1.4.12 Warranties: Special warranties specified in this Section.
1.5.1 Manufacture Qualifications: Engage a manufacture experienced with the

successful production of the specified work similar in design, material and extent
to the scope of this Project, and with a record of successful in-service
performance and completion or projects for, as well as, sufficient production
capability, facilities, and personnel, to produce the required work.
1.5.2 Installer Qualifications: An employer of workers trained and approved by

manufacturer.
 Installer's responsibilities include installing metal roof panel assemblies and

providing professional engineering services needed to assume engineering
responsibility.
 Engineering Responsibility: Preparation of data for metal roof panels, including

Shop Drawings, based on testing and engineering analysis of manufacturer's
standard units in assemblies similar to those indicated for this Project.
 Installer Qualifications: A qualified firm specializing in performing the work of
this Section with minimum 3 years documented experience and that is
approved, authorized, or licensed by the product manufacturer to install his
product and that is eligible to receive manufacturer's warranty. Include project
names and addresses, names and addresses of the Engineers and Employers,
and other information specified.
1.5.3 Testing Agency Qualifications: Qualified according to ASTM E 329 for testing
indicated, as documented according to ASTM E 548.
1.5.4 Source Limitations: Obtain each type of metal roof panels through one source
from a single manufacturer.
1.5.5 Fire-Resistance Ratings: Where indicated, provide metal roof panels identical to
those of assemblies tested for fire resistance per ASTM E 119 by a testing and
inspecting agency acceptable to authorities having jurisdiction.
 Combustion Characteristics: ASTM E 136.

 Fire-Resistance Ratings: Indicated by design designations from UL's "Fire
Resistance Directory" or from the listings of another testing and inspecting
agency.
 Metal roof panels shall be identified with appropriate markings of applicable
testing and inspecting agency.
 Fire Rating Period: As indicated on Drawings.
1.5.6 Surface-Burning Characteristics: Provide insulated metal roof panels having
insulation core material with the following surface-burning characteristics as
determined by testing identical products, per ASTM E 84 by UL or another testing
and inspecting agency acceptable to authorities having jurisdiction or the
Engineer:
 Flame-Spread Index: 25 or less, unless otherwise indicated.

 Smoke-Developed Index: 450 or less, unless otherwise indicated.
1.5.7 Mockups: Build mockups to verify selections made under Sample Submittals and
to demonstrate aesthetic effects and qualities of materials and execution.
 Build mockup of typical roof area, including fascia, and soffit as selected by the
Engineer; approximately 2000 mm square by full thickness, including
insulation, attachments, and accessories.
 Approval of mockups does not constitute approval of deviations from the
Contract Documents contained in mockups unless such deviations are
specifically approved by the Engineer in writing.
 Approved mockups will become part of the completed Work if undisturbed at

1.6.1 Deliver components, sheets, metal roof panels, and other manufactured items so
as not to be damaged or deformed. Package metal roof panels for protection
during transportation and handling.
1.6.2 Unload, store, and erect metal roof panels in a manner to prevent bending,
warping, twisting, and surface damage.
1.6.3 Stack metal roof panels on platforms or pallets, covered with suitable weather
tight and ventilated covering. Store metal roof panels to ensure dryness. Do not
store metal roof panels in contact with other materials that might cause staining,
denting, or other surface damage.
1.6.4 Protect strippable protective covering on metal roof panels from exposure to
sunlight and high humidity, except to extent necessary for period of metal roof
panel installation.
weather conditions permit assembly of metal roof panels to be performed
according to manufacturers' written instructions and warranty requirements.
1.7.2 Field Measurements: Verify locations of roof framing and roof opening
dimensions by field measurements before metal roof panel fabrication and
indicate measurements on Shop Drawings.

delaying the Work, either establish framing and opening dimensions and
proceed with fabricating metal roof panels without field measurements, or
allow for field-trimming of panels. Coordinate roof construction to ensure that
actual building dimensions, locations of structural members, and openings
correspond to established dimensions.
1.8 COORDINATION
1.8.1 Coordinate metal roof panel assemblies with rain drainage work, flashing, trim,
and construction of purlins and rafters, parapets, walls, and other adjoining work
to provide a leak-proof, secure, and noncorrosive installation.
1.9 WARRANTY
1.9.1 Special Warranty: Manufacturer's standard form in which manufacturer agrees to

repair or replace components of metal roof panel assemblies that fail in materials
or workmanship within specified warranty period.
 Failures include, but are not limited to, the following:
 Structural failures, including rupturing, cracking, or puncturing.

 Deterioration of metals, metal finishes, and other materials beyond normal

weathering.
 Warranty Period: Five (5) years from date of Substantial Completion.
1.9.2 Special Warranty on Panel Finishes: Manufacturer's standard form in which

manufacturer agrees to repair finish or replace metal roof panels that show
evidence of deterioration of factory-applied finishes within specified warranty
period.
 Finish Warranty Period: twenty (20) years from date of Substantial

Completion.
1.9.3 Special Weather tightness Warranty: Manufacturer's standard form in which

manufacturer agrees to repair or replace metal roof panel assemblies that fail to
remain weather tight, including leaks, within specified warranty period.
 Weather tight Warranty Period: Ten (10) years from date of Substantial
Completion.
PART 2 PRODUCTS
2.1 PANEL MATERIALS
2.1.1 Metallic-Coated Steel Sheet Prepainted with Coil Coating: Steel sheet metallic
coated by the hot-dip process and prepainted by the coil-coating process to
comply with ASTM A 755M.
 Galvanized Steel Sheet: ASTM A 653M, Z275 coating designation; structural

quality.
coated by the hot-dip process and prepainted by the coil-coating process to
comply with ASTM A 755/A 755M.
 Zinc-Coated (Galvanized) Steel Sheet: ASTM A 653/A 653M, G90 (Z275) coating
designation; structural quality.
 Concealed Finish: Apply pretreatment and manufacturer's standard white or light-
colored acrylic or polyester backer finish, consisting of prime coat and wash coat with
a minimum total dry film thickness of 0.5 mil (0.013 mm).
2.2.1 General: Provide materials and types of fasteners, solder, welding rods,
protective coatings, separators, sealants, and accessory items as required for a
complete roofing system and as recommended by sheet metal manufacturer and
fabricator for metal roofing work, unless otherwise indicated.
2.2.2 Fasteners: Self-tapping screws, bolts, nuts, self-locking rivets and bolts, end-
welded studs, and other suitable fasteners designed to withstand design loads.
Provide exposed fasteners with heads matching color of metal roof panels by

means of plastic caps or factory-applied coating.
 Fasteners for Roof Panels: Self-drilling or self-tapping 410 stainless steel hex
washer head, with EPDM washer under heads of fasteners bearing on weather
side of metal roof panels.
 Fasteners for Flashing and Trim: Blind fasteners or self-drilling screws with hex
washer head. Use high-strength aluminum of matching finish or stainless-
steel.
2.2.3 Sealants:
 Sealant Tape: Pressure-sensitive, 100 percent solids, gray polyisobutylene

compound sealant tape with release-paper backing. Provide permanently
elastic, nonsag, nontoxic, nonstaining tape 13 mm wide and 3 mm thick.
 Joint Sealant: ASTM C 920; elastomeric polyurethane, or silicone sealant; of
type, grade, class, and use classifications required to seal joints in metal roof
panels and remain weather tight; and as recommended in writing by metal
roof panel manufacturer.
 Butyl-Rubber-Based, Solvent-Release Sealant: ASTM C 1311.
2.2.4 Expanded-Metal Lath: Comply with ASTM C 847 for material, type, configuration,
and other characteristics indicated below.
 Material: Fabricate expanded-metal lath from sheet metal conforming to the

following:
 Galvanized Steel: Structural-quality, zinc-coated (galvanized) steel sheet
complying with ASTM A 653M, Z180 minimum coating designation, unless
 Diamond-Mesh Lath: Comply with the following requirements:
 Configuration: Flat.
 Weight: 1.8 kg/sq. m.
2.3 FOAMED-INSULATION-CORE METAL ROOF PANELS
2.3.1 General: Provide factory-formed and -assembled metal roof panels fabricated
from two sheets of metal with insulation core foamed-in-place during fabrication
with joints between panels designed to form weather tight seals. Include
accessories required for weather tight installation.
 Panel Performance:
 Flatwise Tensile Strength: 200 kPa when tested according to ASTM C 297.
 Humid Aging: Volume increase not greater than 6.0 percent and no
delamination or metal corrosion when tested for 7 days at 60 deg C and
100 percent relative humidity according to ASTM D 2126.
 Heat Aging: Volume increase not greater than 2.0 percent and no
delamination, surface blistering, or permanent bowing when tested for 7
days at 93 deg C according to ASTM D 2126.

 Cold Aging: Volume decrease not more than 1.0 percent and no
delamination, surface blistering, or permanent bowing when tested for 7
days at minus 29 deg C according to ASTM D 2126.
 Fatigue: No evidence of delamination, core cracking, or permanent bowing
when tested to a 958-kPa positive and negative wind load and with
deflection of L/180 for 2 million cycles.
 Autoclave: No delamination when exposed to 13.8-kPa pressure at a
temperature of 100 deg C for 2-1/2 hours.
 Insulation Core: Manufactured standard material to achieve the required fire
rating and U value as indicated on Drawings.
2.3.2 Lap-Seam-Profile, Foamed-Insulation-Core Metal Roof Panels: Formed for
lapping side edges of adjacent panels and mechanically attaching to supports
using exposed fasteners in side laps.
 Facings: Fabricate panel with exterior and interior facings of same material
and thickness.
 Material: galvanized steel sheet, 0.50 mm thick.
 Clips: One piece; zinc-coated galvanized steel sheet, thickness as
recommended by manufacture.
 Panel Coverage: As indicated.
 Panel Thickness: 100 mm unless otherwise indicated on Drawings and as per
manufacture recommendation to achieve required u value.
 Uplift Rating: UL 90.
2.4 MISCELLANEOUS METAL FRAMING
2.4.1 General: Comply with ASTM C 754 for conditions indicated.
 Steel Sheet Components: Complying with ASTM C 645 requirements for metal
and with ASTM A 653M, Z180, hot-dip galvanized zinc coating.
2.4.2 Hat-Shaped, Rigid Furring Channels: ASTM C 645.
 Minimum Base Metal Thickness: As recommended by manufacture, but not

less than 0.45 mm.
 Depth: As indicated.
2.4.3 Cold-Rolled Furring Channels: 1.37-mm bare steel thickness, with minimum 13-
mm wide flange.
 Furring Brackets: Adjustable, corrugated-edge type of steel sheet with
minimum bare steel thickness of 0.79 mm.
 Tie Wire: ASTM A 641M, Class 1 zinc coating, soft temper, 1.59-mm diameter
wire, or double strand of 1.21-mm diameter wire.

2.4.4 Z-Shaped Furring: With slotted or nonslotted web, face flange of 32 mm, wall
attachment flange of 22 mm, minimum bare metal thickness of 0.45 mm, and
depth required to fit insulation thickness indicated.
2.4.5 Fasteners for Metal Framing: Of type, material, size, corrosion resistance, holding
power, and other properties required to fasten steel members to substrates.
2.5 ACCESSORIES
2.5.1 Roof Panel Accessories: Provide components required for a complete metal roof
panel assembly including trim, copings, fasciae, corner units, ridge closures, clips,
flashings, sealants, gaskets, fillers, closure strips, and similar items. Match
material and finish of metal roof panels, unless otherwise indicated.
 Closures: Provide closures at eaves and ridges, fabricated of same metal as

metal roof panels.
 Backing Plates: Provide metal backing plates at panel end splices, fabricated
from material recommended by manufacturer.
 Closure Strips: Closed-cell, expanded, cellular, rubber or cross-linked,
polyolefin-foam or closed-cell laminated polyethylene; minimum 25 mm thick,
flexible closure strips; cut or premolded to match metal roof panel profile.
Provide closure strips where indicated or necessary to ensure weather tight
construction.
2.5.2 Flashing and Trim: Formed from 0.45-mm-thick, zinc-coated (galvanized) steel
same alloy and finish as roofing panels prepainted with coil coating. Provide
flashing and trim as required to seal against weather and to provide finished
appearance. Locations include, but are not limited to, eaves, rakes, corners,
bases, framed openings, ridges, fasciae, and fillers. Finish flashing and trim with
same finish system as adjacent metal roof panels.
2.5.3 Gutters: Formed from 0.80 mm thick, galvanized steel sheets same alloy and
finish as roofing panels prepainted with coil coating. Match profile of gable trim,
complete with end pieces, outlet tubes, and other special pieces as required.
Fabricate in minimum 2400 mm long sections. Furnish gutter supports spaced 900
mm o.c., fabricated from same metal as gutters. Provide bronze, copper, or
aluminum wire ball strainers at outlets
2.6 FABRICATION
2.6.1 General: Fabricate sheet metal roofing to comply with details shown, with metal
roofing manufacturer's instructions, that apply to the design, dimensions, metal,
and other characteristics of installation indicated.
 Fabricate and finish metal roof panels and accessories at the factory to
greatest extent possible, by manufacturer's standard procedures and
processes, as necessary to fulfill indicated performance requirements
demonstrated by laboratory testing. Comply with indicated profiles and with
dimensional and structural requirements.

2.6.2 Provide panel profile, including major ribs and intermediate stiffening ribs, if any,
for full length of panel.
2.6.3 Where indicated, fabricate metal roof panel joints with factory-installed captive
gaskets or separator strips that provide a tight seal and prevent metal-to-metal
contact, in a manner that will minimize noise from movements within panel
assembly.
2.6.4 Sheet Metal Accessories: Fabricate flashing and trim to comply with
recommendations in manufacture standard that apply to the design, dimensions,
metal, and other characteristics of item indicated.
 Form exposed sheet metal accessories that are without excessive oil canning,
buckling, and tool marks and that are true to line and levels indicated, with
exposed edges folded back to form hems.
 Sealed Joints: Where movable, nonexpansion-type joints are indicated or
required to produce weather tight seams, form metal to provide for proper
installation of elastomeric sealant.
 Expansion Provisions: Fabricate sheet metal to allow for expansion in running
work sufficient to prevent leakage, damage, and deterioration of the Work.
Form exposed sheet metal work to fit substrates without excessive oil canning,
buckling, and tool marks, true to line and levels indicated, and with exposed
edges folded back to form hems. Where lapped or bayonet-type expansion
provisions in the Work cannot be used, or would not be sufficiently
waterproof and weatherproof, form expansion joints of intermeshing hooked
flanges, not less than 25 mm deep, filled with sealant concealed within joints.
 Fabricate cleats and attachment devices from same metal specified here after
in this Section.
 Size: As recommended by metal panel manufacturer for application but not
less than thickness of metal being secured.
2.6.5 Separations: Separate metal from non-compatible metal or corrosive substrates

by coating concealed surfaces at locations of contact with bituminous coating or
other permanent separation as recommended by manufacturer or fabricator.
2.7 GALVANIZED CORRUGATED STEEL SHEET ROOF DECK
2.7.1 Shall comply with following:
 Shall be standard decking with manufacturers of the roof panels with

consideration of spans, structural performance and design load as indicated on
Drawings and specified in this Section, but not less than 0.60 mm thick.
 Shall be corrugated trapezoidal sheets fabricated from hot-dip galvanized steel
sheets.
 Corrugated steel sheets shall be finished with 7-micron thick approved epoxy
primer on top faces as installed.
 Exposed to view, as installed, bottom surfaces shall be finished with polyester

power coating as specified. Color shall be selected by the Engineer.
2.8.1 Protect mechanical and painted finishes on exposed surfaces from damage by
applying a strippable, temporary protective covering before shipping.
2.8.2 Appearance of Finished Work: Variations in appearance of abutting or adjacent

pieces are acceptable if they are within one-half of the range of approved
Samples. Noticeable variations in the same piece are not acceptable. Variations in
appearance of other components are acceptable if they are within the range of
approved Samples and are assembled or installed to minimize contrast.
2.8.3 High-Performance Organic Finish: 3-coat fluoropolymer finish complying with

AAMA 2605 and containing not less than 70 percent PVDF resin by weight in both
color coat and clear topcoat. Prepare, pretreat, and apply coating to exposed
metal surfaces to comply with coating and resin manufacturers' written
instructions.
 Color and Gloss: As selected by Engineer from manufacturer's full range.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine substrates, areas, and conditions, with Installer present, for compliance
with requirements for installation tolerances, metal roof panel supports, and
other conditions affecting performance of Work.
 Examine primary and secondary roof framing to verify that rafters, purlins,
angles, channels, and other structural panel support members and anchorages
have been installed within alignment tolerances required by metal roof panel
manufacturer.
 For the record, prepare written report, endorsed by Installer, listing conditions
detrimental to performance of Work.
3.1.2 Proceed with installation only after unsatisfactory conditions have been
corrected.
3.2 PREPARATION
3.2.1 Clean substrates of substances harmful to insulation, including removing

projections capable of interfering with insulation attachment.
3.2.2 Coordinate metal roofing with rain drainage work, flashing, trim, and construction
of decks, parapets, walls, and other adjoining work to provide a leak proof,
secure, and noncorrosive installation.
3.2.3 Promptly remove protective film, if any, from exposed surfaces of metal roofing.
Strip with care to avoid damage to finish.

3.2.4 Examine supporting frame and field conditions for compliance with requirements
for installation tolerances and other conditions affecting performance, of steel
deck.
3.2.5 Install deck panels and accessories according to applicable specifications and
commentary in SDI Publication No. 29, manufacturer's written instructions, and
requirements in this Section.
3.2.6 Install temporary shoring before placing deck panels, if required to meet
deflection limitations.
3.2.7 Locate decking bundles to prevent overloading of supporting members.
3.2.8 Place deck panels on supporting frame and adjust to final position with ends
accurately aligned and bearing on supporting frame before being permanently
fastened. Do not stretch or contract side-lap interlocks.
 Align cellular deck panels for entire length of cell runs and align cells at ends of
abutting panels.
3.2.9 Place deck panels flat and square and fasten to supporting frame without warp or
deflection.
3.2.10 Cut and neatly fit deck panels and accessories around openings and other work
projecting through or adjacent to decking.
3.2.11 Provide additional reinforcement and closure pieces at openings as required for
strength, continuity of decking, and support of other work.
3.2.12 Mechanical fasteners shall be used to fasten deck. Locate mechanical fasteners
and install according to deck manufacturer's written instructions.
3.3 STEEL SHEET DECK INSTALLATION
3.3.1 Side-Lap and Perimeter Edge Fastening: Fasten side laps and perimeter edges of
panels between supports, at intervals not exceeding the lesser of 1/2 of the span
or 450 mm, and as follows:
 Mechanically fasten with self-drilling 4.8 mm diameter or larger carbon-steel

screws.
 Mechanically clinch or button punch.
3.3.2 End Bearing: Install deck ends over supporting frame with a minimum end
bearing of 38 mm, with end joints as follows:
 End Joints: 50 mm.
3.3.3 Miscellaneous Roof Deck Accessories: Install ridge and valley plates, finish strips,
cover plates, end closures, and reinforcing channels according to deck
manufacturer's written instructions. Weld to substrate to provide a complete
deck installation.

3.3.4 Flexible Closure Strips: Install flexible closure strips over partitions, walls, and
where indicated. Install with adhesive according to manufacturer's written
instructions to ensure complete closure.
3.4 METAL ROOF PANEL INSTALLATION, GENERAL
3.4.1 General: Provide metal roof panels of full length from eave to ridge, unless
otherwise indicated or restricted by shipping limitations. Anchor metal roof
panels and other components of the Work securely in place, with provisions for
thermal and structural movement.
 Field cutting of metal roof panels by torch is not permitted.

 Install panels perpendicular to purlins.
 Rigidly fasten eave end of metal roof panels and allow ridge end free
movement due to thermal expansion and contraction. Predrill panels.
 Provide metal closures at peaks, rake edges, rake walls and each side of ridge
and hip caps.
 Flash and seal metal roof panels with weather closures at eaves, rakes, and at
perimeter of all openings. Fasten with self-tapping screws.
 Locate and space fastenings in uniform vertical and horizontal alignment.
 Install ridge and hip caps as metal roof panel work proceeds.
 Locate panel splices over, but not attached to, structural supports. Stagger
panel splices and end laps to avoid a 4-panel lap splice condition.
 Lap metal flashing over metal roof panels to allow moisture to run over and
off the material.
3.4.2 Fasten metal roof panels to supports with concealed clips in accordance with
manufacturer's instructions.
 Install clips at each support with self-drilling/self-tapping fasteners.

 At end laps of panels, install tape caulk between panels.
 Complete seaming of panel joints by operation of portable power-driven
equipment of type recommended by panel manufacturer to provide a
weathertight joint.
 Galvanized steel roof: Use aluminum or stainless-steel fasteners
3.4.3 Joint Sealers: Install gaskets, joint fillers, and sealants where indicated and where
required for weatherproof performance of metal roof panel assemblies. Provide
types of gaskets, fillers, and sealants indicated or, if not indicated, types
recommended by metal roof panel manufacturer.
 Seal metal roof panel end laps with double beads of tape or sealant, full width
of panel. Seal side joints where recommended by metal roof panel
manufacturer.
 Prepare joints and apply sealants to comply with requirements in Division 7

Section "Joint Sealants."
3.4.4 Form and fabricate sheets, seams, strips, cleats, valleys, ridges, edge treatments,
integral flashings, and other components of metal roofing to profiles, patterns,
and drainage arrangements shown and as required for leakproof construction.
Provide for thermal expansion and contraction of sheet metal roofing. Seal joints
as shown and as required for leakproof construction.
3.4.5 Fabricate and install Work with lines and corners of exposed units true and
accurate. Form exposed faces flat and free of buckles, excessive waves, and tool
marks, considering temper and reflectivity of metal. Provide uniform, neat seams
with minimum exposure of solder, welds, and sealant. Fold back sheet metal to
form a hem on concealed side of exposed edges, unless otherwise indicated.
3.5 FOAMED INSULATION CORE METAL ROOF PANEL INSTALLATION
3.5.1 General: Apply continuous ribbon of sealant to panel joint on concealed side of
insulated metal roof panels as vapor seal; apply sealant to panel joint on exposed
side of panels for weather seal.
3.5.2 Lap Seam, Foamed-Insulation Core Metal Roof Panels: Fasten insulated metal
roof panels to supports with fasteners at each lapped joint at location and spacing
recommended by manufacturer.
 Arrange and nest side-lap joints so prevailing winds blow over, not into, lapped
joints. Lap ribbed or fluted sheets one full rib corrugation. Apply panels and
associated items for neat and weathertight enclosure. Avoid "panel creep" or
application not true to line.
 Provide metal-backed washers under heads of exposed fasteners bearing on

weather side of insulated metal roof panels.
 Locate and space exposed fasteners in uniform vertical and horizontal

alignment. Use proper tools to obtain controlled uniform compression for
positive seal without rupture of washer.
 Provide sealant tape at lapped joints of insulated metal roof panels and
between panels and protruding equipment, vents, and accessories.
 Apply a continuous ribbon of sealant tape to panel side laps and elsewhere as
needed to make panels weatherproof to driving rains.
 Delete subparagraph below if not required; coordinate with products retained

in Part 2.
 Apply snap-on battens to insulated metal roof panel seams to conceal

fasteners.
3.6 ACCESSORY INSTALLATION
3.6.1 General: Install accessories with positive anchorage to building and weathertight

mounting and provide for thermal expansion. Coordinate installation with
flashings and other components.
 Install components required for a complete metal roof panel assembly

including trim, copings, ridge closures, seam covers, flashings, sealants,
gaskets, fillers, closure strips, and similar items.
3.6.2 Flashing and Trim: Comply with performance requirements, manufacturer's

written installation instructions, and SMACNA's "Architectural Sheet Metal
Manual." Provide concealed fasteners where possible, and set units true to line
and level as indicated. Install work with laps, joints, and seams that will be
permanently watertight and weather resistant.
 Install exposed flashing and trim that is without excessive oil canning, buckling,
and tool marks and that is true to line and levels indicated, with exposed
edges folded back to form hems. Install sheet metal flashing and trim to fit
substrates and to result in waterproof and weather-resistant performance.
 Expansion Provisions: Provide for thermal expansion of exposed flashing and
trim. Space movement joints at a maximum of 3 m with no joints allowed
within 600 mm of corner or intersection. Where lapped or bayonet-type
expansion provisions cannot be used or would not be sufficiently weather
resistant and waterproof, form expansion joints of intermeshing hooked
flanges, not less than 25 mm deep, filled with mastic sealant (concealed within
joints).
3.6.3 Gutters: Join sections with riveted or lapped and sealed joints. Attach gutters to
have with gutter hangers spaced not more than 1.2 m o.c. using manufacturer's
standard fasteners. Provide end closures and seal watertight with sealant. Provide
for thermal expansion.
3.7 ERECTION TOLERANCES
3.7.1 Installation Tolerances: Shim and align metal roof panel units within installed
tolerance of 6 mm in 6 m on slope and location lines as indicated and within 3
mm offset of adjoining faces and of alignment of matching profiles.
3.8.1 Manufacturer's Field Service: Engage a factory-authorized service representative

to inspect completed metal roof panel installation, including accessories. Report
results in writing.
3.8.2 Remove and replace applications of metal roof panels where inspections indicate
that they do not comply with specified requirements.
3.8.3 Additional inspections, at the Contractor's expense, will be performed to

determine compliance of replaced or additional work with specified
requirements.
3.9 CLEANING AND PROTECTION

3.9.1 Remove temporary protective coverings and strippable films, if any, as metal roof
panels are installed, unless otherwise indicated in manufacturer's written
installation instructions. On completion of metal roof panel installation, clean
finished surfaces as recommended by metal roof panel manufacturer. Maintain in
a clean condition during construction.
3.9.2 Replace metal roof panels that have been damaged or have deteriorated beyond
successful repair by finish touchup or similar minor repair procedures.
3.9.3 Provide final protection and maintain conditions, in a manner acceptable to

manufacturer and installer that ensure sheet metal roofing is without damage or
deterioration at the time of Substantial Completion.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. METAL WALL PANELS
CAIRO - EGYPT 07412 – 2039 0

CONTENTS
SECTION 07412
METAL WALL PANELS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.4 Submittals 3
1.8 Coordination 6
1.9 Warranty 6
PART 2 PRODUCTS 7
2.1 Panel Materials 7
2.2 Thermal Insulation For Factory-Assembled Metal Wall
Panels 7
2.3 Miscellaneous Metal Framing 7
2.5 Foamed-Insulation-Core Metal Wall Panels 8
2.6 Accessories 9
2.7 Fabrication 9
PART 3 EXECUTION 11
3.1 Examination 11
3.2 Preparation 11
3.3 Factory Assembled Metal Wall Panel Installation 12
3.4 Accessory Installation 12
3.5 Erection Tolerances 13
Metal Wall Panels Section 07412

SECTION 07412
METAL WALL PANELS
PART 1 GENERAL
mentary Conditions apply to this Section.
1.2 SUMMARY
 Factory-formed and -assembled, foamed-insulation -core metal wall panels.

 Factory-formed and -assembled, foamed-insulation -core metal wall panels,
fire rated.
 Division 7 Section "Metal Roof Panels" for factory-formed metal soffit panels.
 Division 7 Section "Joint Sealants" for field-applied sealants not otherwise
specified in this Section.
1.3.1 General: Provide metal wall panel assemblies that comply with performance re-
quirements specified as determined by testing manufacturers' standard assem-
blies similar to those indicated for this Project, by a qualified testing and inspect-
ing agency.
1.3.2 Air Infiltration: Air leakage through assembly of not more than 0.3 L/s per sq. m
of wall area when tested according to ASTM E 283 at a static-air-pressure differ-
ence of 300 Pa.
1.3.3 Water Penetration: No water penetration when tested according to ASTM E 331
at a minimum differential pressure of 20 percent of inward-acting, wind-load de-
sign pressure of not less than 300 Pa and not more than 575 Pa.
1.3.4 Water Absorption: Maximum 1.0 percent absorption rate by volume when tested
according to ASTM C 209.
1.3.5 Structural Performance: Provide metal wall panel assemblies capable of with-
standing the effects of gravity loads
 Wind Loads: According to the Egyptian code of practice no. 201-2003, basic
wind speed (v) = 33.0 m/sec.

 Deflection Limits: Engineer metal wall panel assemblies to withstand test pres-
sures with deflection no greater than 1/180 of the span and no evidence of
material failure, structural distress, or permanent deformation exceeding 0.2
percent of the clear span.
 Test Pressures: 150 percent of inward and outward wind-load design pres-
sures.
1.3.6 Thermal Movements: Provide metal wall panel assemblies that allow for thermal
movements resulting from the following maximum change (range) in ambient and
surface temperatures by preventing buckling, opening of joints, overstressing of
components, failure of joint sealants, failure of connections, and other detri-
mental effects. Base engineering calculation on surface temperatures of materials
due to both solar heat gain and nighttime-sky heat loss.
 Temperature Change (Range): 35 deg C, ambient; 60 deg C, material surfaces.
1.3.7 Thermal Performance: Provide insulated metal wall panel assemblies with ther-
mal-resistance value (R-value) indicated when tested according to ASTM C 236 or
ASTM C 518.
1.4 SUBMITTALS
1.4.1 Product Data: Include construction details, material descriptions, dimensions of

individual components and profiles, and finishes for each type of metal wall panel
and accessory.
1.4.2 Shop Drawings: Show fabrication and installation layouts of metal wall panels;
details of edge conditions, joints, panel profiles, corners, anchorages, attachment
system, trim, flashings, closures, and accessories; and special details. Distinguish
between factory- and field-assembled work.
1.4.3 Coordination Drawings: Exterior elevations drawn to scale and coordinating pen-
etrations and wall-mounted items. Show the following:
 Wall panels and attachments.

 Wall-mounted items including doors, windows, louvers, and lighting fixtures.
1.4.4 Samples for Initial Selection: For each type of metal wall panel indicated with
factory-applied color finishes.
 Include similar Samples of trim and accessories involving color selection.

 Include manufacturer's color charts consisting of strips of cured sealants show-
ing the full range of colors available for each sealant exposed to view.
Samples of size indicated below.
 Metal Wall Panels: 300 mm long by actual panel width. Include fasteners, clo-
sures, and other metal wall panel accessories.

 Trim and Closures: 300 mm long. Include fasteners and other exposed acces-
sories.
 Accessories: 300-mm long Samples for each type of accessory.
 Exposed Gaskets: 300 mm long.
 Exposed Sealants: For each type and color of joint sealant required. Install
joint sealants in 13-mm wide joints formed between two 150-mm long strips of
material matching the appearance of metal wall panels adjacent to joint seal-
ants.
1.4.7 Compatibility and Adhesion Test Reports: From sealant manufacturer indicating
the following:
 Materials forming joint substrates and joint sealant backings have been tested
for compatibility and adhesion with joint sealants.
 Interpretation of test results and written recommendations for primers and
substrate preparation needed for adhesion.
1.4.8 Field quality-control test reports.
1.4.9 Product Test Reports: Based on evaluation of comprehensive tests performed by

a qualified testing agency, for the following:
 Metal Wall Panels: Include reports for air infiltration, water penetration, ther-
mal performance, fire rating, fire-test-response characteristics, and structural
performance.
 Insulation: Include reports for thermal resistance, fire-test-response charac-
teristics, water-vapor transmission, and water absorption
1.4.10 Maintenance Data: For metal wall panels to include in maintenance manuals.
1.5.1 Manufacture Qualifications: Engage a manufacture experienced with the success-

ful production of the specified work similar in design, material and extent to the
scope of this Project, and with a record of successful in-service performance and
completion or projects, as well as, sufficient production capability, facilities, and
personnel, to produce the required work.
1.5.2 Installer Qualifications: An employer of workers trained and approved by manu-

facturer.
 Installer's responsibilities include fabricating and installing metal wall panel as-
semblies and providing professional engineering services needed to assume
engineering responsibility.

 Engineering Responsibility: Preparation of data for metal wall panels, including
Shop Drawings, based on testing and engineering analysis of manufacturer's
standard units in assemblies similar to those indicated for this Project.
1.5.3 Fire-Resistance Ratings: Where indicated, provide metal wall panels identical to
those of assemblies tested for fire resistance per ASTM E 119 by a testing and in-
specting agency acceptable to authorities having jurisdiction.
 Combustion Characteristics: ASTM E 136.

 Fire-Resistance Ratings: Indicated by design designations from UL's "Fire Resistance
Directory" or from the listings of another testing and inspecting agency.
 Metal wall panels shall be identified with appropriate markings of applicable testing
and inspecting agency.
 Fire Rating Period: As indicted on Drawings.
1.5.4 Testing Agency Qualifications: Qualified according to ASTM E 329 for testing indi-
cated, as documented according to ASTM E 548.
1.5.5 Source Limitations: Obtain each type of metal wall panel through one source
1.5.6 Mockups: Build mockups to verify selections made under sample Submittals and
 Build mockup of typical corner wall panel as shown on Drawings; approximate-

ly 1200 mm square by full thickness, including insulation, supports, attach-
ments, and accessories.
 Approval of mockups does not constitute approval of deviations from the Con-
tract Documents contained in mockups unless such deviations are specifically
approved by Engineer in writing.
1.6.1 Deliver components, sheets, metal wall panels, and other manufactured items so
as not to be damaged or deformed. Package metal wall panels for protection dur-
ing transportation and handling.
1.6.2 Unload, store, and erect metal wall panels in a manner to prevent bending, warp-
ing, twisting, and surface damage.
1.6.3 Stack metal wall panels horizontally on platforms or pallets, covered with suitable
weather tight and ventilated covering. Store metal wall panels to ensure dryness,
with positive slope for drainage of water. Do not store metal wall panels in con-
tact with other materials that might cause staining, denting, or other surface
damage.

1.6.4 Protect strippable protective covering on metal wall panels from exposure to sun-
light and high humidity, except to extent necessary for period of metal wall panel
installation.
weather conditions permit assembly of metal wall panels to be performed accord-
ing to manufacturers' written instructions and warranty requirements.
1.7.2 Field Measurements: Verify locations of structural members and wall opening
dimensions by field measurements before metal wall panel fabrication and indi-
cate measurements on Shop Drawings.

delaying the Work, either establish framing and opening dimensions and pro-
ceed with fabricating metal wall panels without field measurements, or allow
for field trimming of panels. Coordinate wall construction to ensure that
actual building dimensions, locations of structural members, and openings
correspond to established dimensions.
1.8 COORDINATION
1.8.1 Coordinate metal wall panel assemblies with rain drainage work, flashing, trim,
and construction of soffits, and other adjoining work to provide a leak-proof, se-
cure, and noncorrosive installation.
1.9 WARRANTY
1.9.1 Special Warranty: Manufacturer's standard form in which manufacturer agrees to

repair or replace components of metal wall panel assemblies that fail in materials
or workmanship within specified warranty period.
 Failures include, but are not limited to, the following:
 Structural failures, including rupturing, cracking, or puncturing.

 Deterioration of metals, metal finishes, and other materials beyond normal
weathering.
 Warranty Period: 10 years from date of Substantial Completion.
1.9.2 Special Warranty on Panel Finishes: Manufacturer's standard form in which man-
ufacturer agrees to repair finish or replace metal wall panels that show evidence
of deterioration of factory-applied finishes within specified warranty period.
 Finish Warranty Period: twenty (20) years from date of Substantial Completion.
1.9.3 Special Weather tightness Warranty: Manufacturer's standard form in which

manufacturer agrees to repair or replace metal wall panel assemblies that fail to
remain weather tight, including leaks, within specified warranty period.

 Weather tight Warranty Period: 10 years from date of Substantial Completion.
PART 2 PRODUCTS
2.1 PANEL MATERIALS
coated by the hot-dip process and prepainted by the coil-coating process to com-
ply with ASTM A 755M.
 Galvanized Steel Sheet: ASTM A 653M, Z275 coating designation; structural quality.
2.1.2 Panel Sealants:
 Sealant Tape: Pressure-sensitive, 100 percent solids, gray polyisobutylene

compound sealant tape with release-paper backing. Provide permanently
elastic, nonsag, nontoxic, nonstaining tape 13 mm wide and 3 mm thick.
 Joint Sealant: ASTM C 920; elastomeric polyurethane, polysulfide, or silicone
sealant; of type, grade, class, and use classifications required to seal joints in
metal wall panels and remain weather tight; and as recommended in writing
by metal wall panel manufacturer.
 Butyl-Rubber-Based, Solvent-Release Sealant: ASTM C 1311.
2.2 THERMAL INSULATION FOR FACTORY-ASSEMBLED METAL WALL PANELS
2.2.1 Insulation Core: Manufactured standard to achieve required U value and fire rat-
ing period.
2.3 MISCELLANEOUS METAL FRAMING
2.3.1 Steel Sheet Components, General: Complying with ASTM C 645 requirements for
metal and with ASTM A 653M, (Z180), hot-dip galvanized zinc coating.
2.3.2 Subgirts: C- or Z-shaped sections fabricated from 1.5-mm bare steel thickness,
shop-painted, cold-formed, metallic-coated steel sheet.
2.3.3 Zee Clips: 2.0-mm bare steel thickness, cold-formed, galvanized steel sheet.
2.3.4 Base or Sill Angles and Channels: 2.0-mm bare steel thickness, cold-formed, gal-
vanized steel sheet.
 Minimum Base Metal Thickness: As recommended by manufacture to comply

with performance requirements, but not less than 0.45 mm.
2.3.6 Cold-Rolled Furring Channels: 1.37-mm bare steel thickness, with minimum 13-
mm wide flange.

 Depth: 19 mm.
 Furring Brackets: Adjustable, corrugated-edge type of steel sheet with mini-
mum bare steel thickness of 0.79 mm.
 Tie Wire: ASTM A 641M, Class 1 zinc coating, soft temper, 1.59-mm diameter
2.3.7 Z-Shaped Furring: With slotted or nonslotted web, face flange of 32 mm, wall at-
tachment flange of 22 mm, minimum bare metal thickness of 0.45 mm, and depth
required to fit insulation thickness indicated.
2.3.8 Fasteners for Metal Framing: of type, material, size, corrosion resistance, holding
power, and other properties required to fasten steel members to substrates.
2.4.1 Fasteners: Self-tapping screws, bolts, nuts, self-locking rivets and bolts, end-
welded studs, and other suitable fasteners designed to withstand design loads.
Provide exposed fasteners with heads matching color of metal wall panels by
means of plastic caps or factory-applied coating.
 Fasteners for Wall Panels: Self-drilling or self-tapping, zinc-plated, hex-head

carbon-steel screws, with a stainless-steel cap or zinc-aluminum-alloy head
and EPDM or neoprene sealing washer.
 Exposed Fasteners for Composite Panels: Stainless steel.
 Fasteners for Flashing and Trim: Blind fasteners or self-drilling screws with hex
washer head.
 Blind Fasteners: High-strength aluminum or stainless-steel rivets.
2.5 FOAMED-INSULATION-CORE METAL WALL PANELS
2.5.1 General: Provide factory-formed and -assembled metal wall panels fabricated
from two metal facing sheets and insulation core foamed-in-place during fabrica-
tion with joints between panels designed to form weather tight seals. Include ac-
cessories required for weather tight installation.
 Panel Performance:
 Flatwise Tensile Strength: 200 kPa when tested according to ASTM C 297.
 Humid Aging: Volume increase not greater than 6.0 percent and no delami-
nation or metal corrosion when tested for 7 days at 60 deg C and 100 per-
cent relative humidity according to ASTM D 2126.
 Heat Aging: Volume increase not greater than 2.0 percent and no delamina-
tion, surface blistering, or permanent bowing when tested for 7 days at 93
deg C according to ASTM D 2126.
 Cold Aging: Volume decrease not more than 1.0 percent and no delamina-
tion, surface blistering, or permanent bowing when tested for 7 days at mi-
nus 29 deg C according to ASTM D 2126.

 Fatigue: No evidence of delamination, core cracking, or permanent bowing
when tested to a 958-kPa positive and negative wind load and with deflec-
tion of L/180 for 2 million cycles.
 Autoclave: No delamination when exposed to 13.8-kPa pressure at a tem-
perature of 100 deg C for 2-1/2 hours.
 Fire-Test-Response Characteristics: Class A according to ASTM E 108.
2.5.2 Concealed-Fastener, Foamed-Insulation-Core Metal Wall Panels: Formed with

tongue-and-groove panel edges; designed for sequential installation by interlock-
ing panel edges and mechanically attaching panels to supports using concealed
clips or fasteners.
 Facings: Fabricate panel with exterior and interior facings of same material and
thickness.
 Material: Galvanized steel; 0.5 mm thick.
 Panel Thickness: As indicted on Drawings.
2.6 ACCESSORIES
2.6.1 Wall Panel Accessories: Provide components required for a complete metal wall
panel assembly including trim, copings, fasciae, mullions, sills, corner units, clips,
flashings, sealants, gaskets, fillers, closure strips, and similar items. Match mate-
rial and finish of metal wall panels, unless otherwise indicated.
 Closures: Provide closures at eaves and rakes, fabricated of same metal as

metal wall panels.
 Backing Plates: Provide metal backing plates at panel end splices, fabricated
from material recommended by manufacturer.
 Closure Strips: Closed-cell, expanded, cellular, rubber or cross-linked, polyole-
fin-foam or closed-cell laminated polyethylene; minimum (25-mm-) thick, flex-
ible closure strips; cut or premolded to match metal wall panel profile. Provide
closure strips where indicated or necessary to ensure weather tight construc-
tion.
2.6.2 Flashing and Trim: Same material, finish, and color as adjacent metal-plate wall
panels, minimum 0.76 mm thick, unless otherwise indicated.
2.6.3 Downspouts: Formed from 0.45-mm thick, zinc-coated (galvanized) steel sheet or
aluminum-zinc alloy-coated steel sheet prepainted with coil coating; in 3-m long
sections, complete with formed elbows and offsets. Finish downspouts to match
metal wall panels.
2.7 FABRICATION
2.7.1 General: Fabricate and finish metal wall panels and accessories at the factory to
greatest extent possible, by manufacturer's standard procedures and processes,
as necessary to fulfill indicated performance requirements demonstrated by la-
boratory testing. Comply with indicated profiles and with dimensional and struc-

tural requirements.
 Fabricate wall panels with panel stiffeners as required to maintain fabrication

tolerances and to withstand design loads.
2.7.2 Fabricate metal wall panels in a manner that eliminates condensation on interior
side of panel and with joints between panels designed to form weather tight
seals.
2.7.3 Provide panel profile, including major ribs and intermediate stiffening ribs, if any,
for full length of panel.
2.7.4 Where indicated, fabricate metal wall panel joints with factory-installed captive
gaskets or separator strips that provide a tight seal and prevent metal-to-metal
contact, in a manner that will minimize noise from movements within panel as-
sembly.
2.7.5 Metal-Plate Wall Panels: Fabricate panels with panel stiffeners as required to
comply with deflection limits. Weld and grind panel corners smooth. Fabricate
panels to the following dimensional tolerances:
 Length and Width: Plus or minus 0.8 mm up to 1219 mm; 1.6 mm more than
1219 mm.
 Diagonal: Plus or minus 4.76 mm.

 Panel Bow: Not more than 0.2 percent of panel width or length up to 4.76 mm
maximum.
 Thickness: Plus or minus 0.2 mm.
 Squareness: 4.76-mm difference between diagonal measurements.
 Camber: 0.8 mm.
2.7.6 Sheet Metal Accessories: Fabricate flashing and trim to comply with recommen-
dations in SMACNA's "Architectural Sheet Metal Manual" that apply to the design,
dimensions, metal, and other characteristics of item indicated.
 Form exposed sheet metal accessories that are without excessive oil canning,
buckling, and tool marks and that are true to line and levels indicated, with ex-
posed edges folded back to form hems.
 Seams: Fabricate nonmoving seams in accessories with flat-lock seams. Tin
edges to be seamed, form seams, and solder.
 Sealed Joints: Form nonexpansion but movable joints in metal to accommo-
date elastomeric sealant to comply with SMACNA standards.
 Conceal fasteners and expansion provisions where possible. Exposed fasteners
are not allowed on faces of accessories exposed to view.
 Fabricate cleats and attachment devices from same material as accessory be-
ing anchored or from compatible, noncorrosive metal recommended by metal
wall panel manufacturer.

 Size: As recommended by SMACNA's" Architectural Sheet Metal Manual"
or metal wall panel manufacturer for application but not less than thickness
of metal being secured.
2.8.1 Protect mechanical and painted finishes on exposed surfaces from damage by ap-
plying a strippable, temporary protective covering before shipping.

pieces are acceptable if they are within one-half of the range of approved Sam-
ples. Noticeable variations in the same piece are not acceptable. Variations in ap-
pearance of other components are acceptable if they are within the range of ap-
proved Samples and are assembled or installed to minimize contrast.
2.8.3 High-Performance Organic Finish: 3-coat fluoropolymer finish complying with

AAMA 2605 and containing not less than 70 percent PVDF resin by weight in both
color coat and clear topcoat. Prepare, pretreat, and apply coating to exposed
metal surfaces to comply with coating and resin manufacturers' written instruc-
tions.

PART 3 EXECUTION
3.1 EXAMINATION
with requirements for installation tolerances, metal wall panel supports, and oth-
er conditions affecting performance of work.
 Examine primary and secondary wall framing to verify that girts, angles, chan-
nels, studs, and other structural panel support members and anchorage have
been installed within alignment tolerances required by metal wall panel manu-
facturer.
 For the record, prepare written report, endorsed by Installer, listing conditions
detrimental to performance of work.
3.1.2 Examine roughing-in for components and systems penetrating metal wall panels
to verify actual locations of penetrations relative to seam locations of metal wall
panels before metal wall panel installation.
3.1.3 Proceed with installation only after unsatisfactory conditions have been correct-
ed.
3.2 PREPARATION
3.2.1 Clean substrates of substances harmful to insulation, including removing projec-

tions capable of interfering with insulation attachment.
3.2.2 Install flashings and other sheet metal to comply with requirements specified in

Division 7 Section "Sheet Metal Flashing and Trim."
3.2.3 Install fasciae and copings to comply with requirements specified in Division 7
Section "Sheet Metal Flashing and Trim.
3.2.4 Miscellaneous Framing: Install subgirts, base angles, sills, furring, and other mis-
cellaneous wall panel support members and anchorage according to ASTM C 754
and metal wall panel manufacturer's written recommendations.
3.3 FACTORY ASSEMBLED METAL WALL PANEL INSTALLATION
3.3.1 General: Apply continuous ribbon of sealant to panel joint on concealed side of
insulated metal wall panels as vapor seal; apply sealant to panel joint on exposed
side of panels for weather seal.
 Fasten insulated metal wall panels to supports with fasteners at each lapped
joint at location, spacing, and with fasteners recommended by manufacturer.
 Arrange and nest side-lap joints so prevailing winds blow over, not into, lapped
joints. Lap ribbed or fluted sheets one full rib corrugation. Apply panels and
associated items for neat and weather tight enclosure. Avoid "panel creep" or
application not true to line.
 Provide metal-backed washers under heads of exposed fasteners bearing on
weather side of insulated metal wall panels.
 Locate and space exposed fasteners in uniform vertical and horizontal align-
ment. Use proper tools to obtain controlled uniform compression for positive
seal without rupture of washer.
 Provide sealant tape at lapped joints of insulated metal wall panels and be-
tween panels and protruding equipment, vents, and accessories.
 Apply a continuous ribbon of sealant tape to panel side laps and elsewhere as
needed to make panels weatherproof to driving rains.
3.3.2 Foamed-Insulation-Core Metal Wall Panels: Fasten metal wall panels to supports
with concealed clips at each joint at location, spacing, and with fasteners recom-
mended by manufacturer. Fully engage tongue and groove of adjacent panels.
 Install clips to supports with self-tapping fasteners.
3.4 ACCESSORY INSTALLATION
3.4.1 General: Install accessories with positive anchorage to building and weather tight
mounting and provide for thermal expansion. Coordinate installation with flash-
ings and other components.
 Install components required for a complete metal wall panel assembly includ-
ing trim, copings, corners, seam covers, flashings, sealants, gaskets, fillers, clo-
sure strips, and similar items.
3.4.2 Flashing and Trim: Comply with performance requirements, manufacturer's writ-

ten installation instructions, and SMACNA's "Architectural Sheet Metal Manual."
Provide concealed fasteners where possible, and set units true to line and level as
indicated. Install work with laps, joints, and seams that will be permanently wa-
tertight and weather resistant.
 Install exposed flashing and trim that is without excessive oil canning, buckling,
and tool marks and that is true to line and levels indicated, with exposed edges
folded back to form hems. Install sheet metal flashing and trim to fit sub-
strates and to result in waterproof and weather-resistant performance.
 Expansion Provisions: Provide for thermal expansion of exposed flashing and
trim. Space movement joints at a maximum of 3 m with no joints allowed
within 600 mm of corner or intersection. Where lapped or bayonet-type ex-
pansion provisions cannot be used or would not be sufficiently weather re-
sistant and waterproof, form expansion joints of intermeshing hooked flanges,
not less than 25 mm deep, filled with mastic sealant (concealed within joints).
3.4.3 Downspouts: Join sections with 38-mm telescoping joints. Provide fasteners de-
signed to hold downspouts securely 25 mm away from walls; locate fasteners at
top and bottom and at approximately 1500 mm o.c. in between.
 Tie downspouts to underground drainage system indicated.
3.5 ERECTION TOLERANCES
3.5.1 Installation Tolerances: Shim and align metal wall panel units within installed
tolerance of 6 mm in 6 m, noncumulative, on level, plumb, and location lines as
indicated and within 3-mm offset of adjoining faces and of alignment of matching
profiles.
3.6.1 Testing Agency: Engage a qualified independent testing and inspecting agency to
perform field tests and inspections and prepare test reports.
3.6.2 Manufacturer's Field Service: Engage a factory-authorized service representative

to inspect completed metal wall panel installation, including accessories. Report
results in writing.
3.6.3 Remove and replace applications of metal wall panels where inspections indicate
that they do not comply with specified requirements.
3.6.4 Additional tests and inspections, at Contractor's expense, will be performed to

determine compliance of replaced or additional work with specified require-
ments.
3.7.1 Remove temporary protective coverings and strippable films, if any, as metal wall
panels are installed, unless otherwise indicated in manufacturer's written installa-
tion instructions. On completion of metal wall panel installation, clean finished

surfaces as recommended by metal wall panel manufacturer. Maintain in a clean
condition during construction.
3.7.2 After metal wall panel installation, clear weep holes and drainage channels of ob-
structions, dirt, and sealant.
3.7.3 Replace metal wall panels that have been damaged or have deteriorated beyond
successful repair by finish touchup or similar minor repair procedures.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. EPDM SINGLE-PLY MEMBRANE
CAIRO - EGYPT ROOFING 07531 – 2039 0

CONTENTS
SECTION 07531
EPDM SINGLE-PLY MEMBRANE ROOFING

Page
PART 1 GENERAL 2
1.2 Summary 2
1.4 Submittals 2
1.8 Warranty 4
PART 2 PRODUCTS 5
2.1 Epdm Sheet 5
2.2 Auxiliary Materials 5
2.3 Insulation Materials 6
2.4 Insulation Accessories 6
2.5 Vapor Retarder 6
2.6 Roof Pavers 6
PART 3 EXECUTION 7
3.1 Examination 7
3.2 Preparation 7
3.3 Vapor-Retarder Installation 8
3.4 Insulation Installation 8
3.5 Adhered Sheet Installation 8
3.6 Seam Installation 9
3.7 Flashing Installation 9
3.8 Coating Installation 10
3.9 Roof Pavers Installations 10
3.11 Protecting And Cleaning 11
EPDM Single-Ply Membrane Roofing Section 07531

SECTION 07531
EPDM SINGLE-PLY MEMBRANE ROOFING
PART 1 GENERAL
Section.
1.2 SUMMARY
 Adhered membrane roofing system.

 Roof insulation.
 Roof Pavers set with mortar bedding
 Vapor retarder.
 Division 3 Section "Cement-Based Screed" for cementitious screed above the

roof deck
 Division 7 Section "Joint Sealants."
 Division 15 Section "Plumbing Specialties" for roof drains.
1.3.1 General: Install a free draining, watertight membrane roofing system including
upstands, flashings and coverings, with compatible components, that will not
permit the passage of liquid water and will withstand wind loads, thermally
induced movement, and exposure to weather without failure.
 Roofing system is to be without patches as far as practicable. If patches are

unavoidable, obtain Engineer's written approval and comply with
manufacturer's recommendations and limitations as to the number, location
and size of patches.
1.3.2 Material Compatibility: Provide roofing materials that are compatible with one
another under conditions of service and application required, as demonstrated by
roofing system manufacturer based on testing and field experience.
1.4 SUBMITTALS
1.4.1 Product Data: For each type of roofing product specified, including all auxiliary
materials and accessories. Include data substantiating that materials comply with
requirements.

1.4.2 Shop Drawings: Include plans, sections, and details of the following:
 Base flashings and membrane terminations.
1.4.3 Samples for Verification: Of the following products:
 300-by-300-mm square of sheet roofing, of color specified, including T-shaped

side and end lap seam.
 300-by-300-mm square of roof insulation.
 4.5 kg of aggregate ballast in color and gradation indicated.
 full-size concrete roof paver in each color and color required.
 300-mm length of metal termination bars.
 Roof cover fasteners of each type, length, and finish.
1.4.4 Installer Certificates: Signed by product manufacturer certifying that Installer is

approved, authorized, or licensed by manufacturer to install his products.
1.4.5 Manufacturer Certificates: Signed by roofing manufacturer certifying that the

roofing system complies with requirements specified in the "Performance
Requirements" Article. Upon request, submit evidence of meeting requirements.
engineers/engineers and employers, and other information specified.
1.4.7 Product Test Reports: Based on evaluation of tests performed by manufacturer

and witnessed by a qualified independent testing agency, indicate compliance of
components of roofing system with requirements based on comprehensive
testing of current product compositions.
1.4.9 Warranty: Sample copy of roofing system manufacturer's proposed warranty

complying with specified requirements, and stating obligations, remedies,
limitations, and exclusions of warranty.
1.4.10 Inspection Report: Copy of roofing system manufacturer's inspection report of

completed roofing installation.

performance and completion or projects, as well as, sufficient production
1.5.2 Installer Qualifications: Engage an experienced installer to perform work of this

Section who has specialized in installing roofing similar to that required for this
Project and who is approved, authorized, or licensed by the roofing system
manufacturer to install manufacturer's product and eligible to receive
manufacturer's warranty.
 Experience: A minimum of five projects of a similar nature carried out

successfully by the installer with the same product, and endorsed by the
manufacturer’s representative.
1.5.3 Fire-Test-Response Characteristics: Provide roofing materials with the fire-test-

response characteristics indicated as determined by testing identical products per
test method indicated below by UL, FM, or another testing and inspecting agency
acceptable to Engineer. Identify materials with appropriate markings of
applicable testing and inspecting agency.
 Exterior Fire-Test Exposure: Class A; ASTM E 108, for application and slopes
indicated.
1.6.1 Deliver roofing materials to Project site in original containers with seals unbroken
and labeled with manufacturer's name, product brand name and type, date of
manufacture, and directions for storing and mixing with other components.
1.6.2 Store liquid materials in their original undamaged containers in a clean, dry,
protected location and within the temperature range required by roofing system
manufacturer. Protect stored liquid material from direct sunlight.
 Discard and legally dispose of liquid material that cannot be applied within its
stated shelf life.
1.6.3 Protect roof insulation materials from physical damage and from deterioration by
sunlight, moisture, soiling, and other sources. Store in a dry location. Comply
with insulation manufacturer's written instructions for handling, storing, and
protecting during installation.
1.6.4 Handle and store roofing materials and place equipment in a manner to avoid
permanent deflection of deck.
1.7.1 Weather Limitations: Proceed with roofing work only when existing and
forecasted weather conditions permit roofing to be installed according to
manufacturers' written instructions and warranty requirements.
1.8 WARRANTY
1.8.1 Roofing Warranty: Provide written warranty, in a form acceptable to the

Engineer, signed by roofing system manufacturer, Installer and Contractor,
undertaking to repair or replace, without limitations, all or any part of the
membrane roofing system which fails or becomes defective in materials or
workmanship within twenty years. Failure includes, but is not limited to: water

penetration, deterioration in membranes and coatings other than due to normal
ageing and weathering; and any defects in adhesion, sealants, flashings, fixings,
coverings and other components of the work.
1.8.2 Warranty Period: 20 years from date of Substantial Completion.
PART 2 PRODUCTS
2.1 EPDM SHEET
2.1.1 EPDM Sheet: Uniform, flexible sheet formed from a terpolymer of ethylene-
propylene-diene, complying with ASTM D 4637, Type 1, of the following grade,
class, thickness, backing, and exposed face color:
 Grade and Class: Grade 1 and Class U, unreinforced.

 Thickness: 1.50 mm, nominal for fully bonded applications.
 Width: Provide membrane in largest available, but not less than 3.0 m,
extruded width.
 Backing: Unbacked.
 Exposed Face Color: Black.
2.2 AUXILIARY MATERIALS
2.2.1 General: Furnish auxiliary materials recommended by roofing system

manufacturer for intended use and compatible with EPDM membrane roofing.
2.2.2 Sheet Flashing: 1.5-mm thick EPDM, uncured or cured, according to application.
2.2.3 Bonding Adhesive: Manufacturer's standard bonding adhesive.
2.2.4 Splice Primer and Tape: Manufacturer's standard synthetic rubber polymer
primer and 75-mm- wide minimum, butyl splice tape with release film.
2.2.5 Lap Sealant: Manufacturer's standard single-component sealant.
2.2.6 Water Cutoff Mastic: Manufacturer's standard butyl mastic sealant.
2.2.7 Metal Termination Bars: Manufacturer's standard aluminum bars, approximately

25 mm wide, roll formed and prepunched.
2.2.8 Metal Battens: Manufacturer's standard aluminum-zinc-alloy-coated or zinc-

coated steel sheet, approximately 25 mm wide by 1.3 mm thick, prepunched.
2.2.9 Fasteners: Factory-coated steel fasteners and metal or plastic plates meeting
corrosion-resistance provisions of FM 4470, designed for fastening sheet to
substrate, and acceptable to roofing system manufacturer.
2.2.10 Miscellaneous Accessories: Provide pourable sealers, preformed cone and vent
sheet flashings, preformed inside and outside corner sheet flashings, T-joint

covers, in-seam sealants, termination reglets, and other accessories
recommended by roofing system manufacturer for intended use.
2.2.11 Liquid coating, specifically formulated for coating EPDM sheet roofing, of the
following type and color:
 Type: Acrylic emulsion or hypalon.

 Color: White.
2.3 INSULATION MATERIALS
2.3.1 Extruded-Polystyrene Board Insulation: Rigid, cellular polystyrene thermal

insulation formed from polystyrene base resin by an extrusion process using
HCFCs as blowing agents to comply with ASTM C 578 for type and with other
requirements indicated below:
 Type VI, 29-kg/cu. m minimum density.
2.4 INSULATION ACCESSORIES
2.4.1 General: Furnish roof insulation accessories recommended by insulation

manufacturer for intended use and compatible with sheet roofing material.
2.4.2 Protection Fabric: Woven or nonwoven polypropylene, polyolefin, or polyester

fabric mat, water permeable and resistant to ultraviolet degradation, type and
weight as recommended by roofing system manufacturer for application.
Minimum weight shall be 136g/m².
2.4.3 Cover Board: ASTM C 1177/C 1177M, glass-mat, water-resistant gypsum

substrate, 13 mm thick.
2.5 VAPOR RETARDER
2.5.1 Polyethylene Vapor Retarder: ASTM D 4397, 6 mils (0.15 mm) thick, minimum,
with maximum permeance rating of 0.13 perm (7.5 ng/Pa x s x sq. m).
 Tape: Pressure-sensitive tape of type recommended by vapor-retarder

manufacturer for sealing joints and penetrations in vapor retarder.
2.6 ROOF PAVERS
2.6.1 General: Unless otherwise indicated on Drawings, nominal size of cement tiles
shall be 400 x 400 x 20 mm & conforming to E.S 269/1. Tiles shall not be delivered
to site before full curing.
2.6.2 Water Absorption: total water absorption for each tile shall not exceed 8 % of
weight.
2.6.3 Compressive Strength: 25 MPa, Minimum.
2.6.4 Edge Profile: Straight with beveled top edges.

2.6.5 Finish of Exposed Surfaces: Smooth plain Surfaces.
2.6.6 Colors and Pattern: As selected by Engineer from manufacturer’s full range.
2.6.7 Mortar Bedding and Grouting material : shall be as following
 Cement: Portland cement E.S.S 4756.

 Aggregate for Mortar: E.S.S. No. 1108; except for joints less than 6.5 mm
thick, use aggregate graded with 100 percent passing the No. 26 (1.41-mm)
sieve.
 Aggregate for Grout: E.S.S. No. 1109, fine aggregate located in second grade
zone, with maximum size of aggregates of 5 mm passing the number 19 sieve.
 Water: Potable.
 The mortar for setting beds shall be composed of 350 kg cement per cu m of
sand with sufficient mixing water.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine substrates, areas, and conditions under which roofing will be applied,
with Installer present, for compliance with requirements.
 Verify that roof openings and penetrations are in place and set and braced and
that roof drains are properly clamped into position.
 Verify that concrete substrate is visibly dry and free of moisture. Test for
capillary moisture by plastic sheet method according to ASTM D 4263.
 Do not proceed with installation until after the minimum concrete curing
period recommended by roofing system manufacturer.
 Do not proceed with installation until unsatisfactory conditions have been
corrected.
3.2 PREPARATION
3.2.1 Clean substrate of dust, debris, and other substances detrimental to roofing
installation according to roofing system manufacturer's written instructions.
Remove sharp projections.
3.2.2 Prevent materials from entering and clogging roof drains and conductors and
from spilling or migrating onto surfaces of other construction. Remove roof-drain
plugs when no work is taking place or when rain is forecast.
3.2.3 Complete terminations and base flashings and provide temporary seals to
prevent water from entering completed sections of the roofing system at the end
of the workday or when rain is forecast. Remove and discard temporary seals
before beginning work on adjoining roofing.

3.3 VAPOR-RETARDER INSTALLATION
3.3.1 Loosely lay polyethylene-film vapor retarder in a single layer over area to receive
vapor retarder, side and end lapping each sheet a minimum of 50 mm and 150
mm, respectively.
3.3.2 Completely seal vapor retarder at terminations, obstructions, and penetrations to

prevent air movement into membrane roofing system.
3.4 INSULATION INSTALLATION
3.4.1 Coordinate installing roofing system components so insulation is not exposed to

precipitation or left exposed at the end of the workday.
3.4.2 Comply with roofing system manufacturer's written instructions for installing roof
insulation.
3.4.3 Trim surface of insulation where necessary at roof drains so completed surface is
flush and does not restrict flow of water.
3.4.4 Install insulation with long joints of insulation in a continuous straight line with
end joints staggered between rows, abutting edges and ends between boards.
Fill gaps exceeding 6 mm with insulation.
 Cut and fit insulation within 6 mm of projections, and penetrations.
3.4.5 Loosely Laid Insulation: Loosely lay insulation units.
3.4.6 Install cover boards over insulation with long joints in continuous straight lines
with end joints staggered between rows. Loosely butt cover boards together and
fasten to roof deck.
 Fasten insulation to resist uplift pressure at corners, perimeter, and field of

roof.
3.5 ADHERED SHEET INSTALLATION
3.5.1 Install EPDM sheet over area to receive roofing according to roofing system
manufacturer's written instructions. Unroll sheet and allow to relax for a
minimum of 30 minutes.
3.5.2 Start installation of sheet in presence of roofing system manufacturer's technical

personnel.
3.5.3 Accurately align sheets and maintain uniform side and end laps of minimum
dimensions required by manufacturer. Stagger end laps.
3.5.4 Apply bonding adhesive to substrate and underside of sheet at rate required by
manufacturer and allow to partially dry. Do not apply bonding adhesive to splice
area of sheet.
3.5.5 Mechanically and adhesively fasten sheet securely at the perimeter of each roof

level, roof section, expansion joint, curb, skylight, interior wall, penthouse, at any
angle change which exceeds 16 cm/m, and at other penetrations in accordance
with manufacturer’s details.
 Install washers/pressure plates to lie completely flat and not less than 10 mm
from edge being fixed.
 Extend overlapping sheet beyond washers/pressure plates by not less than 50
mm.
3.5.6 Apply roofing sheet with side laps shingled with slope of roof deck where
possible.
3.5.7 Spread sealant or mastic bed over deck drain flange at deck drains and securely
seal roofing sheet in place with clamping ring.
3.6 SEAM INSTALLATION
3.6.1 Clean both faces of splice areas, apply splicing cement, and firmly roll side and
end laps of overlapping sheets according to manufacturer's written instructions to
ensure a watertight seam installation. Apply lap sealant and seal exposed edges
of sheet terminations.
 Apply a continuous bead of in-seam sealant before closing splice if required by

roofing system manufacturer.
3.6.2 Clean and prime both faces of splice areas, apply splice tape, and firmly roll side
and end laps of overlapping sheets according to manufacturer's written
instructions to ensure a watertight seam installation. Apply lap sealant and seal
exposed edges of sheet terminations.
3.6.3 Repair tears, voids, and lapped seams in roofing that does not meet
requirements.
3.7 FLASHING INSTALLATION
3.7.1 Install sheet flashings and preformed flashing accessories and adhere to
substrates according to roofing system manufacturer's written instructions.
3.7.2 Apply bonding adhesive to substrate and underside of flashing sheet at required
rate and allow to partially dry. Do not apply bonding adhesive to seam area of
flashing.
3.7.3 Flash penetrations and field-formed inside and outside corners with cured or
uncured sheet flashing as recommended by manufacturer.
3.7.4 Clean splice areas, apply splicing cement, and firmly roll side and end laps of
overlapping sheets according to manufacturer's written instructions to ensure a
watertight seam installation. Apply lap sealant and seal exposed edges of sheet
flashing terminations.
3.7.5 Terminate and seal top of sheet flashings and mechanically anchor to substrate

through termination bars.
3.8 COATING INSTALLATION
3.8.1 Apply coatings to sheet roofing and flashings according to manufacturer's

recommendations, by spray, roller, or other suitable application method.
3.9 ROOF PAVERS INSTALLATIONS
3.9.1 Saturate concrete with clean water several hours before placing setting bed.
Remove surface water about one hour before placing setting bed.
3.9.2 Apply mortar bed bond coat to damp concrete and broom to provide an even
coating that completely covers the concrete. Do not exceed 1.5-mm thickness.
Limit area of mortar bed bond coat to avoid its drying out before placing setting
bed.
3.9.3 Apply mortar bed immediately after applying mortar-bed bond coat. Spread,
tamp, and screed to uniform thickness at elevations required for setting stone to
finished elevations indicated. Thick of mortar bedding shall be 25-30 mm
3.9.4 Mix and place only that amount of mortar bed that can be covered with Roof
Paver before initial set. Cut back, bevel edge, and discard material that has
reached initial set before stone can be placed.
3.9.5 Place Paver before initial set of mortar occurs. Immediately before placing stone
on setting bed, apply uniform 1.5-mm thick bond coat to bed or to back of each
stone unit.
3.9.6 Tamp and beat Paver to obtain full contact with setting bed and to bring finished
surfaces within indicated tolerances. Set each unit in a single operation before
initial set of mortar.
3.9.7 Rake out joints to depth required to receive pointing mortar as units are set.
3.9.8 Movement (Control) Joints in Floors: Divide floor areas into controllable bays
with movement (Control) joints as recommended in BS 5385: Part 1, unless
otherwise indicated on Drawings. Also install movement joints around island
columns, stairs and wherever movement is anticipated including at junctions with
walls.
3.10.1 Final Roof Inspection: Arrange for roofing system manufacturer's technical
personnel to inspect roofing installation on completion and submit report to
Engineer.
 Notify Engineer 48 hours in advance of the date and time of inspection.
3.10.2 Flood Test: Perform flood test at each separate roof area upon completion of
membrane roofing installation. Prior to testing, thoroughly examine and verify
that all necessary roofing work, including upstands and flashings, is complete and

any apparent defects have been satisfactorily remedied:
 Notify Engineer 48 hours in advance of the date and time of each test.
 Subject to Engineer’s approval, divide large roof areas into sections with
approved barriers.
 Externally cover and seal all roof outlets and protect against damage from
water pressure with temporary kerbs. Do not use plugs to seal outlets.
 Carefully flood to a depth of 100 mm, unless otherwise approved by Engineer,

but in no case higher than lowest kerb or upstand level.
 Maintain test for 24 hours. Monitor water level and inspect for leaks at
regular intervals.
 On completion of test, slowly drain roof area, ensuring that outlets do not
overload or flood.
 Where leaks have occurred, submit detailed proposals and obtain approval for
remedial measures.
 After completion of remedial works, re-test the affected roof areas.
3.11 PROTECTING AND CLEANING
3.11.1 Protect sheet membrane roofing from damage and wear during remainder of
construction period. When remaining construction will not affect or endanger
roofing, inspect roofing for deterioration and damage, describing its nature and
extent in a written report, to Engineer.
3.11.2 Correct deficiencies in or remove roofing that does not comply with
requirements, repair substrates, reinstall roofing, and repair sheet flashings to a
condition free of damage and deterioration at the time of Substantial Completion
and according to warranty requirements.
3.11.3 Clean overspray and spillage from adjacent construction using cleaning agents
and procedures recommended by manufacturer of affected construction.


ISSUED FOR
PURCHASE
CONSTRUCTION
x
NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. SBS-MODIFIED BITUMINOUS
CAIRO - EGYPT MEMBRANE 07552 – 2039 0

CONTENTS
SECTION 07552
SBS-MODIFIED BITUMINOUS MEMBRANE
Page
PART 1 GENERAL 2
1.1 Summary 2
1.2 Submittals 2
1.4 Warranty 2
PART 2 Products 2
2.1 Sbs-Modified Bituminous Membrane 2
2.2 Auxiliary Waterproofing Membrane Materials 3
PART 3 EXECUTION 4
3.1 Preparation 4
3.2 Sbs-Modified Bituminous Membrane Installation 4
3.3 Protection and Cleaning 4
SBS-Modified Bituminous Membrane Section 07552

SECTION 07552
SBS-MODIFIED BITUMINOUS MEMBRANE
PART 1 GENERAL
1.1 SUMMARY
1.1.1 This Section includes SBS-modified bituminous membrane waterproofing for

water tanks.
1.2 SUBMITTALS
1.2.1 Product Data: For each type of product indicated.
1.2.3 Samples:
 300-by-300-mm square of waterproofing membrane.
1.3.1 Delivery materials to project site in original containers with seals unbroken and
labeled with manufacturer’s name, product brand name and type, date of
manufacture, and directions for storage.
1.3.2 Store liquid materials in their original undamaged containers in a clean, dry,
protected location and within the temperature range required by waterproofing
system manufacturers. Protect stored liquid material from direct sunlight.
 Discard and legally dispose of liquid material that cannot be applied within its
stated shelf life.
1.4 WARRANTY
1.4.1 Special Warranty: Manufacturer’s form, without monetary limitation, in which

manufacturer agrees to repair or replace components of tanking system that fail
in materials or workmanship within specified warranty period.
 Warranty Period: Ten (10) years from date of substantial completion.
PART 2 PRODUCTS
2.1 SBS-MODIFIED BITUMINOUS MEMBRANE
2.1.1 SBS-modified Bituminous Membrane; polyester reinforced, smooth surfaced;

suitable for application method specified. The lower surface is covered with fine
sand and the upper surface is covered with find sand.

2.1.2 Comply with the following requirements:
Parameter Standard Unit Value

Thickness mm 4
Softening Point (Ring and Ball) ASTM D-36 °C ≥ 130

Cold Temperature Flexibility ASTM D 5147 °C -20
Tensile Strength Long ASTM D 5147 N/5cm 1000
Wide N/5cm 700
Elongation Long ASTM D 5147 % 45
Wide % 50
Tear Resistance Long EN 12310-1 N 280
(Nail-Shank) Wide N 340
Joint Tensile Strength Long EN12317-1 N 1000
Wide N 700
Dimensional Stability Long EN 1107 % ± 0.3
Wide % ± 0.3
Water Absorption ASTM D-5147 % 0.15 max
2
Adhesion to Concrete EN 12316 N/cm 40
2.2 AUXILIARY WATERPROOFING MEMBRANE MATERIALS
2.2.1 General: Auxiliary materials recommended by waterproofing system

manufacturer for intended use and compatible with waterproofing membrane.
2.2.2 Asphalt Primer: ASTM D 41.
2.2.3 Cold-Applied Adhesive: Waterproofing system manufacturer's standard asphalt-

based, one- or two-part, asbestos-free, cold-applied adhesive specially
formulated for compatibility and use with membrane.
2.2.4 Mastic Sealant: Polyisobutylene, plain or modified bitumen, non-hardening, non-

migrating, non-skinning, and nondrying.
2.2.5 Fasteners: Factory-coated steel fasteners and metal or plastic plates meeting
high corrosion-resistance, designed for fastening waterproofing membrane
components to substrate, tested by manufacturer for required pullout strength,
and acceptable to waterproofing system manufacturer.
2.2.7 Separator Sheet: Polyethylene sheet, 0.1 mm thick, minimum.

PART 3 EXECUTION
3.1 PREPARATION
3.1.1 Clean substrate of dust, debris, moisture, and other substances detrimental to
waterproofing installation according to manufacturer's written instructions.
Remove sharp projections.
3.1.2 Prevent materials from entering and clogging drains and conductors and from
spilling or migrating onto surfaces of other construction. Remove roof-drain
plugs when no work is taking place or when rain is forecast.
3.2 SBS-MODIFIED BITUMINOUS MEMBRANE INSTALLATION
3.2.1 Install modified bituminous waterproofing membrane according to

waterproofing manufacturer's written instructions.
3.2.2 Laps: Accurately align waterproofing membrane, without stretching, and

maintain uniform side and end laps. Stagger end laps. Completely bond and seal
laps, leaving no voids.
 Repair tears and voids in laps and lapped seams not completely sealed.
3.3 PROTECTION AND CLEANING
3.3.1 Protect waterproofing system from damage and wear during remainder of
construction period.
3.3.2 Correct deficiencies in or remove waterproofing system that does not comply
with requirements, repair substrates, and repair or reinstall waterproofing
system to a condition free of damage and deterioration at time of Substantial
Completion and according to warranty requirements.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. SHEET METAL FLASHING
CAIRO - EGYPT 07620 – 2039 0
ECG Form No. E409 Rev. 5/0 Sheet of 7

CONTENTS
SECTION 07620
SHEET METAL FLASHING

Page
PART 1 GENERAL 2
1.2 Summary 2
1.4 Submittals 2
PART 2 PRODUCTS 3
2.1 Flashing Materials 3
2.2 Miscellaneous Materials And Accessories 3
2.3 Manufactured Sheet Metal Flashing And Trim 4
2.4 Fabrication Of Metal Flashing Sheets 4
2.5 Finishes 5
PART 3 EXECUTION 5
3.1 Examination 5
3.3 Roof Flashing Installation 6
Sheet Metal Flashing Section 07620

SECTION 07620
SHEET METAL FLASHING
PART 1 GENERAL
1.1.1 Drawings and General Provisions of the Contract, including General Conditions,
Conditions of Particular Application and Division-1 Specification Sections, apply to
work of this Section.
1.2 SUMMARY
1.2.1 This section covers the metal flashing work as required by the Contract.
1.3.1 General: Install sheet metal flashing and trim to withstand wind loads, structural
movement, thermally induced movement, and exposure to weather without fail-
ing, rattling, leaking, and fastener disengagement
1.3.2 Thermal Movements: Provide sheet metal flashing and trim that allow for ther-
mal movements resulting from the following maximum change (range) in ambient
and surface temperatures by preventing buckling, opening of joints, hole elonga-
tion, overstressing of components, failure of joint sealants, failure of connections,
and other detrimental effects. Provide clips that resist rotation and avoid shear
stress as a result of sheet metal and trim thermal movements. Base engineering
calculation on surface temperatures of materials due to both solar heat gain and
nighttime-sky heat loss.
 Temperature Change (Range): 35 deg C, ambient; 70 deg C, material surfaces.
1.4 SUBMITTALS
1.4.1 Product Data: For each type of product indicated. Include construction details,
material descriptions, dimensions of individual components and profiles, and fin-
ishes.
1.4.2 Shop Drawings: Show layouts of sheet metal flashing and trim, including plans
and elevations. Distinguish between shop- and field-assembled work. Include the
following:
 Identify material, thickness, weight, and finish for each item and location in Project.
 Details for forming sheet metal flashing and trim, including profiles, shapes, seams,
and dimensions.
 Details for fastening, joining, supporting, and anchoring sheet metal flashing and
trim, including fasteners, clips, cleats, and attachments to adjoining work.
 Details of expansion-joint covers, including showing direction of expansion and con-
traction.

1.4.3 Samples: For each type of exposed finish required, prepared on Samples of size
indicated below:
 Sheet Metal Flashing: 300 mm long. Include fasteners, cleats, clips, closures, and
other attachments.
 Trim: 300 mm long. Include fasteners and other exposed accessories.
 Accessories: Full-size Sample.
1.6.1 Deliver sheet metal flashing materials and fabrications undamaged. Protect sheet
metal flashing and trim materials and fabrications during transportation and han-
dling.
1.6.2 Unload, store, and install sheet metal flashing materials and fabrications in a
manner to prevent bending, warping, twisting, and surface damage.
1.6.3 Stack materials on platforms or pallets, covered with suitable weathertight and
ventilated covering. Do not store sheet metal flashing and trim materials in con-
tact with other materials
PART 2 PRODUCTS
2.1 FLASHING MATERIALS
2.1.1 Prepainted, Metallic-Coated Steel Sheet: Steel sheet metallic coated by the hot-
dip process and prepainted by the coil-coating process to comply with
ASTM A 755/A 755M.
 Zinc-Coated (Galvanized) Steel Sheet: ASTM A 653/A 653M, Z275 coating designa-
tion; structural quality.
2.2 MISCELLANEOUS MATERIALS AND ACCESSORIES
2.2.1 General: Provide materials and types of fasteners, solder, welding rods, protective
coatings, separators, sealants, and other miscellaneous items as required for
complete sheet metal flashing and trim installation.
2.2.2 Fasteners: Wood screws, annular threaded nails, self-tapping screws, self-locking
rivets and bolts, and other suitable fasteners designed to withstand design loads.
 Fasteners: Galvanized steel.

 Fasteners for Flashing and Trim: Blind fasteners or self-drilling screws, gasketed,
with hex washer head.
 Blind Fasteners: High-strength aluminum or stainless-steel rivets.
 Spikes and Ferrules: Same material as gutter; with spike with ferrule matching in-
ternal gutter width.
2.2.3 Sealing Tape: Pressure-sensitive, 100 percent solids, polyisobutylene compound

sealing tape with release-paper backing. Provide permanently elastic, nonsag,
nontoxic, nonstaining tape.
2.2.4 Elastomeric Sealant: ASTM C 920, elastomeric polyurethane, polysulfide or sili-

cone polymer sealant; of type, grade, class, and use classifications required to seal
joints in sheet metal flashing and trim and remain watertight.
2.2.5 Butyl Sealant: ASTM C 1311, single-component, solvent-release butyl rubber seal-
ant, polyisobutylene plasticized, heavy bodied for hooked-type expansion joints
with limited movement.
2.3 MANUFACTURED SHEET METAL FLASHING AND TRIM
2.3.1 Flashing: Fabricate from sheets to details indicated on Drawings and approved
shop drawings. Thickness shall not be less than 0.7 mm.
2.4 FABRICATION OF METAL FLASHING SHEETS
2.4.1 General: Custom fabricate sheet metal flashing and trim to comply with recom-
mendations in SMACNA's "Architectural Sheet Metal Manual" that apply to de-
sign, dimensions, metal, and other characteristics of item indicated. Shop fabri-
cates items where practicable. Obtain field measurements for accurate fit before
shop fabrication.
2.4.2 Fabricate sheet metal flashing and trim in thickness or weight needed to comply
with performance requirements, but not less than that specified for each applica-
tion and metal.
2.4.3 Fabricate sheet metal flashing and trim without excessive oil canning, buckling,
and tool marks and true to line and levels indicated, with exposed edges folded
back to form hems.
 Seams for Other: Fabricate nonmoving seams in accessories with flat-lock seams.
Tin edges to be seamed, form seams, and solder.
2.4.4 Sealed Joints: Form nonexpansion but movable joints in metal to accommodate
elastomeric sealant to comply with SMACNA recommendations.
2.4.5 Expansion Provisions: Where lapped or bayonet-type expansion provisions in the

Work cannot be used, form expansion joints of intermeshing hooked flanges, not
less than 25 mm deep, filled with elastomeric sealant concealed within joints.
2.4.6 Conceal fasteners and expansion provisions where possible on exposed-to-view

sheet metal flashing and trim, unless otherwise indicated.
2.4.7 Fabricate cleats and attachment devices from same material as accessory being
anchored or from compatible, noncorrosive metal.
 Thickness: As recommended by SMACNA's "Architectural Sheet Metal Manual" for

application but not less than thickness of metal being secured.
2.4.8 Separate metal from noncompatible metal or corrosive substrates by coating con-
cealed surfaces at locations of contact with asphalt mastic or other permanent
separation as recommended by manufacturer.
2.5 FINISHES
2.5.1 Protect mechanical and painted finishes on exposed surfaces from damage by ap-
plying a strippable, temporary protective covering before shipping.

pieces are acceptable if they are within one-half of the range of approved Sam-
ples. Noticeable variations in the same piece are not acceptable. Variations in
appearance of other components are acceptable if they are within the range of
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine substrates, areas, and conditions, with the Installer present, to verify ac-
tual locations, dimensions and other conditions affecting performance of work.
 Verify that substrate is sound, dry, smooth, clean, sloped for drainage, and securely
anchored.
 Proceed with installation only after unsatisfactory conditions have been corrected.
3.2.1 General: Anchor sheet metal flashing and trim and other components of the
Work securely in place, with provisions for thermal and structural movement. Use
fasteners, solder, welding rods, protective coatings, separators, sealants, and oth-
er miscellaneous items as required to complete sheet metal flashing and trim sys-
tem.
 Torch cutting of sheet metal flashing and trim is not permitted.

3.2.2 Metal Protection: Where dissimilar metals will contact each other or corrosive
substrates, protect against galvanic action by painting contact surfaces with bitu-
minous coating or by other permanent separation as recommended by fabricator
or manufacturers of dissimilar metals.
 Underlayment: Where installing metal flashing directly on cementitious or wood

substrates, install a course of felt underlayment and cover with a slip sheet or install
a course of polyethylene underlayment.
 Bed flanges in thick coat of asphalt roofing cement where required for waterproof
performance.
3.2.3 Install exposed sheet metal flashing and trim without excessive oil canning, buck-
ling, and tool marks.
3.2.4 Install sheet metal flashing and trim true to line and levels indicated. Provide uni-
form, neat seams with minimum exposure of solder, welds, and elastomeric seal-
ant.

3.2.5 Install sheet metal flashing and trim to fit substrates and to result in watertight
performance. Verify shapes and dimensions of surfaces to be covered before fab-
ricating sheet metal.
 Space cleats not more than 300 mm apart. Anchor each cleat with two fasteners.
Bend tabs over fasteners.
 Expansion Provisions: Provide for thermal expansion of exposed flashing and trim.
Space movement joints at a maximum of 3 m with no joints allowed within 600 mm
of corner or intersection. Where lapped or bayonet-type expansion provisions can-
not be used or would not be sufficiently watertight, form expansion joints of inter-
meshing hooked flanges, not less than 25 mm deep, filled with elastomeric sealant
concealed within joints.
3.2.6 Fasteners: Use fasteners of sizes that will penetrate substrate not less than 32
mm for nails and not less than 20 mm for wood screws.
 Galvanized or Prepainted, Metallic-Coated Steel: galvanized steel.
3.2.7 Seal joints with elastomeric sealant as required for watertight construction.
 Where sealant-filled joints are used, embed hooked flanges of joint members not
less than 25 mm into sealant. Form joints to completely conceal sealant. When am-
bient temperature at time of installation is moderate, between 4 and 21 deg. C, set
joint members for 50 percent movement either way. Adjust setting proportionately
for installation at higher ambient temperatures. Do not install sealant-type joints at
temperatures below 4 deg. C.
 Prepare joints and apply sealants to comply with requirements in Division 7 Section
"Joint Sealants."
3.2.8 Aluminum Flashing: Rivet or weld joints in uncoated aluminum where necessary
for strength.
3.3 ROOF FLASHING INSTALLATION
3.3.1 General: Install sheet metal roof flashing and trim to comply with performance
requirements, sheet metal manufacturer's written installation instructions. Pro-
vide concealed fasteners where possible, set units true to line, and level as indi-
cated. Install work with laps, joints, and seams that will be permanently water-
tight.
3.3.2 Counterflashing: Coordinate installation of counterflashing with installation of

base flashing. Insert counterflashing in reglets or receivers and fit tightly to base
flashing. Extend counterflashing 100 mm over base flashing. Lap counterflashing
joints a minimum of 100 mm and bed with elastomeric sealant.
 Secure in a waterproof manner by means of snap-in installation and sealant or lead

wedges and sealant.
3.3.3 Roof-Penetration Flashing: Coordinate installation of roof-penetration flashing

with installation of roofing and other items penetrating roof. Install flashing as
follows:

 Turn lead flashing down inside vent piping, being careful not to block vent piping
with flashing.
 Seal with elastomeric sealant and clamp flashing to pipes penetrating roof except for
lead flashing on vent piping.
3.4.1 Cleaning: Clean exposed metal surfaces, removing substances, which might cause
corrosion of metal, or deterioration of finishes.
3.4.2 Protection: Provide and maintain required procedures for protection of flashings
metal work during construction to ensure that work will be without damage or
deterioration, other than natural weathering, at time of substantial completion.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. THROUGH-PENETRATION FIRESTOP
CAIRO - EGYPT SYSTEMS 07841 -2039 0

CONTENTS
SECTION 07841
THROUGH-PENETRATION FIRESTOP SYSTEMS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.4 Submittals 3
1.8 Coordination 6
PART 2 PRODUCTS 6
2.1 Firestopping, General 6
2.2 Fill Materials 6
2.3 Mixing 8
PART 3 EXECUTION 8
3.1 Examination 8
3.2 Preparation 9
3.3 Through-Penetration Firestop System Installation 9
3.5 Identification 10
3.6 Cleaning and Protection 10
Through-Penetration Firestop Systems Section 07841

SECTION 07841
THROUGH-PENETRATION FIRESTOP SYSTEMS
PART 1 GENERAL
Supplementary Conditions and Division 1 Specifications Sections, apply to this
Section.
1.2 SUMMARY
1.2.1 This Section includes through-penetration firestop systems for penetrations

through the following fire-resistance-rated assemblies, including both empty
openings and openings containing penetrating items:
 Floors.
 Roofs.
 Walls and partitions.
 Construction enclosing compartmentalized areas.
 Division 3 Section "Cast-in-Place Concrete" for construction of openings in

concrete slabs and walls.
 Division 4 Section “Unit Masonry Assemblies” for construction of openings in
fire rated masonry assemblies.
 Division 15 Sections specifying duct and piping penetrations.
 Division 16 Sections specifying cable and conduit penetrations.
1.3.1 General: For constructions and work items where fire-rating is indicated on
Drawings provide through-penetration firestop systems that are produced and
installed to resist spread of fire according to requirements indicated, resist
passage of smoke and other gases, and maintain original fire-resistance rating of
assembly penetrated.
 Fire-resistance-rated non-load-bearing walls, including partitions, with fire-

protection-rated openings.
 Fire-resistance-rated floor assemblies.
 Fire-resistance-rated roof assemblies.
1.3.2 F-Rated Systems: For the following conditions, provide through-penetration fire-
stop systems with F-ratings indicated, as determined per ASTM E814, but not less

than that equaling or exceeding fire-resistance rating of construction penetrated.
 Minimum fire rating of fire-rated system shall be as indicated on Fire Design

Drawing for the assembly that will be penetrated or opened.
1.3.3 T-Rated Systems: For the following conditions, provide through-penetration

firestop systems with T-ratings indicated, as well as F-ratings, as determined, per
ASTM E 814, where systems protect penetrating items exposed to potential
contact with adjacent materials in occupiable floor areas:
 Penetrations located outside fire-resistive shaft enclosures.

 Penetrations located in construction containing fire-protection-rated openings.
 Penetrating items larger than 100 mm diameter nominal pipe or 100 sq. cm in
overall cross-sectional area.
1.3.4 For through-penetration firestop systems exposed to view, traffic, moisture, and
physical damage, provide products that after curing do not deteriorate when
exposed to these conditions both during and after construction.
 For piping penetrations for plumbing and wet-pipe sprinkler systems, provide
moisture-resistant through-penetration firestop systems.
 For floor penetrations with annular spaces exceeding 100 mm in width and
exposed to possible loading and traffic, provide firestop systems capable of
supporting floor loads involved either by installing floor plates or by other
means.
 For penetrations involving insulated piping, provide through-penetration
firestop systems not requiring removal of insulation.
1.3.5 For through-penetration firestop systems exposed to view, provide products with
flame-spread ratings of less than 25 and smoke-developed ratings of less than
450, as determined, per ASTM E 84.
1.3.6 Provide through-penetration firestop systems complying with specified US

standards or any approved equivalent European standards such as Euronorm or
ISO.
1.3.7 Fire Resistive Joint Sealants: Provide joint sealants with fire resistance ratings as
determined per ASTM E 119.
1.4 SUBMITTALS
1.4.1 Product Data: For each type of through-penetration firestop system product
indicated.
1.4.2 Shop Drawings: For each through-penetration firestop system, show each kind of
construction condition penetrated, relationships to adjoining construction, and
kind of penetrating item. Include firestop design designation of testing and
inspecting agency acceptable to authorities having jurisdiction that evidences
compliance with requirements for each condition indicated.

 Submit documentation, including illustrations, from a qualified testing and
inspecting agency that is applicable to each through-penetration firestop
system configuration for construction and penetrating items.
 Where Project conditions require modification of qualified testing and
inspecting agency's illustration to suit a particular through-penetration firestop
condition, submit illustration, with modifications marked, approved by
through-penetration firestop system manufacturer's fire-protection engineer.
1.4.3 Qualification Data: For firms and persons specified in "Quality Assurance" Article
to demonstrate their capabilities and experience. Include lists of completed
projects with project names and addresses, names and addresses of Engineers
and employers, and other information specified.
1.4.4 Product Certificates: Signed by manufacturers of through-penetration firestop

system products certifying that products furnished comply with requirements.
1.4.5 Product Test Reports: From a qualified testing agency indicating through-
penetration firestop system complies with requirements, based on
comprehensive testing of current products.
1.4.6 Field-Constructed Mockup: Prior to installing firestopping, erect mockups for

each different through-penetration firestop system indicated to verify selections
made and to demonstrate qualities of materials and execution. Build mockups to
comply with the following requirements, using materials indicated for final
installations.
 Locate mockups on site in locations indicated or, if not indicated, as directed by

Engineer.
 Notify Engineer 1 week in advance of the dates and times when mockups will
be erected.
 Obtain Engineer's acceptance of mockups before start of final unit of Work.
 Retain and maintain mockups during construction in an undisturbed condition
as a standard for judging completed unit of Work.
 Accepted mockups in an undisturbed condition at time of Substantial
Completion may become part of completed unit of Work.

1.5.2 Installer Qualifications: An experienced installer who is qualified by having the

necessary experience, staff, and training to install manufacturer's products per
specified requirements. The installer should have completed through-penetration
firestop systems similar in material, design, and extent to that indicated for this
Project and whose work has resulted in construction with a record of successful

in-service performance.
1.5.3 Source Limitations: Obtain through-penetration firestop systems, for each kind of
penetration and construction condition indicated, from a single manufacturer.
1.5.4 Fire-Test-Response Characteristics: Provide through-penetration firestop

systems that comply with the following requirements and those specified in
"Performance Requirements" Article:
 Firestopping tests are performed by a qualified testing and inspecting agency.

A qualified testing and inspecting agency is UL, or another agency performing
testing and follow-up inspection services for firestop systems acceptable to the
Engineer.
 Through-penetration firestop systems are identical to those tested per
ASTM E814. Provide rated systems complying with the following requirements:
 Through-penetration firestop system products bear classification marking of
qualified testing and inspecting agency.
 Fire resistance rating and separation achieved by the firestop system shall
be equal or exceed the fire resistance rating of the penetrated construction
as specified or indicated in the Contract Documents.
 Through-penetration firestop systems correspond to those indicated by
reference to through-penetration firestop system designations listed by the
following:
 UL in its "Fire Resistance Directory."
1.5.5 Provide firestopping products containing no detectable asbestos as determined by

the method specified in 40 CFR Part 763, Subpart F, Appendix A, Section 1,
"Polarized Light Microscopy."
1.6.1 Deliver through-penetration firestop system products to Project site in original,

unopened containers or packages with intact and legible manufacturers' labels
identifying product and manufacturer; date of manufacture; lot number; shelf life,
if applicable; qualified testing and inspecting agency's classification marking
applicable to Project; curing time; and mixing instructions for multicomponent
materials.
1.6.2 Store and handle materials for through-penetration firestop systems to prevent
their deterioration or damage due to moisture, temperature changes,
contaminants, or other causes.
1.7.1 Environmental Limitations: Do not install through-penetration firestop systems

when ambient or substrate temperatures are outside limits permitted by through-
penetration firestop system manufacturers or when substrates are wet due to
rain, frost, condensation, or other causes.
1.7.2 Ventilate through-penetration firestop systems per manufacturer's written

instructions by natural means or, where this is inadequate, forced-air circulation.
1.8 COORDINATION
1.8.1 Coordinate construction of openings and penetrating items to ensure that

through-penetration firestop systems are installed according to specified
requirements.
1.8.2 Coordinate sizing of sleeves, openings, core-drilled holes, or cut openings to

accommodate through-penetration firestop systems.
PART 2 PRODUCTS
2.1 FIRESTOPPING, GENERAL
2.1.1 Only firestop products which have been third party tested in accordance with
UL1479 - ASTM E-814 for specific fire rated construction penetrations shall be
considered and used. Items shall be tested to specific parameters including the
type and number of penetrating items, the size of the penetrating items, the
maximum allowable annular space, and rated for the hourly requirement of the
structure.
2.1.2 Compatibility: Provide through-penetration firestop systems that are compatible

with one another, with the substrates forming openings, and with the items, if
any, penetrating through-penetration firestop systems, under conditions of
service and application, as demonstrated by through-penetration firestop system
manufacturer based on testing and field experience.
2.1.3 Accessories: Provide components for each through-penetration firestop system

that are needed to install fill materials and to comply with "Performance
Requirements" Article. Use only components specified by through-penetration
firestop system manufacturer and approved by the qualified testing and
inspecting agency for firestop systems indicated. Accessories include, but are not
limited to, the following items:
 Permanent forming/damming/backing materials, including the following:
 Slag-/rock-wool-fiber insulation.
 Sealants used in combination with other forming/damming/backing
materials to prevent leakage of fill materials in liquid state.
 Fire-rated form board.
 Fillers for sealants.
 Substrate primers.
 Collars.
2.2 FILL MATERIALS
2.2.1 Cast-in-Place Firestop Devices: Factory-assembled devices for use in cast-in-place

concrete floors and consisting of an outer metallic sleeve lined with a n

intumescent strip, a radial extended flange attached to one end of the sleeve for
fastening to concrete formwork, and a neoprene gasket.
2.2.2 Latex Sealants: Single-component latex formulations that after cure do not re-
emulsify during exposure to moisture. Use for sealing nominal openings with
penetrations of non-combustible items including; cast and steel pipe, copper pipe,
conduit, electrical metallic tubing (EMT) .
2.2.3 Silicone Sealants: Moisture-curing, single component, silicone based, neutral

curing elastomeric sealants of grade indicated below:
 Grade: Pourable(self-leveling) formulation for openings in floors and other

horizontal surfaces and nonsag formulation of openings in vertical and other
surfaces requiring a nonslumping, gunnable sealant, unless indicated firestop
system limits use to nonsag grade for both opening conditions.
 Grade for Vertical Surfaces: Nonsag formulation for openings invertical and
other surfaces.
2.2.4 Firestop Devices: Factory-assembled collars formed from galvanized steel and
lined with intumescent material sized to fit specific diameter of penetrant.
2.2.5 Intumescent Composite Sheets: Rigid panels consisting of aluminum-foil-faced

elastomeric sheet bonded to galvanized steel sheet. Use for large size - complex
penetrations which accommodate individual or combinations of cable trays,
multiple steel or copper pipes, electrical conduits, busways, or
electrical/data/telecommunications cables.
2.2.6 Mortars: Prepackaged, dry mixes consisting of a blend of inorganic binders,

hydraulic cement, fillers, and lightweight aggregate formulated for mixing with
water at Project site to form a nonshrinking, homogeneous mortar. Use for large
size - complex penetrations which accommodate individual or combinations of
cable trays, multiple steel or copper pipes, electrical conduits, busways, or
electrical/data/telecommunications cables.
2.2.7 Intumescent Putties: Nonhardening dielectric, water resistant putties containing

no solvents, inorganic fibers, or silicone compounds.
2.2.8 Intumescent Wrap Strips: Single component intumescent elastomeric sheets with
aluminum foil on one side.
2.2.9 Pillows/Bags: Reusable, heat-expanding pillows/bags consisting of glass-fiber

cloth cases filled with a combination of mineral-fiber, water-insoluble expansion
agents and fire-retardant additives. Use for large size - complex penetrations
which accommodate individual or combinations of cable trays, multiple steel or
copper pipes, electrical conduits, busways, or electrical/data/telecommunications
cables.
2.2.10 Ceramic-Fiber and Mastic Coating: Ceramic fibers in bulk form formulated for use
with mastic coating, and ceramic fiber manufacturer's mastic coating.
2.2.11 Ceramic-Fiber Sealant: Single-component formulation of ceramic fibers and

inorganic binders.
2.2.12 Job-Mixed Vinyl Compound: Prepackaged vinyl-based powder product for mixing
with water at Project site to produce a paintable compound, passing ASTM E 136,
with flame-spread and smoke-developed ratings of zero, per ASTM E 84.
2.2.13 Multi-Diameter Sealing Module: Consists of Multidiameter two halves, with

removable layers and a center core, one single module can seal a cable or pipe
over a span of several different diameters simply by peeling layers from the
module halves to ensure a perfect fit. Modules are used together with a frame
and a compression unit to provide protection against water, dust, chemical,
insects and rodents, and the following requirements:
 Liquid pressure up: 4 bar, minimum.

 Gas pressure up: 2.6 bar minimum.
 Vibrations.
2.2.14 Multi-diameter sealing module composed of the following, but not limited to:
 Frames.
 Wedge: Highly efficient compression unit for the frame. The complete
compression unit consists of only one piece which, by turning the screws in the
front, both compresses and decompresses the wedge.
 Stay plates: To be inserted between each row of modules to anchor them
axially in the frame. Width as recommended by manufacture to suit frame
opening.
 Provide all necessary accessories for sealing modules system
2.3 MIXING
2.3.1 For those products requiring mixing before application, comply with through-
penetration firestop system manufacturer's written instructions for accurate
proportioning of materials, water (if required), type of mixing equipment,
selection of mixer speeds, mixing containers, mixing time, and other items or
procedures needed to produce products of uniform quality with optimum
performance characteristics for application indicated.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine substrates and conditions, with Installer present, for compliance with
requirements for opening configurations, penetrating items, substrates, and other
conditions affecting performance.
corrected.

3.2 PREPARATION
3.2.1 Surface Cleaning: Clean out openings immediately before installing through-
penetration firestop systems to comply with written recommendations of firestop
system manufacturer and the following requirements:
 Remove from surfaces of opening substrates and from penetrating items

foreign materials that could interfere with adhesion of through-penetration
firestop systems.
 Clean opening substrates and penetrating items to produce clean, sound
surfaces capable of developing optimum bond with through-penetration
firestop systems. Remove loose particles remaining from cleaning operation.
 Remove laitance and form-release agents from concrete.
3.2.2 Priming prime substrates where recommended in writing by through-penetration

firestop system manufacturer using that manufacturer's recommended products
and methods. Confine primers to areas of bond; do not allow spillage and
migration onto exposed surfaces.
3.2.3 Masking Tape: Use masking tape to prevent through-penetration firestop systems
from contacting adjoining surfaces that will remain exposed on completion of
Work and that would otherwise be permanently stained or damaged by such
contact or by cleaning methods used to remove smears from firestop system
materials. Remove tape as soon as possible without disturbing firestop system's
seal with substrates.
3.3 THROUGH-PENETRATION FIRESTOP SYSTEM INSTALLATION
3.3.1 General: Install through-penetration firestop systems to comply with

"Performance Requirements" Article and firestop system manufacturer's written
installation instructions and published drawings for products and applications
indicated.
3.3.2 Install forming/damming/backing materials and other accessories of types

required to support fill materials during their application and in the position
needed to produce cross-sectional shapes and depths required to achieve fire
ratings indicated.
 After installing fill materials, remove combustible forming materials and other
accessories not indicated as permanent components of firestop systems.
3.3.3 Install fill materials for firestop systems by proven techniques to produce the
following results:
 Fill voids and cavities formed by openings, forming materials, accessories, and
penetrating items as required to achieve fire-resistance ratings indicated.
 Apply materials so they contact and adhere to substrates formed by openings
and penetrating items.
 For fill materials that will remain exposed after completing Work, finish to

produce smooth, uniform surfaces that are flush with adjoining finishes.
3.4.1 Manufacture Field Service: Manufacture/fabricator’s qualified technical

representative, not a sales representative, shall inspect first days work and
periodically inspect work of this Section to insure installation is proceeding in
accordance with manufacture/fabricator’s recommendations and warranty
requirements. Representative shall submit written reports of each visit indicating
observations, findings and conclusion of inspection
3.4.2 Inspecting Agency: Engage a qualified independent inspecting agency to inspect

through-penetration firestop systems and to prepare test reports.
 Inspecting agency will state in each report whether inspected through-

penetration firestop systems comply with or deviate from requirements.
3.4.3 Proceed with enclosing through-penetration firestop systems with other

construction only after inspection reports are issued.
3.4.4 Where deficiencies are found, repair or replace through-penetration firestop

systems so they comply with requirements.
3.5 IDENTIFICATION
3.5.1 Identify through-penetration firestop systems with pressure-sensitive, self-

adhesive, preprinted vinyl labels. Attach labels permanently to surfaces of
penetrated construction on both sides of each firestop system installation where
labels will be visible to anyone seeking to remove penetrating items or firestop
systems. Include the following information on labels:
 The words: "Warning--Through-Penetration Firestop System--Do Not Disturb.

Notify Building Management of Any Damage."
 The Contractor's name, address, and phone number.
 Through-penetration firestop system designation of applicable testing and
inspecting agency.
 Date of installation.
 Through-penetration firestop system manufacturer's name.
 The Installer's name.
3.6.1 Clean off excess fill materials adjacent to openings as Work progresses by
methods and with cleaning materials that are approved in writing by through-
penetration firestop system manufacturers and that do not damage materials in
which openings occur.
3.6.2 Provide final protection and maintain conditions during and after installation that
ensure through-penetration firestop systems are without damage or deterioration

at time of Substantial Completion. If, despite such protection, damage or
deterioration occurs, cut out and remove damaged or deteriorated through-
penetration firestop systems immediately and install new materials to produce
through-penetration firestop systems complying with specified requirements.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. JOINT SEALANTS
CAIRO - EGYPT 07920 - 2039 0

CONTENTS
SECTION 07920
JOINT SEALANTS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.4 Submittals 2
1.8 Warranty 4
PART 2 PRODUCTS 5
2.1 Materials, General 5
2.2 Elastomeric Joint Sealants 5
2.3 Solvent-Release Joint Sealants 6
2.4 Latex Joint Sealants 6
2.5 Acoustical Joint Sealants 6
2.6 Joint-Sealant Backing 6
PART 3 EXECUTION 7
3.1 Examination 7
3.2 Preparation 7
3.3 Installation Of Joint Sealants 8
3.5 Cleaning 10
3.6 Protection 10
3.7 Elastomeric Joint-Sealant Schedule 10
3.8 Latex Joint-Sealant Schedule 12
3.9 Acoustical Joint-Sealant Schedule 12
Joint Sealants Section 07920

SECTION 07920
JOINT SEALANTS
PART 1 GENERAL
Section.
1.2 SUMMARY
1.2.1 This Section includes sealants for applications indicated on Drawings or specified
by reference to this Section.
 Division 7 Section "Through Penetration Firestop Systems” for fire-resistant

building joint-sealant systems.
1.3.1 Provide elastomeric joint sealants that establish and maintain watertight and
airtight continuous joint seals without staining or deteriorating joint substrates.
1.3.2 Provide joint sealants for interior applications that establish and maintain airtight
and water-resistant continuous joint seals without staining or deteriorating joint
substrates.
1.4 SUBMITTALS
1.4.1 Product Data: For each joint-sealant product indicated.
1.4.2 Samples for Initial Selection: Manufacturer's color charts consisting of strips of
cured sealants showing the full range of colors available for each product exposed
to view.
1.4.3 Samples for Verification: For each type and color of joint sealant required. Install
joint sealants in 13-mm- wide joints formed between two 150-mm- long strips of
material matching the appearance of exposed surfaces adjacent to joint sealants.
1.4.4 Product Certificates.
1.4.6 Preconstruction Field Test Reports.
1.4.7 Product Test Reports: From a qualified testing agency indicating sealants comply
with requirements, based on comprehensive testing of current product

formulations.
1.5.1 Installer Qualifications: An experienced installer who has specialized in installing

joint sealants similar in material, design, and extent to those indicated for this
Project and whose work has resulted in joint-sealant installations with a record of
1.5.2 Source Limitations: Obtain each type of joint sealant through one source from a
single manufacturer.
1.5.3 Preconstruction Field-Adhesion Testing: Before installing elastomeric sealants,

field test their adhesion to joint substrates as follows:
 Locate test joints where indicated or, if not indicated, as directed by Engineer.
 Conduct field tests for each application indicated below:
 Each type of elastomeric sealant and joint substrate indicated.

 Each type of nonelastomeric sealant and joint substrate indicated.
 Notify Engineer seven days in advance of dates and times when test joints will
be erected.
 Arrange for tests to take place with joint sealant manufacturer's technical
representative present.
 Test Method: Test joint sealants according to Method A, Field-Applied Sealant
Joint Hand Pull Tab, in Appendix X1 in ASTM C 1193:
 For joints with dissimilar substrates, verify adhesion to each substrate
separately; extend cut along one side, verifying adhesion to opposite side.
Repeat procedure for opposite side.
 Report whether sealant in joint connected to pulled-out portion failed to
adhere to joint substrates or tore cohesively. Include data on pull distance
used to test each type of product and joint substrate. For sealants that fail
adhesively, retest until satisfactory adhesion is obtained.
 Evaluation of Preconstruction Field-Adhesion-Test Results: Sealants not
evidencing adhesive failure from testing, in absence of other indications of
noncompliance with requirements, will be considered satisfactory. Do not use
sealants that fail to adhere to joint substrates during testing.
1.5.4 Mockups: Before installing joint sealants, apply elastomeric sealants as follows to
verify selections made under sample Submittals and to demonstrate aesthetic
effects and qualities of materials and execution:
 Joints in mockups of assemblies specified in other Sections that are indicated

to receive elastomeric joint sealants, which are specified by reference to this
Section.

1.6.1 Deliver materials to Project site in original unopened containers or bundles with
labels indicating manufacturer, product name and designation, color, expiration
date, pot life, curing time, and mixing instructions for multicomponent materials.
1.6.2 Store and handle materials in compliance with manufacturer's written instructions
to prevent their deterioration or damage due to moisture, high or low
temperatures, contaminants, or other causes.
1.7.1 Environmental Limitations: Do not proceed with installation of joint sealants

under the following conditions:
 When ambient and substrate temperature conditions are outside limits

permitted by joint sealant manufacturer.
 When ambient and substrate temperature conditions are outside limits
permitted by joint sealant manufacturer or are below 5 deg C.
 When joint substrates are wet.
1.7.2 Joint-Width Conditions: Do not proceed with installation of joint sealants where
joint widths are less than those allowed by joint sealant manufacturer for
applications indicated.
1.7.3 Joint-Substrate Conditions: Do not proceed with installation of joint sealants until
contaminants capable of interfering with adhesion are removed from joint
substrates.
1.8 WARRANTY
1.8.1 General Warranty: Special warranties specified in this Article shall not deprive
Employer of other rights Employer may have under other provisions of the
Contract Documents and shall be in addition to, and run concurrent with, other
warranties made by Contractor under requirements of the Contract Documents.
1.8.2 Special Installer's Warranty: Written warranty, signed by Installer agreeing to

repair or replace elastomeric joint sealants that do not comply with performance
and other requirements specified in this Section within specified warranty period.
 Warranty Period: Two years from date of Taking Over by Employer.
1.8.3 Special Manufacturer's Warranty: Written warranty, signed by elastomeric

sealant manufacturer agreeing to furnish elastomeric joint sealants to repair or
replace those that do not comply with performance and other requirements
specified in this Section within specified warranty period.
 Warranty Period: Two years from date of Taking Over by Employer.
1.8.4 Special warranties specified in this Article exclude deterioration or failure of

elastomeric joint sealants from the following:

 Movement of the structure resulting in stresses on the sealant exceeding
sealant manufacturer's written specifications for sealant elongation and
compression caused by structural settlement or errors attributable to design or
construction.
 Disintegration of joint substrates from natural causes exceeding design
specifications.
 Mechanical damage caused by individuals, tools, or other outside agents.
 Changes in sealant appearance caused by accumulation of dirt or other
atmospheric contaminants.
PART 2 PRODUCTS
2.1 MATERIALS, GENERAL
2.1.1 Compatibility: Provide joint sealants, backings, and other related materials that
are compatible with one another and with joint substrates under conditions of
service and application, as demonstrated by sealant manufacturer based on
testing and field experience.
2.1.2 Colors of Exposed Joint Sealants: As selected by Engineer from manufacturer's

full range for this characteristic.
2.2 ELASTOMERIC JOINT SEALANTS
2.2.1 Elastomeric Sealant Standard: Comply with ASTM C 920 and other requirements
indicated for each liquid-applied chemically curing sealant in the Elastomeric
Joint-Sealant Schedule at the end of Part 3, including those referencing
ASTM C 920 classifications for type, grade, class, and uses.
2.2.2 Additional Movement Capability: Where additional movement capability is

specified in the Elastomeric Joint-Sealant Schedule, provide products with the
capability, when tested for adhesion and cohesion under maximum cyclic
movement per ASTM C 719, to withstand the specified percentage change in the
joint width existing at the time of installation and remain in compliance with other
requirements of ASTM C 920 for uses indicated.
2.2.3 Stain-Test-Response Characteristics: Where elastomeric sealants are specified in

the Elastomeric Joint-Sealant Schedule to be non staining to porous substrates,
provide products that have undergone testing according to ASTM C 1248 and
have not stained porous joint substrates indicated for Project.
2.2.4 Continuous-Immersion-Test-Response Characteristics: Where elastomeric

sealants will be immersed continuously in water, provide products that have
undergone testing according to ASTM C 1247, including initial six-week immersion
period and additional immersion periods specified below, and have not failed in
adhesion or cohesion when tested with substrates indicated for Project.
 Three additional four-week immersion periods.
2.2.5 Suitability for Immersion in Liquids. Where elastomeric sealants are indicated for

Use I for joints that will be continuously immersed in liquids, provide products
that have undergone testing according to ASTM C 1247 and qualify for the length
of exposure indicated by reference to ASTM C 920 for Class 1 or 2. Liquid used for
testing sealants is deionized water, unless otherwise indicated.
2.3 SOLVENT-RELEASE JOINT SEALANTS
2.3.1 Either ASTM C 1311 or FS TT-S-00230 is the standard referenced by manufacturers

for solvent-release joint sealants despite the fact that withdrawal of the ASTM
standard is pending and withdrawal of the Federal Specification by the Federal
Supply Service has already taken place. No new standards are currently being
developed to replace them. See Evaluations.
2.3.2 Acrylic-Based Solvent-Release Joint Sealant: Comply with ASTM C 1311 or FS TT-
S-0023
2.4 LATEX JOINT SEALANTS
2.4.1 Latex Sealant Standard: Comply with ASTM C 834.
2.5 ACOUSTICAL JOINT SEALANTS
2.5.1 Acoustical Sealant for Exposed and Concealed Joints. Provide manufacturer's
standard nonsag, paintable, nonstaining latex sealant complying with ASTM C 834
and the following:
 Product effectively reduces airborne sound transmission through perimeter

joints and openings in building construction as demonstrated by testing
representative assemblies according to ASTM E 90.
2.6 JOINT-SEALANT BACKING
2.6.1 General: Provide sealant backings of material and type that are nonstaining; are
compatible with joint substrates, sealants, primers, and other joint fillers; and are
approved for applications indicated by sealant manufacturer based on field
experience and laboratory testing.
2.6.2 Cylindrical Sealant Backings: ASTM C 1330, of type indicated below and of size
and density to control sealant depth and otherwise contribute to producing
optimum sealant performance:
 Type C: Closed-cell material with a surface skin.
2.6.3 Elastomeric Tubing Sealant Backings: Neoprene, butyl, EPDM, or silicone tubing
complying with ASTM D 1056, nonabsorbent to water and gas, and capable of
remaining resilient at temperatures down to minus 32 deg C. Provide products
with low compression set and of size and shape to provide a secondary seal, to
control sealant depth, and otherwise contribute to optimum sealant performance.
2.6.4 Bond-Breaker Tape: Polyethylene tape or other plastic tape recommended by

sealant manufacturer for preventing sealant from adhering to rigid, inflexible
joint-filler materials or joint surfaces at back of joint where such adhesion would

result in sealant failure. Provide self-adhesive tape where applicable.
2.7.1 Primer: Material recommended by joint sealant manufacturer where required for
adhesion of sealant to joint substrates indicated, as determined from
preconstruction joint-sealant-substrate tests and field tests.
2.7.2 Cleaners for Nonporous Surfaces: Chemical cleaners acceptable to manufacturers

of sealants and sealant backing materials, free of oily residues or other substances
capable of staining or harming joint substrates and adjacent nonporous surfaces
in any way, and formulated to promote optimum adhesion of sealants with joint
substrates.
2.7.3 Masking Tape: Nonstaining, nonabsorbent material compatible with joint

sealants and surfaces adjacent to joints.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine joints indicated to receive joint sealants, with Installer present, for
compliance with requirements for joint configuration, installation tolerances, and
other conditions affecting joint-sealant performance.
corrected.
3.2 PREPARATION
3.2.1 Surface Cleaning of Joints: Clean out joints immediately before installing joint
sealants to comply with joint sealant manufacturer's written instructions and the
following requirements:
 Remove all foreign material from joint substrates that could interfere with
adhesion of joint sealant, including dust, paints (except for permanent,
protective coatings tested and approved for sealant adhesion and
compatibility by sealant manufacturer), old joint sealants, oil, grease,
waterproofing, water repellents, water, surface dirt, and frost.
 Clean porous joint substrate surfaces by brushing, grinding, blast cleaning,
mechanical abrading, or a combination of these methods to produce a clean,
sound substrate capable of developing optimum bond with joint sealants.
Remove loose particles remaining from above cleaning operations by
vacuuming or blowing out joints with oil-free compressed air. Porous joint
surfaces include the following:
 Concrete.
 Remove laitance and form-release agents from concrete.
 Clean nonporous surfaces with chemical cleaners or other means that do not
stain, harm substrates, or leave residues capable of interfering with adhesion

of joint sealants.
 Metal.
3.2.2 Joint Priming: Prime joint substrates where recommended in writing by joint
sealant manufacturer, based on preconstruction joint-sealant-substrate tests or
prior experience. Apply primer to comply with joint sealant manufacturer's
written instructions. Confine primers to areas of joint-sealant bond; do not allow
spillage or migration onto adjoining surfaces.
3.2.3 Masking Tape: Use masking tape where required to prevent contact of sealant
with adjoining surfaces that otherwise would be permanently stained or damaged
by such contact or by cleaning methods required to remove sealant smears.
Remove tape immediately after tooling without disturbing joint seal.
3.3 INSTALLATION OF JOINT SEALANTS
3.3.1 General: Comply with joint sealant manufacturer's written installation

instructions for products and applications indicated, unless more stringent
requirements apply.
3.3.2 Sealant Installation Standard: Comply with recommendations of ASTM C 1193 for
use of joint sealants as applicable to materials, applications, and conditions
indicated.
3.3.3 Acoustical Sealant Application Standard: Comply with recommendations of

ASTM C 919 for use of joint sealants in acoustical applications as applicable to
materials, applications, and conditions indicated.
3.3.4 Install sealant backings of type indicated to support sealants during application
and at position required to produce cross-sectional shapes and depths of installed
sealants relative to joint widths that allow optimum sealant movement capability.
 Do not leave gaps between ends of sealant backings.

 Do not stretch, twist, puncture, or tear sealant backings.
 Remove absorbent sealant backings that have become wet before sealant
application and replace them with dry materials.
3.3.5 Install bond-breaker tape behind sealants where sealant backings are not used
between sealants and back of joints.
3.3.6 Install sealants by proven techniques to comply with the following and at the
same time backings are installed:
 Place sealants so they directly contact and fully wet joint substrates.
 Completely fill recesses provided for each joint configuration.
 Produce uniform, cross-sectional shapes and depths relative to joint widths
that allow optimum sealant movement capability.
3.3.7 Tooling of Nonsag Sealants: Immediately after sealant application and before
skinning or curing begins, tool sealants according to requirements specified below

to form smooth, uniform beads of configuration indicated; to eliminate air
pockets; and to ensure contact and adhesion of sealant with sides of joint.
 Remove excess sealants from surfaces adjacent to joint.

 Use tooling agents that are approved in writing by sealant manufacturer and
that do not discolor sealants or adjacent surfaces.
 Provide joint configuration indicated in ASTM C 1193, according to the
instructions of the Engineer.
 Use masking tape to protect adjacent surfaces of recessed tooled joints.
3.4.1 Field-Adhesion Testing: Field-test joint-sealant adhesion to joint substrates as

follows:
 Extent of Testing: Test completed elastomeric sealant joints as follows:
 Perform 10 tests for the first 300 m of joint length for each type of
elastomeric sealant and joint substrate.
 Perform one test for each 300 m of joint length thereafter or one test per
each floor per elevation.
 Test Method: Test joint sealants by Method A, Field-Applied Sealant Joint
Hand Pull Tab:
 For joints with dissimilar substrates, check adhesion to each substrate
separately. Do this by extending cut along one side, checking adhesion to
opposite side, and then repeating this procedure for opposite side.
 Inspect joints for complete fill, for absence of voids, and for joint configuration
complying with specified requirements. Record results in a field adhesion test
log.
 Inspect tested joints and report on the following:
 Whether sealants in joints connected to pulled-out portion failed to adhere

to joint substrates or tore cohesively. Include data on pull distance used to
test each type of product and joint substrate. Compare these results to
determine if adhesion passes sealant manufacturer's field- adhesion hand-
pull test criteria.
 Whether sealants filled joint cavities and are free from voids.
 Whether sealant dimensions and configurations comply with specified
requirements.
 Record test results in a field adhesion test log. Include dates when sealants
were installed, names of persons who installed sealants, test dates, test
locations, whether joints were primed, adhesion results and percent
elongations, sealant fill, sealant configuration, and sealant dimensions.
 Repair sealants pulled from test area by applying new sealants following same
procedures used to originally seal joints. Ensure that original sealant surfaces
are clean and new sealant contacts original sealant.

3.5 CLEANING
3.5.1 Clean off excess sealants or sealant smears adjacent to joints as the Work
progresses by methods and with cleaning materials approved in writing by
manufacturers of joint sealants and of products in which joints occur.
3.6 PROTECTION
3.6.1 Protect joint sealants during and after curing period from contact with
contaminating substances and from damage resulting from construction
operations or other causes so sealants are without deterioration or damage at
time of Substantial Completion. If, despite such protection, damage or
deterioration occurs, cut out and remove damaged or deteriorated joint sealants
immediately so installations with repaired areas are indistinguishable from the
original work.
3.7 ELASTOMERIC JOINT-SEALANT SCHEDULE
3.7.1 Single-Component Nonsag Polysulfide Sealant: Where joint sealants of this type
are indicated, provide products complying with the following:
 Type and Grade: S (single component) and NS (nonsag).

 Class: 25.
 Use Related to Exposure: NT (nontraffic).
 Uses Related to Joint Substrates: M, G, A, and, as applicable to joint substrates
indicated, O.
 Use O Joint Substrates: Concrete and Concrete blocks and bricks
 Applications: Joints in masonry assemblies.
3.7.2 Low-Modulus Nonacid-Curing Silicone Sealant: Where joint sealants of this type
are indicated, provide products complying with the following:

 Class: 25.
 Additional Movement Capability: 50 percent movement in extension and 50
percent movement in compression for a total of 100 percent movement.
 Use Related to Exposure: NT (non traffic).
indicated, O.
 Use O Joint Substrates: Coated glass, aluminum coated with a high-
performance coating, marble cladding
 Stain-Test-Response Characteristics: Non staining to porous substrates per
ASTM C 1248.
 Applications: Aluminum assemblies for facades, composite panel assemblies
claddings for facades except when may be subject to traffic in ceilings and
other external applications in facades.

3.7.3 Medium-Modulus Neutral-Curing Silicone Sealant: Where joint sealants of this
type are indicated, provide products complying with the following:

 Class: 25.
indicated, O.
 Use O Joint Substrates: Coated glass, vitreons enamel, galvanized steel,
granite, marble, ceramic tile, and wood.
 Stain-Test-Response Characteristics: Nonstaining to porous substrates per
ASTM C 1248.
 Applications: Internal applications.
3.7.4 Medium-Modulus Neutral-Curing Silicone Sealant: Where joint sealants of this

type are indicated, provide products complying with the following:

 Class: 25.
 Additional Movement Capability: 50 percent movement in extension and 50
percent movement in compression for a total of 100 percent movement.
 Uses Related to Exposure: T traffic.
indicated, O.
 Use O Joint Substrates: Coated glass, aluminum coated with a high-
performance coating, galvanized steel, brick, granite, limestone, marble,
ceramic tile, and wood.
 Applications: For external and internal applications that will be subject to
traffic.
3.7.5 Mildew-Resistant Silicone Sealant: Where joint sealants of this type are
indicated, provide products formulated with fungicide that are intended for
sealing interior ceramic tile joints and other nonporous substrates that are subject
to in-service exposures of high humidity and temperature extremes, and that
comply with the following:

 Class: 25.
 Uses Related to Joint Substrates: G, A, and, as applicable to joint substrates
indicated, O.
 Use O Joint Substrates: Coated glass, color anodic aluminum, aluminum
coated with a high-performance coating, galvanized steel, and ceramic tile.

 Applications: For use in Hygiene sensitive areas, food preparations areas,
water tanks and building spaces specified for first aid.
3.8 LATEX JOINT-SEALANT SCHEDULE
3.8.1 Applications: For internal applications where joint sealants need to be painted.
3.9 ACOUSTICAL JOINT-SEALANT SCHEDULE
3.9.1 Applications: For sealing joints in:
 Acoustical panel ceilings


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. STEEL DOORS AND FRAMES
CAIRO - EGYPT 08114 - 2039 0

CONTENTS
SECTION 08114
STEEL DOORS AND FRAMES
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
PART2 PRODUCTS 3
2.1 Materials 3
2.2 Doors 3
2.3 Frames 4
2.4 Door Louvers 5
2.5 Stops And Moldings 5
2.6 Louvered Steel Doors 5
2.7 Fabrication 6
2.8 Metallic-Coated Steel Finishes 7
PART3 EXECUTION 7
3.1 Examination 7
3.2 Preparation 7
3.3 Installation 8
Steel Doors And Frames Section 08114

SECTION 08114
STEEL DOORS AND FRAMES
PART 1 GENERAL
1.2 SUMMARY
 Steel doors and frames.

 Fire-rated door and frame assemblies.
 Louvers in doors.
 Steel louvered door.
1.3 SUBMITTALS
1.3.1 Product Data: Include construction details, material descriptions, core descrip-
tions, label compliance, sound and fire-resistance ratings, and finishes for each
type of door and frame specified.
1.3.2 Shop Drawings: Provide a schedule of steel doors and frames using same refer-
ence numbers for details and openings as those on Drawings.
Samples not less than 75 by 125 mm and of same thickness and material indicated
for the Work. If finishes involve normal color and texture variations, include sam-
ple sets showing the full range of variations expected.
1.3.4 Qualification Data: For manufacture/fabricator and installer.
1.3.5 Product Test Report.
1.4.1 Manufacturer Qualifications: A firm experienced in manufacturing custom steel

doors and frames similar to those indicated for this Project and with a record of
1.4.2 Testing Agency Qualifications: An independent agency qualified according ac-

cepted by Engineer.
1.4.3 Comply with applicable requirements of DD171 of category “Heavy Duty”.
1.4.4 Source Limitations: Obtain steel doors and frames through one source from a
1.4.5 Fire-Rated Door Assemblies: Provide certified evidence, in the form of a product
conformity certificate, directly relevant fire test report or engineering assessment,
that each door/ doorset/ assembly supplied will comply with the specified re-
quirements for fire resistance if tested to BS 476-22, BS EN 1634-1 or BS EN 1634-
3. Such certification must cover door and frame materials, glass and glazing mate-
rials and their installation, essential and ancillary ironmongery, hinges and seals
 Fire doors and frames including fire seals and all associated materials and in-
stallation shall comply with the requirements of BS 8214.
1.4.6 Smoke-Control Door Assemblies: Comply with BS 476.
1.5.1 Deliver doors and frames palleted, wrapped, or crated to provide protection dur-
ing transit and Project site storage. Do not use nonvented plastic.
1.5.2 Deliver welded frames with two removable spreader bars across bottom of
frames, tack welded to jambs and mullions.
PART2 PRODUCTS
2.1 MATERIALS
2.1.1 Metallic-Coated Steel Sheets: BS EN ISO 1461, with coating designation 275
(Coating mass minimum 275 gm/m2 including both surfaces). Comply with BS EN
10143 for tolerances on Dimensions and Shape.
2.1.2 Cold-Rolled Steel Sheet: BS ISO 16162, commercial steel, suitable for exposed
applications.
2.1.3 Inserts, Bolts, and Fasteners: Manufacturer's standard units. Where items are to
be built into exterior walls, zinc coat according to ASTM A 153/A 153M, Class C or
D as applicable.
2.1.4 Grout: EN 13888.
2.2 DOORS
2.2.1 General: Provide flush-design doors, 44 mm thick unless otherwise indicated, of

seamless hollow construction, unless otherwise indicated. Construct doors with
smooth, flush surfaces without visible joints or seams on exposed faces or stile
edges.
 Visible joints or seams around glazed or louvered panel inserts are permitted.
2.2.2 Metallic Core Construction: Provide the following core construction welded to
both door faces:
 Steel-Stiffened Core: Steel vertical stiffeners extending full-door height.

2.2.3 Fire Door Cores: Steel stiffened core as required to provide fire-protection and
temperature-rise ratings. Intensity of mineral insulation is to be as required to at-
tain fire rating indicated.
2.2.4 Fire Rated Doors: Thickness of face sheets is to be as required for fire rated indi-
cated in Door Schedule.
2.2.5 Astragals: As required by BS 476 to provide fire ratings indicated.
2.2.6 Hardware Reinforcement: Fabricate reinforcing plates from the same material as
door.
2.2.7 Interior Doors: Fabricate face sheets of doors from two minimum 1.20-mm-
thick, cold-rolled, stretcher-leveled steel sheets and other metal components
from cold-rolled steel sheets.
2.2.8 Exterior Steel Doors: Fabricate face sheets of doors from two minimum 1.5-mm-
thick, stretcher-leveled, metallic-coated steel sheets. Provide weep-hole openings
in bottom of doors to permit entrapped moisture to escape. Seal joints in top
edges of doors against water penetration.
2.3 FRAMES
2.3.1 Comply with BS 1245, fabricate frames of full-welded unit construction, with cor-
ners mitered, reinforced, and continuously welded full depth and width of frame.
Knockdown frames are not acceptable.
 For exterior use, form frames from 1.7-mm- thick, metallic-coated steel sheets.
 For interior use, form frames from cold-rolled steel sheet of the following
thicknesses:
 Openings up to and Including 1200 mm Wide: 1.3 mm.
 Openings More Than 1200 mm Wide: 1.7 mm.
2.3.2 Hardware Reinforcement: Fabricate from same material as frame.
2.3.3 Supports and Anchors: After fabricating, galvanize units to be built into exterior
walls according to BS EN ISO 1461.
2.3.4 Jamb Anchors: Weld jamb anchors to frames near hinges and directly opposite
on strike jamb as required to secure frames to adjacent construction.
2.3.5 Floor Anchors: Provide floor anchors for each jamb and mullion that extends to
floor.
2.3.6 Head Anchors: Provide 2 head anchors for frames more than 1066 mm wide and
mounted in steel-stud walls.
2.3.7 Spreader Bars: Provide removable spreader bar across bottom of frames, tack
welded to jambs and mullions
2.3.8 Vision Panel : Comply with requirements in Division 8 Section "Glazing."

2.4 DOOR LOUVERS
2.4.1 Door Louvers: Fabricate louvers and mount flush into doors without overlapping
moldings on surface of door face sheets. Provide internal support as recom-
mended by louver manufacturer. Prime paint steel louvers after fabrication.
 Interior Louvers: Sight proof, stationary type, constructed of inverted Y-shaped

blades formed of same material as door.
 Steel: 0.8 mm thick.
 Exterior Louvers: 1.3-mm- thick, metallic-coated steel sheet. Fabricate units
with stationary, weatherproof Z-shaped blades and U-shaped frames; 35 mm
thick. Space louver blades not more than 38 mm o.c. Assemble units by weld-
ing. Provide removable insect screens on interior side of louver frame, consist-
ing of 1.4-by-1.8-mm mesh formed with 0.28-mm- diameter, galvanized steel
wire in rigid, formed-metal frame.
 Fire-Rated Automatic Louvers: Sight proof louver inserts fabricated from 1.3-
mm- thick steel, spring operated, and released by 57 deg C fusible links listed
and labeled for use in fire-rated door assemblies of type and fire-resistance rat-
ing indicated by the same testing and inspecting agency that established fire-
resistance rating of door assembly.
2.5 STOPS AND MOLDINGS
2.5.1 Provide stops and moldings around glazed and louvered panels where indicated.
2.5.2 Form fixed stops and moldings integral with frame, unless otherwise indicated.
2.5.3 Provide removable stops and moldings where indicated or required, formed of
0.8-mm- thick steel sheets matching steel frames. Secure with countersunk flat or
oval head machine screws spaced uniformly not more than 300 mm o.c. Form
corners with butted hairline joints.
2.5.4 Coordinate rabbet width between fixed and removable stops with type of glass or
panel and type of installation indicated.
2.6 LOUVERED STEEL DOORS
2.6.1 Louvered Steel Doors, Generally: Are to be heavy-duty construction, stile-and-

rail door leaves with prefabricated framed steel louver panels mechanically fixed
flush with stiles and rail of the door leaf frame.
2.6.2 Stiles and rails are to of tubular construction with sound deadening core material.
Stiles and top rail are to be 75 mm wide, bottom rail 250 mm high, unless other-
wise indicated on Drawings.
2.6.3 Stiles and rails are from galvanized sheet steel as specified, 1.30 mm thick mini-
mum. Reinforcement for hinge installation is to be minimum 4.00 thick galva-
nized steel plates. Drilling and tapping for surface applied ironmongery may be
done on Project Site.

2.6.4 Louver panels are to be pre-fabricated panels as specified in this Section.
2.6.5 Furnish doors with louver panels pre-assembled and finished with factory applied
baked enamel system as specified in this Section.
2.6.6 Louver panel fasteners are to be galvanized steel of matching finish.
2.6.7 Top and Bottom Channels: Spot weld metal channel not less than thickness of
face sheet to face sheets not more than 150 mm o.c.
 Reinforce tops and bottoms of doors with inverted horizontal channels of same
material as face sheet so flanges of channels are even with bottom and top
edges of face sheets.
 Provide covers for top and bottom channels of same material and finish speci-
fied for door and channels.
2.6.8 Hardware Reinforcement: Fabricate reinforcing plates from the same material as
door to comply with the following:
 Hinges and Pivots: 4.00 mm thick by 38 mm wide by 150 mm longer than

hinge, secured by not less than 6 spot welds.
 Lock Face, Flush Bolts, Closers, and Concealed Holders: 2.30 mm thick.
 All Other Surface-Mounted Hardware: 1.30 mm thick.
2.7 FABRICATION
2.7.1 Fabricate doors and frames rigid, neat in appearance, and free of defects, warp, or
buckle. Accurately form metal to required sizes and profiles. Weld exposed joints
continuously; grind, fill, dress, and make smooth, flush, and invisible. Where prac-
tical, fit and assemble units in manufacturer's plant. Clearly identify work that
cannot be permanently factory assembled before shipment, to assure proper as-
sembly at Project site.
 Damage arising from forces applied under normal conditions of use (repetitive
stresses) and anticipated abuse, including:
 Breakage of components and assemblies.
 Loss of rigidity or loosening up of joints.
 Cracking or splitting of timber and veneer.
 Indentation.
 Improper functioning of ironmongery resulting in impaired door operation.
 Distortion arising from moisture changes, temperature changes and applied
forces including cupping, bowing or twisting which prevents the ability of the
door to comply with the fire, smoke and sound requirements.
2.7.2 For doors with metallic core construction, weld cores to both door face sheets.
2.7.3 For doors with nonmetallic core construction, laminate core material to both door
face sheets with waterproof adhesive.
2.7.4 Exposed Fasteners: Provide countersunk flat or oval heads for exposed screws
and bolts, unless otherwise indicated.
2.7.5 Hardware Preparation: Prepare doors and frames to receive hardware, including
cutouts, reinforcement, mortising, drilling, and tapping, according to final hard-
ware schedule and templates provided by hardware supplier. Comply with appli-
cable requirements of DD171 of category “Heavy Duty”.
 Reinforce doors and frames to receive surface-applied hardware. Drilling and

tapping for surface-applied hardware may be done at Project site.
2.8 METALLIC-COATED STEEL FINISHES
2.8.1 Surface Preparation: Clean surfaces with nonpetroleum solvent so surfaces are
free of oil and other contaminants. After cleaning, apply a conversion coating
suited to the organic coating to be applied over it. Clean welds, mechanical con-
nections, and abraded areas, and apply galvanizing repair paint.
 Galvanizing Repair Paint: High-zinc-dust-content paint for regalvanizing welds

in steel.
2.8.2 Factory Finish: Polyurethane system over epoxy primer, comply with require-
ments as specified in Division 9 Section “Painting”.
PART3 EXECUTION
3.1 EXAMINATION
with requirements for installation tolerances and other conditions affecting per-
formance of custom steel doors and frames.
 Examine roughing-in for embedded and built-in anchors to verify actual loca-
tions of custom steel frame connections before frame installation.
 Proceed with installation only after unsatisfactory conditions have been cor-
rected.
3.2 PREPARATION
3.2.1 Remove welded-in shipping spreaders installed at factory.
3.2.2 Prior to installation and with installation spreaders in place, adjust and securely
brace custom steel door frames for squareness, alignment, twist, and plumb to
the following tolerances:
 Squareness: Plus or minus 1.6 mm, measured at door rabbet on a line 90 de-
grees from jamb perpendicular to frame head.
 Alignment: Plus or minus 1.6 mm, measured at jambs on a horizontal line par-
allel to plane of wall.

 Twist: Plus or minus 1.6 mm, measured at opposite face corners of jambs on
parallel lines, and perpendicular to plane of wall.
 Plumbness: Plus or minus 1.6 mm, measured at jambs on a perpendicular line
from head to floor.
3.3 INSTALLATION
3.3.1 General: Provide doors of sizes, thicknesses, and designs indicated. Install custom
steel doors and frames plumb, rigid, properly aligned, and securely fastened in
place; comply with Drawings and manufacturer's written instructions.
3.3.2 Frames: BS 1245, install steel frames for doors, transoms, sidelights, borrowed
lights, and other openings, of size and profile indicated.
 Set masonry anchorage devices where required for securing frames to in-place
concrete or masonry construction.
 Set anchorage devices opposite each anchor location according to details on
Shop Drawings and anchorage device manufacturer's written instructions.
Leave drilled holes rough, not reamed, and free of dust and debris
 At fire-protection-rated openings, install frames according to BS 476.
 Where frames are fabricated in sections due to shipping or handling limita-
tions, field splice at approved locations by welding face joint continuously;
grind, fill, dress, and make splice smooth, flush, and invisible on exposed
faces.
 Install frames with removable glazing stops located on secure side of open-
ing.
 Install door silencers in frames before grouting.
 Remove temporary braces necessary for installation only after frames have
been properly set and secured.
 Check plumb, squareness, and twist of frames as walls are constructed.
Shim as necessary to comply with installation tolerances.
 Apply bituminous coating to backs of frames that are filled with mortar,
grout, and plaster containing antifreezing agents.
 Floor anchors may be set with powder-actuated fasteners instead of masonry
anchorage devices and machine screws, if so indicated on Shop Drawings.
 Placing Frames: Set frames accurately in position; plumb; align, and brace se-
curely until permanent anchors are set. After wall construction is complete,
remove temporary braces and spreaders, leaving surfaces smooth and undam-
aged.
 Masonry Walls: Coordinate installation of frames to allow for solidly filling
space between frames and masonry with mortar as specified in Division 4
Section "Unit Masonry Assemblies."
 Concrete Walls: Solidly fill space between frames and concrete with grout.
Install grout in lifts and take precautions, including bracing frames, to en-
sure that frames are not deformed or damaged by grout forces.
 In-Place Concrete or Masonry Construction: Secure frames in place with
postinstalled expansion anchors. Countersink anchors, and fill and make
smooth, flush, and invisible on exposed faces.
 Installation Tolerances: Adjust custom steel door frames for squareness,
alignment, twist, and plumb to the following tolerances:
 Squareness: Plus or minus 1.6 mm, measured at door rabbet on a line 90
degrees from jamb perpendicular to frame head.
 Alignment: Plus or minus 1.6 mm, measured at jambs on a horizontal line
parallel to plane of wall.
 Twist: Plus or minus 1.6 mm, measured at opposite face corners of jambs
on parallel lines, and perpendicular to plane of wall.
 Plumbness: Plus or minus 1.6 mm, measured at jambs at floor.
3.3.3 Doors: Fit hollow-metal doors accurately in frames, within clearances indicated
below. Shim as necessary.
 Fit non-fire-rated doors accurately in their respective frames, with the follow-
ing clearances:
 Jambs and Head: 2 mm.
 Meeting Edges, Pairs of Doors: 3 mm.
 Bottom: 9 mm, if no threshold or carpet.
 Bottom: 3 mm, at threshold or carpet.
 Fire-Rated Doors: Install with clearances as specified in BS 476.
 Smoke Control Doors: Install according to BS 476.
3.4.1 Final Adjustments: Check and readjust operating hardware items just before final
inspection. Leave work in complete and proper operating condition. Remove and
replace defective work, including doors or frames that are warped, bowed, or
otherwise unacceptable.
3.4.2 Clean grout and other bonding material off custom steel doors and frames imme-
diately after installation.
3.4.3 Finish-Coat Touchup: Immediately after erection, sand smooth any rusted or
damaged areas of prime coat and apply touchup of compatible air-drying primer.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
0 Apr. 2015 R.E.. 9 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. OVERHEAD COILING DOORS
CAIRO - EGYPT 08331– 2039 0

CONTENTS
SECTION 08331
OVERHEAD COILING DOORS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Definitions 2
1.5 Submittals 2
1.8 Coordination 4
PART 2 PRODUCTS 4
2.1 Door Curtain Materials And Construction 4
2.2 Hoods And Accessories 5
2.3 Counterbalancing Mechanism 6
2.4 Electric Door Operators 7
2.6 Steel And Galvanized Steel Finishes 8
PART 3 EXECUTION 8
3.1 Examination 8
3.2 Preparation 9
3.3 Installation 9
3.4 Adjusting 9
3.5 Demonstration 9
Overhead Coiling Doors Section 08331

SECTION 08331
OVERHEAD COILING DOORS
PART 1 GENERAL
Section.
1.2 SUMMARY
1.2.1 This Section includes the following types of overhead coiling doors:
 Service doors.
 Fire rated service doors.
 Division 5 Section "Metal Fabrications" for miscellaneous steel supports.

 Division 16 Specification Sections for electrical service and connections for
powered operators, and accessories.
1.3 DEFINITIONS
1.3.1 Operation Cycle: One complete cycle of a door begins with the door in the closed
position. The door is then moved to the open position and back to the closed
position.
1.4.1 Structural Performance: Provide overhead coiling doors capable of withstanding

the effects of gravity loads and the following loads and stresses without
evidencing permanent deformation of door components:
 Wind Load: Egyptian code of practice for calculating loads and forces in
Structural and building works, Ministerial Decree 367/2003; basic wind
pressure equal to 100 kg/Sq.m.
1.4.2 Operation-Cycle Requirements: Design overhead coiling door components and

operator to operate for not less than 20,000 cycles.
1.5 SUBMITTALS
1.5.1 Product Data: For each type and size of overhead coiling door and accessory.
Include details of construction relative to materials, dimensions of individual
components, profiles, and finishes. Provide roughing-in diagrams, operating
instructions, and maintenance information. Include the following:

 Setting drawings, templates, and installation instructions for built-in or
embedded anchor devices.
 Summary of forces and loads on walls and jambs.
 Motors: Show nameplate data and ratings; characteristics; mounting
arrangements; size and location of winding termination lugs, conduit entry,
and grounding lug; and coatings.
 Fire-Rated Doors: Information describing fire-release system, including testing
and resetting instructions.
1.5.2 Shop Drawings: For special components and installations not dimensioned or
detailed in manufacturer's data sheets.
 Wiring Diagrams: Detail wiring for power, signal, and control systems.
Differentiate between manufacturer-installed and field-installed wiring and
between components provided by door manufacturer and those provided by
others.
1.5.3 Samples for Initial Selection: Manufacturer's color charts showing the full range
of colors available for units with factory-applied finishes.
1.5.4 Samples for Verification: Of each type of exposed finish required, prepared on
Samples of size indicated below and of same thickness and material indicated for
Work. Where finishes involve normal color and texture variations, include Sample
sets showing the full range of variations expected.
 Curtain Slats: 300-mm length.

 Bottom Bar: 150-mm length.
 Guides: 150-mm length.
 Brackets: 150 mm square.
 Hood: 150 mm square.
1.5.5 Installer Certificates: Signed by manufacturer certifying that installers comply

with specified requirements.

1.6.2 Installer Qualifications: Engage an experienced installer who is an authorized

representative of the overhead coiling door manufacturer for both installation
and maintenance of units required for this Project.
1.6.3 Source Limitations: Obtain overhead coiling doors through one source from a

 Obtain operators and controls from the overhead coiling door manufacturer.
1.6.4 Fire-Rated Door Assemblies: Provide assemblies complying with NFPA 80 that
are identical to door and frame assemblies tested for fire-test-response
characteristics per UL 10b and UL1784, and that are labeled and listed for fire
ratings indicated by UL, FM, ITS/Warnock Hersey, or another testing and
inspecting agency acceptable to authorities having jurisdiction.
1.6.5 Oversize Fire-Rated Door Assemblies: For units exceeding sizes of tested
assemblies, provide certification by a testing agency acceptable to the Engineer
that doors comply with all standard construction requirements of tested and
labeled fire-rated door assemblies, except for size.
1.6.6 Listing and Labeling: Provide electrically operated fixtures specified in this
Section that are listed and labeled.
 The Terms "Listed" and "Labeled": As defined in NFPA 70, Article 100.
1.6.7 Automatic Closing: Provide automatic closing device and self-adjusting governor,
interfaced with the fire alarm system, for smoother and quieter closing operation.
Construct governor unit to be inoperative during normal door operations. Design
release mechanism to reset easily.
1.7.1 Field Measurements: Where products and systems are indicated to fit walls and
other construction, verify dimensions by field measurements before fabrication
and indicated measurements on Shop Drawings. Coordinate fabrication schedule
with construction progress to avoid delaying the Work.
1.7.2 Established Dimensions: Where field measurements cannot be made without

delaying the Work, establish dimensions and proceed with fabricating products
and systems without field measurements. Coordinate construction to ensure that
actual dimensions correspond to established dimensions. Allow for trimming and
fitting.
1.8 COORDINATION
1.8.1 Coordinate installation of products and systems with interfacing and adjoining
construction to provide a successful installation without failure.
PART 2 PRODUCTS
2.1 DOOR CURTAIN MATERIALS AND CONSTRUCTION
2.1.1 Door Curtain: Fabricate overhead coiling door curtain of interlocking slats,
designed to withstand wind loading indicated, in a continuous length for width of
door without splices. Unless otherwise indicated, provide slats of material
thickness recommended by door manufacturer for performance, size, and type of
door indicated, and as follows:

 Steel Door Curtain Slats: Structural-quality, cold-rolled galvanized steel sheets
complying with ASTM A 653, with G90 (ASTM A 653M, with Z275) zinc coating.
Thickness is to b as recommended by door manufacturer to obtain fire rating
on Drawings but not less than 0.70 mm.
2.1.2 Endlocks and Windlocks for Service Doors: Malleable-iron casings galvanized
after fabrication, secured to curtain slats with galvanized rivets or high-strength
nylon. Provide locks on not less than alternate curtain slats for curtain alignment
and resistance against lateral movement.
2.1.3 Bottom Bar for Service Door: Manufacturer's standard continuous channel or
tubular shape, stainless-steel to suit type of curtain slats.
2.1.4 Curtain Jamb Guides: Fabricate curtain jamb guides of steel angles, or channels
and angles, with sufficient depth and strength to retain curtain, to allow curtain to
operate smoothly, and to withstand loading. Build up units with not less than 5-
mm- thick, galvanized steel sections complying with ASTM A 36 (ASTM A 36M),
and ASTM A 123. Slot bolt holes for guide adjustment. Provide removable stops
on guides to prevent over travel of curtain and a continuous bar for holding
windlocks.
2.2 HOODS AND ACCESSORIES
2.2.1 Hood: Form to entirely enclose coiled curtain and operating mechanism at
opening head and act as weatherseal. Contour to suit end brackets to which hood
is attached. Roll and reinforce top and bottom edges for stiffness. Provide closed
ends for surface-mounted hoods and fascia for any portion of between-jamb
mounting projecting beyond wall face. Provide intermediate support brackets as
required to prevent sag.
 Fabricate steel hoods, for steel doors, of not less than 0.7-mm thick, hot-dip
galvanized steel sheet with Z275 zinc coating, complying with ASTM A 653M.
 Fabricate hoods for aluminum doors, alloy and temper recommended by
aluminum producer and finisher for type of use and finish indicated; 0.8-mm
minimum thickness, complying with ASTM B 209M.
 Shape: Square, unless otherwise indicated.
 Exterior Mounted Door: Fabricate hood with sealant-joint bead profile for
applying joint sealant.
2.2.2 Integral Frame, Hood, and Fascia: Provide welded assemblies of the following
sheet metal:
 Fabricate of not less than 1.6-mm- thick, hot-dip galvanized steel sheet with
Z275 zinc coating, complying with ASTM A 653 (ASTM A 653M).
2.2.3 Integral Sills: Fabricate sills as integral part of frame assembly of same sheet
metal, but not less than 2.0 mm thick.
2.2.4 Smoke Seals: Provide UL-listed and -tested smoke-seal perimeter gaskets.
2.2.5 Weather seals: Provide replaceable, adjustable, continuous, compressible

weather-stripping gaskets fitted to bottom and at top of exterior doors, unless
otherwise indicated. At door head, use 3-mm- thick, replaceable, continuous
sheet secured to inside of curtain coil hood.
 Provide motor-operated doors with combination bottom weather seal and

sensor edge.
 In addition, provide replaceable, adjustable, continuous, flexible, 3-mm-thick
seals of flexible vinyl, rubber, or neoprene at door jambs for a weather tight
installation.
2.2.6 Push/Pull Handles: For push-up-operated or emergency-operated doors, provide

galvanized steel lifting handles on each side of door.
 Provide pull-down straps or pole hooks for doors more than 2130 mm high.
2.2.7 Slide Bolt: Fabricate with side locking bolts to engage through slots in tracks for
locking by padlock, located on both left and right jamb sides, operable from coil
side.
2.2.8 Fabricate locking device assembly with lock, spring-loaded dead bolt, operating
handle, cam plate, and adjustable locking bar to engage through slots in tracks.
 Locking Bars: Single-jamb side, operable from inside and outside.

2.2.9 Lock cylinder: standard with manufacturer Where door unit is power operated,
provide safety interlock switch to disengage power supply when door is locked.
2.2.10 Provide automatic-closing device inoperative during normal door operations, with
governor unit complying with requirements of NFPA 80, with easily tested and
reset release mechanism, and designed to be activated by the following:
 Manufacturer's standard UL-labeled smoke detector and door-holder-release

devices.
2.3 COUNTERBALANCING MECHANISM
2.3.1 General: Counterbalance doors by means of adjustable-tension steel helical

torsion spring, mounted around a steel shaft and contained in a spring barrel
connected to door curtain with required barrel rings. Use grease-sealed bearings
or self-lubricating graphite bearings for rotating members.
2.3.2 Counterbalance Barrel: Fabricate spring barrel of hot-formed, structural-quality,

welded or seamless carbon-steel pipe, of sufficient diameter and wall thickness to
support rolled-up curtain without distortion of slats and to limit barrel deflection
to not more than 2.5 mm/m of span under full load.
2.3.3 Provide spring balance of one or more oil-tempered, heat-treated steel helical
torsion springs. Size springs to counterbalance weight of curtain, with uniform
adjustment accessible from outside barrel. Provide cast-steel barrel plugs to
secure ends of springs to barrel and shaft.
2.3.4 Fabricate torsion rod for counterbalance shaft of cold-rolled steel, sized to hold
fixed spring ends and carry torsional load.
2.3.5 Brackets: Provide mounting brackets of manufacturer's standard design, either
cast-iron or cold-rolled steel plate with bell-mouth guide groove for curtain.
2.4 ELECTRIC DOOR OPERATORS
2.4.1 General: Provide electric door operator assembly of size and capacity
recommended and provided by door manufacturer for door and operational life
specified, with electric motor and factory-prewired motor controls, starter, gear-
reduction unit, solenoid-operated brake, clutch, remote-control stations, control
devices, integral gearing for locking door, and accessories required for proper
operation.
2.4.2 Comply with NFPA 70.
2.4.3 Disconnect Device: Provide hand-operated disconnect or mechanism for

automatically engaging sprocket-chain operator and releasing brake for
emergency manual operation while disconnecting motor, without affecting timing
of limit switch. Mount disconnect and operator so they are accessible from floor
level. Include interlock device to automatically prevent motor from operating
when emergency operator is engaged.
2.4.4 Design operator so motor may be removed without disturbing limit-switch

adjustment and without affecting emergency auxiliary operator.
2.4.5 Provide control equipment complying with NEMA ICS 1, NEMA ICS 2, and
NEMA ICS 6, with NFPA 70 Class 2 control circuit, maximum 24-V, ac or dc.
2.4.6 Door-Operator Type: Provide wall-mounted, jackshaft, gear-head-type door

operator unit consisting of electric motor, enclosed worm-gear running-in-oil
primary drive, chain and sprocket secondary drive, and quick disconnect-release
for manual operation.
2.4.7 Electric Motors: Provide high-starting torque, reversible, continuous-duty, Class A

insulated, electric motors, complying with NEMA MG 1, with overload protection,
sized to start, accelerate, and operate door in either direction, from any position,
at not less than 0.2 m/s or more than 0.3 m/s, without exceeding nameplate
ratings or considering service factor.
 Type: Polyphase, medium-induction type.

 Service Factor: According to NEMA MG 1, unless otherwise indicated.
 Coordinate wiring requirements and electric characteristics of motors with
building electrical system.
 Provide open dripproof-type motor, and controller with NEMA ICS 6, Type 1
enclosure.
 Provide totally enclosed, nonventilated or fan-cooled motors, fitted with
plugged drain, and controller with NEMA ICS 6, Type 4 enclosure where
indicated.
2.4.8 Remote-Control Station: Provide momentary-contact, 3-button control station

with push-button controls labeled "Open," "Close," and "Stop."

 Provide interior units, full-guarded, surface-mounted, heavy-duty type, with
general-purpose NEMA ICS 6, Type 1 enclosure.
 Provide exterior units, full-guarded, standard-duty, surface-mounted,
weatherproof type, NEMA ICS 6, Type 4 enclosure, key operated.
2.4.9 Obstruction Detection Device: Provide each motorized door with indicated
external automatic safety sensor able to protect full width of door opening.
Activation of sensor immediately stops and reverses downward door travel.
 Sensor Edge: Provide each motorized door with an automatic safety sensor
edge, located within astragal or weather stripping mounted to bottom bar.
Contact with sensor immediately stops and reverses downward door travel.
Connect to control circuit using manufacturer's standard take-up reel or self-
coiling cable.
 Provide electrically actuated automatic bottom bar.
 Self-Monitoring Type: Provide self-monitoring, 4-wire configured device.
2.4.10 Limit Switches: Provide adjustable switches, interlocked with motor controls and
set to automatically stop door at fully opened and fully closed positions.
2.5.1 General: Comply with NAAMM's "Metal Finishes Manual for Architectural and
Metal Products" for recommendations for applying and designating finishes.

Samples. Noticeable variations in the same piece are not acceptable. Variations
in appearance of other components are acceptable if they are within the range of
2.6 STEEL AND GALVANIZED STEEL FINISHES
2.6.1 Powder-Coat Finish: Manufacturer's standard powder-coat finish consisting of

primer and topcoat according to coating manufacturer's written instructions for
cleaning, pretreatment, application, thermosetting, and minimum dry film
thickness.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Acceptance of Surfaces and Conditions: examine substrates to receive overhead

coiling doors and associated to which doors will be applied for compliance with
requirements and other conditions affecting performance. Proceed only when
unsatisfactory conditions have been corrected in a manner complying with
Contract Documents. Starting work within a particular area will be construed as
acceptance of surface conditions.

3.2 PREPARATION
3.2.1 General: Comply with manufacturer’s instruction, recommendations and

specifications for cleaning and surface preparation. Surfaces shall have no defects
which would result in poor or potentially defective installation o would cause
latent defects in Work
3.3 INSTALLATION
3.3.1 General: Install door and operating equipment complete with necessary
hardware, jamb and head mold strips, anchors, inserts, hangers, and equipment
supports according to Shop Drawings, manufacturer's written instructions, and as
specified.
 Install fire-rated doors to comply with NFPA 80.
3.4 ADJUSTING
3.4.1 Lubricate bearings and sliding parts; adjust doors to operate easily, free from
warp, twist, or distortion and fitting weathertight for entire perimeter.
3.5 DEMONSTRATION
3.5.1 Startup Services: Engage a factory-authorized service representative to perform

startup services and to train Employer’s maintenance personnel as specified
below:
 Test and adjust controls and safeties. Replace damaged and malfunctioning
controls and equipment.
 Train Employer’s maintenance personnel on procedures and schedules related
to startup and shutdown, troubleshooting, servicing, preventive maintenance,
and procedures for testing and resetting release devices.
 Review data in the maintenance manuals. Refer to the requirements of the
Special Conditions of Contract.
 Schedule training with Employer with at least 7 days' advance notice.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. SPECIAL FUNCTION DOORS
CAIRO - EGYPT 08340– 2039 0

CONTENTS
SECTION 08340
SPECIAL FUNCTION DOORS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Coordination 3
PART 2 PRODUCTS 3
2.1 Door Curtain Materials And Construction 3
2.2 Hoods And Accessories 4
2.3 Electric Door Operators 4
PART 3 EXECUTION 6
3.1 Examination 6
3.2 Preparation 6
3.3 Installation 6
3.4 Adjusting 6
3.5 Demonstration 6
Special Function Doors Section 08340

SECTION 08340
SPECIAL FUNCTION DOORS
PART 1 GENERAL
Section.
1.2 SUMMARY
1.2.1 This Section includes the following types of overhead coiling doors:
 Rolling service PVC doors.
 Division 5 Section "Metal Fabrications" for miscellaneous steel supports.

 Division 16 Specification Sections for electrical service and connections for
powered operators, and accessories.
1.3 SUBMITTALS
1.3.1 Product Data: For each type and size of overhead coiling door and accessory.
Include details of construction relative to materials, dimensions of individual
components, profiles, and finishes. Provide roughing-in diagrams, operating
instructions, and maintenance information. Include the following:
 Setting drawings, templates, and installation instructions for built-in or

embedded anchor devices.
 Motors: Show nameplate data and ratings; characteristics; mounting
arrangements; size and location of winding termination lugs, conduit entry,
and grounding lug; and coatings.
1.3.2 Shop Drawings: For special components and installations not dimensioned or
detailed in manufacturer's data sheets.
 Wiring Diagrams: Detail wiring for power, signal, and control systems.
Differentiate between manufacturer-installed and field-installed wiring and
between components provided by door manufacturer and those provided by
others.
of colors available for units with factory-applied finishes.
1.3.4 Samples for Verification: Of each type of exposed finish required, prepared on
Samples of size indicated below and of same thickness and material indicated for

Work. Where finishes involve normal color and texture variations, include Sample
sets showing the full range of variations expected.
 Curtain Fabric: 300-mm square.

 Bottom Bar: 150-mm length.
 Guides: 150-mm length.
 Brackets: 150 mm square.
 Hood: 150 mm square.

1.4.2 Installer Qualifications: Engage an experienced installer who is an authorized

representative of the overhead coiling door manufacturer for both installation
and maintenance of units required for this Project.
1.4.3 Source Limitations: Obtain overhead coiling doors through one source from a
 Obtain operators and controls from the overhead coiling door manufacturer.
1.4.4 Listing and Labeling: Provide electrically operated fixtures specified in this Section
that comply with IEC and BS.
1.5 COORDINATION
1.5.1 Coordinate installation of products and systems with interfacing and adjoining
construction to provide a successful installation without failure.
PART 2 PRODUCTS
2.1 DOOR CURTAIN MATERIALS AND CONSTRUCTION
2.1.1 General: Provide high speed service rolling PVC door, specially designed for
applications with high demands for hygiene. Comply with the following
requirements:
 Door Curtain: Fabricate from one single piece of PVC fabric. The door curtain
rolls up above the door opening. Door curtain shall be equipped with window
located on the full width of the door curtain with center height of 1600 mm.
 Top. The top of the fabric is connected to a fabric roll, located in the header
box above the door opening.
 Side: The left and right sides of the door curtain are constructed with a

patented retaining strap. If the door is hit by a vehicle, a part of this retaining
strap is pulled out of the side column, and then the door reinserts itself
automatically within the next open and close cycle. The self repair function
acts a as a zipper to put the retaining strap back in the side column.
 The operator is completely enclosed in a spray-water protected operator cover
made of stainless steel.
 Fabric Type: Reinforced PVC.
 Fabric Thickness: 1.5 mm, minimum
 Color Fabric: As selected by Engineer from manufacture full range.
 Fabric Vision Panel Thickness: 2.0 mm.
 Fabric Vision Panel Color: Transparent.
 Door Size: As indicated on Drawings.
 Fabric Tearing Resistance: 600 N, according to DIN 53363.
 Comply with safety requirements according to DIN 13241.
 Warning Lights
 Red Light: A red warning light on each side of inside and outside walls
beside walls. Flashing light seconds before and during door movement.
 Green Light: A green light installed on each side of inside and outside
walls beside walls of the door indicating the open position door by
continuous light signal
2.1.2 Bottom for Service Door: Provide replaceable, adjustable, continuous

compressible soft gasket fitted to bottom, unless otherwise indicated.
2.1.3 Curtain Jamb Guides: Fabricate curtain jamb guides of stainless steel angles, or
channels and angles, with sufficient depth and strength to retain curtain, to allow
curtain to operate smoothly, and to withstand loading. Stainless steel grade to be
V2A minimum. The frame thickness to be as recommended by manufacture, but
not less than 3 mm.
2.2 HOODS AND ACCESSORIES
2.2.1 Hood: Form to entirely enclose coiled curtain and operating mechanism at
opening head and act as weatherseal. Contour to suit end brackets to which hood
is attached. Roll and reinforce top and bottom edges for stiffness. Provide closed
ends for surface-mounted hoods and fascia for any portion of between-jamb
mounting projecting beyond wall face. Provide intermediate support brackets as
required to prevent sag.
2.2.2 Where door unit is power operated, provide safety interlock switch to disengage
power supply when door is locked.
2.3 ELECTRIC DOOR OPERATORS
2.3.1 General: Provide electric door operator assembly of size and capacity
recommended and provided by door manufacturer for door and operational life

specified, with electric motor and factory-prewired motor controls, starter, gear-
reduction unit, solenoid-operated brake, clutch, remote-control stations, control
devices, integral gearing for locking door, and accessories required for proper
operation.
2.3.2 Design operator so motor may be removed without disturbing limit-switch

adjustment and without affecting emergency auxiliary operator.
2.3.3 Electric Motors: Provide high-starting torque, reversible, continuous-duty,

electric motors, with overload protection, sized to start, accelerate, and operate
door in either direction, from any position.
 Type: Single phase, 230 V, N, PE.

 Speed:
 Open: 1.5 m/s, minimum.
 Close: 0.8 m/s, minimum.
2.3.4 Protection inside the control panel shall be via circuit breaker or slow acting fuse.
2.3.5 Protection Category Operator, Control System: IP 65.
2.3.6 Coordinate wiring requirements and electric characteristics of motors with

building electrical system.
2.3.7 Closing edge safety device: With energy chain
2.3.8 Remote-Control Station: Provide momentary-contact, 3-button control station

with push-button controls labeled "Open," "Close," and "Stop."
2.3.9 Obstruction Detection Device: Provide each motorized door with indicated
external automatic safety sensor able to protect full width of door opening.
Activation of sensor immediately stops and reverses downward door travel.
 Photoelectric Sensor: Manufacturer's standard system designed to detect an

obstruction in door opening without contact between door and obstruction.
 Self-Monitoring Type: Designed to interface with door operator control
circuit to detect damage to or disconnection of sensing device. When self-
monitoring feature is activated, door closes only with sustained pressure on
close button.
2.3.10 Limit Switches: Provide adjustable switches, interlocked with motor controls and
set to automatically stop door at fully opened and fully closed positions.


PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Acceptance of Surfaces and Conditions: examine substrates to receive overhead

coiling doors and associated to which doors will be applied for compliance with
requirements and other conditions affecting performance. Proceed only when
unsatisfactory conditions have been corrected in a manner complying with
Contract Documents. Starting work within a particular area will be construed as
acceptance of surface conditions.
3.2 PREPARATION
3.2.1 General: Comply with manufacturer’s instruction, recommendations and

specifications for cleaning and surface preparation. Surfaces shall have no defects
which would result in poor or potentially defective installation o would cause
latent defects in Work
3.3 INSTALLATION
3.3.1 General: Install door and operating equipment complete with necessary
hardware, jamb and head mold strips, anchors, inserts, hangers, and equipment
supports according to Shop Drawings, manufacturer's written instructions, and as
specified.
3.4 ADJUSTING
3.4.1 Lubricate bearings and sliding parts; adjust doors to operate easily, free from
warp, twist, or distortion and fitting weather tight for entire perimeter.
3.5 DEMONSTRATION
3.5.1 Startup Services: Engage a factory-authorized service representative to perform

startup services and to train Employer’s maintenance personnel as specified
below:
 Test and adjust controls and safeties. Replace damaged and malfunctioning
controls and equipment.
 Train Employer’s maintenance personnel on procedures and schedules related
to startup and shutdown, troubleshooting, servicing, preventive maintenance,
and procedures for testing and resetting release devices.
 Review data in the maintenance manuals. Refer to the requirements of the
Special Conditions of Contract.
 Schedule training with Employer with at least 7 days' advance notice.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. ALUMINUM WINDOWS
CAIRO - EGYPT 08520– 2039 0

CONTENTS
SECTION 08520
ALUMINUM WINDOWS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.4 Submittals 3
1.7 Warranty 5
PART 2 PRODUCTS 6
2.1 Materials, General 6
2.2 Glazing 6
2.3 Hardware 6
2.4 Fabrication 7
2.5 Insect Screens 8
2.6 Finishes 8
PART 3 EXECUTION 8
3.1 Examination 8
3.2 Installation 9
3.3 Adjusting 9
3.5 Protection And Cleaning 10
Aluminum Windows Section 08520

SECTION 08520
ALUMINUM WINDOWS
PART 1 GENERAL
Section.
1.2 SUMMARY
1.2.1 This Section includes the following types of aluminum-framed windows:
 Aluminum windows.
 Division 8 Section "Aluminum Entrances and Storefronts."

 Division 8 Section "Glazing" for glazing requirements for aluminum windows,
including those specified to be factory glazed.
1.3.1 General: Provide exterior aluminum windows engineered, fabricated, and

installed to withstand normal thermal movement, wind loading, and impact
loading without failure, as demonstrated by testing manufacturer's standard
window assemblies representing types, grades, classes, and sizes required for
Project according to test methods indicated.
1.3.2 Test Criteria: Testing shall be performed by a qualified independent testing

agency based on the following criteria:
 Design wind loads:
 Egyptian code of practice for calculating loads an forces in structural and

building works, ministerial decree 367/2003; basic pressure equal to 100
kg/sq.m.
 Heights of window units above grade at window centerline can be determined
from the Drawings. Consult with the Engineer, if necessary, to confirm
required loading and test pressures.
 Test Procedures: Test window units according to ASTM E 283 for air
infiltration, both ASTM E 331 and ASTM E 547 for water penetration, and
ASTM E 330 for structural performance.
1.3.3 Performance Requirements: Testing shall demonstrate compliance with following

requirements:
 Air-Infiltration Rate for Operating Units: Not more than 0.56 cu. m/h per m of
operable sash joint for an inward test pressure of 299 Pa.

 Air-Infiltration Rate for Fixed Windows: Not more than 1.09 cu. m/h per m of
area for an inward test pressure of 299 Pa.
 Water Penetration: No water penetration as defined in the test method at an
inward test pressure of 20 percent of the design pressure, but not more than
580 Pa.
 Uniform Load Deflection: No deflection in excess of 1/175 of any member's
span during the imposed load, for a positive (inward) and negative (outward)
test pressure of 2873 Pa.
1.3.4 Thermal Movements: Provide exterior aluminum windows, including anchorage,

that accommodate thermal movements of units resulting from the following
maximum change (range) in ambient and surface temperatures without buckling,
distortion, opening of joints, failure of joint sealants, damaging loads and stresses
on glazing and connections, and other detrimental effects. Base engineering
calculation on actual surface temperatures of materials due to solar heat gain and
nighttime-sky heat loss.
 Temperature Change (Range): 35 C, ambient; 60 C material surfaces.
1.4 SUBMITTALS
1.4.1 Product Data: Include construction details, material descriptions, fabrication

methods, dimensions of individual components and profiles, hardware, finishes,
and operating instructions for each type of aluminum window indicated.
1.4.2 Shop Drawings: Include plans, elevations, sections, details, hardware,

attachments to other Work, operational clearances, and the following:
 Mullion details, including reinforcement and stiffeners.

 Joinery details.
 Expansion provisions.
 Flashing and drainage details.
 Weather-stripping details.
 Glazing details.
 Window cleaning provisions.
 For installed products indicated to comply with design loads, include structural
analysis data signed and sealed by the consulting engineer responsible for their
preparation and used to determine the following:
 Structural test pressures and design pressures from basic wind speeds
indicated.
 Deflection limitations of glass framing systems.
1.4.3 Samples for Initial Selection: For units with factory-applied color finishes.
1.4.4 Samples for Verification: For aluminum window components required, prepared
on Samples of size indicated below.
 Main Framing Member: 300-mm- long, full-size sections of extrusions with

factory-applied color finish.
 Hardware: Full-size units with factory-applied finish.
 Weather Stripping: 300-mm- long sections.
 Sash Frame and Beads: 300mm long sections.
 Corner Samples: For windows types selected by the Engineer, 300mm long
sides, for main frame and movable sash including glass and glazing materials.
 Engineer reserves the right to require additional samples that show fabrication
techniques, workmanship, and design of hardware and accessories.
1.4.5 Qualification Data: For Installer, consulting professional engineer and testing
agency.
1.4.6 Field Quality-Control Test Reports: From a qualified testing and inspecting
agency engaged by Contractor.
1.4.7 Product Test Reports: Based on evaluation of comprehensive tests performed

within the last four years by a qualified testing agency, for each type, grade, and
size of aluminum window. Test results based on use of down-sized test units will
not be accepted. Test results based on manufacturer’s own test facilities will not
be accepted.
1.4.8 Maintenance Data: For operable window sash, operating hardware, weather
stripping, and finishes to include in maintenance manuals.

1.5.2 Installer Qualifications: An installer acceptable to aluminum window

manufacturer for installation of units required for this Project.
1.5.3 Testing Agency Qualifications: An independent testing agency, acceptable to

authorities having jurisdiction, with the experience and capability to conduct the
testing indicated, as documented according to ASTM E 548.
1.5.4 Source Limitations: Obtain aluminum windows through one source from a single
manufacturer.
1.5.5 Product Options: Information on Drawings and in Specifications establishes

requirements for aluminum windows' aesthetic effects and performance
characteristics. Aesthetic effects are indicated by dimensions, arrangements,
alignment, and profiles of components and assemblies as they relate to sightlines,
to one another, and to adjoining construction. Performance characteristics are
indicated by criteria subject to verification by one or more methods including
preconstruction testing, field testing, and in-service performance.
 Do not modify intended aesthetic effects, as judged solely by Engineer, except

with Engineer's approval. If modifications are proposed, submit
comprehensive explanatory data to Engineer for review.
1.5.6 Fenestration Standard: Comply with AAMA/NWWDA 101/I.S.2, "Voluntary
Specifications for Aluminum, Vinyl (PVC) and Wood Windows and Glass Doors,"
for minimum standards of performance, materials, components, accessories, and
fabrication unless more stringent requirements are indicated.
1.5.7 Mockups: Build mockups to verify selections made under sample Submittals and
 Build mockup in building envelope wall in locations approved by the Engineer.

 Build mock-ups for the following types of aluminum windows complete
including glass, as specified in Division 8, Section "Glazing", glazing materials,
sealants, gaskets, hardware, sub-frames and covers:
 Fixed windows

1.6.1 Field Measurements: Verify aluminum window openings by field measurements

before fabrication and indicate measurements on Shop Drawings.

delaying the Work, establish opening dimensions and proceed with fabricating
aluminum windows without field measurements. Coordinate wall construction
to ensure that actual opening dimensions correspond to established
dimensions.
1.7 WARRANTY
1.7.1 Special Warranty: Manufacturer's standard form in which manufacturer agrees

to repair or replace aluminum windows that fail in materials or workmanship
within specified warranty period. Failures include, but are not limited to, the
following:
 Failure to meet performance requirements.

 Structural failures including excessive deflection.
 Water leakage, air infiltration, or condensation.
 Faulty operation of movable sash and hardware.
 Deterioration of metals, metal finishes, and other materials beyond normal
weathering.
 Insulting glass failure.
1.7.2 Warranty Period: Ten years from date of Taking Over by the Employer.
1.7.3 Warranty Period for Metal Finishes: Twenty years from date of Taking Over by
the Employer.

PART 2 PRODUCTS
2.1 MATERIALS, GENERAL
2.1.1 Aluminum Extrusions: Alloy and temper recommended by aluminum window

manufacturer for strength, corrosion resistance, and application of required
finish, but not less than 150-MPa ultimate tensile strength, not less than 110-MPa
minimum yield strength, and not less than 2.0 mm thickness at any location for
the main frame and sash members.
2.1.2 Fasteners: Aluminum, nonmagnetic stainless steel, epoxy adhesive, or other

materials warranted by manufacturer to be noncorrosive and compatible with
aluminum window members, trim, hardware, anchors, and other
components. Cadmium-plated steel fasteners are not permitted.
 Reinforcement: Where fasteners screw-anchor into aluminum less than 3.2

mm thick, reinforce interior with aluminum or nonmagnetic stainless steel to
receive screw threads, or provide standard, noncorrosive, pressed-in, splined
grommet nuts.
 Exposed Fasteners: Unless unavoidable for applying hardware, do not use
exposed fasteners. For application of hardware, use fasteners that match
finish of member or hardware being fastened, as appropriate.
2.1.3 Anchors, Clips, and Accessories: Aluminum, nonmagnetic stainless steel, or zinc-
coated steel or iron complying with ASTM B 633 for SC 3 severe service
conditions; provide sufficient strength to withstand design pressure
indicated. Cadmium-plated steel anchors, clips, and accessories are not permitted.
2.1.4 Compression-Type Weather Stripping: Provide compressible weather stripping

designed for permanently resilient sealing under bumper or wiper action, and
completely concealed when aluminum window is closed.
 Compression Weather Stripping: Molded neoprene complying with

ASTM D 2000 requirements.
2.1.5 Replaceable Weather Seals: Comply with AAMA 701/702.
2.1.6 Sealant: For sealants required within fabricated windows, provide window
manufacturer's standard, permanently elastic, nonshrinking, and nonmigrating
type recommended by sealant manufacturer for joint size and movement.
2.2 GLAZING
2.2.1 Glass and Glazing Materials: Refer to Division 8 Section "Glazing" for glass types
and glazing requirements applicable to glazed aluminum window units.
2.2.2 Glazing System: Manufacturer's standard factory-glazing system that produces

weathertight seal in conformance with requirements indicated in Division 8
Section "Glazing”.
2.3 HARDWARE
2.3.1 General: Provide manufacturer's standard hardware fabricated from aluminum,

designed to smoothly operate, tightly close, and securely lock aluminum windows
and sized to accommodate sash or ventilator weight and dimensions. Cadmium-
plated hardware is not permitted. Do not use aluminum in frictional contact with
other metals. Where exposed, provide extruded, cast, or wrought aluminum with
clear anodized satin finish.
2.3.2 Hardware, General: Comply with AAMA 902.
2.3.3 Sill Cap/Track: Extruded-aluminum with finish matching that of window track of
thickness, dimensions, and profile indicated; designed to comply with
performance requirements indicated and to drain to the exterior.
2.3.4 Locks and Latches: Designed to allow unobstructed movement of the sash across
adjacent sash in direction indicated and operated from the inside only.
2.3.5 Roller Assemblies: Low-friction design.
2.3.6 Four- or Six-Bar Friction Hinges: Comply with AAMA 904.
 Locking mechanism and handles for manual operation.

 Friction Shoes: Provide friction shoes of nylon or other nonabrasive, non-
staining, non-corrosive, durable material.
2.3.7 Limit Devices: Provide limit devices designed to restrict sash or ventilator
opening.
 Safety Devices: Limit clear opening to 150 mm for ventilation; with custodial
key release.
2.4 FABRICATION
2.4.1 General: Fabricate aluminum windows, in sizes indicated, that comply with
AAMA/NWWDA 101/I.S.2 for performance class and performance grade
indicated. Include a complete system for assembling components and anchoring
windows.
2.4.2 Fabricate aluminum windows that are reglazable without dismantling sash or
ventilator framing.
2.4.3 Weather Stripping: Provide full-perimeter weather stripping for each operable
sash and ventilator.
2.4.4 Weep Holes: Provide weep holes and internal passages to conduct infiltrating
water to exterior.
2.4.5 Mullions: Provide mullions and cover plates as shown, matching window units,
complete with anchors for support to structure and installation of window units.
Allow for erection tolerances and provide for movement of window units due to
thermal expansion and building deflections, as indicated. Provide mullions and
cover plates capable of withstanding design loads of window units.
2.4.6 Sub frames: Provide sub frames with anchors for window units as shown, of
profile and dimensions indicated but not less than 1.6-mm- thick extruded
aluminum. Miter or cope corners, and weld and dress smooth with concealed
mechanical joint fasteners. Finish to match window units. Provide sub frames
capable of withstanding design loads of window units.
2.4.7 Factory-Glazed Fabrication: Glaze aluminum windows in the factory where

practical and possible for applications indicated. Comply with requirements in
Division 8 Section "Glazing" and with AAMA/NWWDA 101/I.S.2.
2.4.8 Glazing Stops: Provide snap-on glazing stops coordinated with Division 8 Section
"Glazing" and glazing system indicated. Provide glazing stops to match sash and
ventilator frames.
2.5 INSECT SCREENS
2.5.1 General: Design windows and hardware to accommodate screens in a tight-

fitting, removable arrangement, with a minimum of exposed fasteners and
latches. Locate screens on outside of window and provide for each operable
exterior sash or ventilator.
 Aluminum Insect Screen Frames: Manufacturer's standard aluminum alloy

complying with SMA 1004. Fabricate frames with mitered or coped joints,
concealed fasteners, adjustable rollers, and removable PVC spline/anchor
concealing edge of frame.
 Finish: Match aluminum window members.
 Stainless-Steel Wire Fabric: 1.13-by-1.3-mm mesh of 0.28-mm-diameter,

nonmagnetic stainless-steel wire, Type 304 or 316, complying with FS RR-W-
365, Type VI.
2.6 FINISHES
2.6.1 General: Comply with NAAMM's "Metal Finishes Manual for Architectural and
Metal Products" for recommendations for applying and designating finishes.
2.6.2 Finish designations prefixed by AA comply with the system established by the
Aluminum Association for designating aluminum finishes.
2.6.3 High-Performance Organic Finish (2-Coat Fluoropolymer): AA-C12C40R1x

(Chemical Finish: cleaned with inhibited chemicals; Chemical Finish: conversion
coating; Organic Coating: manufacturer's standard 2-coat, thermocured system
consisting of specially formulated inhibitive primer, fluoropolymer color coat, and
clear fluoropolymer topcoat, with both color coat and clear topcoat containing
not less than 70 percent polyvinylidene fluoride resin by weight). Prepare,
pretreat, and apply coating to exposed metal surfaces to comply with AAMA 2604
and with coating and resin manufacturers' written instructions
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine openings, substrates, structural support, anchorage, and conditions, with
Installer present, for compliance with requirements for installation tolerances;
rough opening dimensions; levelness of sill plate; coordination with wall flashings,
vapor retarders, and other built-in components; operational clearances; accurate
locations of connections to building electrical system; and other conditions
affecting performance of work.
 Masonry Surfaces: Visibly dry and free of excess mortar, sand, and other
construction debris.
 Metal Surfaces: Dry; clean; free of grease, oil, dirt, rust, corrosion, and welding
slag; without sharp edges or offsets at joints.
corrected.
3.2 INSTALLATION
3.2.1 General: Comply with manufacturer's written instructions for installing windows,
hardware, accessories, and other components; Drawings; and Shop Drawings.
3.2.2 Install windows level, plumb, square, true to line, without distortion or impeding
thermal movement, anchored securely in place to structural support, and in
proper relation to wall flashing and other adjacent construction.
3.2.3 Set sill members in bed of sealant or with gaskets, as indicated, for weathertight
construction.
3.2.4 Install windows and components to drain condensation, water penetrating joints,
and moisture migrating within windows to the exterior.
3.2.5 Metal Protection: Separate aluminum and other corrodible surfaces from sources
of corrosion or electrolytic action at points of contact with other materials by
complying with requirements specified in "Dissimilar Materials" Paragraph in
Appendix B in AAMA/NWWDA 101/I.S.2.
3.3 ADJUSTING
3.3.1 Adjust operating sashes and ventilators, screens, hardware, operators, and
accessories for a tight fit at contact points and weather stripping for smooth
operation and weathertight closure. Lubricate hardware and moving parts.
3.4.1 Manufacture Field Service: Manufacture/fabricator’s qualified technical

representative, not a sales representative, shall inspect first days work and
periodically inspect work of this Section to insure installation is proceeding in
accordance with manufacture/fabricator’s recommendations and warranty
requirements. Representative shall submit written reports of each visit indicating
observations, findings and conclusion of inspection
3.4.2 Testing Laboratory Field Service: Contractor shall engage and pay an approved
qualified independent testing laboratory to perform field quality control.
Materials and installation failing to meet specified requirements shall be replaced
at Contractor’s expense. Retesting of materials and installation failing to meet
specified requirements shall be done at Contractor’s expense.
3.5 PROTECTION AND CLEANING
3.5.1 Protect window surfaces from contact with contaminating substances resulting
from construction operations. In addition, monitor window surfaces adjacent to
and below exterior concrete and masonry surfaces during construction for
presence of dirt, scum, alkaline deposits, stains, or other contaminants. If
contaminating substances do contact window surfaces, remove contaminants
immediately according to manufacturer's written recommendations.
3.5.2 Clean aluminum surfaces immediately after installing windows. Avoid damaging
protective coatings and finishes. Remove excess sealants, glazing materials, dirt,
and other substances.
3.5.3 Clean factory-glazed glass immediately after installing windows. Comply with
manufacturer's written recommendations for final cleaning and maintenance.
Remove nonpermanent labels and clean surfaces.
3.5.4 Remove and replace glass that has been broken, chipped, cracked, abraded, or
damaged during construction period.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. DOOR HARDWARE
CAIRO - EGYPT 08710 - 2039 0

CONTENTS
SECTION 08710
DOOR HARDWARE
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.6 Coordination 5
1.7 Warranty 5
1.8 Maintenance Service 5
PART 2 PRODUCTS 6
2.1 Scheduled Door Hardware 6
2.2 Hinges And Pivots 6
2.3 Locks And Latches 6
2.4 Door Bolts 7
2.5 Exit Devices 7
2.6 Cylinders And Keying 8
2.7 Operating Trim 9
2.8 Closers 9
2.9 Floor Spring 10
2.10 Stops And Holders 11
2.11 Door Gasketing 11
2.12 Thresholds 11
2.13 Door Protection Plates 11
2.14 Fabrication 12
2.15 Finishes 12
PART 3 EXECUTION 13
3.1 Examination 13
3.2 Installation 13
3.3 Adjusting 13
Door Hardware Section 08710

SECTION 08710
DOOR HARDWARE
PART 1 GENERAL
Section.
1.2 SUMMARY
 Commercial door hardware for the following:
 Swinging doors.
 Cylinders for doors specified in other Sections.
1.3 SUBMITTALS
1.3.1 Product Data: Include installation details, material descriptions, dimensions of

individual components and profiles, and finishes.
1.3.2 Samples: For exposed door hardware of each type indicated below, in specified
finish, full size. Tag with full description for coordination with the Door Hardware
Schedule. Submit samples before, or concurrent with, submission of the final
Door Hardware Schedule.
 Door Hardware: As follows:

 Hinges.
 Pivots.
 Locks and latches.
 Bolts.
 Exit devices.
 Cylinders and keys.
 Closers.
 Coordinators.
 Stops and holders.
 Door gasketing.
 Miscellaneous items.
 Samples will be returned to Contractor. Units that are acceptable and remain

undamaged through submittal, review, and field comparison process may,
after final check of operation, be incorporated into the Work, within
limitations of keying requirements.
1.3.3 Door Hardware Schedule: Prepared by or under the supervision of supplier,

detailing fabrication and assembly of door hardware, as well as procedures and
diagrams. Coordinate the final Door Hardware Schedule with doors, frames, and
related work to ensure proper size, thickness, hand, function, and finish of door
hardware.
 Format: Comply with Engineer’s requirements.

 Organization: Organize the Door Hardware Schedule into door hardware sets
indicating complete designations of every item required for each door or
opening.
 Content: Include the following information:
 Type, style, function, size, label, hand, and finish of each door hard-ware
item.
 Manufacturer of each item.
 Fastenings and other pertinent information.
 Location of each door hardware set, cross-referenced to Drawings, both on
floor plans and in door and frame schedule.
 Explanation of abbreviations, symbols, and codes contained in schedule.
 Mounting locations for door hardware.
 Door and frame sizes and materials.
 Submittal Sequence: Submit the final Door Hardware Schedule at earliest
possible date, particularly where approval of the Door Hardware Schedule
must precede fabrication of other work that is critical in the Project
construction schedule. Include Product Data, Samples, Shop Drawings of other
work affected by door hardware, and other information essential to the
coordinated review of the Door Hardware Schedule.
1.3.4 Keying Schedule: Prepared by or under the supervision of supplier, detailing

Employer's final keying instructions for locks. Include schematic keying diagram
and index each key set to unique door designations.
1.4.1 Installer Qualifications: An experienced installer who has completed door

hardware similar in material, design, and extent to that indicated for this Project
and whose work has resulted in construction with a record of successful in-service
performance.

1.4.2 Manufacture Qualifications: Manufacture Qualifications: A firm experienced in
manufacture products similar to those indicated for this Project and with a record
of successful in-service performance not less than 10 years, as well as sufficient
production capacity to produce required units, without delaying the work.
 Scheduling Responsibility: Preparation of door hardware and keying

schedules.
1.4.3 Source Limitations: Obtain each type and variety of door hardware from a single
manufacturer, unless otherwise indicated.
1.4.4 CE Markings:
 All items of hardware shall be CE marked in accordance with Annex ZA of the

relevant BS EN.
 CE marking shall be on an area of the item that will not be visible when
installed.
1.4.5 General Hardware Requirements: Hardware/ironmongery shall be capable of
meeting the minimum performance criteria to BS EN 12209 and BS EN 1906.
1.4.6 The work shall retain its specified appearance and performance when maintained
in accordance with an accepted maintenance program, without:
 Malfunction of operating components during normal usage due to defective

products or workmanship.
 Loss or loosening of fixings.
 Corrosion resulting in malfunctions of operating components, pitting or defects
due to contact with users or natural elements in the environment.
 Discoloration or unacceptable changes in appearance.
1.4.7 Automatic door closers shall permit the doors to be operated without exerting an
initial force of over 30N and a remaining operating force of 20N, at the handle
position.
1.4.8 Fire-Rated Door Assemblies: Provide door assemblies included in successful tests
to BS 476-22 or BS EN 1634-1 on door assemblies similar to those proposed,
assemblies should be listed and labeled by a testing and inspecting agency
acceptable to authorities having jurisdiction, for fire ratings indicated.
 Melting Points of components (except decorative non-functional parts): 800° C

minimum.
1.4.9 Keying Conference: Conduct conference at Project site to comply with

requirements to discuss keying conference decisions into final keying schedule
after reviewing door hardware keying system.
1.5.1 Inventory door hardware on receipt and provide secure lock-up for door hardware

delivered to Project site.
1.5.2 Tag each item or package separately with identification related to the final Door
Hardware Schedule, and include basic installation instructions with each item or
package.
1.5.3 Deliver keys to manufacturer of key control system.
1.6 COORDINATION
1.6.1 Templates: Obtain and distribute to the parties involved templates for doors,
frames, and other work specified to be factory prepared for installing door
hardware. Check Shop Drawings of other work to confirm that adequate
provisions are made for locating and installing door hardware to comply with
indicated requirements.
1.7 WARRANTY
1.7.1 General Warranty: Special warranties specified in this Article shall not deprive
Employer of other rights Employer may have under other provisions of the
Contract Documents and shall be in addition to, and run concurrent with, other
warranties made by Contractor under requirements of the Contract Documents.
1.7.2 Special Warranty: Written warranty, executed by manufacturer agreeing to

repair or replace components of door hardware that fail in materials or
workmanship within specified warranty period. Failures include, but are not
limited to, the following:
 Structural failures including excessive deflection, cracking, or breakage.

 Faulty operation of operators and door hardware.
weathering.
1.7.3 Warranty Period: 10 years from date of Taking Over by the Employer, unless
1.7.4 Warranty Period for Manual Closers: 10 years from date of Taking Over by the
Employer.
1.8 MAINTENANCE SERVICE
1.8.1 Maintenance Service: Beginning at Date of Tanking Over by the Employer provide
six months' full maintenance by skilled employees of door hardware Installer.
Include quarterly preventive maintenance, repair or replacement of worn or
defective components, lubrication, cleaning, and adjusting as required for proper
door hardware operation. Provide parts and supplies as used in the manufacture
and installation of original products.

PART 2 PRODUCTS
2.1 SCHEDULED DOOR HARDWARE
2.1.1 General: Provide door hardware for each door to comply with requirements in
this Section and door hardware requirements.
 Door Hardware Sets: Requirements for quantity, item, design, grade, function,
finish, size, and other distinctive qualities of each type of door hardware are
indicated in the Door Schedule.
2.1.2 Base Metal: Unless otherwise indicated in Door Schedule, base metal for
manufacture of Hardware is to be:
 Stainless steel alloy 304.

2.2 HINGES AND PIVOTS
2.2.1 Hinges shall comply with BS EN 1935.
2.2.2 Hinges shall be marked in accordance with BS EN 1935.
2.2.3 Hinges shall be of the strength class to suit the door weight, duty, number of
hinges and other factors as recommended in BS EN 1935.
2.2.4 Hinges shall be stainless steel, class 13-14.
2.2.5 Hinges to fire doors shall have intumescent card between the hinge and the door
frame and shall meet the requirements of BS EN 1634: Parts 1 and 3.
2.2.6 Fasteners: Comply with the following:
 Machine Screws: For metal doors and frames. Install into drilled and tapped
holes.
 Threaded-to-the-Head Wood Screws: For fire-rated wood doors.
 Screws: Phillips flat-head screws; machine screws (drilled and tapped holes)
for metal doors, wood screws for wood doors and frames. Finish screw heads
to match surface of hinges.
2.3 LOCKS AND LATCHES
2.3.1 Standards: Comply with the following:
 Locks and latches mechanically operated shall comply with BS EN 12209.

 Locks and latches electromechanically operated shall comply with BS EN
14846.
2.3.2 Lock Trim: Comply with the following:
 Lever Handles: Lever handles shall comply with BS EN 1906.

 Lever: Cast Wrought, forged, or cast.
 Escutcheon (Rose): Cast.
 Dummy Trim: Match lever lock trim and escutcheons.
 Lockset Designs: Provide the lockset design designated below or, if sets are
provided by another manufacturer, provide designs that match those
designated:
2.3.3 Lock Throw: Comply with testing requirements for length of bolts to comply with
labeled fire door requirements, and as follows:
 Mortise Locks: Minimum 19-mm latchbolt throw.

 Deadbolts: Minimum 25-mm bolt throw.
2.3.4 Mortise Locks: Mortise locks are to be:
 Constructed from stamped steel case and stainless steel components.

 Types produced for extra heavy duty applications and lock lever of anti-
vandalism construction.
 Of 6 mm minimum inner diameter of threading bars where threaded bars are
used to assemble the two pieces of lock spindle, and
 ADA compliant marine grade for exterior doors.
2.3.5 Rabbeted Doors: Provide special rabbeted front and strike on locksets for
rabbeted meeting stiles.
2.3.6 Backset: 70 mm, unless otherwise indicated.
2.4 DOOR BOLTS
2.4.1 Standards: Comply with BS EN 12051.
 Fire-Rated Surface Bolts: Minimum 25-mm throw; listed and labeled for fire-
rated doors.
2.4.2 Minimum Classification Grade:
 Category of use: 3.
 Fire safety: 0 for no-fire rated doors and 1 for fire rated doors.
 Corrosion resistance: 3.
2.5 EXIT DEVICES
2.5.1 Emergency exit devices operated by a lever handle or push pad shall comply with
BS EN 179.
2.5.2 Horizontal panic exit devices shall comply with BS EN 1125.
2.5.3 Electronically controlled panic exit systems shall comply with prEN 13633.

2.5.4 Electronically controlled emergency exit systems shall comply with prEN 13637
2.5.5 Fire Exit Devices: Complying with BS 476 that are listed and labeled by a testing
and inspecting agency acceptable to authorities having jurisdiction, for fire and
panic protection, for fire ratings indicated.
2.5.6 Outside Trim: Lever with cylinder; material and finish to match locksets, unless
 Match design for locksets and latchsets, unless otherwise indicated.
2.5.7 Fire and panic exit devices shall be of concealed latches. No exposed latches shall
be accepted.
2.6 CYLINDERS AND KEYING
 Standards: Cylinders shall conform to BS EN 1303.
2.6.1 Cylinders: Manufacturer's standard tumbler type, constructed from brass or

bronze, stainless steel, or nickel silver, and complying with the following:
 Number of Pins: Seven.

 Mortise Type: Threaded cylinders with rings and straight- or clover-type cam.
2.6.2 Cores: Manufacturer's standard; finish face to match lockset; complying with the
following:
 Interchangeable Cores: Core insert, removable by use of a special key, and

usable with other manufacturers' cylinders.
2.6.3 Keying System: Provide a factory-registered keying system complying with the
following:
 Grand Master Key System: Cylinders are operated with a Change key, a Master
key and a Grand Master key. Comply with Employer’s requirements for
number of master key systems required,
2.6.4 Keys: Provide stainless steel keys complying with the following:
 Quantity: In addition to one extra blank key for each lock, provide the
following:
 Cylinder Change Keys: Five, as directed by the Employer.
 Master Keys: Three.
2.6.5 Stamping: Permanently inscribe each key with a visual key control number and
include the following notation:
 Notation: Information to be furnished by Employer.
2.6.6 Key Control System: To including key-holding hooks, labels, two sets of key tags
with self-locking key holders, key-gathering envelopes, and temporary and

permanent markers. Contain system in metal cabinet with baked-enamel finish.
 Wall-Mounted Cabinet: Cabinet with hinged-panel door equipped with key-

holding panels and pin-tumbler cylinder door lock.
 Capacity: Able to hold keys for 150 percent of the number of locks.
2.7 OPERATING TRIM
2.7.1 Standard: Comply with BS 8424.
2.7.2 Door handles shall have returns in direction of door, straight handles shall not be
accepted.
2.7.3 Handles shall be with round (rose) cover plates.
2.7.4 Materials: Fabricate from stainless steel, unless otherwise indicated.
2.7.5 Push-Pull Design: As indicated on Drawings.
2.8 CLOSERS
2.8.1 Standard: Comply with BS EN 1154
2.8.2 Closers, General: Closer shall be tested for one million cycles and shall be
provided with all weather hydraulic fluid. Closer shall be equipped with the
function of variable back check and delayed action. Closer shall be provided with
ten years warranty against leaks. Closer will be non-banded, provided with
adjustable with speed and hold open facility. Concealed door closer shall be
completely hidden and components shall minimize tempering and vandalism.
 Size of Units: Unless otherwise indicated, comply with the manufacturer’s

recommendation for size of door control unit depending on size of door and
exposure to weather and drafts.
 Arms: Provide parallel arms for overhead closers, unless otherwise indicated.
Provide closer unit one size larger than recommended for use with standard
arms.
 Closing Cycle: Comply with requirements of authorities having jurisdiction or
the disabilities.
 Construction: Provide marine-grade construction for closers in non-air
conditioned areas and in door swimming pool areas, consisting of
nonferrous and stainless steel components.
2.8.3 Minimum Classification Grades:
 Category of use: 4.
 Door closer power size: Adjustable, as recommended by manufacture to
comply with door width and mass, adjustable 3–6.
 Suitability for use on fire/ smoke doors: Grade 0 for non fire rated door and

Grade 1 for fire rated doors.
 Corrosion resistance: 3, according to BS EN 1670.
 Type: As indicated on Drawings and door Hardware Schedule.
2.8.4 Hold-Open Closers/Detectors: Coordinate and interface integral smoke detector

and closer device with fire alarm system.
2.8.5 Flush Floor Plates: Provide finish cover plates for floor closers unless thresholds
are indicated. Match door hardware finish, unless otherwise indicated.
2.8.6 Recessed Floor Plates: Provide recessed floor plates with insert of floor finish
material for floor closers unless thresholds are indicated. Provide extended closer
spindle to accommodate thickness of floor finish.
2.8.7 Door closers with hold-open facility are to release automatically from hold-open
position in case of fire. Provide closer holder release devices that comply with
requirements of reference standard in his Section and execute all field-installed
necessary wiring according to approved shop drawings.
2.8.8 Coordinate and interface integral smoke detector and closer device with fire
alarm system. Fire rated doors with closers of hold open facility shall release
automatically in case of fire based on signal from the fire alarm system (electric
release door closer). System of release device for double leaf fire rated doors
shall be adjustable so as the inactive leaf shall close prior to the active leaf and
that active leave shall positively latch to the inactive leaf at final closing position
(electric release door closers and door coordinator).
2.8.9 Door Coordinates: BS EN 1158. Provide coordinator for each pair of doors
equipped with closers on both leaves and an overlapping astragal. To be
concealed type and shall be capable of holding the active door of a pair open until
the inactive door ahs preceded it in the closing cycle.
 Do not use gravity type coordinators.
2.8.10 Weather Comply with manufacturer's written recommendation of exposure to

weather. Provide factory-sized closers, adjustable to meet field conditions and
requirements for opening force.
2.9 FLOOR SPRING
2.9.1 Standard: Comply with BS EN 1154
2.9.2 Operational Adjustment:
 Variable Power: Matched to size, weight and location of doors.

 Latched Doors: Override latches and/or door seals when fitted.
 Unlatched Doors: Hold shut under normal working conditions.
 Closing against smoke seals of fire doors: Positive. No gaps

2.10 STOPS AND HOLDERS
2.10.1 Standards: Comply with the following:
 Electromagnetic Door Holders: BS EN 1155.
2.10.2 Floor Stops: For doors, unless wall or other type stops are scheduled or indicated.
Do not mount floor stops where they will impede traffic.
 Where floor or wall stops are not appropriate, provide overhead holders.
2.10.3 Silencers for Metal Door Frames: Neoprene or rubber, minimum diameter 13
mm; fabricated for drilled-in application to frame.
2.11 DOOR GASKETING
2.11.1 General: Provide continuous weather-strip gasketing on exterior doors and

provide smoke, light, or sound gasketing on interior doors where indicated or
scheduled. Provide noncorrosive fasteners for exterior applications and
elsewhere as indicated.
 Perimeter Gasketing: Apply to head and jamb, forming seal between door and
frame.
2.11.2 Air Leakage: Not to exceed 0.000774 cu. m/s per m of crack length for gasketing
other than for smoke control, as tested according to ASTM E283
2.11.3 Fire-Labeled Gasketing: Assemblies complying with NFPA 80 that are listed and
labeled by a testing and inspecting agency acceptable to authorities having
jurisdiction, for fire ratings indicated, based on testing according to UL 10B or
NFPA 252.
2.11.4 Replaceable Seal Strips: Provide only those units where resilient or flexible seal
strips are easily replaceable and readily available from stocks maintained by
manufacturer.
2.11.5 Gasketing Materials: Comply with ASTM D2000 and AAMA702/701.
2.12 THRESHOLDS
2.12.1 Standard: comply with BHMA A156.21.
2.13 DOOR PROTECTION PLATES
2.13.1 General: Door protection plates are to include:
 Kick plates fixed on both stop and pull sides of the door at the bottom.
 Trolley plates fixed on stop side of the door with centerline of plate at height
of the trolley selected for the project.
2.13.2 Material and Thickness for Metal Doors: Stainless steel alloy 304, 1.2 mm thick,
minimum.

2.13.3 Height: Unless otherwise indicated height is to be as follows:
 200 mm for kick plates
2.13.4 Width: Kick plates and trolley plates fixed on stop side of the door are to be 30
mm less than door width with equal clearance (15 mm) from edge at both stop
and hinge stiles of the door. Kick plates on pull side of the door are to be of width
equal to width of the door.
2.13.5 Fixation of Metal Plates: Use two rows of exposed stainless steel screws with 200
maximum intervals on center between adjoining screws in the same raw. Provide
50 mm clearance from plate vertical edges and 20 mm from horizontal edges.
2.14 FABRICATION
2.14.1 Manufacturer's Nameplate: Do not provide manufacturers' products that have

manufacturer's name or trade name displayed in a visible location (omit
removable nameplates) except in conjunction with required fire-rated labels and
as otherwise approved by Engineer.
 Manufacturer's identification will be permitted on rim of lock cylinders only.
2.14.2 Fasteners: Provide door hardware manufactured to comply with published

templates generally prepared for machine, wood, and sheet metal screws.
Provide screws according to commercially recognized industry standards for
application intended. Provide Phillips flat-head screws with finished heads to
match surface of door hardware, unless otherwise indicated.
 Concealed Fasteners: For door hardware units that are exposed when door is
closed, except for units already specified with concealed fasteners. Do not use
through bolts for installation where bolt head or nut on opposite face is
exposed unless it is the only means of securely attaching the door hardware.
Where through bolts are used on hollow door and frame construction, provide
sleeves for each through bolt.
 Steel Through Bolts: For the following fire-rated applications, unless door
blocking is provided:
 Surface hinges to doors.
 Closers to doors and frames.
 Surface-mounted exit devices.
 Spacers or Sex Bolts: For through bolting of hollow metal doors.
2.15 FINISHES
2.15.1 Protect mechanical finishes on exposed surfaces from damage by applying a

strippable, temporary protective covering before shipping.
2.15.2 Satin stainless steel, over stainless-steel base metal, unless otherwise indicated.

PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine doors and frames, with Installer present, for compliance with
requirements for installation tolerances, labeled fire door assembly construction,
wall and floor construction, and other conditions affecting performance.
corrected.
3.2 INSTALLATION
3.2.1 Mounting Heights: Mount door hardware units at heights indicated on Drawings
or approved shop drawings for each type of doors.
3.2.2 Install each door hardware item to comply with manufacturer's written
instructions. Where cutting and fitting are required to install door hardware onto
or into surfaces that are later to be painted or finished in another way, coordinate
removal, storage, and reinstallation of surface protective trim units with finishing
work specified in Division 9 Sections. Do not install surface-mounted items until
finishes have been completed on substrates involved.
 Set units level, plumb, and true to line and location. Adjust and reinforce
attachment substrates as necessary for proper installation and operation.
 Drill and countersink units that are not factory prepared for anchorage
fasteners. Space fasteners and anchors according to industry standards.
3.2.3 Key Control System: Place keys on markers and hooks in key control system
cabinet, as determined by final keying schedule.
3.3 ADJUSTING
3.3.1 Initial Adjustment: Adjust and check each operating item of door hardware and
each door to ensure proper operation or function of every unit. Replace units
that cannot be adjusted to operate as intended. Adjust door control devices to
compensate for final operation of heating and ventilating equipment and to
comply with referenced accessibility requirements.
 Door Closers: Adjust sweep period so that, from an open position of 70

degrees, the door will take at least 3 seconds to move to a point 75 mm from
the latch, measured to the leading edge of the door.
3.4.1 Clean adjacent surfaces soiled by door hardware installation.
3.4.2 Clean operating items as necessary to restore proper function and finish.
3.4.3 Provide final protection and maintain conditions that ensure door hardware is

without damage or deterioration at time of Substantial Completion.

THE NATURE OF THE REVISION IS BRIEFLY NOTED UNDER REMARKS BUT ISSUED FOR
THESE REMARKS ARE NOT A PART OF THE SPECIFICATION. THE REVISED REVIEW/COMMENTS
PAGES BECOME PART OF THE ORIGINAL SPECIFICATION AND SHALL BE TENDER/QUOTATION
COMPLETED WITHIN THEIR ENTIRELY. PURCHASE X
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. GLAZING
CAIRO - EGYPT 08800 - 2036 0

CONTENTS
SECTION 08800
GLAZING
Page
PART 1 GENERAL 2
1.2 Summary 2
1.4 Submittals 2
PART 2 PRODUCTS 3
2.1 Glass Products 3
2.4 Glazing Gaskets 3
2.5 Glazing Sealants 4
2.5 Miscellaneous Glazing Materials 4
2.6 Fabrication Of Glazing Units 5
PART 3 EXECUTION 5
3.1 Glazing 5
Glazing Section 08800

[
SECTION 08800
GLAZING
PART 1 GENERAL
1.2 SUMMARY
1.2.1 This Section includes glazing for windows.
1.3.1 General: Provide glazing systems capable of withstanding normal thermal

movement and wind and impact loads (where applicable) without failure, includ-
ing loss or glass breakage attributable to the following: defective manufacture,
fabrication, and installation; failure of sealants or gaskets to remain watertight
and airtight; deterioration of glazing materials; or other defects in construction.
- Glass Thicknesses: Select minimum glass thicknesses to comply with

ASTM E 1300, according to the following requirements:
 Design Wind Loads: Egyptian code of practice for calculating loads an

forces in structural and building works, ministerial decree 367/2003; basic
pressure equal to 100 kg/sq.m.
 Minimum Glass Thickness for Exterior Lites: Not less than 6.0 mm.
1.3.2 Thermal Movements: Provide glazing that allows for thermal movements result-
ing from the following maximum change (range) in ambient and surface tempera-
tures acting on glass framing members and glazing components. Base engineer-
ing calculation on surface temperatures of materials due to both solar heat gain
and nighttime-sky heat loss.
- Temperature Change (Range): 35 deg C, ambient; 60 deg C, material surfaces.

1.4 SUBMITTALS
1.4.1 Product Data: For each glass product and glazing material indicated.
1.4.2 Samples: 300-mm square, for each type of glass product indicated, other than
monolithic clear float glass.
1.5.1 Single Source Responsibility for Glazing Accessories: Obtain glazing accessories

[
from one source for each product and installation method indicated.
1.5.2 Safety Glass: Category II materials complying with testing requirements in

16 CFR 1201 and ANSI Z97.1.
- Subject to compliance with requirements, permanently mark safety glass with cer-
tification label of Safety Glazing Certification Council or another certification agen-
cy acceptable to authorities having jurisdiction.
1.5.3 Glazing Publications: Comply with published recommendations of glass product

manufacturers.
1.6.1 Protect glazing materials according to manufacturer's written instructions and as

needed to prevent damage to glass and glazing materials from condensation,
temperature changes, direct exposure to sun, or other causes.
PART 2 PRODUCTS
2.1 GLASS PRODUCTS
2.1.1 Annealed Float Glass: ASTM C 1036, Type I (transparent flat glass), Quality-Q3; of
class indicated.
2.1.2 Body Tinted Float Glass: ASTM C1036 Type I Transparent glass, flat class 2 tinted
quality Q3, color of tinting will be brown, unless otherwise as indicated Drawings
2.1.3 Heat-Treated Float Glass: ASTM C 1048; Type I (transparent flat glass); Quality-
Q3; of class 1 (clear), kind, and condition indicated.
- Provide Kind FT (fully tempered) float glass.

- Provide Kind HS (heat-strengthened) float glass in place of annealed float glass
where needed to resist thermal stresses induced by differential shading of indi-
vidual glass lites and to comply with glass design requirements specified in Part 1
"Performance Requirements" Article.
- For uncoated glass, comply with requirements for Condition A.
- Fabrication Process: By horizontal (roller-hearth) process with roll-wave distortion

parallel to bottom edge of glass as installed, unless otherwise indicated.
2.4 GLAZING GASKETS
2.4.1 Dense Compression Gaskets: Molded or extruded gaskets of material indicated

below, complying with standards referenced with name of elastomer indicated
below, and of profile and hardness required to maintain watertight seal:
- EPDM, ASTM C 864.

[
2.4.2 Soft Compression Gaskets: Extruded or molded, closed-cell, integral-skinned
gaskets of material indicated below; complying with ASTM C 509, Type II, black;
and of profile and hardness required to maintain watertight seal:
- EPDM.
2.5 GLAZING SEALANTS
2.5.1 General: Provide products of type indicated, complying with the following re-
quirements:
- Compatibility: Select glazing sealants that are compatible with one another
and with other materials they will contact, including glass products, seals of in-
sulating-glass units, and glazing channel substrates, under conditions of service
and application, as demonstrated by sealant manufacturer based on testing
and field experience.
- Suitability: Comply with sealant and glass manufacturers' written instructions

for selecting glazing sealants suitable for applications indicated and for condi-
tions existing at time of installation.
- Colors of Exposed Glazing Sealants: As selected by Engineer from manufactur-

er's full range.
2.5.2 Elastomeric Glazing Sealants: Comply with ASTM C 920 and other requirements
indicated for each liquid-applied chemically curing sealant specified, including
those referencing ASTM C 920 classifications for type, grade, class, and uses relat-
ed to exposure and joint substrates.
- Single-Component Neutral-Curing Silicone Glazing Sealants :
 Type and Grade: S (single component) and NS (nonsag).
 Use Related to Exposure: NT (nontraffic).
 Uses Related to Glazing Substrates: M, G, A, and, as applicable to

glazing substrates indicated, O.
2.5 MISCELLANEOUS GLAZING MATERIALS
2.5.1 General: Provide products of material, size, and shape complying with referenced
glazing standard, requirements of manufacturers of glass and other glazing mate-
rials for application indicated, and with a proven record of compatibility with sur-
faces contacted in installation.
2.5.2 Cleaners, Primers, and Sealers: Types recommended by sealant or gasket manu-
facturer.
2.5.3 Setting Blocks: Elastomeric material with a Shore, Type A durometer hardness of
85, plus or minus 5.

[
2.5.5 Edge Blocks: Elastomeric material of hardness needed to limit glass lateral
movement (side walking).
2.5.6 Cylindrical Glazing Sealant Backing: ASTM C 1330, Type O (open-cell material), of
size and density to control glazing sealant depth and otherwise produce optimum
glazing sealant performance.
2.6 FABRICATION OF GLAZING UNITS
2.6.1 Fabricate glazing units in sizes required to glaze openings indicated for Project,
with edge and face clearances, edge and surface conditions, and bite complying
with written instructions of product manufacturer and referenced glazing publica-
tions, to comply with system performance requirements.
PART 3 EXECUTION
3.1 GLAZING
3.1.1 General: Comply with combined written instructions of manufacturers of glass,

gaskets, and other glazing materials, unless more stringent requirements are indi-
cated, including those in referenced glazing publications.
- Glazing channel dimensions, as indicated on Drawings, provide necessary bite on

glass, minimum edge and face clearances, and adequate sealant thicknesses,
with reasonable tolerances. Adjust as required by Project conditions during in-
stallation.
- Protect glass edges from damage during handling and installation. Remove
damaged glass from Project site and legally dispose of off Project site. Damaged
glass is glass with edge damage or other imperfections that, when installed,
could weaken glass and impair performance and appearance.
- Install setting blocks in sill rabbets, sized and located to comply with referenced
glazing publications, unless otherwise required by glass manufacturer. Set
blocks in thin course of compatible sealant suitable for heel bead.
- Do not exceed edge pressures stipulated by glass manufacturers for installing
glass lites.
- Provide spacers for glass lites where length plus width is larger than 1270 mm.
- Provide edge blocking where indicated or needed to prevent glass lites from
moving sideways in glazing channel, as recommended in writing by glass manu-
facturer and according to requirements in referenced glazing publications.
3.1.2 Gasket Glazing (Dry): Fabricate compression gaskets in lengths recommended by

gasket manufacturer to fit openings exactly, with allowance for stretch during in-
stallation.
- Insert soft compression gasket between glass and frame or fixed stop so it is se-
curely in place with joints miter cut and bonded together at corners.
- Center glass lites in openings on setting blocks and press firmly against soft com-
pression gasket by inserting dense compression gaskets formed and installed to
[
lock in place against faces of removable stops. Start gasket applications at cor-
ners and work toward centers of openings. Compress gaskets to produce a
weathertight seal without developing bending stresses in glass. Seal gasket
joints with sealant recommended by gasket manufacturer.
- Install gaskets so they protrude past face of glazing stops.
3.2.1 Protect exterior glass from damage immediately after installation by attaching
crossed streamers to framing held away from glass. Do not apply markers to glass
surface. Remove nonpermanent labels, and clean surfaces. Protect glass from
contact with contaminating substances resulting from construction operations,
including weld splatter. If, despite such protection, contaminating substances do
come into contact with glass, remove substances immediately as recommended
by glass manufacturer.
3.2.2 Remove and replace glass that is broken, chipped, cracked, or abraded or that is
damaged from natural causes, accidents, and vandalism, during construction pe-
riod.

[

ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. PORTLAND CEMENT PLASTER
CAIRO - EGYPT 09220 – 2039 0

CONTENTS
SECTION 09220
PORTLAND CEMENT PLASTER

Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
PART 2 PRODUCTS 3
2.1 Accessories 3
2.2 Plaster Materials 4
2.4 Plaster Mixes and Compositions 4
2.5 Mixing 5
PART 3 EXECUTION 5
3.1 Examination 5
3.2 Preparation for Plastering 5
3.3 Installation of Plastering Accessories 6
3.4 Plaster Application 6
3.5 Cutting and Patching 8
Portland Cement Plaster Section 09220

[
SECTION 09220
PORTLAND CEMENT PLASTER
PART 1 GENERAL
Section.
1.2 SUMMARY
- Portland cement plaster.
1.3 SUBMITTALS
1.3.4 Include similar Samples of material for joints and accessories involving color
selection.
1.3.5 Material Certificates: certificate signed by manufacturer for each kind of plaster
aggregate certifying that materials comply with requirements.
1.4.1 Mockups: Prior to installing plaster work, construct panels for each type of finish
and application required to verify selections made under Sample submittals and
to demonstrate aesthetic effects as well as qualities of materials and execution.
Build mockups to comply with the following requirements, using materials
indicated for final unit of Work.
1.4.2 Erect mockups 1200 by 1200 mm by full thickness in presence of Engineer using
materials, including lath, support system, and control joints, indicated for final
Work.
1.4.4 Retain and maintain mockups during construction in an undisturbed condition as

a standard for judging the completed Portland cement plaster Work.
1.4.5 When directed, remove mockups from Project site.
1.5.1 Deliver cementitious materials to Project site in original packages, containers, or

bundles, labeled with manufacturer's name, product brand name, and lot

[
number.
1.5.2 Store materials inside, under cover, and dry, protected from weather, direct
sunlight, surface contamination, aging, corrosion, and damage from construction
traffic and other causes.
1.6.1 Warm-Weather Requirements: Protect plaster against uneven and excessive

evaporation and from strong flows of dry air, both natural and artificial. Apply
and cure plaster as required by climatic and job conditions to prevent dry out
during cure period. Provide suitable coverings, moist curing, barriers to deflect
sunlight and wind, or combinations of these, as required.
1.6.2 Exterior Plaster Work: Do not apply plaster when ambient temperature is below
5 deg C.
1.6.3 Interior Plaster Work: Maintain at least 10 deg C temperature in areas to be

plastered for at least 48 hours before, during, and after application.
1.6.4 Ventilation: Provide natural or mechanical means of ventilation to properly dry

interior spaces after Portland cement plaster has cured.
1.6.5 Protect contiguous work from soiling and moisture deterioration caused by
plastering. Provide temporary covering and other provisions necessary to
minimize harmful spattering of plaster on other work.
PART 2 PRODUCTS
2.1 ACCESSORIES
2.1.1 General: Comply with material provisions of ASTM C 1063 and the requirements
indicated below; coordinate depth of accessories with thicknesses and number of
plaster coats required.
2.1.2 Galvanized Steel Components: Fabricated from zinc-coated (galvanized) steel

sheet complying with ASTM A 653M, Z90 minimum coating designation.
2.1.3 Metal Corner Reinforcement: Expanded, large-mesh, diamond-metal lath

fabricated from zinc-alloy or welded-wire mesh fabricated from 1.2-mm-
diameter, zinc-coated (galvanized) wire and specially formed to reinforce external
corners of Portland cement plaster on exterior exposures while allowing full
plaster encasement.
2.1.4 Cornerbeads: Small nose cornerbeads fabricated from the following metal, with
expanded flanges of large-mesh diamond-metal lath allowing full plaster
encasement.
 Galvanized Steel: Minimum 0.44 mm thick.

2.1.5 Casing Beads: Square-edged style, with expanded flanges of the following
material:

[
2.1.6 Control Joints: Prefabricated, of material and type indicated below:

 Two-Piece Type: Pair of casing beads with back flanges formed to provide slip-
joint action, adjustable for joint widths from 3 to 16 mm.
 Provide removable protective tape on plaster face of control joints.
2.1.7 Lath Attachment Devices: Material and type required by ASTM C 1063 for
installations indicated.
2.2 PLASTER MATERIALS
2.2.1 Portland Cement: Egyptian Standard Specifications (E.S.S.) No. 4756.
2.2.3 Plasticier: ASTM C260, air entraining admixtures as a workability aid.
2.2.4 Sand Aggregate for Base Coats: E.S.S. No. 1108, Table 1, Gradation for scratch
and base coats.
2.2.5 Aggregate for Finish Coats: Table 1, Gradation for finish coat.
 Natural sand, white in color.
2.3.1 Fiber for Base Coat: Alkaline-resistant glass or polypropylene fibers, 13 mm long,
free of contaminants, manufactured for use in Portland cement plaster.
2.3.2 Water for Mixing and Finishing Plaster: Potable.
2.3.3 Bonding Agent: ASTM C 932.
2.3.4 Acid-Etching Solution: Muriatic acid (10 percent solution of commercial

hydrochloric acid) mixed 1 part to not less than 6 nor more than 10 parts water.
2.3.5 Dash-Coat Material: 400 kg parts Portland cement to 1 m3 fine sand, mixed with
water to a mushy-paste consistency.
2.3.7 Steel drill screws complying with ASTM C 1002 for fastening metal lath to wood or
steel members less than 0.84 mm thick.
2.4 PLASTER MIXES AND COMPOSITIONS
2.4.1 General: Comply with Egyptian Standard.
2.4.2 Fiber Content: Add fiber to following mixes after ingredients have mixed at least 2
minutes. Comply with fiber manufacturer's written instructions but do not exceed
16 kg/cu. m of cementitious materials. Reduce aggregate quantities accordingly to
maintain workability.

[
2.4.3 One-Coat Work over Concrete Unit Masonry:
 Coat Mixes and Compositions: 200 Kg Portland cement per 1 m3 aggregate.

Aerating plasticiser as per manufacturer’s printed instructions.
2.4.4 Job-Mixed Coats: Proportion materials for finish coats in parts by volume for
cementitious materials and parts by volume per sum of cementitious materials to
comply with the following requirements:
Proportions using sand aggregates as indicated below:

 part Portland cement, 3 parts aggregate, aerating plasticiser as per
manufacturer’s printed instructions.
2.5 MIXING
2.5.1 Mechanically mix cementitious and aggregate materials for plasters to comply
with applicable referenced application standard. Hand mixing is not permitted.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine areas and substrates, with Installer present, and including welded
hollow-metal frames, cast-in anchors, and structural framing, for compliance with
requirements and other conditions affecting performance.
3.1.2 Protect adjacent work from soiling, spattering, moisture deterioration, and other
harmful effects caused by plastering.
3.1.3 Prepare solid-plaster bases that are smooth or that do not have the suction
capability required to bond with plaster according to ASTM C 926.
3.2 PREPARATION FOR PLASTERING
3.2.1 Clean plaster bases and substrates for direct application of plaster, removing
loose material and substances that may impair the Work.
3.2.2 Etch concrete and concrete unit masonry surfaces indicated for direct plaster
application. Scrub with acid-etching solution on previously wetted surface and
rinse thoroughly with clean water. Repeat application, if necessary, to obtain
adequate suction and mechanical bond of plaster (where dash coat, bonding
agent, or additive is not used).
3.2.3 Apply bonding agent on concrete and concrete unit masonry surfaces indicated
for direct plaster application; comply with manufacturer's written instructions for
application.
3.2.4 Apply dash coat on concrete surfaces indicated for direct plaster application.
Moist-cure dash coat for at least 24 hours after application and before plastering.
3.2.5 Install temporary grounds and screeds to ensure accurate rodding of plaster to

[
true surfaces; coordinate with scratch-coat work.
3.2.6 Surface Conditioning: Immediately before plastering, dampen concrete and

concrete unit masonry surfaces that are indicated for direct plaster application,
except where a bonding agent has been applied. Determine and apply amount of
moisture and degree of saturation that will result in optimum suction for
plastering.
3.2.7 Dissimilar Backgrounds: where rendering is to be continued without break across

joints between dissimilar solid backgrounds which are in the same plane and
rigidly bonded or tied together, cover joints with 150 mm wide strip of building
paper overlaid with 300mm wide galvanized steel lathing fixed with corrosion
resistant fasteners at not more than 600 mm centers along both edges.
3.2.8 Before starting preparation and applying plaster coats ensure that backgrounds
are secure, adequately true and level to achieve specified tolerances, free from
contamination and loose areas, reasonably dry and in a suitable condition to
receive specified coatings. Ensure also that all cutting, chasing, fixing of concealed
conduits, service outlets, fixing pads and the like and making good of the
background are completed.
3.3 INSTALLATION OF PLASTERING ACCESSORIES
3.3.1 Install according to ASTM C 1063 and at locations indicated on Drawings.
3.3.2 General: Comply with referenced lathing and furring installation standards for
provision and location of plaster accessories of type indicated. Miter or cope
accessories at corners; install with tight joints and in alignment. Attach
accessories securely to plaster bases to hold accessories in place and in alignment
during plastering. Install accessories of type indicated at following locations:
 External Corners: Install corner reinforcement at external corners.

 Terminations of Plaster: Install casing beads, unless otherwise indicated.
3.3.3 Control Joints: Install at locations indicated or, if not indicated, at locations
complying with the following criteria and approved by the Engineer:
 Where an expansion or contraction joint occurs in surface of construction

directly behind plaster membrane.
 Distance between Control Joints: Not to exceed 5.4 m in either direction or a
length-to-width ratio of 2-1/2 to 1.
 Wall Areas: Not more than 13 sq. m.
 Horizontal Surfaces: Not more than 9 sq. m in area.
 Where plaster panel sizes or dimensions change, extend joints full width or
height of plaster membrane.
3.4 PLASTER APPLICATION
3.4.1 Plaster Application Standard: Apply plaster materials, composition, and mixes to

[
comply with Egyptian Standards.
3.4.2 Do not use materials that are caked, lumpy, dirty, or contaminated by foreign
materials.
3.4.3 Do not use excessive water in mixing and applying plaster materials.
3.4.4 Flat Surface Tolerances: Do not deviate more than plus or minus 3 mm in 3 m
from a true plane in finished plaster surfaces, as measured by a 3-m straightedge
placed at any location on surface.
3.4.5 Full grout hollow-metal frames, bases, and similar work occurring in plastered
areas, with base-coat plaster material, and before lathing where necessary.
3.4.6 Sequence plaster application with installation and protection of other work so
that neither will be damaged by installation of other.
3.4.7 Plaster flush with frames and other built-in items or metal accessories that act as
a plaster ground, unless otherwise indicated.
3.4.8 Where interior plaster is not terminated at metal frame by casing beads, cut base
coat free from metal frame before plaster sets and groove finish coat at junctures
with metal.
3.4.9 Corners: Make internal corners and angles square; finish external corners flush
with corner beads on interior work, square and true with plaster faces on exterior
work.
3.4.10 Number of Coats: Excluding dash-coat, apply plaster of composition indicated, to

comply with the following requirements:
 One Coats: Over the following plaster bases:

 Concrete unit masonry.
 Concrete, cast-in-place or precast when surface condition complies with
ASTM C 926 for plaster bonded to solid base.
3.4.11 Finish Coats: Apply finish coats to comply with the following requirements:
 Float Finish: Apply finish coat to a minimum thickness of 3 mm to completely

cover base coat, uniformly floated to a true even plane with fine-textured
finish matching Engineer's sample.
3.4.12 Total thickness of plaster: Excluding dash-coat, apply plaster to the following total
thickness:
 Internal Plaster: 15 mm.

 External Plaster: 20 mm.
 One plaster base coat (15 mm thick) for walls to be finished with tiles set with
thin bed adhesive.

[
3.4.13 Moist-cure plaster base and finish coats to comply with ASTM C 926.
3.4.14 If dubbing out is necessary to correct inaccuracies, dub out in thicknesses of not
more than 10 mm in same mix as undercoat; total thickness of dubbing must not
exceed 25 mm unless otherwise approved. Comb surface of each dubbing out
coat as specified; allow each coat to dry before the next is applied.
3.4.15 Combed Surfaces are to be for base coat covered with tiles. Carry out as the base
coat stiffeners using a suitable comb to produce evenly spaced wavy horizontal
and 4 mm deep to provide a key.
3.5 CUTTING AND PATCHING
3.5.1 Cut, patch, replace, repair, and point up plaster as necessary to accommodate
other work. Repair cracks and indented surfaces. Point-up finish plaster surfaces
around items that are built into or penetrate plaster surfaces. Repair or replace
work to eliminate blisters, buckles, check cracking, dry outs, efflorescence,
excessive pinholes, and similar defects. Repair or replace work as necessary to
comply with required visual effects.
3.6.1 Remove temporary covering and other provisions made to minimize spattering of
plaster on other work. Promptly remove plaster from door frames, windows, and
other surfaces not to be plastered. Repair surfaces stained, marred or otherwise
damaged during plastering work. When plastering work is completed, remove
unused materials, containers, equipment, and plaster debris.

Engineer, that ensure plaster work is without damage or deterioration at the time
of Taking Over by the Employer.

[

ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. GYPSUM BOARD
CAIRO - EGYPT 09260 – 2039 0
ECG Form No. E409 Rev. 5/0 Sheet 0of 10

CONTENTS
SECTION 09260
GYPSUM BOARD
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Storage And Handling 3
PART 2 PRODUCTS 3
2.1 Panels, General 3
2.2 Interior Gypsum Board 4
2.3 Cement Board Ceiling 4
2.4 Trim Accessories 4
2.5 Steel Partition And Soffit Framing 5
2.6 Joint Treatment Materials 6
2.7 Auxiliary Materials 7
PART 3 EXECUTION 7
3.1 Examination 7
3.2 Applying And Finishing Panels, General 7
3.3 Applying Interior Gypsum Board 8
3.4 Applying Exterior Cement Board For Ceilings And Soffits 9
3.5 Installing Trim Accessories 9
3.6 Finishing Gypsum Board 9
3.7 Protection 9
Gypsum Board Section 09260

SECTION 09260
GYPSUM BOARD
PART 1 GENERAL
Section.
1.2 SUMMARY
 Gypsum board for suspended ceilings.

 Cement board for suspended ceiling.
 Fire rated gypsum partitions.
1.3 SUBMITTALS
1.3.2 Samples: For the following products:
 Trim Accessories: Full-size sample in 300-mm- long length for each trim accessory
indicated.
 Finishes: Manufacturer's standard size for each finish indicated and on same
backing indicated for Work.
1.3.3 Product Certificates: Signed by manufacturers of gypsum board assembly

components certifying that their products comply with specified requirements.
1.3.4 Installer Certificates: Signed by the product manufacturer certifying that the
Installer is approved, authorized, or licensed by the manufacturer to install his
products.
1.3.5 Installer Experience: List of five projects (minimum) of a similar nature carried out
successfully by the installer with the same product endorsed by the
manufacturer’s representative.
1.3.6 Product Test Report.
1.4.1 Mockups: Before beginning gypsum board installation, install mockups of at least
9 sq. m in surface area to demonstrate aesthetic effects and set quality standards
for materials and execution.

 Install mockups for the following applications:
 Each level of gypsum board finish indicated for use in exposed locations.
 Each texture finish indicated.
 Apply or install final decoration indicated, including painting and wall coverings, on
exposed surfaces for review of mockups.
 Simulate finished lighting conditions for review of mockups.
 Approved mockups may become part of the completed Work if undisturbed at time
1.4.2 Installer Qualifications: A qualified firm specializing in performing the work of this
Section with minimum ten years documented experience and that is approved,
authorized, or licensed by the product manufacturer to install his product and
that is eligible to receive manufacturer's warranty. Include project names and
addresses, names and addresses of Engineers and Employers, and other
information specified
1.4.3 Single-Source Responsibility: Except where specified otherwise, obtain gypsum

board products, trim, joint treatment, and accessories from single manufacturer
or from manufacturers recommended by prime manufacturer of gypsum board
products.
1.5 STORAGE AND HANDLING
1.5.1 Store materials inside under cover and keep them dry and protected against
damage from weather, condensation, direct sunlight, construction traffic, and
other causes. Stack panels flat to prevent sagging.
1.6.1 Environmental Limitations: Comply with ASTM C 840 requirements or gypsum

board manufacturer's written recommendations, whichever are more stringent.
1.6.2 Do not install interior products until installation areas are enclosed and
conditioned.
1.6.3 Do not install panels that are wet, those that are moisture damaged, and those
that are mold damaged.
 Indications that panels are wet or moisture damaged include, but are not limited to,
discoloration, sagging, or irregular shape.
 Indications that panels are mold damaged include, but are not limited to, fuzzy or
splotchy surface contamination and discoloration.
PART 2 PRODUCTS
2.1 PANELS, GENERAL
2.1.1 Size: Provide in maximum lengths and widths available that will minimize joints in

each area and that correspond with support system indicated.
2.2 INTERIOR GYPSUM BOARD
2.2.1 General: Complying with ASTM C 36/C 36M or ASTM C 1396/C 1396M, as
applicable to type of gypsum board indicated and whichever is more stringent.
2.2.2 Regular Type:
 Thickness: 12.7 mm, unless otherwise indicated

 Long Edges: Tapered.
2.2.3 Type X:
 Thickness: To comply with the required fire rating, but not less than 15.9 mm
 Location: As indicated on Drawings
2.2.4 Moisture- and Mold-Resistant Type: With moisture- and mold-resistant core and
surfaces.
 Core: 12.5 mm.

2.3 CEMENT BOARD CEILING
2.3.1 General: Cementitious, water durable, surfaced with fiberglass reinforcing mesh,
complying with ANSI A118.9 and ASTM C 1325, suitable for exterior applications.
2.3.2 Long Edges: Wrapped.
2.3.3 Thickness: 13 mm, unless otherwise indicated on Drawings.
2.3.4 Water Absorption: 10% maximum, according to ASTM C473.
2.3.5 Flexural Strength: 5 MPa, according to ASTM C947.
2.3.6 Surface Burning Characteristics: According to E84.
 Smoke index: 0
 Flame spread index: 5
2.4 TRIM ACCESSORIES
2.4.1 Interior Trim: ASTM C 1047.
 Material: Galvanized or aluminum-coated steel sheet or rolled zinc.

 Shapes:
 Corner bead.

 Bullnose bead.
 LC-Bead: J-shaped; exposed long flange receives joint compound.
 L-Bead: L-shaped; exposed long flange receives joint compound.
 U-Bead: J-shaped; exposed short flange does not receive joint compound.
 Expansion (control) joint.
 Curved-Edge Corner bead: With notched or flexible flanges.
2.4.2 Exterior Trim: ASTM C 1047.
 Material: Hot-dip galvanized steel sheet or rolled zinc.

 Shapes:
 Cornerbead.
 LC-Bead: J-shaped; exposed long flange receives joint compound.
 Expansion (Control) Joint: One-piece, rolled zinc with V-shaped slot and
removable strip covering slot opening.
2.5 STEEL PARTITION AND SOFFIT FRAMING
2.5.1 Components, General: As follows:
 Comply with ASTM C 754 for conditions indicated.

 Steel Sheet Components: Complying with ASTM C 645 requirements for metal and
with ASTM A 653/A 653M, Z180, hot-dip galvanized zinc coating.
2.5.2 Steel Studs and Runners: ASTM C 645.
 Minimum Base Metal Thickness: 0.45 mm, unless otherwise recommended by

manufacture.
 Depth: As required to obtain thickness indicated on Drawings.
2.5.3 Deep-Leg Deflection Track: ASTM C 645 top runner with 50.8-mm deep flanges.
2.5.4 Proprietary Deflection Track: Steel sheet top runner manufactured to prevent
cracking of gypsum board applied to interior partitions resulting from deflection
of structure above; in thickness indicated for studs and in width to accommodate
depth of studs.
2.5.5 Proprietary Firestop Track: Top runner manufactured to allow partition heads to
expand and contract with movement of the structure while maintaining continuity
of fire-resistance-rated assembly indicated; in thickness not less than indicated for
studs and in width to accommodate depth of studs.
2.5.6 Flat Strap and Backing Plate: Steel sheet for blocking and bracing in length and
width indicated.

manufacture.

2.5.7 Cold-Rolled Channel Bridging: 1.37-mm bare steel thickness, with minimum 12.7-
mm wide flange.
 Depth: As indicated, but not less than 38.1 mm.

 Clip Angle: 38.1 by 38.1 mm, 1.73-mm thick, galvanized steel.

manufacture.
2.5.9 Resilient Furring Channels: 12.7-mm deep, steel sheet members designed to
reduce sound transmission.
 Configuration: Asymmetrical or hat shaped.
2.5.10 Cold-Rolled Furring Channels: 1.37-mm bare steel thickness, with minimum 12.7-
mm wide flange.

 Furring Brackets: Adjustable, corrugated-edge type of steel sheet with minimum
bare steel thickness of 0.79 mm.
 Tie Wire: ASTM A 641/A 641M, Class 1 zinc coating, soft temper, 1.59-mm diameter
2.5.11 Z-Shaped Furring: With slotted or non-slotted web, face flange of 31.8 mm, wall
attachment flange of 22.2 mm, minimum bare metal thickness of 0.45 mm, and
depth required to fit insulation thickness indicated.
2.5.12 Fasteners for Metal Framing: Of type, material, size, corrosion resistance, holding
power and other properties required to fasten steel members to substrates.
2.5.13 Resilient Hanger/Clips: Should have sufficient capacity to sustain continuously

applied ceiling without settling after initial deflection.
 Acoustic hangers are to be anti-vibration, corrosion resistant, incorporate high-

deflection steel springs and resilient molded neoprene noise and vibration isolation
pad. Springs and neoprene pads shall be incorporated into a stamped steel hanger
assembly which support isolated ceiling.
 Acoustical Performance: As recommended by manufacturer for sound proof ceiling.
 The isolation hanger deflection shall be as recommended by the manufacturer.
 Extent of Work: Suspended ceiling below the light train via duct
2.6 JOINT TREATMENT MATERIALS
2.6.1 General: Comply with requirements of ASTM C 475and manufacturer’s

recommendations.

2.6.2 Joint Tape:
 Interior Gypsum Wallboard: Paper.

 Glass-Mat Gypsum Sheathing Board: 10-by-10 glass mesh.
 Tile Backing Panels: As recommended by panel manufacturer.
2.6.3 Joint Compound for Interior Gypsum Wallboard: For each coat use formulation
that is compatible with other compounds applied on previous or for successive
coats.
 Prefilling: At open joints, rounded or beveled panel edges, and damaged surface
areas, use setting-type taping compound.
 Embedding and First Coat: For embedding tape and first coat on joints, fasteners,
and trim flanges, use drying-type, all-purpose compound.
 Fill Coat: For second coat, use drying-type, all-purpose compound.
 Finish Coat: For third coat, use setting-type, sandable topping compound.
 Skim Coat: For final coat of Level 5 finish, use setting-type, sandable topping
compound.
2.7 AUXILIARY MATERIALS
2.7.1 General: Provide auxiliary materials that comply with referenced installation
standards and manufacturer's written recommendations.
2.7.2 Steel Drill Screws: ASTM C 1002, unless otherwise indicated:
 Use screws complying with ASTM C 954 for fastening panels to steel members from
0.84 to 2.84 mm thick.
 For fastening cementitious backer units, use screws of type and size recommended
by panel manufacturer.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine areas and substrates, with Installer present, and including welded
hollow-metal frames and framing, for compliance with requirements and other
conditions affecting performance.
3.1.2 Examine panels before installation. Reject panels that are wet, moisture
damaged, and mold damaged.
corrected.
3.2 APPLYING AND FINISHING PANELS, GENERAL
3.2.1 Comply with ASTM C 840.

3.2.2 Install ceiling panels across framing to minimize the number of abutting end joints
and to avoid abutting end joints in central area of each ceiling. Stagger abutting
end joints of adjacent panels not less than one framing member.
3.2.3 Install panels with face side out. Butt panels together for a light contact at edges
and ends with not more than 1.5 mm of open space between panels. Do not
force into place.
3.2.4 Locate edge and end joints over supports, except in ceiling applications where
intermediate supports or gypsum board back-blocking is provided behind end
joints. Do not place tapered edges against cut edges or ends. Stagger vertical
joints on opposite sides of partitions. Do not make joints other than control joints
at corners of framed openings.
3.2.5 Form control and expansion joints with space between edges of adjoining gypsum
panels.
3.2.6 Cover both faces of support framing with gypsum panels in concealed spaces
(above ceilings, etc.), except in chases braced internally.
 Unless concealed application is indicated or required for sound, fire, air, or smoke
ratings, coverage may be accomplished with scraps of not less than 0.7 sq. m in area.
 Fit gypsum panels around ducts, pipes, and conduits.
 Where partitions intersect structural members projecting below underside of
floor/roof slabs and decks, cut gypsum panels to fit profile formed by structural
members; allow 6.4- to 9.5-mm wide joints to install sealant.
3.2.7 Isolate perimeter of gypsum board applied to non-load-bearing partitions at

structural abutments, except floors. Provide 6.4- to 12.7-mm wide spaces at
these locations, and trim edges with edge trim where edges of panels are
exposed. Seal joints between edges and abutting structural surfaces with
acoustical sealant.
3.2.8 Attachment to Steel Framing: Attach panels so leading edge or end of each panel
is attached to open (unsupported) edges of stud flanges first.
3.3 APPLYING INTERIOR GYPSUM BOARD
3.3.1 Install interior gypsum board in locations as indicated on Drawings.
3.3.2 Single-Layer Application:
 On ceilings, apply gypsum panels before wall/partition board application to greatest

extent possible and at right angles to framing, unless otherwise indicated.
 At stairwells and other high walls, install panels horizontally, unless otherwise
indicated or required by fire-resistance-rated assembly.
 On Z-furring members, apply gypsum panels vertically (parallel to framing) with no
end joints. Locate edge joints over furring members.
 Fastening Methods: Apply gypsum panels to supports with steel drill screws.

3.4 APPLYING EXTERIOR CEMENT BOARD FOR CEILINGS AND SOFFITS
3.4.1 Apply boards perpendicular to supports, with end joints staggered and located
over supports.
 Install with 6.4-mm open space where boards abut other construction or structural
penetrations.
 Fasten with corrosion-resistant screws.
3.5 INSTALLING TRIM ACCESSORIES
3.5.1 General: For trim with back flanges intended for fasteners, attach to framing with
same fasteners used for boards. Otherwise, attach trim according to
manufacturer's written instructions.
3.5.2 Control Joints: Install control joints according to ASTM C 840 and in specific
locations approved by Engineer for visual effect.
3.6 FINISHING GYPSUM BOARD
3.6.1 General: Treat gypsum board joints, interior angles, edge trim, control joints,
penetrations, fastener heads, surface defects, and elsewhere as required to
prepare gypsum board surfaces for decoration. Promptly remove residual joint
compound from adjacent surfaces.
3.6.2 Prefill open joints, rounded or beveled edges, and damaged surface areas.
3.6.3 Apply joint tape over gypsum board joints, except those with trim having flanges
not intended for tape.
3.6.4 Gypsum Board Finish: Taped seamless finish as follows:
 Level 1: Ceiling plenum areas, concealed areas, and where indicated.

 Level 2: Panels that are substrate for tile and Where indicated.
 Level 5:
 Primer and its application to surfaces are specified in other Division 09

Sections.
3.6.5 Cement Board Finish: Primer and its application to surfaces are specified in other
Division 09 Sections.
3.7 PROTECTION
3.7.1 Protect installed products from damage from weather, condensation, direct
sunlight, construction, and other causes during remainder of the construction
period.
3.7.2 Remove and replace panels that are wet, moisture damaged, and mold damaged.
 Indications that panels are wet or moisture damaged include, but are not limited to,

discoloration, sagging, or irregular shape.
 Indications that panels are mold damaged include, but are not limited to, fuzzy or
splotchy surface contamination and discoloration.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. CERAMIC TILE
CAIRO - EGYPT 09310 – 2039 0

CONTENTS
SECTION 09310
CERAMIC TILE
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Definitions 2
1.4 Submittals 2
PART 2 PRODUCTS 4
2.1 Products, General 4
2.2 Tile Products 5
2.3 Setting Materials 5
2.4 Grouting Materials 5
2.5 Elastomeric Sealants 6
2.7 Mixing Mortars and Grout 6
PART 3 EXECUTION 6
3.1 Examination 6
3.2 Preparation 7
3.4 Wall Tile Installation 8
3.6 Ceramic Tile Wall Installation Schedule 9
Ceramic Tile Section 09310

SECTION 09310
CERAMIC TILE
PART 1 GENERAL
Supplementary Conditions and Division 1, Specification Sections, apply to this
Section.
1.2 SUMMARY
 Glazed wall tile.

 Division 7 Section "Joint Sealants" for sealing of expansion, contraction,

control, and isolation joints in tile surfaces.
 Division 9 Section "Portland Cement Plaster" for Portland cement. Plaster
under ceramic tiles.
1.3 DEFINITIONS
1.3.1 Module Size: Actual tile size (minor facial dimension as measured per
ASTM C 499) plus joint width indicated.
1.3.2 Facial Dimension: Actual tile size (minor facial dimension as measured per
ASTM C 499).
1.4 SUBMITTALS
1.4.1 Product Data: For each type of tile, mortar, grout, and other products specified.
1.4.2 Shop Drawings: For the following:
 Tile patterns and locations.

 Widths, details, and locations of expansion, contraction, control, and isolation
joints in tile substrates and finished tile surfaces.
1.4.3 Tile Samples for Initial Selection: Manufacturer's color charts consisting of actual
tiles or sections of tiles showing the full range of colors, textures, and patterns
available for each type and composition of tile indicated. Include Samples of
accessories involving color selection.
1.4.4 Grout Samples for Initial Selection: Manufacturer's color charts consisting of
actual sections of grout showing the full range of colors available for each type of
grout indicated.

1.4.5 Samples for Verification: Of each item listed below, prepared on Samples of size
and construction indicated. Where products involve normal color and texture
variations, include Sample sets showing the full range of variations expected.
 Each type and composition of tile and for each color and texture required, at
least 300 mm square, mounted on braced cementitious backer units, and with
grouted joints using product complying with specified requirements and
approved for completed work in color or colors selected by Engineer.
 Full-size units of each type of trim and accessory for each color required.
1.4.7 Tile Test Reports: Indicate and interpret test results for compliance of special-
purpose tile with specified requirements.
1.4.8 Setting Material Test Reports: Indicate and interpret test results for compliance
of tile-setting and -grouting products with specified requirements.
1.5.1 Manufacture Qualifications: Manufacture with experience of successful

production of products and systems similar to scope of this Project, with a record
of successful in-service performance and completion of projects with sufficient
production capability, facility, and personal to produce required Work.
1.5.2 Installer Qualifications: Engage an experienced installer who has completed tile
installations similar in material, design, and extent to that indicated for this
Project and with a record of successful in-service performance.
1.5.3 Source Limitations for Tile: Obtain each color, grade, finish, type, composition,
and variety of tile from one source with resources to provide products from the
same production run for each contiguous area of consistent quality in appearance
and physical properties without delaying the Work.
1.5.4 Source Limitations for Setting and Grouting Materials: Obtain ingredients of a
uniform quality for each mortar, adhesive, and grout component from a single
manufacturer and each aggregate from one source or producer.
1.5.5 Mockups: Before installing tile, construct mockups for each form of construction
and finish required to verify selections made under Sample submittals and to
demonstrate aesthetic effects and qualities of materials and execution. Build
mockups to comply with the following requirements, using materials indicated for
completed Work.
 Locate mockups in the location and of the size as directed by Engineer.

 Notify the Engineer 7 days in advance of the dates and times when mockups
will be constructed.
 Demonstrate the proposed range of aesthetic effects and workmanship.
 Obtain Engineer’s approval of mockups before proceeding with final unit of
Work

 Maintain mockups during construction in an undisturbed condition as a
standard for judging the completed Work.
 When directed, demolish and remove mockups from Project site.
 Approved mockups in an undisturbed condition at the time of Substantial
Completion may become part of the completed Work.
1.6.1 Deliver and store packaged materials in original containers with seals unbroken
and labels intact until time of use.
1.6.2 Handle tile with temporary protective coating on exposed surfaces to prevent
coated surfaces from contacting backs or edges of other units. If coating does
contact bonding surfaces of tile, remove coating from bonding surfaces before
setting tile.
PART 2 PRODUCTS
2.1 PRODUCTS, GENERAL
2.1.1 ANSI Tile Standard: Unless otherwise reference is made to other standard
specifications, provide tile that complies with ANSI A137.1, "Specifications for
Ceramic Tile," for types, compositions, and other characteristics indicated.
 Provide tile complying with Standard Grade requirements, unless otherwise

indicated.
 For facial dimensions of tile, comply with requirements relating to tile sizes
specified in Part 1 "Definitions" Article.
2.1.2 ANSI Standards for Tile Installation Materials: Provide materials complying with
ANSI standards referenced in "Setting Materials" and "Grouting Materials"
articles.
2.1.3 Colors, Textures, and Patterns: Where manufacturer's standard products are
indicated for tile, grout, and other products requiring selection of colors, surface
textures, patterns, and other appearance characteristics, provide specific products
or materials complying with the following requirements:
 Provide Engineer's selections from manufacturer's full range of colors,

textures, and patterns for products of type indicated.
 Provide tile trim and accessories as selected by the Engineer from
manufacturer’s full range.
2.1.4 All tiles are to be of keyed back surfaces.

2.2 TILE PRODUCTS
2.2.1 Glazed Wall Tile: Provide flat tile complying with the following requirements:
 Module Size: As indicated on Drawings.

 Water Absorption: 3%<E≤6%,
 Thickness: minimum 6.00 mm.
 Face: Plain with modified square edges or cushion edges.
 Surface Finish: mutt
2.2.2 Base Units: Provide tile trim units to match characteristics of adjoining flat tile
and to comply with the following requirements:
 Size: As indicated, coordinated with sizes and coursing of adjoining flat tile
where applicable.
 Shapes: street
2.3 SETTING MATERIALS
2.3.1 Portland Cement Mortar (Thickset) Installation Materials: Provide materials

complying with ANSI A108.1A and as specified below:
 Latex additive (water emulsion) described below, serving as replacement for

part or all of gauging water, of type specifically recommended by latex additive
manufacturer for use with job-mixed Portland cement and aggregate mortar
bed.
 Latex Additive: Styrene butadiene rubber.
 Cement: Ordinary Portland to E.S.S. No. 4756

 Sand: E.S.S. No. 1108, Natural, grading similar to grading for masonry mortar
included in Table No. 1.
 Mortar Mix: Job-mixed cement-sand mortar consisting of 1 part ordinary
Portland cement and 3-4 parts sand (by volume). Use Latex Additive as per
manufacturer’s printed recommendations.
 Latex-Modified Portland Cement Slurry Bond Coat: Proportion and mix
Portland cement, aggregate, and latex additive for slurry bond coat to comply
with latex additive manufacturer's written instruction.
2.4 GROUTING MATERIALS
2.4.1 General: Color of grout material shall be selected by the Engineer from
manufacturer's full range.
2.4.2 Chemical-Resistant, Water-Cleanable, Tile-Setting and -Grouting Epoxy:

ANSI A118.3

2.5 ELASTOMERIC SEALANTS
2.5.1 General: Provide manufacturer's standard chemically curing, elastomeric sealants

of base polymer and characteristics indicated that comply with applicable
requirements of Division 7 Section "Joint Sealants."
2.5.2 Colors: Provide colors of exposed sealants to match colors of grout in tile
adjoining sealed joints, unless otherwise indicated.
2.6.1 Tile Cleaner: A neutral cleaner capable of removing soil and residue without
harming tile and grout surfaces, specifically approved for materials and
installations indicated by tile and grout manufacturers.
2.6.2 Trowelable Underlayments and Patching Compounds: Latex-modified, Portland-

cement-based formulation provided or approved by manufacturer of tile-setting
materials for installations indicated.
2.7 MIXING MORTARS AND GROUT
2.7.1 Mix mortars and grouts to comply with referenced standards and mortar and
grout manufacturers' written instructions.
2.7.2 Add materials, water, and additives in accurate proportions.
2.7.3 Obtain and use type of mixing equipment, mixer speeds, mixing containers,
mixing time, and other procedures to produce mortars and grouts of uniform
quality with optimum performance characteristics for installations indicated.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine substrates, areas, and conditions where tile will be installed, with
Installer present, for compliance with requirements for installation tolerances and
other conditions affecting performance of installed tile.
 Verify that substrates for setting tile are firm; dry; clean; free from oil, waxy
films, and curing compounds; and within flatness tolerances required by
referenced ANSI A108 series of tile installation standards for installations
indicated.
 Verify that installation of grounds, anchors, recessed frames, electrical and
mechanical units of work, and similar items located in or behind tile has been
completed before installing tile.
 Verify that joints and cracks in tile substrates are coordinated with tile joint
locations; if not coordinated, adjust latter in consultation with Engineer.
3.1.2 Do not proceed with installation until unsatisfactory conditions have been
corrected.

3.2 PREPARATION
3.2.1 Remove coatings, including curing compounds, and other substances that contain
soap, wax, oil, or silicone and are incompatible with tile-setting materials by using
a terrazzo or concrete grinder, a drum sander, or a polishing machine equipped
with a heavy-duty wire brush.
3.2.2 Provide substrates for wall tile installed latex-Portland cement mortars that
comply with flatness tolerances specified in referenced ANSI A108 series of tile
installation standards for installations indicated.
 Use cement plaster, with expanded mesh reinforcement where necessary, and
patching compounds per tile-setting material manufacturer's written
instructions to fill cracks, holes, and depressions.
3.2.3 Field-Applied Temporary Protective Coating: Where indicated under tile type or
needed to prevent grout from staining or adhering to exposed tile surfaces,
precoat them with continuous film of temporary protective coating, taking care
not to coat unexposed tile surfaces.
3.3.1 ANSI Tile Installation Standards: Comply with parts of ANSI A108 series of tile
installation standards in "Specifications for Installation of Ceramic Tile" that apply
to types of setting and grouting materials and to methods indicated in ceramic tile
installation schedules.
3.3.2 Extend tile work into recesses and under or behind equipment and fixtures to
form a complete covering without interruptions, unless otherwise indicated.
Terminate work neatly at obstructions, edges, and corners without disrupting
pattern or joint alignments.
3.3.3 Accurately form intersections and returns. Perform cutting and drilling of tile
without marring visible surfaces. Carefully grind cut edges of tile abutting trim,
finish, or built-in items for straight aligned joints. Fit tile closely to electrical
outlets, piping, fixtures, and other penetrations so plates, collars, or covers
overlap tile.
3.3.4 Jointing Pattern: Lay tile in grid pattern, unless otherwise indicated or directed by
the Engineer. Align joints when adjoining tiles on walls, and trim are the same
size. Lay out tile work and center tile fields in both directions in each space or on
each wall area. Adjust to minimize tile cutting. Provide uniform joint widths,
3.3.5 Grout tile to comply with the requirements of the following tile installation
standards:
 For chemical-resistant epoxy grouts, comply with ANSI A108.6.
3.3.6 Coordination, General: Coordinate the work of ceramic tile inlay through natural
stone floors or facings with the work of adjoining stone paving or facing as
specified in Division 9, Section “Stone Paving and Flooring” or Section “Interior

Stone Facing”.
 Finish adjoining ceramic tiles and stone flooring perfectly flush.

3.4 WALL TILE INSTALLATION
3.4.1 Install types of tile designated for wall installations to comply with requirements
in the Ceramic Tile Wall Installation Schedule and ANSI A108 series of installation
standards.
3.4.2 Install metal base plaster coat over dash-coat to walls.
3.4.3 Joint Widths: Install tile on walls with the following joint widths:
 Wall Tile: 3.00 mm.

 Use Plastic spacers to maintain joint widths.
3.5.1 Cleaning: On completion of placement and grouting, clean all ceramic tile
surfaces so they are free of foreign matter.
 Remove latex-Portland cement grout residue from tile as soon as possible.

 Unglazed tile may be cleaned with acid solutions only when permitted by tile
and grout manufacturer's written instructions, but no sooner than 10 days
after installation. Protect metal surfaces, cast iron, and vitreous plumbing
fixtures from effects of acid cleaning. Flush surface with clean water before
and after cleaning.
 Remove temporary protective coating by method recommended by coating
manufacturer that is acceptable to brick and grout manufacturer. Trap and
remove coating to prevent it from clogging drains.
3.5.2 Finished Tile Work: Leave finished installation clean and free of cracked, chipped,
broken, unbonded, and otherwise defective tile work.

Engineer, that ensure tile is without damage or deterioration at the time of
Substantial Completion.
 When recommended by tile manufacturer, apply a protective coat of neutral

protective cleaner to completed tile walls. Protect installed tile work with kraft
paper or other heavy covering during construction period to prevent staining,
damage, and wear.
3.5.4 Before final inspection, remove protective coverings and rinse neutral cleaner
from tile surfaces.

3.6 CERAMIC TILE WALL INSTALLATION SCHEDULE
3.6.1 Install types of tile designated for wall installations to comply with TCA
installations methods and ANSI setting-bed standards. Install metal lath and
scratch coat to walls to comply with ANSI A108.1A, Section 4.1.
 Latex Portland Cement Mortar with Epoxy Grout over Cement Sand Plaster:
ANSI A108.1B


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. GYPSUM UNITS CEILINGS
CAIRO - EGYPT 09561 - 2039 0

CONTENTS
SECTION 09561
GYPSUM UNITS CEILINGS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.7 Coordination 4
PART 2 PRODUCTS 4
2.1 Gypsum Units 4
2.2 Metal Suspension Systems, General 4
2.3 Acoustical Sealant 5
PART 3 EXECUTION 5
3.1 Examination 5
3.2 Preparation 5
3.3 Installation 5
3.4 Cleaning 7
3.5 Gypsum Units Schedule 7
Gypsum Units Ceilings Section 09561

SECTION 09561
GYPSUM UNITS CEILINGS
PART 1 GENERAL
Section.
1.2 SUMMARY
 Ceilings consisting of panels fabricated from gypsum complete with

suspension systems.
 Division 15 and 16 Sections for Lighting Fixtures, Sprinklers and Air Distribution
Components.
1.3 SUBMITTALS
1.3.1 Product Data: For each type of product specified.
1.3.2 Coordination Drawings: Reflected ceiling plans drawn to scale and coordinating
penetrations and ceiling-mounted items. Show the following:
 Ceiling suspension system members.

 Method of attaching suspension system hangers to building structure.
 Initial direct-access openings.
 Ceiling-mounted items including light fixtures; air outlets and inlets; speakers;
sprinklers; and special moldings at walls, column penetrations, and other
junctures of acoustical ceilings with adjoining construction.
 Minimum Drawing Scale: 1:50.
1.3.3 Samples for Initial Selection: Manufacturer's color charts consisting of actual
gypsum units or sections of gypsum units, suspension systems, and moldings
showing the full range of colors, textures, and patterns available for each type of
ceiling assembly indicated.
1.3.4 Samples for Verification: Full-size units of each type of ceiling assembly indicated;
in sets for each color, texture, and pattern specified, showing the full range of
variations expected in these characteristics.
 Full-size samples of each type of gypsum units, pattern, and color.

 Set of 300-mm long samples of concealed suspension system members.
 Set of 300-mm long samples of exposed moldings for each color and system
type required.
1.3.5 Qualification Data: For firms and persons specified in "Quality Assurance" Article
to demonstrate their capabilities and experience. Include lists of completed
projects with project names and addresses, names and addresses of engineers
and employers, and other information specified.
1.3.6 Product Test Reports: Indicate compliance of gypsum units ceilings and
components with requirements based on comprehensive testing of current
products.
1.4.1 Installer Qualifications: Engage an experienced installer who has completed

gypsum units ceilings similar in material, design, and extent to that indicated for
this Project and with a record of successful in-service performance.
1.4.2 Source Limitations for Ceiling Units: Obtain each type of gypsum units tile from
one source with resources to provide products of consistent quality in
appearance and physical properties without delaying the Work.
1.4.3 Source Limitations for Suspension System: Obtain each suspension system from
one source with resources to provide products of consistent quality in
appearance and physical properties without delaying the Work.
 Obtain both gypsum ceiling units and suspension system from the same
manufacturer.
 Products are identified with appropriate markings of applicable testing and
inspecting agency.
1.5.1 Deliver gypsum units and suspension system components to Project site in
original, unopened packages and store them in a fully enclosed space where they
will be protected against damage from moisture, direct sunlight, surface
contamination, and other causes.
1.5.2 Before installing gypsum units, permit them to reach room temperature and a
stabilized moisture content.
1.5.3 Handle gypsum units carefully to avoid chipping edges or damaging units in any
way.
1.6.1 Environmental Limitations: Do not install gypsum units ceilings until spaces are
enclosed and weatherproof, wet-work in spaces is complete and dry, work above
ceilings is complete, and ambient temperature and humidity conditions are
maintained at the levels indicated for Project when occupied for its intended use.

1.7 COORDINATION
1.7.1 Coordinate layout and installation of acoustical tiles and suspension system with
other construction that penetrates ceilings or is supported by them, including
light fixtures, HVAC equipment, fire-suppression system, and partition assemblies.
PART 2 PRODUCTS
2.1 GYPSUM UNITS
2.1.1 Generally: systems are to be fully integrated with the mechanical and electrical
installations, including the provision of additional hangers, framing etc. and are to
be supplied complete with manufacturers' standard edge trims, accessories,
connectors, fixing clips and fixings.
2.1.2 Unit Characteristics: Comply with requirements indicated in the Gypsum Unit
Schedule at the end of Part 3.
2.2 METAL SUSPENSION SYSTEMS, GENERAL
2.2.1 Metal Suspension System Standard: Provide manufacturer's standard metal

suspension systems of types, structural classifications, and finishes indicated that
comply with applicable BS EN 13964 requirements.
2.2.2 Metal Suspension System Characteristics: Comply with requirements indicated in

the Acoustical Panel Ceiling Schedule at the end of Part 3.
2.2.3 Finishes and Colors, General: Provide manufacturer's standard factory-applied

finish for type of system indicated.
2.2.4 Attachment Devices: Size for five times design load indicated in ASTM C 635,
Table 1, Direct Hung, unless otherwise indicated.
 Postinstalled Anchors in Concrete: Anchors of type and material indicated

below, with holes or loops for attaching hangers of type indicated and with
capability to sustain, without failure, a load equal to five times that imposed
by ceiling construction, as determined by testing per ASTM E 488, conducted
by a qualified testing and inspecting agency.
 Type: Postinstalled expansion anchors.
 Corrosion Protection: Carbon-steel components zinc plated to comply with
ASTM B 633, Class Fe/Zn 5 (0.005 mm) for Class SC service condition (mild).
2.2.5 Adjustable Hangers: Manufacturer’s standard fabricated from corrosion-resistant

material.
2.2.6 Sheet-Metal Edge Moldings and Trim: Type and profile indicated or, if not
indicated, manufacturer's standard moldings for edges and penetrations that fit
acoustical tile edge details and suspension systems indicated; formed from sheet
metal of same material and finish as that used for exposed flanges of suspension
system runners.

 For circular penetrations of ceiling, provide edge moldings fabricated to
diameter required to fit penetration exactly.
2.3 ACOUSTICAL SEALANT
2.3.1 Acoustical Sealant for Exposed and Concealed Joints: Manufacturer's standard
nonsag, paintable, nonstaining latex sealant complying with BS EN ISO 11600 and
the following requirements:
 Product is effective in reducing airborne sound transmission through

perimeter joints and openings in building construction as demonstrated by
testing representative assemblies according BS EN ISO 140.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine substrates and structural framing to which gypsum units ceilings attach
or abut, with Installer present, for compliance with requirements specified in this
and other Sections that affect ceiling installation and anchorage, and other
conditions affecting performance of acoustical tile ceilings.
corrected.
3.2 PREPARATION
3.2.1 Measure each ceiling area and establish layout of acoustical tiles to balance
border widths at opposite edges of each ceiling. Avoid using less-than-half-width
units at borders, and comply with layout shown on reflected ceiling plans.
3.3 INSTALLATION
3.3.1 General: Install gypsum units ceilings to comply with standards referenced below
per manufacturer's written instructions.
 Standard for Ceiling Suspension System Installations: Comply with BS EN

13964.
3.3.2 Suspend ceiling hangers from building's structural members and as follows:
 Install hangers plumb and free from contact with insulation or other objects
within ceiling plenum that are not part of supporting structure or of ceiling
suspension system.
 Splay hangers only where required to miss obstructions; offset resulting
horizontal forces by bracing, countersplaying, or other equally effective
means.
 Splay hangers only where required and, if permitted with fire-resistance-rated
ceilings, to miss obstructions; offset resulting horizontal forces by bracing,

countersplaying, or other equally effective means.
 Where width of ducts and other construction within ceiling plenum produces
hanger spacings that interfere with location of hangers at spacings required to
support standard suspension system members, install supplemental
suspension members and hangers in form of trapezes or equivalent devices.
Size supplemental suspension members and hangers to support ceiling loads
within performance limits established by referenced standards and
publications.
 Secure hangers to ceiling suspension members and to supports above with a
minimum of three tight turns. Connect hangers directly either to structures or
to inserts, eye screws, or other devices that are secure; that are appropriate
for substrate; and that will not deteriorate or otherwise fail due to age,
corrosion, or elevated temperatures.
 Do not support ceilings directly from permanent metal forms or floor deck.
Fasten hangers to drilled-in anchors that extend through into concrete.
 Do not attach hangers to steel deck tabs.
 Do not attach hangers to steel roof deck. Attach hangers to structural
members.
 Space hangers as recommended by manufacturers in his printed instructions.
3.3.3 Secure bracing wires to ceiling suspension members and to supports with a
minimum of four tight turns. Suspend bracing from building's structural members
as required for hangers, without attaching to permanent metal forms, steel deck,
or steel deck tabs. Fasten bracing wires into concrete with postinstalled anchors.
3.3.4 Install edge moldings and trim of type indicated at perimeter of acoustical tile
ceiling area and where necessary to conceal edges of acoustical units.
 Apply acoustical sealant in a continuous ribbon concealed on back of vertical

legs of moldings before they are installed.
 Screw attach moldings to substrate at intervals not more than 400 mm o.c.
and not more than 75 mm from ends, leveling with ceiling suspension system
to a tolerance of 3 mm in 3.6 m. Miter corners accurately and connect
securely.
 Do not use exposed fasteners, including pop rivets, on moldings and trim.
3.3.5 Install suspension system runners so they are square and securely interlocked
with one another. Remove and replace dented, bent, or kinked members.
3.3.6 Arrange directionally patterned acoustical tiles as follows:
 As indicated on reflected ceiling plans.
3.3.7 Install gypsum units in coordination with suspension system and exposed
moldings and trim. For concealed suspension systems.
 Fit adjoining tile to form flush, tight joints. Scribe and cut tile for accurate fit

at borders and around penetrations through tile.
 Fabricate access units for special suspension system access members and tile
units modified as required to allow for removal of access units.
 Protect lighting fixtures and air ducts to comply with requirements indicated
for fire-resistance-rated assembly.
3.4 CLEANING
3.4.1 Clean exposed surfaces of tile ceilings, including trim, edge moldings, and
suspension system members. Comply with manufacturer's written instructions for
cleaning and touchup of minor finish damage. Remove and replace tiles and
other ceiling components that cannot be successfully cleaned and repaired to
permanently eliminate evidence of damage.
3.5 GYPSUM UNITS SCHEDULE
3.5.1 Gypsum Tile Suspended Ceilings: are to be gypsum-based tiles complying with BS
EN 520 Type A and the following:
 Surface Pattern and Treatment: Plain, unperforated or perforated, finished on

exposed surface with water-based paint.
 Color: White.
 Light Reflectance Coefficient: LR Not less than 0.82.
 Moisture Resistance: Not affected by normal levels of humidity up to 70%.
2
 Weight: 10.00 Kg/m , maximum.
 Edge Detail: Square.
 Thickness: 12.50 mm for tiles.
 Tile size: 600 x 600 mm, unless otherwise indicated.
3.5.2 Moisture-Resistant Gypsum Panel Suspended Ceilings: are to be gypsum based

panels complying with the following:
 Surface Pattern and Treatment: BS EN 520 Type H, plain, solid (imperforated),

machine laminated on exposed face with fissured vinyl face and on back with
polyethylene foil
 Color: White.
 Light Reflectance Coefficient: LR Not less than 0.82.
 Moisture Resistance: Max deflection of 1: 350 at 90% relative humidity at 25
C.
2
 Weight: 10.00 Kg/m , maximum.
 Edge Detail: Square
 Thickness: 12.50 mm.
 Size: 600 x 600 mm, unless otherwise indicated..

3.5.3 Suspension system is to be indirect-hung suspension system, exposed suspension
system main and cross runners roll formed from cold-rolled steel sheet,
prepainted, electrolytically zinc coated, or hot-dip galvanized according to
manufacturer’s standard method, other characteristics as follows:
 Structural Classification: heavy-duty system.

 Carrying Channels: Cold-rolled steel, 1.52 mm minimum base (uncoated) metal
thickness, 15 mm wide flanges minimum by 38-mm deep steel channels, 0.707
kg/m minimum hot-dip galvanized according to Z180 coating designation.
 Finish: Manufacturer’s standard baked-on coating on exposed parts, of color
as selected by the Engineer


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. STONE PAVING AND FLOORING
CAIRO - EGYPT 09638 – 2039 0
ECG Form No. E409 Rev. 5/0 Sheet 0of 11

CONTENTS
SECTION 09638
STONE PAVING AND FLOORING
Page
PART 1 GENERAL 2
1.2 Summary 2
1.4 Submittals 2
PART 2 PRODUCTS 4
2.1 Stone, General 4
2.2 Stone Types 5
2.3 Stone Thresholds 5
2.4 Mortar Materials 5
2.5 Grout 6
2.6 Accessories 6
2.7 Stone Fabrication 6
2.8 Mortar And Grout Mixes 7
PART 3 EXECUTION 8
3.1 Examination 8
3.2 Preparation 8
3.4 Installation Tolerances 9
3.5 Installing Stone 9
3.6 Installing Stone Thresholds 10
3.7 Grouting of Stone Paving and Flooring 10
3.9 Protection 11
Stone Paving and Flooring Section 09638

SECTION 09638
STONE PAVING AND FLOORING
PART 1 GENERAL
Section.
1.2 SUMMARY
 Stone flooring.
 Stone landing.
 Stone stair treads and risers.
 Stone thresholds.
 Stone bases.
1.3.1 Stone Abrasion Resistance: Minimum abrasive-hardness value of 12, as

determined per ASTM C 241.
1.3.2 Static Coefficient of Friction: ASTM C 1028, values as follows:
 Level Surfaces: A minimum of 0.6.

 Step Treads: A minimum of 0.6.
1.4 SUBMITTALS
1.4.1 Product Data: For each variety of stone, stone accessory, and other manufactured
products specified.
 For stone varieties proposed for use on Project, include data on physical properties
required by referenced ASTM standards.
1.4.2 Shop Drawings: Show details of fabrication and installation of stone paving and
flooring, including dimensions and profiles of stone units; arrangement and details
of jointing; and details showing relationship with, attachment to, and reception of
related work.
 Include large-scale details of decorative surfaces and inscriptions.
1.4.3 Grout Samples for Initial Selection: Manufacturer's standard samples of actual
products showing the full range of colors available.

1.4.4 Stone Samples for Verification: Sets for each color, grade, finish, and variety of
stone required; not less than 300 mm square. Include 2 or more samples in each
set showing the full range of variations in appearance characteristics expected in
completed Work.
engineers and employers, and other information specified.
1.4.6 Maintenance Data: For stone paving and flooring to include in the maintenance
manuals specified in the Special Conditions of the Contract. Include Product Data
for stone-care products used or recommended by Installer and the names,
addresses, and telephone numbers of local sources for products.
1.5.1 Installer Qualifications: Engage an experienced installer who has completed stone
paving and flooring similar in material, design, and extent to that indicated for
Project that has resulted in construction with a record of successful in-service
performance.
1.5.2 Fabricator Qualifications: Engage a firm experienced in producing stone paving

and flooring similar to that indicated for this Project and with a record of
successful in-service performance, as well as sufficient production capacity to
produce required units without delaying the Work.
1.5.3 Source Limitations for Stone: Obtain each variety of stone, regardless of finish,
from a single quarry with resources to provide materials of consistent quality in
appearance and physical properties and to cut and finish material without
delaying the Work.
 Obtain each variety of stone from a single quarry, whether specified in this Section
or in another Section of the Specifications.
1.5.4 Source Limitations for Other Materials: Obtain each type of cementitious
material, grout, admixture, stone accessory, sealant, and other material from a
single manufacturer for each product.
1.5.5 Mockups: Before installing stone paving and flooring, construct mockups to verify
selections made under Sample submittals and to demonstrate aesthetic effects
and qualities of materials and execution. Build mockups to comply with the
following requirements, using materials indicated for completed Work.
 Locate mockups in the location indicated or as directed by Engineer.

 Build mockups approximately 2400 mm square.
 Maintain mockups during construction in an undisturbed condition as a standard for
judging the completed Work.

 Approval of mockups does not constitute approval of deviations from
Contract Documents contained in mockups, unless such deviations are
specifically approved by Engineer in writing.
 When directed, demolish and remove mockups from Project site.
 Approved mockups in an undisturbed condition at the time of Substantial
Completion may become part of the completed Work.
1.6.1 Deliver materials to Project site in undamaged condition.
1.6.2 Store and handle stone and related materials to prevent deterioration or damage
due to moisture, temperature changes, contaminants, corrosion, breaking,
chipping, or other causes.
1.6.3 Store stone on wood A-frames or pallets with nonstaining separators and
nonstaining, waterproof covers. Ventilate under covers to prevent condensation.
1.6.4 Store cementitious materials on elevated platforms, under cover, and in a dry
location. Do not use cementitious materials that have become damp.
1.7.1 Do not set stone flooring when air temperature or material temperature is below
10 deg C.
1.7.2 Hot-Weather Requirements for Stone Paving: Protect stone paving when
temperature and humidity conditions produce excessive evaporation of setting
beds and grout. Provide artificial shade and windbreaks and use cooled materials
as required. Do not apply mortar to substrates with temperatures of 38 deg C and
above.
PART 2 PRODUCTS
2.1 STONE, GENERAL
2.1.1 Match samples approved by the Engineer for variety, color, finish, and other stone
characteristics relating to aesthetic effects. Types of stone are indicated in
Finishing Tables and on Drawings.
 Where 2 or more stone types listed in the Stone Schedule are identical except for
finish, provide the same variety from the same source for each type.
2.1.2 Provide stone that is free of cracks, seams, and starts impairing structural integrity
or function.
2.1.3 Provide stone from a single quarry for each variety of stone required.

 Provide matched blocks extracted from contiguous locations in a single bed of quar-
ry stratum unless stone from blocks randomly selected for aesthetic effect is ap-
proved by Engineer.
2.1.4 Quarry stone in a manner to ensure as-quarried block orientations yield finished
stone with required characteristics.
2.1.5 Make quarried blocks available for examination by Engineer for appearance
characteristics.
2.2 STONE TYPES
2.2.1 Granite: Provide granite complying with ASTM C 615.
2.3 STONE THRESHOLDS
2.3.1 General: Provide stone thresholds free of cracks, seams, and starts impairing
structural integrity or function and from one source for each stone type and
quality specified.
2.3.2 Size and Profile: As indicated or required to provide transition between adjacent
floor finishes.
2.4 MORTAR MATERIALS
2.4.1 Portland cement: E.S.S. 4756 for natural color and E.S.S. 1031 for white, or a
blend to produce mortar color indicated.
2.4.2 Aggregate: E.S.S. 1108 and as indicated below:
 For joints narrower than 6 mm, use aggregate graded with 100 percent passing 1.18-
mm sieve.
 For pointing mortar, use aggregate graded with 100 percent passing 1.18-mm sieve.
 White-Mortar Aggregates: Natural, white sand or ground, white stone.
 Colored-Mortar Aggregates: Natural, colored sand or ground marble, granite, or
other sound stone, as required to match Engineer's sample.
2.4.3 Mortar Pigments: BS EN 12878, natural and synthetic iron oxides and chromium
oxides, compounded for use in mortar mixes. Use only pigments with record of
satisfactory performance in stone mortars.
2.4.4 Latex additive (water emulsion) described below, serving as replacement for part
of or all gauging water, of type specifically recommended by latex-additive
manufacturer for use with job-mixed portland cement mortar and not containing
a retarder.
 Latex Additive: Styrene-butadiene rubber.

2.5 GROUT
2.5.1 Grout Colors: As selected by Engineer from manufacturer's full range.
2.5.2 Latex-Portland Cement Grout: ANSI A118.6, for materials described in

Paragraph H-2.4, composed as follows:
 Mixture of Dry-Grout Mix and Latex Additive: Mixture of factory-prepared, dry-grout

mix and latex additive complying with the following requirements:
 Unsanded Dry-Grout Mix: Dry-set grout complying with ANSI A118.6.
 Latex Additive: Styrene-butadiene rubber.
2.5.3 Chemical-Resistant, Water-Cleanable, Tile-Grouting Epoxy: ANSI A118.3, non-

staining.
2.6 ACCESSORIES
2.6.1 Setting Shims: Resilient plastic shims, non staining to stone, sized to suit joint
thicknesses.
2.6.2 Divider Strips and Edging: Metal or combination of metal and PVC or neoprene
base, designed specifically for flooring applications, in longest lengths available,
and as follows:
 Exposed-Edge Material: Stainless steel; ASTM A 666, Type 302, unless otherwise in-
dicated on Drawings.
 Height: Equal to stone thickness plus depth of setting bed.
 Width: 1.5 mm.
 Control-Joint Filler: Neoprene, in color selected by Engineer from manufacturer's full
range.
2.6.3 Cork Joint Filler: Preformed strips complying with ASTM D 1752, Type II.
2.6.4 Cleaner: Provide stone cleaners specifically formulated for stone types, finishes,
and applications indicated as recommended by stone producer and sealer
manufacturer if a sealer is specified, by sealer manufacturer. Do not use cleaning
compounds containing acids, caustics, harsh fillers, or abrasives.
2.6.5 Floor Sealer: Colorless, slip- and stain-resistant sealer not affecting color or
physical properties of stone surfaces, as recommended by stone producer for
application indicated.
2.6.6 Sealants: Comply with Division 7, Section “Joint Sealants”.
2.6.7 Abrasive Strips: Silicon carbide or aluminum oxide in epoxy-resin binder.
2.7 STONE FABRICATION

2.7.1 General: Fabricate stone paving and flooring in sizes and shapes required to
comply with requirements indicated, including details on Drawings and Shop
Drawings.
2.7.2 Cut stone to fit stone pattern as indicated on Drawings and Shop Drawings.
Produce units to minimize field cutting for thickness, face sizes, and within
fabrication tolerances recommended by applicable stone association or, if none,
by stone source.
 Thickness of Stone Units: Provide thickness indicated, but not less than thickness
recommended by stone manufacturer or supplier and the following unless other-
wise indicated on Drawings:
 Nominal thickness for flooring and stair landing: 20 mm.
 Nominal thickness for stair treads: 40 mm
 Nominal thickness for stair risers: 20 mm
 Nominal thickness for bases: 20 mm.
 Nominal Thickness threshold: 20/ 40 mm, location of each thickness to be
as indicated on Drawings.
 Stone Edges: As follows:
 Square for floor tiles or slabs.

 Comply with details indicated on Drawings or approved shop drawings: for
bases, treads and risers.
 Cut stone to produce joints of uniform width and in locations indicated.
 Joint Width: 1.5 mm, unless otherwise indicated.

 Clean sawn backs of stones to remove rust stains and iron particles.
2.7.3 Carefully inspect finished stone units at fabrication plant for compliance with
requirements for appearance, material, and fabrication. Replace defective units.
 Grade and mark stone for overall uniform appearance when assembled in place.
Natural variations in appearance are acceptable if installed stone units match range
of colors and other appearance characteristics represented in approved samples and
mockups.
2.7.4 Finish exposed faces and edges of stone to comply with requirements indicated
for finish under each type of stone required and to match approved samples and
mockups.
 Polished Finish: Grind exposed surfaces and edges in the workshop to a high luster
with reflection.
2.8 MORTAR AND GROUT MIXES
2.8.1 General: Comply with referenced standards and with manufacturers' written
instructions for mix proportions, mixing equipment, mixer speeds, mixing
containers, mixing time, and other procedures needed to produce mortar and

grout of uniform quality and with optimum performance characteristics.
 Do not use admixtures, including pigments, air-entraining agents, accelerators, re-

tarders, water-repellent agents, or other admixtures, unless otherwise indicated. Do
not use calcium chloride.
 Mixing: Combine and thoroughly mix cementitious materials, water, and aggregates
in a mechanical batch mixer, unless otherwise indicated. Discard mortar and grout
when they have reached initial set.
2.8.2 Latex-Modified-Portland Cement Setting-Bed Mortar: Proportion and mix

Portland cement, aggregate, and latex additive for setting bed to comply with
latex additive manufacturer's written instructions and as necessary to produce
stiff mixture with a moist surface when bed is ready to receive stone. Minimum
cement content shall be 30 kg per each cubic meter of sand. For latex-modified-
Portland cement setting-bed mortar, substitute latex admixture for part or all of
water according to latex additive manufacturer's written instructions.
2.8.3 Cement-Paste Slush Coat: Mix slush coat to a consistency similar to that of thick
cream and consisting of either neat cement and water or cement, sand, and
water.
 Latex-Modified Portland Cement Slurry Bond Coat: Proportion and mix Portland
cement, aggregate, and latex additive for slurry bond coat to comply with latex addi-
tive manufacturer’s written instructions.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine surfaces to receive stone paving and flooring and conditions under which
stone will be installed, with Installer present, for compliance with requirements
for installation tolerances and other conditions affecting performance of stone
paving and flooring.
 For the record, prepare written report, endorsed by Installer, listing conditions det-
rimental to performance of stone paving and flooring.
 Do not proceed with installation until unsatisfactory conditions have been corrected.
3.2 PREPARATION
3.2.1 Vacuum clean concrete substrates to remove dirt, dust, debris, and loose
particles.
3.2.2 Remove substances from concrete substrates that could impair mortar bond,
including curing and sealing compounds, form oil, and laitance.
3.2.3 Clean stone surfaces that have become dirty or stained by removing soil, stains,
and foreign materials before setting. Clean stone by thoroughly scrubbing with
fiber brushes and then drenching with clear water. Use only mild cleaning
compounds that contain no caustic or harsh materials or abrasives.

3.3.1 Execute stone paving and flooring installation by skilled mechanics and employ
skilled stone fitters at the site to do necessary field cutting as stone is set.
3.3.2 Use power saws to cut stone. Produce lines cut straight and true, with edges
eased slightly to prevent snipping.
3.3.3 Set stone to comply with Drawings and Shop Drawings. Match for color and
pattern by using units numbered in sequence as indicated on Shop Drawings.
3.3.4 Scribe and field-cut stone as necessary to fit at obstructions. Produce tight and
neat joints.
3.3.5 Expansion- and Control-Joint Installation: Locate and install according to Drawings
and Shop Drawings. Joint-sealant materials and installation are specified in
Division 7 Section "Joint Sealants."
3.4 INSTALLATION TOLERANCES
3.4.1 Variation in Line: For position shown in plan for edges of steps or treads, changes
in color or finish, and continuous joint lines, do not exceed 3 mm in 2400 mm, 6
mm in 6 m, or 10 mm maximum.
3.4.2 Variation in Surface Plane of Flooring: Do not exceed 3 mm in 3 m, 6 mm in 6 m,

or 10 mm maximum from level or slope indicated, gradual variation.
3.4.3 Variation in Joint Width: Do not vary joint thickness more than 1.5 mm or one-
fourth of the nominal joint width, whichever is less.
3.4.4 Variation in Plane between Adjacent Units (Lipping): Do not exceed 0.8-mm
difference between planes of adjacent units.
3.5 INSTALLING STONE
3.5.1 Saturate substrate with clean water several hours before placing setting bed.
Remove surface water about one hour before placing setting bed.
3.5.2 Apply cement-paste slush coat over surface of substrate about 15 minutes before
placing setting bed. Limit area of slush coat to avoid its drying out before placing
setting bed. Do not exceed 1.5-mm thickness for cement-paste slush coat.
3.5.3 Apply mortar setting bed over cement-paste slush coat immediately after slush
coat has been applied. Spread and screed setting bed to uniform thickness at sub
grade elevations required for accurate setting of stone to finished grades
indicated.
3.5.4 Mix and place only as much mortar setting bed as can be covered with stone
before initial set. Cut back, bevel edge, remove, and discard setting-bed material
that has reached initial set before placing stone.

3.5.5 Place stone before initial set of cement occurs. Immediately before placing stone
on setting bed, apply uniform 1.5-mm- thick, slurry bond coat to bed or to back of
each stone unit with a flat trowel.
3.5.6 Tamp and beat stone with a wooden block or rubber mallet to obtain full contact
with setting bed and to bring finished surfaces within indicated tolerances. Set
each unit in a single operation before initial set of mortar; do not return to areas
already set and disturb stone for purposes of realigning finished surfaces or
adjusting joints.
3.5.7 Point joints after setting. Fill full with mortar type and color indicated. Tool joints
flat, uniform, and smooth, without visible voids.
3.5.8 Movement (Control) Joints in Floors: Divide floor areas into controllable bays with
movement (Control) joints as recommended in BS 5385: Part 1, unless otherwise
indicated on Drawings. Also install movement joints around columns, stairs, lift
wells and wherever movement is anticipated including at junctions with walls.
3.5.9 Expansion Joints: Provide expansion joints in stone floors at same locations as
joints in the under laying slabs on grade or structural slabs. Comply with details
indicated on Drawings and requirements of Division 5, Section “Architectural Joint
Systems”.
3.6 INSTALLING STONE THRESHOLDS
3.6.1 At locations adjacent to stone flooring, install stone thresholds in same type of
setting bed as abutting stone flooring, unless otherwise indicated.
 Set thresholds in thin-set, latex-Portland cement mortar at locations where mortar

bed would otherwise be exposed above other adjacent flooring.
3.6.2 At locations not adjacent to stone flooring, cut back and discard any setting bed
material from the other finish side and leave mortar surface uniform with surface
of threshold.
3.7 GROUTING OF STONE PAVING AND FLOORING
3.7.1 Grout stone joints to comply with ANSI A108.10 and manufacturer's written
instructions.
 Do not use sanded grout for polished stone.

 Use epoxy grouting in wet areas.
3.7.2 Grout joints as soon as possible after initial set of setting bed. Force grout into
joints, taking care not to smear grout on adjoining stone and other surfaces. After
initial set of grout, finish joints by tooling to produce a slightly concave polished
joint, free of drying cracks.
3.7.3 Cure grout by maintaining in a damp condition for seven days except as otherwise
recommended by latex-additive manufacturer.

3.8.1 Remove and replace stone paving and flooring of the following description:
 Broken, chipped, stained, or otherwise damaged stone. Stone may be repaired if

methods and results are approved by Engineer.
 Defective joints.
 Stone paving, flooring, and joints not matching approved samples and mockups.
 Stone paving and flooring not complying with other requirements indicated.
3.8.2 Replace in a manner that results in stone paving and flooring's matching approved
samples and mockups, complying with other requirements, and showing no
evidence of replacement.
3.8.3 In-Progress Cleaning: Clean stone paving and flooring as work progresses.
Remove mortar fins and smears before tooling joints.
3.8.4 Clean stone paving and flooring after setting and pointing are complete. Use
procedures recommended by stone fabricator for types of application.
3.8.5 Apply sealer to cleaned stone flooring according to sealer manufacturer's written
instructions.
3.9 PROTECTION
3.9.1 Prohibit traffic from installed stone for a minimum of 72 hours.
3.9.2 Protect stone paving and flooring during construction with non staining Kraft
paper. Where adjoining areas require construction work access, cover stone
paving and flooring with a minimum of 19-mm untreated plywood over non
staining Kraft paper.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. RESILIENT FLOOR TILE
CAIRO - EGYPT 09651 – 2039 0

CONTENTS
SECTION 09651
RESILIENT FLOOR TILE

Page
PART 1 GENERAL 2
1.1 Summary 2
1.2 Submittals 2
PART 2 PRODUCTS 2
2.1 Solid Vinyl Floor Tile 2
2.2 Installation Materials 3
PART 3 EXECUTION 3
3.1 Preparation 3
3.2 Installation 4
Resilient Floor Tile

SECTION 09651
RESILIENT FLOOR TILE
PART 1 GENERAL
1.1 SUMMARY
 Solid vinyl floor tile.
1.2 SUBMITTALS
1.2.1 Product Data: For each product indicated.
1.2.2 Samples: Full-size units of each color and pattern of resilient floor tile required.
1.3.1 Maintain temperatures within range recommended by manufacturer, but not less
than (21 deg C or more than 35 deg C, in spaces to receive floor tile during the
following time periods:
 48 hours before installation.

 During installation.
 48 hours after installation.
1.3.2 After post installation period, maintain temperatures within range recommended
by manufacturer, but not less than 13 deg C or more than 35 deg C.
1.3.3 Close spaces to traffic during floor covering installation.
1.3.4 Close spaces to traffic for 48 hours after floor covering installation.
1.3.5 Install resilient products after other finishing operations, including painting, have
been completed.
PART 2 PRODUCTS
2.1 SOLID VINYL FLOOR TILE
2.1.1 Comply with ASTM F 1700 and the following:
2.1.2 Color and Pattern: As selected by Engineer from manufacturer's full range
2.1.3 Class: I, Monolithic Vinyl Tile

 Type: A, Smooth Surface.
2.1.4 Thickness: 2.5 mm.
2.1.5 Size: 600X600 mm.
2.1.6 Fire-Test-Response Characteristics:
 Critical Radiant Flux Classification: Class I, not less than 0.45 W/sq. cm per
ASTM E 648.
2.2 INSTALLATION MATERIALS
2.2.1 Trowelable Leveling and Patching Compounds: Latex-modified, portland cement

based or blended hydraulic cement based formulation provided or approved by
resilient product manufacturer for applications indicated.
2.2.2 Adhesives: Water-resistant type recommended by manufacturer to suit resilient

products and substrate conditions indicated.
PART 3 EXECUTION
3.1 PREPARATION
3.1.1 Prepare substrates according to manufacturer's written recommendations to

ensure adhesion of resilient products.
3.1.2 Concrete Substrates: Prepare according to ASTM F 710.
 Verify that substrates are dry and free of curing compounds, sealers, and hardeners.
 Alkalinity and Adhesion Testing: Perform tests recommended by manufacturer.
Proceed with installation only after substrates pass testing.
 Moisture Testing:
 Perform tests recommended by manufacturer. Proceed with installation

only after substrates pass testing.
3.1.3 Remove substrate coatings and other substances that are incompatible with
adhesives and that contain soap, wax, oil, or silicone, using mechanical methods
recommended by manufacturer. Do not use solvents.
3.1.4 Use trowelable leveling and patching compound to fill cracks, holes, and
depressions in substrates.
3.1.5 Move resilient products and installation materials into spaces where they will be
installed at least 48 hours in advance of installation.
 Do not install resilient products until they are same temperature as space where
they are to be installed.

3.1.6 Sweep and vacuum clean substrates to be covered by resilient products
immediately before installation. After cleaning, examine substrates for moisture,
alkaline salts, carbonation, and dust. Proceed with installation only after
unsatisfactory conditions have been corrected.
3.2 INSTALLATION
3.2.1 Lay out tiles from center marks established with principal walls, discounting minor
offsets, so tiles at opposite edges of room are of equal width. Adjust as necessary
to avoid using cut widths that equal less than one-half tile at perimeter.
 Lay tiles as indicated pattern on Drawings.
3.2.2 Match tiles for color and pattern by selecting tiles from cartons in the same
sequence as manufactured and packaged, if so numbered. Discard broken,
cracked, chipped, or deformed tiles.
3.2.3 Scribe, cut, and fit tiles to butt neatly and tightly to vertical surfaces and
permanent fixtures including built-in furniture, cabinets, pipes, outlets, edgings,
door frames, thresholds, and nosings.
3.2.4 Extend tiles into toe spaces, door reveals, closets, and similar openings.
3.2.5 Maintain reference markers, holes, and openings that are in place or marked for
future cutting by repeating on floor tiles as marked on substrates. Use chalk or
other nonpermanent, nonstaining marking device.
3.2.6 Install tiles on covers for telephone and electrical ducts and similar items in
finished floor areas. Maintain overall continuity of color and pattern with pieces
of tile installed on covers. Tightly adhere tile edges to substrates that abut covers
and to cover perimeters.
3.2.7 Adhere tiles to flooring substrates using a full spread of adhesive applied to
substrate to produce a completed installation without open cracks, voids, raising
and puckering at joints, telegraphing of adhesive spreader marks, and other
surface imperfections.
3.2.8 Perform the following operations immediately after completing resilient product
installation:
 Remove adhesive and other blemishes from exposed surfaces.

 Sweep and vacuum surfaces thoroughly.
 Damp-mop surfaces to remove marks and soil.
 Do not wash surfaces until after time period recommended by

manufacturer.

3.2.9 Protect resilient products from mars, marks, indentations, and other damage from
construction operations and placement of equipment and fixtures during
remainder of construction period. Use protection methods recommended in
writing by manufacturer.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. RESINOUS FLOORING
CAIRO - EGYPT 09671 - 2039 0

CONTENTS
SECTION 09671
RESINOUS FLOORING
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.7 Warranty 3
PART 2 PRODUCTS 4
2.1 Self Leveling High Performance Epoxy Floor 4
2.2 Accessory Materials 4
PART 3 EXECUTION 4
3.1 Preparation 4
3.2 Application 5
3.4 Cleaning And Protecting 6
Resinous Flooring Section 09671

SECTION 09671
RESINOUS FLOORING
PART 1 GENERAL
1.2 SUMMARY
 High performance polyurethane floor coating.
1.3 SUBMITTALS
1.3.1 Product Data: For each type of product specified. Include manufacturer's tech-
nical data, installation instructions, and recommendations for each resinous floor-
ing component required.
1.3.2 Installer Certificates: Signed by product manufacturer certifying that Installer is

approved, authorized, or licensed by manufacturer to install his products.
of colors, textures, and patterns available for each resinous flooring system indi-
cated.
1.3.4 Samples for Verification: Of each resinous flooring system required, 150 mm
square, applied by Installer for this Project to a rigid backing, in color, texture, and
finish indicated. Where finishes involve normal color and texture variations, in-
clude Sample sets showing the full range of variations expected.
1.3.5 Material Test Reports: From a qualified independent testing agency indicating
and interpreting test results of the resinous flooring's reaction to chemicals and
other reagents and substantiating compliance with requirements.
1.3.6 Maintenance Data: For resinous flooring to include in the maintenance manuals
specified in Division 1.
1.4.1 Manufacture Qualifications: Engage a manufacture experienced with the success-

ful production of the specified work similar in design, material and extent to the
scope of this Project, and with a record of successful in-service performance and
completion or projects for a period of not less than 5 years, as well as, sufficient
production capability, facilities, and personnel, to produce the required work.
1.4.2 Installer Qualifications: Engage an experienced installer (applicator) who has spe-
cialized in installing resinous flooring similar in material, design, and extent to that
indicated for this Project and who is acceptable to resinous flooring manufacturer.
 Engage an installer who employs only persons trained and approved by resinous
flooring manufacturer for installing resinous flooring systems specified.
 Engage an installer who is certified in writing by resinous flooring manufacturer as
qualified to install resinous flooring systems specified.
1.4.3 Source Limitations: Obtain primary resinous flooring materials, including primers,
resins, hardening agents, and sealing or finish coats, through one source from a
single manufacturer. Provide secondary materials including patching and fill mate-
rial, joint sealant, and repair materials of type and from source recommended by
manufacturer of primary materials.
1.5.1 Deliver materials in original packages and containers, with seals unbroken, bear-
ing manufacturer's labels indicating brand name and directions for storage and
mixing with other components.
1.5.2 Store materials to comply with manufacturer's written instructions to prevent de-
terioration from moisture, heat, cold, direct sunlight, or other detrimental effects.
1.6.1 Environmental Limitations: Comply with resinous flooring manufacturer's written

instructions for substrate temperature, ambient temperature, moisture, ventila-
tion, and other conditions affecting resinous flooring installation.
1.6.2 Lighting: Provide permanent lighting or, if permanent lighting is not in place,
simulate permanent lighting conditions during resinous flooring installation.
1.6.3 Close spaces to traffic during resinous flooring application and for not less than 24
hours after application, unless manufacturer recommends a longer period.
1.7 WARRANTY
1.7.1 General Warranty: The special warranty specified in this Article shall not deprive
Employer of other rights Employer may have under other provisions of the Con-
tract Documents and shall be in addition to, and run concurrent with, other war-
ranties made by Contractor under requirements of the Contract Documents.
1.7.2 Special Warranty: Submit a written warranty, executed by the manufacturer,

agreeing to repair or replace resinous flooring that fail in materials, finishes or
workmanship within specified warranty period. Failures include, but are not lim-
ited to, the following:
 Failure in adhesion to substrate.

 Failure to provide required performance.
 Deterioration of finish beyond normal weathering.
 Chipping.

1.7.3 Warranty Period: Three years from date of Substantial Completion.
PART 2 PRODUCTS
2.1 SELF LEVELING HIGH PERFORMANCE EPOXY FLOOR
2.1.1 System Physical Properties: Provide resinous flooring system with the following
minimum physical property requirements when tested according to test methods
indicated:
 Compressive Strength: 92 MPa per ASTM C 579.
 Tensile Strength: 68 MPa per ASTM C 307.
 Flexural Modulus of Elasticity: 34 MPa per ASTM C 580.
 Water Absorption: 0% per ASTM C 413.
 Indentation: 6% percent maximum per MIL-D-3134.
 Impact Resistance: No chipping, cracking, or delamination and not more than 1.6-
mm permanent indentation per MIL-D-3134.
 Resistance to Elevated Temperature: No slip or flow of more than 1.6 mm per MIL-
D-3134.
 Abrasion Resistance: 0.070 gm maximum weight loss per ASTM D 4060.
 Flammability: Self-extinguishing per ASTM D 635.
 Hardness: 75-85, Shore D per ASTM D 2240.
 Thickness: min 1.00 mm.
2.2 ACCESSORY MATERIALS
2.2.1 Patching and Fill Material: Resinous product of or approved by resinous flooring
manufacturer and recommended by manufacturer for application indicated.
2.2.2 Joint Sealant: Type recommended or produced by resinous flooring manufacturer

for type of service and joint condition indicated. Comply with requirements as
specified in Division 7 Section “Joint Sealants”
PART 3 EXECUTION
3.1 PREPARATION
3.1.1 General: Prepare and clean substrate according to resinous flooring manufactur-
er's written instructions for substrate indicated. Provide clean, dry, and neutral
substrate for resinous flooring application.

3.1.2 Cement-Based Substrates: Provide sound cement-based surfaces free of laitance,
glaze, efflorescence, curing compounds, form-release agents, dust, dirt, grease,
oil, and other contaminates incompatible with resinous flooring.
 Concrete Substrates: Mechanically abrade concrete surfaces to a uniform profile ac-

cording to ASTM D 4259. Do not acid etch.
 Comply with ASTM C 811 requirements, unless manufacturer's written instructions
are more stringent.
 Repair damaged and deteriorated concrete according to resinous flooring manufac-
turer's written recommendations.
3.1.3 Resinous Materials: Mix components and prepare materials according to resinous
flooring manufacturer's written instructions.
3.1.4 Use patching and fill material to fill holes and depressions in substrates according
to manufacturer's written instructions.
3.1.5 Treat control joints and other nonmoving substrate cracks to prevent cracks from
reflecting through resinous flooring according to manufacturer's written recom-
mendations.
3.2 APPLICATION
3.2.1 General: Apply components of resinous flooring system according to manufactur-

er's written instructions to produce a uniform, monolithic wearing surface of
thickness indicated.
 Coordinate application of components to provide optimum adhesion of resinous

flooring system to substrate and optimum intercoat adhesion.
 Cure resinous flooring components according to manufacturer's written instructions.
Prevent contamination during application and curing processes.
 At substrate expansion and isolation joints, provide joint in resinous flooring to com-
ply with resinous flooring manufacturer's written recommendations.
 Apply joint sealant to comply with manufacturer's written recommenda-
tions.
3.2.2 Apply primer over prepared substrate at manufacturer's recommended spreading

rate.
3.2.3 Apply self-leveling slurry body coat(s) in thickness indicated.
3.2.4 Integral Cove Base: Apply cove base mix to wall surfaces at locations indicated.
Round internal and external corners. Install cove base according to manufactur-
er's written instructions and details including taping, mixing, priming, sanding, and
topcoating of cove base.
3.2.5 Apply sealing or finish coat(s), of type recommended by resinous flooring manu-
facturer to produce finish indicated. Apply in number of coats and at spreading
rates recommended in writing by manufacturer.

3.3.1 Material Sampling: Employer may at any time and any number of times during
flooring application require material samples for testing for compliance with re-
quirements.
 Employer will engage an independent testing agency to take samples of materials

being used. Material samples will be taken, identified and sealed, and certified in
presence of Contractor.
 Testing agency will test samples for compliance with requirements, using applicable
referenced testing procedures or, if not referenced, using testing procedures listed
in manufacturer's Product Data.
 If test results show installed materials do not comply with specified requirements,
pay for testing, remove noncomplying materials, prepare surfaces coated with unac-
ceptable materials, and reapply flooring materials to comply with requirements.
3.4.1 Protect resinous flooring from damage and wear during the remainder of con-
struction period. Use protective methods and materials, including temporary cov-
ering, recommended in writing by resinous flooring manufacturer.
3.4.2 Clean resinous flooring not more than 4 days before dates scheduled for inspec-
tions intended to establish date of Substantial Completion in each Project area.
Use cleaning materials and procedures recommended in writing by resinous floor-
ing manufacturer.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. PAINTING
CAIRO - EGYPT 09911 – 2039 0

CONTENTS
SECTION 09911
PAINTING
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 3
PART 2 PRODUCTS 5
2.1 Paint Materials, General 5
PART 3 EXECUTION 5
3.1 Examination 5
3.2 Preparation 6
3.3 Application 8
3.4 Cleaning 10
3.5 Protection 10
3.6 Exterior Paint Schedule 10
3.7 Interior Paint Schedule 10
Painting Section 09911

SECTION 09911
PAINTING
PART 1 GENERAL
Section.
1.2 SUMMARY
1.2.1 This Section includes surface preparation and field painting of the following:
 Exposed exterior items and surfaces.

 Exposed interior items and surfaces.
 Surface preparation, priming, and finish coats specified in this Section are in
addition to shop priming and surface treatment specified in other Sections.
1.2.2 Paint exposed surfaces, except where the paint schedules indicate that a surface
or material is not to be painted or is to remain natural. If the paint schedules do
not specifically mention an item or a surface, paint the item or surface the same
as similar adjacent materials or surfaces whether or not schedules indicate colors.
If the schedules do not indicate color or finish, the Engineer will select from
standard colors and finishes available.
 Painting includes field painting of exposed bare and covered pipes and ducts
(including color coding), hangers, exposed steel and iron work, and primed
metal surfaces of mechanical and electrical equipment.
1.2.3 Do not paint prefinished items, concealed surfaces, finished metal surfaces,
operating parts, and labels.
 Prefinished items include the following factory-finished components:
 Finished mechanical and electrical equipment.

 Light fixtures.
 Concealed surfaces include walls or ceilings in the following generally
inaccessible spaces:
 Furred areas.
 Finished metal surfaces include the following:
 Electrostatically coated aluminum.

 Labels: Do not paint over labels or equipment name, identification,
performance rating, or nomenclature plates.

1.3 SUBMITTALS
1.3.1 Product Data: For each paint system specified. Include block fillers and primers.
1.3.2 Material List: Provide an inclusive list of required coating materials. Indicate each
material and cross-reference specific coating, finish system, and application.
Identify each material by manufacturer's catalog number and general
classification.
1.3.3 Manufacturer's Information: Provide manufacturer's technical information,

including label analysis and instructions for handling, storing, and applying each
coating material proposed for use.
of colors available for each type of finish-coat material indicated.
 After color selection, the Engineer will furnish color chips for surfaces to be
coated.
1.3.5 Samples for Verification: Of each color and material to be applied, with texture
to simulate actual conditions, on representative Samples of the actual substrate.
 Provide stepped Samples, defining each separate coat, including block fillers
and primers. Use representative colors when preparing Samples for review.
Resubmit until required sheen, color, and texture are achieved.
 Provide a list of materials and applications for each coat of each sample. Label
each sample for location and application.
 Submit Samples on the following substrates for the Engineer's review of color
and texture only:
 Concrete: Provide two 100-mm- square samples for each color and finish.
 Concrete Masonry: Provide two 100-by-200-mm samples of masonry, with
mortar joint in the center, for each finish and color.
 Painted Wood: Provide two 300-mm- square samples of each color and
material on hardboard.
 Stained or Natural Wood: Provide two 100-by-200-mm samples of natural- or
stained-wood finish on actual wood surfaces.
 Ferrous Metal: Provide two 100-mm- square samples of flat metal and two
200-mm- long samples of solid metal for each color and finish.
engineer’s and employers, and other information specified.

1.3.7 Certificate Test.

performance and completion or projects for a period of not less than 5 years, as
well as, sufficient production capability, facilities, and personnel, to produce the
required work.
1.4.2 Manufacture Technical Representative Qualifications: Direct employee of

technical services department of manufacture with minimum of 5 years
experience in providing recommendations, observations, evaluations, and
problem diagnostics.
1.4.3 Applicator Qualifications: Engage an experienced applicator who has completed

painting system applications similar in material and extent to that indicated for
this Project with a record of successful in-service performance.
1.4.4 Source Limitations: Obtain block fillers, primers, and undercoat materials for
each coating system from the same manufacturer as the finish coats.
1.4.5 Benchmark Samples (Mockups): Provide a full-coat benchmark finish sample of

each type of coating and substrate required on the Project.
 The Engineer will select one room or surface to represent surfaces and
conditions for each type of coating and substrate to be painted.
 Wall Surfaces: Provide samples on at least 9 sq. m of wall surface.
 Small Areas and Items: The Engineer will designate an item or area as
required.
 After permanent lighting and other environmental services have been
activated, apply coatings in this room or to each surface according to the
Schedule or as specified. Provide required sheen, color, and texture on each
surface.
 After finishes are accepted, the Engineer will use the room or surface to
evaluate coating systems of a similar nature.
 Final approval of colors will be from job-applied samples.
1.5.1 Deliver materials to the Project Site in manufacturer's original, unopened

packages and containers bearing manufacturer's name and label, and the
following information:
 Product name or title of material.

 Product description (generic classification or binder type).

 Manufacturer's stock number and date of manufacture.
 Contents by volume, for pigment and vehicle constituents.
 Thinning instructions.
 Application instructions.
 Color name and number.
1.5.2 Store materials not in use in tightly covered containers in a well-ventilated area at
a minimum ambient temperature of 7 deg C. Maintain containers used in storage
in a clean condition, free of foreign materials and residue.
 Keep storage area neat and orderly. Remove oily rags and waste daily. Take
necessary measures to ensure that workers and work areas are protected
from fire and health hazards resulting from handling, mixing, and application.
1.6.1 Apply water-based paints only when the temperature of surfaces to be painted
and surrounding air temperatures are between 10 and 32 deg C.
1.6.2 Apply solvent-thinned paints only when the temperature of surfaces to be

painted and surrounding air temperatures are between 7 and 35 deg C.
1.6.3 Do not apply paint in rain, fog, or mist; or when the relative humidity exceeds 85
percent; or at temperatures less than 3 deg C above the dew point; or to damp or
wet surfaces.
PART 2 PRODUCTS
2.1 PAINT MATERIALS, GENERAL
2.1.1 Material Compatibility: Provide block fillers, primers, undercoats, and finish-coat
materials that are compatible with one another and the substrates indicated
under conditions of service and application, as demonstrated by manufacturer
based on testing and field experience.
2.1.2 Material Quality: Provide manufacturer's best-quality paint material of the

various coating types specified. Paint-material containers not displaying
manufacturer's product identification will not be acceptable.
2.1.3 Colors: Provide color selections made by the Engineer, from manufacture full
range.
PART 3 EXECUTION
3.1 EXAMINATION
3.1.1 Examine substrates, areas, and conditions, with the Applicator present, under

which painting will be performed for compliance with paint application
requirements.
 Do not begin to apply paint until unsatisfactory conditions have been

corrected and surfaces receiving paint are thoroughly dry.
 Start of painting will be construed as the Applicator's acceptance of surfaces
and conditions within a particular area.
3.1.2 Coordination of Work: Review other Sections in which primers are provided to
ensure compatibility of the total system for various substrates. On request,
furnish information on characteristics of finish materials to ensure use of
compatible primers.
 Notify the Engineer about anticipated problems using the materials specified
over substrates primed by others.
3.2 PREPARATION
3.2.1 General: Remove hardware and hardware accessories, plates, machined

surfaces, lighting fixtures, and similar items already installed that are not to be
painted. If removal is impractical or impossible because of the size or weight of
the item, provide surface-applied protection before surface preparation and
painting.
 After completing painting operations in each space or area, reinstall items

removed using workers skilled in the trades involved.
3.2.2 Cleaning: Before applying paint or other surface treatments, clean the substrates
of substances that could impair the bond of the various coatings. Remove oil and
grease before cleaning.
 Schedule cleaning and painting so dust and other contaminants from the
cleaning process will not fall on wet, newly painted surfaces.
3.2.3 Surface Preparation: Clean and prepare surfaces to be painted according to

manufacturer's written instructions for each particular substrate condition and as
specified.
 Provide barrier coats over incompatible primers or remove and reprime.

 Cementitious Materials: Prepare concrete and concrete masonry block,
surfaces to be painted. Remove efflorescence, chalk, dust, dirt, grease, oils,
and release agents. Roughen as required to remove glaze. If hardeners or
sealers have been used to improve curing, use mechanical methods of surface
preparation.
 Use abrasive blast-cleaning methods if recommended by paint
manufacturer.
 Determine alkalinity and moisture content of surfaces by performing
appropriate tests. If surfaces are sufficiently alkaline to cause the finish

paint to blister and burn, correct this condition before application. Do not
paint surfaces where moisture content exceeds that permitted in
 For concrete surfaces and external plaster apply a priming coat and fill blow
holes, minor cracks and other surface defects with compatible stucco and
rub down flush with surface.
 For concrete masonry surfaces, fill holes, cracks and other surfaces defects
with block filler flush with surface and apply one coat of the filler to fully
cover paint area.
 Wood: Clean surfaces of dirt, oil, and other foreign substances with scrapers,
mineral spirits, and sandpaper, as required. Sand surfaces exposed to view smooth
and dust off.
 Scrape and clean small, dry, seasoned knots, and apply a thin coat of white
shellac or other recommended knot sealer before applying primer. After
priming, fill holes and imperfections in finish surfaces with putty or plastic
wood filler. Sand smooth when dried.
 Prime, stain, or seal wood to be painted immediately on delivery. Prime
edges, ends, faces, undersides, and back sides of wood, including cabinets,
counters, cases, and paneling.
 If transparent finish is required, backprime with spar varnish.
 Backprime paneling on interior partitions where masonry, plaster, or other
wet wall construction occurs on back side.
 Seal tops, bottoms, and cutouts of unprimed wood doors with a heavy coat
of varnish or sealer immediately on delivery.
 Ferrous Metals: Clean ungalvanized ferrous-metal surfaces that have not been
shop coated; remove oil, grease, dirt, loose mill scale, and other foreign
substances. Use solvent or mechanical cleaning methods.
 Blast steel surfaces clean as recommended by paint system manufacturer
and according to requirements of SSPC-SP 10.
 Treat bare and sandblasted or pickled clean metal with a metal treatment
wash coat before priming.
 Touch up bare areas and shop-applied prime coats that have been
damaged. Wire-brush, clean with solvents recommended by paint
manufacturer, and touch up with the same primer as the shop coat.
 Galvanized Surfaces: Clean galvanized surfaces with nonpetroleum-based solvents

so surface is free of oil and surface contaminants. Remove pretreatment from
galvanized sheet metal fabricated from coil stock by mechanical methods.
3.2.4 Materials Preparation: Mix and prepare paint materials according to
 Maintain containers used in mixing and applying paint in a clean condition,

free of foreign materials and residue.

 Stir material before application to produce a mixture of uniform density. Stir
as required during application. Do not stir surface film into material. If
necessary, remove surface film and strain material before using.
 Use only thinners approved by paint manufacturer and only within
recommended limits.
3.2.5 Tinting: Tint each undercoat a lighter shade to simplify identification of each coat
when multiple coats of the same material are applied. Tint undercoats to match
the color of the finish coat, but provide sufficient differences in shade of
undercoats to distinguish each separate coat.
3.3 APPLICATION
3.3.1 General: Apply paint according to manufacturer's written instructions. Use

applicators and techniques best suited for substrate and type of material being
applied.
 Paint colors; surface treatments, and finishes are indicated in the schedules.
 Do not paint over dirt, rust, scale, grease, moisture, scuffed surfaces, or
conditions detrimental to formation of a durable paint film.
 Provide finish coats that are compatible with primers used.
 The term "exposed surfaces" includes areas visible when permanent or built-in
fixtures, convector covers, covers for finned-tube radiation, grilles, and similar
components are in place. Extend coatings in these areas, as required, to
maintain the system integrity and provide desired protection.
 Paint surfaces behind movable equipment and furniture the same as similar
exposed surfaces. Before the final installation of equipment, paint surfaces
behind permanently fixed equipment or furniture with prime coat only.
 Sand lightly between each succeeding enamel or varnish coat.
3.3.2 Scheduling Painting: Apply first coat to surfaces that have been cleaned,
pretreated, or otherwise prepared for painting as soon as practicable after
preparation and before subsequent surface deterioration.
 The number of coats and the film thickness required are the same regardless
of application method. Do not apply succeeding coats until the previous coat
has cured as recommended by the manufacturer. If sanding is required to
produce a smooth, even surface according to manufacturer's written
instructions, sand between applications.
 Omit primer on metal surfaces that have been shop primed and touchup
painted.
 If undercoats, stains, or other conditions show through final coat of paint,
apply additional coats until paint film is of uniform finish, color, and
appearance. Give special attention to ensure edges, corners, crevices, welds,
and exposed fasteners receive a dry film thickness equivalent to that of flat
surfaces.

 Allow sufficient time between successive coats to permit proper drying. Do
not recoat surfaces until paint has dried to where it feels firm, does not
deform or feel sticky under moderate thumb pressure, and where application
of another coat of paint does not cause the undercoat to lift or lose adhesion.
3.3.3 Application Procedures: Apply paints and coatings by brush, roller, or other
applicators according to manufacturer's written instructions.
 Brushes: Use brushes best suited for the type of material applied. Use brush
of appropriate size for the surface or item being painted.
 Rollers: Use rollers of carpet, velvet back, or high-pile sheep's wool as
recommended by the manufacturer for the material and texture required.
 Spray Equipment: Use airless spray equipment with orifice size as
recommended by manufacturer for material and texture required.
3.3.4 Minimum Coating Thickness: Apply paint materials no thinner than

manufacturer's recommended spreading rate. Provide the total dry film
thickness of the entire system as recommended by the manufacturer, but not less
than those specified.
3.3.5 Block Fillers: Apply block fillers to concrete masonry block at a rate to ensure
complete coverage with pores filled.
3.3.6 Prime Coats: Before applying finish coats, apply a prime coat of material, as
recommended by the manufacturer, to material that is required to be painted or
finished and that has not been prime coated by others. Recoat primed and sealed
surfaces where evidence of suction spots or unsealed areas in first coat appears,
to ensure a finish coat with no burn through or other defects due to insufficient
sealing.
3.3.7 Pigmented (Opaque) Finishes: Completely cover surfaces as necessary to provide

a smooth, opaque surface of uniform finish, color, appearance, and coverage.
Cloudiness, spotting, holidays, laps, brush marks, runs, sags, ropiness, or other
surface imperfections will not be acceptable.
3.3.8 Transparent (Clear) Finishes: Use multiple coats to produce a glass-smooth

surface film of even luster. Provide a finish free of laps, runs, cloudiness, color
irregularity, brush marks, orange peel, nail holes, or other surface imperfections.
 Provide satin finish for final coats.
3.3.9 Stipple Enamel Finish: Roll and redistribute paint to an even and fine texture.
Leave no evidence of rolling, such as laps, irregularity in texture, skid marks, or
other surface imperfections.
3.3.10 Completed Work: Match approved samples for color, texture, and coverage.
Remove, refinish, or repaint work not complying with requirements.

3.4 CLEANING
3.4.1 Cleanup: At the end of each workday, remove empty cans, rags, rubbish, and
other discarded paint materials from the site.
 After completing painting, clean glass and paint-spattered surfaces. Remove

spattered paint by washing and scraping. Be careful not to scratch or damage
adjacent finished surfaces.
3.5 PROTECTION
3.5.1 Protect work of other trades, whether being painted or not, against damage by
painting. Correct damage by cleaning, repairing or replacing, and repainting, as
3.5.2 Provide "Wet Paint" signs to protect newly painted finishes. Remove temporary
protective wrappings provided by others to protect their work after completing
painting operations.
 At completion of construction activities of other trades, touch up and restore

damaged or defaced painted surfaces.
3.6 EXTERIOR PAINT SCHEDULE
3.6.1 Coordinate the following paint coats with surface preparation steps as specified.
3.6.2 Concrete, Cement Portland Plaster: Provide the following finish system:
 Acrylic Paint system for application onto external Portland cement plaster and
internal surfaces of garage, fair face concrete, shall be 100% - acrylic water
based binder to provide textured surfaces, excellent color retention, UV
resistant, very durable, independently tested to have crack bridging up to 2.0
mm, and also tested for carbon dioxide diffusion, chloride ion diffusion water
vapor transmission and liquid water transmission. Primer and intermediate
coatings shall be the manufacture written recommendations.
3.6.3 Ferrous Metal and Zinc-Coated Metals: Provide the following finish system over
exterior ferrous metal.
 Polyurethane Based Coating System shall be Aliphatic Polyurethane to

produce excellent and color retention coating, applied on epoxy primer and
high molecular-weight epoxy intermediate coat. Comply with the following:
 Appearance: Gloss, semi –gloss or matt as directed by the Engineer.
3.7 INTERIOR PAINT SCHEDULE
3.7.1 Coordinate the following paint coats with surface preparation steps as specified.
3.7.2 Cementitious Surfaces: Provide the following finish systems over ferrous metal:
 Acrylic copolymer emulsion Paint for coating internal Portland cement plaster

or render, concrete surfaces or plaster (gypsum) board surface, to produce a
durable, flexible, suitable for repeated washing and scrubbing and of color
retention properties and high hiding ability.
 Primer and intermediate coatings shall be the manufacture written
recommendations
 Epoxy coating System for internal Portland cement plaster of services rooms as
indicated on Finish Schedule.
 Sealer: Transparent epoxy sealer, having excellent penetrating properties.
 Primer and intermediate coatings shall be the manufacture written
recommendations
 Top coat: Epoxy coating based on polyamide cured epoxy resin to produce
a durable coating that has excellent chemical and solvent resistance, very
good abrasion resistance.
 Semigloss, Alkyd-Enamel Finish: Lead free alkyd paint alkyds, nontoxic,
drying to a smooth, highly opaque surface to produce a durable coating with
excellent adhesion and color retention.
 Primer: Alkali-resistant, alkyd- or latex-based, interior primer, as
recommended by the manufacturer for this substrate.
 Intermediate coatings shall be the manufacture written recommendations
3.7.3 Ferrous Metal: Provide the following finish systems over ferrous metal:
 Finish and undercoat material shall be lead free alkyd paint alkyds, nontoxic,
drying to a smooth, highly opaque surface to produce a durable coating with
excellent adhesion and color retention.
 Finish coat shall be gloss or semigloss as directed by the Engineer.
 Primer and intermediate coatings shall be the manufacture written
recommendations
3.7.4 Wood Works:
 Clear Varnish for internal wood surfaces shall be moisture curing, single
component, polyurethane – based, clear colored as directed by the Engineer
varnish with gloss or matt finish to the selection of the Engineer.
 Stained Woodwork: 2 finish coats of an alkyd-based, clear-satin varnish over a

sealer coat and an alkyd-based, interior wood stain. Wipe wood filler before applying
stain.
 Filler Coat: Paste-wood filler applied at spreading rate recommended by

the manufacturer.
 Stain Coat: Alkyd-based, interior wood stain applied at spreading rate
recommended by the manufacturer.
 Sealer Coat: Clear sanding sealer applied at spreading rate recommended

by the manufacturer.
 First and Second Finish Coats: Alkyd-based or polyurethane varnish, as
recommended by the manufacturer, applied at spreading rate
recommended by the manufacturer.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A.
CAIRO - EGYPT LOUVERS & VENTS 10200 – 2039 0

CONTENTS
SECTION 10200
LOUVERS AND VENTS
Page
PART1 GENERAL 2
1.1 Summary 2
1.3 Submittals 2
PART 2 PRODUCTS 2
2.1 Materials 2
2.3 Sand Trap Louver 3
2.4 Louver Screens 3
2.5 Finishes 4
PART 3 EXECUTION 4
3.1 Installation 4
Louvers & Vents Section 10200

SECTION 10200
LOUVERS AND VENTS
PART1 GENERAL
1.1 SUMMARY
1.1.1 This Section includes fixed, sand trap extruded-aluminum louvers .
1.2.1 Structural Performance: Provide louvers capable of withstanding the effects of

gravity loads and the following loads and stresses within limits and under
conditions indicated without permanent deformation of louver components,
noise or metal fatigue caused by louver blade rattle or flutter, or permanent
damage to fasteners and anchors. Wind pressures shall be considered to act on
vertical projection of louvers.
 Wind loads:
 Egyptian code of practice for calculating loads an forces in structural and

building works, ministerial decree 367/2003; basic pressure equal to 100
kg/sq.m.
1.2.2 Thermal Movements: Provide louvers that allow for thermal movements resulting
from a temperature change (range) of 35 deg C, ambient; 60 deg C, material
surfaces, by preventing buckling, opening of joints, overstressing of components,
failure of connections, and other detrimental effects.
1.3 SUBMITTALS
1.3.2 Shop Drawings: Include plans, elevations, sections, details, and attachments to
other Work.
1.3.3 Samples: For each type of finish.
1.3.4 Product test reports.
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Aluminum Extrusions: ASTM B 221M, alloy 6063-T5 or T-52.
2.1.2 Aluminum Sheet: ASTM B 209M, alloy 3003 or 5005.

2.1.4 Fasteners: of same basic metal and alloy as fastened metal or 300 Series stainless
steel.
2.1.5 Bituminous Paint: Cold-applied asphalt emulsion complying with ASTM D 1187.
2.2.1 Fabricate frames to fit in openings of sizes indicated, with allowances made for
fabrication and installation tolerances, adjoining material tolerances, and
perimeter sealant joints.
2.2.2 Join frame members to each other and to louver blades with fillet welds
concealed from view.
2.2.3 Join frame members to each other and to louver blades with fillet welds, threaded
fasteners, or both, as standard with louver manufacturer, concealed from view.
2.3 SAND TRAP LOUVER
2.3.1 Shall be surface mounted louvers, fabricated from aluminum finished with highly
scratch resistant polyester powder coating not less than 40 microns thick for
topcoat of the system and of same color as used for aluminum windows and
entrances in the project. Thickness of blades shall not be less than 0.70 mm
2.3.2 Sand trap louvers shall be surface-mounted of vertical, U-shaped channel blades,
two-row, site assembled construction in an interlocking pattern with blades
spaced on centres according to the wind loading.
2.3.3 Provide flashing for head, sill and jamb of same material and finish as louvers.
2.3.4 Typical efficiency:
 90 percent on 20 to 200 microns test dust distribution.

 80 percent on 20 to 200 microns
 50 percent on 1 to 70 microns test dust distribution.
2.4 LOUVER SCREENS
2.4.1 General: Provide screen at interior face of each exterior louver.
2.4.2 Louver Screen Frames: Same kind and form of metal as indicated for louver to
which screens are attached.
2.4.3 Louver Screening:
- Bird Screening: Aluminum, 12.7-mm-square mesh, 1.6-mm wire.

2.5 FINISHES
2.5.1 Aluminum, High-Performance Organic Finish: Two-coat thermocured system with

fluoropolymer coats containing not less than 70 percent polyvinylidene fluoride
resin by weight; complying with AAMA 2605.
PART 3 EXECUTION
3.1 INSTALLATION
3.1.1 Locate and place louvers level, plumb, and at indicated alignment with adjacent
work.
3.1.2 Use concealed anchorages where possible. Provide brass or lead washers fitted to
screws where required to protect metal surfaces and to make a weather tight
connection.
3.1.3 Provide perimeter reveals and openings of uniform width for sealants and joint
fillers, as indicated.
3.1.4 Repair damaged finishes so no evidence remains of corrective work. Return items
that cannot be refinished in the field to the factory, make required alterations,
and refinish entire unit or provide new units.
3.1.5 Protect galvanized and nonferrous-metal surfaces from corrosion or galvanic

action by applying a heavy coating of bituminous paint on surfaces that will be in
contact with concrete, masonry, or dissimilar metals.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. SIGNAGE
CAIRO - EGYPT 10445 – 2039 0

CONTENTS
SECTION 10445
SIGNAGE
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.6 Coordination 3
1.7 Warranty 3
PART 2 PRODUCTS 4
2.1 Materials 4
2.2 Dimensional Characters 4
2.3 Panel Signs 5
2.4 Dimensional Characters 6
2.5 Accessories 6
2.6 Fabrication 7
2.8 Aluminum Finishes 7
PART 3 EXECUTION 8
3.1 Examination 8
3.2 Installation 8
Signage Section 10445

SECTION 10445
SIGNAGE
PART 1 GENERAL
Section.
1.2 SUMMARY
 Panel signs.
 Dimensional characters (letters , numbers and logo).
 Signage accessories.
 Division 26 Sections for electrical service and connections for illuminated signs.
1.3 SUBMITTALS
1.3.2 Shop Drawings: Show fabrication and installation details for signs.
 Show sign mounting heights, locations of supplementary supports to be provided by

others, and accessories.
 Provide message list for each sign, including large-scale details of wording, lettering,
artwork, and braille layout.
1.3.3 Samples for Initial Selection: Manufacturer's color charts consisting of actual
units or sections of units showing the full range of colors available for the
following:
 Aluminum.
 Steel sheet
1.3.4 Samples for Verification: For each type of sign, include the following Samples to
verify color selected:
 Panel Signs: Full-size Samples of each type of sign required.

 Include a sample of graphic-image process, screen printing, photopolymer and
encapsulated graphics laminate. Show graphic style and colors and finishes of
letters, numbers, and other graphic devices.
 Approved samples will not be returned for installation into the Project.
1.3.5 Qualification Data: For fabricator.
1.3.6 Maintenance Data: For signs to include in maintenance manuals.
1.4.1 Manufacture Qualifications: Manufacturer shall be experiences reputable in

design and fabrication of signage of similar projects with capabilities to complete
the work at completion dates stated in approved Construction Schedule.
1.4.2 Installer Qualifications: A qualified firm specializing in performing the work of this
Section with minimum 5 years documented experience and that is approved,
authorized, or licensed by the product manufacturer to install his product and
that is eligible to receive manufacturer's warranty.
1.4.3 Source Limitations for Signs: Obtain each sign type indicated from one source
1.4.4 Electrical Components, Devices, and Accessories: Listed and labeled as defined in
NFPA 70, Article 100, by a testing agency acceptable to authorities having
jurisdiction, and marked for intended use.
1.5.1 Field Measurements: Verify recess openings by field measurements before

fabrication and indicate measurements on Shop Drawings.
1.6 COORDINATION
1.6.1 Coordinate placement of anchorage devices with templates for installing signs.
1.7 WARRANTY
1.7.1 Special Warranty: Submit a written warranty, executed by the manufacturer,

agreeing to repair or replace signs that fail in materials, finishes or workmanship
within specified warranty period. Failures include, but are not limited to, the
following:

weathering.
1.7.2 Warranty Period: Two years from date of Substantial Completion.

PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Aluminum Castings: ASTM B 26, of alloy and temper recommended by sign
manufacturer for casting process used and for use and finish indicated.
2.1.2 Aluminum Sheet and Plate: ASTM B 209, alloy and temper recommended by
aluminum producer and finisher for type of use and finish indicated, and with at
least the strength and durability properties of Alloy 5005-H32.
2.1.3 Aluminum Extrusions: ASTM B 221, alloy and temper recommended by aluminum
producer and finisher for type of use and finish indicated, and with at least the
strength and durability properties of Alloy 6063-T5.
2.1.4 Steel: Galvanized Steel Sheet: ASTM A 653/A 653M, G90 (Z275) coating, either
commercial or forming steel.
2.2 DIMENSIONAL CHARACTERS
2.2.1 Cast Characters: Produce characters with smooth flat faces, sharp corners, and
precisely formed lines and profiles, free of pits, scale, sand holes, and other
defects. Cast lugs into back of characters and tap to receive threaded mounting
studs. Alloy and temper recommended by sign manufacturer for casting process
used and for use and finish indicated. Comply with the following requirements.
 Character Material: Aluminum.

 Thickness: As recommended by manufacture.
 Color(s): As selected by Engineer from manufacturer's full range.
2.2.2 Aluminum Extrusions: Comply with the following requirements:
 Finish: Anodized.
 Thickness: As recommended by manufacture.
 Color(s): As selected by Engineer from manufacturer's full range.
2.2.3 Cutout Characters: Provide characters with square-cut, smooth, eased edges.
Comply with the following requirements:
 Aluminum Sheet: 3.18 mm thick.

 Steel Sheet: Painted, not less than 1.27 mm thick for face and 0.78 mm thick for
returns.
 Color: As selected by Engineer from manufacturer's full range.
2.2.4 Fabricated Channel Characters: Form exposed faces and sides of characters to
produce surfaces free from warp and distortion. Include internal bracing for
stability and attachment of mounting accessories. Comply with the following

requirements:
 Aluminum Sheet: Not less than 2.29 mm thick.

 Steel Sheet: Not less than 1.27 mm thick for face and 0.78 mm thick for returns.
2.3 PANEL SIGNS
2.3.1 Interior Panel Signs: Provide smooth sign panel surfaces constructed to remain
flat under installed conditions within a tolerance of plus or minus 1.5 mm
measured diagonally from corner to corner, complying with the following
requirements:

 Steel Sheet: 1.5 mm thick.
 Edge Condition: Beveled, unless otherwise indicated.
 Corner Condition: Rounded, unless otherwise indicated.
 Color: As selected by Engineer from manufacturer's full range.
2.3.2 Exterior Panel Signs: Provide smooth sign panel surfaces constructed to remain
flat under installed conditions within a tolerance of plus or minus 1.5 mm
measured diagonally from corner to corner, complying with the following
requirements:

 Steel Sheet: 2.0 mm thick.
 Edge Condition: Beveled, unless otherwise indicated.
 Corner Condition: Rounded, unless otherwise indicated.
2.3.3 Brackets: Fabricate brackets and fittings for bracket-mounted signs from
extruded aluminum to suit panel sign construction and mounting conditions
indicated. Factory paint brackets in color selected by Engineer.
2.3.4 Panel Sign Frames:
 Extruded-Aluminum Frames: Mitered with concealed anchors and welded.
 Color: As selected by Engineer from manufacturer's full range.

 Profile: Beveled, unless otherwise indicated.
 Corner Condition: Rounded, unless otherwise indicated.
2.3.5 Changeable Message Inserts: Fabricate signs to allow insertion of changeable

messages in the form of slide-in inserts.
2.3.6 Engraved Copy: Machine engrave letters, numbers, symbols, and other graphic
devices into panel sign on face indicated to produce precisely formed copy,
incised to uniform depth.

 Engraved Metal: Fill engraved copy with enamel.
2.3.7 Subsurface Copy: Apply minimum 4-mil- (0.10-mm-) thick vinyl copy to back face
of clear Steel sheet forming panel face to produce precisely formed opaque
image. Image shall be free of rough edges.
 Use reverse silk-screen process to print copy; overspray the copy with an opaque
background color coating.
2.4 DIMENSIONAL CHARACTERS
2.4.1 Aluminum Castings: Provide aluminum castings of alloy and temper

recommended by sign manufacturer for casting process used and for type of use
and finish indicated.
2.4.2 Aluminum Extrusions: ASTM B 221 (ASTM B 221M), alloy and temper
recommended by the aluminum producer and finisher for type of use and finish
indicated, and with not less than the strength and durability properties of 6063-
T5.
2.4.3 Cast Characters: Form individual letters and numbers by casting. Produce
characters with smooth flat faces, sharp corners, and precisely formed lines and
profiles, free from pits, scale, sand holes, and other defects. Cast lugs into back of
characters and tap to receive threaded mounting studs. Comply with
requirements indicated for finish, style, and size.
 Material: Aluminum.
2.4.4 Cutout Characters: Cut characters from solid plate of thickness and metal
indicated. Produce precisely cut characters with square cut, smooth, eased edges.
Comply with requirements indicated for finish, style, and size.
 Metal: Aluminum and steel.
2.4.5 Fabricated Characters: Fabricate letters and numbers to required sizes and styles,
using metals and thicknesses indicated. Form exposed faces and sides of
characters to produce surfaces free from warp and distortion. Include internal
bracing for stability and attachment of mounting accessories. Comply with
requirements indicated for finish, style, and size.
 Aluminum Sheet: Not less than 2.30 mm thick.

 Character Height: As indicated on the signage drawings.
 Character Style: As indicated on the signage drawings.
2.5 ACCESSORIES
2.5.1 Anchors and Inserts: Provide nonferrous-metal or hot-dip galvanized anchors and
inserts for exterior installations and elsewhere as required for corrosion
resistance. Use toothed steel or lead expansion-bolt devices for drilled-in-place
anchors. Furnish inserts, as required, to be set into concrete or masonry work.

2.6 FABRICATION
2.6.1 General: Provide manufacturer's standard signs of configurations indicated.
 Welded Connections: Comply with AWS standards for recommended practices in

shop welding. Provide welds behind finished surfaces without distortion or
discoloration of exposed side. Clean exposed welded surfaces of welding flux and
dress exposed and contact surfaces.
 Mill joints to tight, hairline fit. Form joints exposed to weather to exclude water
penetration.
 Preassemble signs in the shop to greatest extent possible. Disassemble signs only as
necessary for shipping and handling limitations. Clearly mark units for reassembly
and installation, in location not exposed to view after final assembly.
 Conceal fasteners if possible; otherwise, locate fasteners where they will be
inconspicuous.
2.6.2 Graphic Content and Style: Provide sign copy that complies with requirements
indicated in the Drawings and in Door Schedule for size, style, spacing, content,
mounting height and location, material, finishes, and colors of signage.
2.7.1 Comply with NAAMM's "Metal Finishes Manual for Architectural and Metal
Products" for recommendations for applying and designating finishes.
2.7.2 Protect mechanical finishes on exposed surfaces from damage by applying

strippable, temporary protective covering before shipping.

2.8 ALUMINUM FINISHES
2.8.1 Color Anodic Finish: Manufacturer's standard Class 1 integrally colored or

electrolytically deposited color anodic coating, 0.018 mm or thicker, in color and
gloss selected by Engineer, complying with AAMA 611.
2.8.2 Aluminum Finishes:
 Powder Coating Finish: Prepare, treat, and coat metal to comply with resin
manufacturer's written instructions and as follows:
 Prepare metal by a multistage cleaning process to thoroughly remove grease, dirt,
oil, flux, and other foreign matter.
 Pretreat prepared metal with chrome-phosphate conversion coating according to
ASTM B 449, Class 4; rinse; and dry thoroughly.

 Apply thermosetting TGIC (Triglycidyl Isocyanurate) polyester powder coating
electrostatically complying with AAMA 603.8 or BS 6496 and 6497 except with a
cured-film thickness not less than 100 microns (0.10 mm).
2.8.3 STEEL FINISHES:
 Surface Preparation: Remove mill scale and rust, if present, from uncoated steel,
complying with SSPC-SP 5/NACE No. 1, "White Metal Blast Cleaning," or SSPC-SP 8,
"Pickling."
 Factory Priming for Painted Finish: Apply shop primer specified below immediately
after surface preparation and pretreatment.
 Shop Primer: Manufacturer's or fabricator's standard, fast-curing, lead- and

chromate-free, universal primer, selected for resistance to normal atmospheric
corrosion, for compatibility with substrate and field-applied finish paint system
indicated, and for capability to provide a sound foundation for field-applied topcoats
despite prolonged exposure.
- Baked-Enamel Finish: Immediately after cleaning and pretreating, apply

manufacturer's standard two-coat, baked-enamel finish consisting of prime coat and
thermosetting topcoat. Comply with paint manufacturer's written instructions for
applying and baking to achieve a minimum dry film thickness of 2 mils (0.05 mm).
PART 3 EXECUTION
3.1 EXAMINATION
with requirements for installation tolerances and other conditions affecting
performance of work.
3.1.2 Verify that items, including anchor inserts, and electrical power are sized and
located to accommodate signs.
corrected.
3.2 INSTALLATION
3.2.1 Locate signs and accessories where indicated, using mounting methods of types
described and complying with manufacturer's written instructions.
 Install signs level, plumb, and at heights indicated, with sign surfaces free of
distortion and other defects in appearance.
 Interior Wall Signs: Install signs on walls adjacent to latch side of door where
applicable. Where not indicated or possible, such as double doors, install signs on

nearest adjacent walls. Locate to allow approach within 75 mm of sign without
encountering protruding objects or standing within swing of door.
3.2.2 Wall-Mounted Signs: Attach panel signs to wall surfaces using methods indicated
below:
 Two-Face Tape: Mount signs to smooth, nonporous surfaces. Do not use this
method for vinyl-covered or rough surfaces.
 Silicone-Adhesive Mounting: Attach signs to irregular, porous, or vinyl-covered
surfaces.
 Shim Plate Mounting: Provide 3 mm thick, concealed aluminum shim plates with
predrilled and countersunk holes, at locations indicated, and where other mounting
methods are not practicable. Attach plate with fasteners and anchors suitable for
secure attachment to substrate. Attach panel signs to plate using method specified
above.
 Concealed Mechanical Fasteners: Use nonremovable mechanical fasteners placed
through predrilled holes. Attach signs with fasteners and anchors suitable for secure
attachment to substrate as recommended in writing by the sign manufacturer.
 Signs Mounted on Glass: Provide matching opaque plate on opposite side of glass to
conceal mounting materials.
3.2.3 Bracket-Mounted Units: Provide the manufacturer's standard brackets, fittings,

and hardware as appropriate for mounting signs that project at right angles from
walls and ceilings. Attach brackets and fittings securely to walls and ceilings with
concealed fasteners and anchoring devices to comply with the manufacturer's
written instructions.
3.2.4 Dimensional Characters: Mount characters using standard fastening methods

recommended in writing by manufacturer for character form, type of mounting,
wall construction, and condition of exposure indicated. Provide heavy paper
template to establish character spacing and to locate holes for fasteners.
 Flush Mounting: Mount characters with backs in contact with wall surface.
 Projected Mounting: Mount characters at projection distance from wall surface
indicated.
3.3.1 After installation, clean soiled sign surfaces according to the manufacturer's
written instructions. Protect signs from damage until acceptance by the Employer.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. TOILET AND BATH ACCESSORIES
CAIRO - EGYPT 10801 – 2039 0

CONTENTS
SECTION 10801
TOILET AND BATH ACCESSORIES
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Coordination 3
PART 2 PRODUCTS 3
2.1 Materials 3
2.2 Fabrication 3
PART 3 EXECUTION 4
3.1 Installation 4
3.3 Toilet And Bath Accessory Schedule 4
Toilet And Bath Accessories Section 10801

SECTION 10801
TOILET AND BATH ACCESSORIES
PART 1 GENERAL
Section.
1.2 SUMMARY
 Toilet and bath accessories.

 Trash basket
 Warm air dryer
1.3 SUBMITTALS
1.3.1 Product Data: Include construction details, material descriptions and thicknesses,
dimensions, profiles, fastening and mounting methods, specified options, and
finishes for each type of accessory specified.
1.3.2 Samples: For each accessory item to verify design, operation, and finish
requirements.
 Approved full-size Samples will be returned and may be used in the Work.
1.3.3 Setting Drawings: For cutouts required in other work; include templates,
substrate preparation instructions, and directions for preparing cutouts and
installing anchoring devices.
1.3.4 Product Schedule: Indicating types, quantities, sizes, and installation locations by
room of each accessory required. Use designations indicated in the Toilet and
Bath Accessory Schedule and room designations indicated on Drawings in product
schedule.
1.3.5 Maintenance Data: For accessories to include in maintenance manuals specified

in the Special Conditions of Contract. Provide lists of replacement parts and
service recommendations.
1.4.1 Source Limitations: Provide products of same manufacturer for each type of
accessory unit and for units exposed to view in same areas, unless otherwise

1.4.2 Product Options: Accessory requirements, including those for materials, finishes,
dimensions, capacities, and performance, are established by specific products
indicated in the Toilet and Bath Accessory Schedule.
 Products of other manufacturers with equal characteristics, as judged solely by

Engineer, may be provided.
 Do not modify aesthetic effects, as judged solely by Engineer, except with
Engineer's approval. Where modifications are proposed, submit
comprehensive explanatory data to Engineer for review.
1.5 COORDINATION
1.5.1 Coordinate accessory locations with other work to prevent interference with
clearances required for access by disabled persons, proper installation,
adjustment, operation, cleaning, and servicing of accessories.
1.5.2 Deliver inserts and anchoring devices set into concrete or masonry as required to
prevent delaying the Work.
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Stainless Steel: ASTM A 666, Type 304, with No. 4 finish (satin), in 0.8-mm
minimum nominal thickness, unless otherwise indicated.
2.1.2 Fasteners: Screws, bolts, and other devices of same material as accessory unit,
tamper and theft resistant when exposed, and of galvanized steel when
concealed.
2.2 FABRICATION
2.2.1 General: Names or labels are not permitted on exposed faces of accessories. On
interior surface not exposed to view or on back surface of each accessory,
provide printed, waterproof label or stamped nameplate indicating
manufacturer's name and product model number.
2.2.2 Surface-Mounted Toilet Accessories: Unless otherwise indicated, fabricate units

with tight seams and joints, and exposed edges rolled. Hang doors and access
panels with continuous stainless-steel hinge. Provide concealed anchorage where
possible.
2.2.3 Recessed Toilet Accessories: Unless otherwise indicated, fabricate units of all-
welded construction, without mitered corners. Hang doors and access panels
with full-length, stainless-steel hinge. Provide anchorage that is fully concealed
when unit is closed.
2.2.4 Keys: Provide universal keys for internal access to accessories for servicing and
resupplying. Provide minimum of six keys to Employer's representative.

PART 3 EXECUTION
3.1 INSTALLATION
3.1.1 Install accessories according to manufacturers' written instructions, using

fasteners appropriate to substrate indicated and recommended by unit
manufacturer. Install units level, plumb, and firmly anchored in locations and at
heights indicated.
3.1.2 Install grab bars to withstand a downward load of at least 1112 N, when tested
according to method in ASTM F 446.
3.2.1 Adjust accessories for unencumbered, smooth operation and verify that
mechanisms function properly. Replace damaged or defective items.
3.2.2 Remove temporary labels and protective coatings.
3.2.3 Clean and polish exposed surfaces according to manufacturer's written

recommendations.
3.3 TOILET AND BATH ACCESSORY SCHEDULE
3.3.1 Toilet Tissue Dispenser (Toilet Paper Holder): Provide toilet tissue dispenser
complying with the following:
 Type Single-roll dispenser.

 Mounting: Surface mounted with concealed anchorage.
 Material: Stainless steel
 Operation: Noncontrol delivery with mfr's standard spindle.
 Capacity: Designed for standard diameter-core tissue rolls up to 140 mm
diameter (800 sheets)
3.3.2 Soap Dispenser: Provide soap dispensers complying with the following:
 Liquid Soap Dispenser, Vertical-Tank Type: Wall mounted type, minimum

1182.9 ml capacity tank with stainless steel piston, springs, and internal parts
designed to dispenses soap in measured quantity by pump action, and
stainless-steel cover with unbreakable window-type refill indicator.
 Mounting: Designed for wall mounting.
 Soap Valve: Designed for dispensing soap in liquid form
3.3.3 Warm-Air Dryer: Provide warm-air dryer complying with the following:
 Cover: One piece heavy duty, 18 gauge type 304 stainless steel, satin finish.
 Tamper resistant screws. Air intake vents are shielded.
 Motor: Permanently lubricated, 1/10 HP, 3200 RPM.
 Automatic Sensor: 100% solid state design eliminates relay contact failures.
Microprocessor controlled infrared sensor turns dryer on when hands are
under the air outlet. Dryers turns off when hands are removed. Override
turns off in 80 seconds if hands are not removed.
3.3.4 Trash basket: Provide stainless steel floor standing trash basket with vinyl
bumper strip and rubber feet.
 Finish: Satin finish.

 Thickness: 0.8 mm.
 Cover: Self closing with two spring loaded and stainless steel finish piano hinges.
 Capacity: 10 litre.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
A Apr. 2015 M.H. 16 ISSUED FOR CLIENT REVIEW
0 Apr. 2015 M.H. 16 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. FIRE PROTECTION
CAIRO - EGYPT 13916 – 2039 0

CONTENTS
SECTION 13916
FIRE PROTECTION
Page
PART 1 GENERAL 3
1.2 Description Of Work 3
1.4 System Description 3
1.5 Definitions 3
1.6 Submittals 4
1.8 Regulatory Requirements 5
1.9 Sequencing and Scheduling 5
1.10 Extra Materials 5
PART 2 PRODUCTS 5
2.1 Manufacturers 5
2.2 Pipes and Fittings 5
2.3 Joining Materials 5
2.4 General Duty Valves 5
2.5 Specialty Valves 6
2.6 Sprinklers 7
2.7 Sight Test and Drain Connection 8
2.8 Fire Hose Reels 8
2.9 Fire Department Inlet Connection 8
2.10 Fire Hoseand Discharge Nozzle 9
2.11 Fire Hose Couplings 9
2.12 Alarm and Water Flow Detection Devices 10
2.13 Detectors 10
2.14 Sight Test And Drain Connection 10
2.15 Test And Drain Valve 10
2.16 Fire Cabinet 10
2.17 Fire Extinguishers 11
2.18 Identification Signs 11
PART 3 EXECUTION 12
3.1 General 12
3.2 Examination 12
3.3 Piping Installations 12
3.4 Pipe Joint Construction 13
3.5 Valve Installations 13
3.6 Sprinkler Installations 13
3.7 Fire Cabinet Installations 14
3.8 Installation of Zone Control Station 14
Fire Protection Section 13916

3.9 Final Electrical Connections 14
3.10 Fire Protection Block Plan 14
3.11 Remote Alarm 14
3.13 Flushing And Drainage 15
3.14 Spare Parts 15
3.15 Maintenance of The System 15
3.16 Warranty 15
3.17 Training 16

SECTION 13916
FIRE PROTECTION
PART 1 GENERAL
Drawings and General provisions of Contract, including General and

Supplementary Conditions and Division-1 Specification Sections, apply to this
section.
1.2 DESCRIPTION OF WORK
1.2.1 This section specifies automatic sprinkler system, fire hose reel system and fire
department valves (standpipe) system. Materials and equipment specified in this
Section include:
 Pipe, fittings, valves, and specialties.

 Sprinklers, fire hose reel, hose valves, fire department inlet connection, fire
cabinets and accessories.
 Portable fire extinguishers.
 Products furnished but not installed: Include sprinkler head cabinets with
spare sprinkler heads.
1.3.1 The following Sections contain requirements which relate to this Section:
 15100 Valves
 15145 Hangers and Supports
 15417 Steel Pipes and Fittings for Fire Protection Systems
 13927 Fire Water and Jockey Pump
1.4 SYSTEM DESCRIPTION
Fire protection system is an automatic sprinkler system using automatic sprinklers

attached to a wet piping system and connected to a fire water pumping station so
that water discharges immediately from sprinklers, opened by fire. The system is
also provided with wet stand-pipe risers and hose valves. Manual fire water hose
reels and various types of portable fire extinguishers are distributed to provide
first aid protection.
1.5 DEFINITIONS
1.5.1 Pipe Sizes: used in this Specification are Nominal Pipe Size (NPS) in mm.

1.5.2 Other Definitions for fire protection systems are listed in NFPA 13 and 14
Standards.
1.5.3 Working Plans as used in this section means those documents (including
drawings and calculations) prepared by contractor pursuant to the requirements
contained in NFPA 13 for obtaining the approval of the Engineer.
1.6 SUBMITTALS
Submit the following in accordance with Conditions of the Contract and Division 1
Specifications Sections.
Product Data: For each type of sprinkler heads, valves, piping specialty, fire
protection specialty, fire department connection, hose reel, fire department
valves, hoses, fire extinguishers and fire cabinets.
Computer Calculation: For the automatic sprinkler system, hose reels according
to the regulations of NFPA 13 and NFPA 14.
Shop Drawings: Prepared in accordance with latest edition of NFPA 13 identified

as "Working Plans", showing layout and connections.
Record Drawings: At project close-out, submit drawings of installed systems in

accordance with requirements of Division-1.
Maintenance Data: For each type of sprinkler heads, valves, piping specialty, fire
protection specialty, fire department connection, hose reel, fire department
valves, hoses, fire extinguishers and fire cabinets. For inclusion in operation and
maintenance manual specified in Division-1.
Samples: Submit catalogs or representative samples of all materials to be used in

the work.
Install Welder’s Qualification Certificates.
1.7.1 Design Criteria:
Provide complete fire protection systems as indicated on the drawings and as

required by local authorities.
Where there is conflict between local authority (Civil Defense) requirements and
the drawings, specifications or other standard agency requirements, the
requirements of local authorities shall govern.
1.7.2 Installer Qualifications: Installation of fire protection piping, equipment,

specialties and accessories, repair and servicing of equipment shall be performed
only by a qualified installer, having a minimum of 5 previous projects similar in
size and scope to this project and familiar with all precautions required. Submit

evidence of such qualifications to the Engineer.
1.7.3 Qualifications for Welding Processes and Operators: Comply with the
requirements of AWS D10.9, Specifications for Qualifications of Welding
Procedures and Welders for Piping and Tubing, Level AR-3".
1.7.4 Single Source Responsibility: Obtain components, and accessories from a single
source. Include the source with responsibility and accountability to answer and
resolve problems regarding compatibility, installation, performance and
acceptance set.
1.8 REGULATORY REQUIREMENTS
1.8.1 Comply with the requirements of the following codes:
 NFPA 10 Portable Fire Extinguishers

 NFPA 13 Installation of Sprinkler Systems
 NFPA 14 Stand-pipe and hose systems
1.9 SEQUENCING AND SCHEDULING
Schedule rough-in installations with installations of other building components.
1.10 EXTRA MATERIALS
1.10.1 Valve Wrenches: Furnish to Employer, 2 valve wrenches for each type of valves
installed.
1.10.2 Sprinkler Heads and Cabinets: Furnish extra sprinkler heads of each style
included in the project as indicated on drawings. Furnish each style with its own
sprinkler head cabinet and special wrenches as specified in this Section.
PART 2 PRODUCTS
2.1 MANUFACTURERS
Manufacturers are subject to compliance with the specification requirements of

this section.
2.2 PIPES AND FITTINGS
Refer to specification section 15417 and the general notes drawing.
2.3 JOINING MATERIALS
Refer to specification section 15417 and the general notes drawing.
2.4 GENERAL DUTY VALVES
Valves used within the fire protection systems shall be UL listed, FM approved

rated for 1200 KPa working pressure.
2.4.1 Gate Valves - 50 mm and Smaller outside screw and yoke gate valves, 1,200 kPa
(12 bar), bronze body, bronze mounted, screwed bonnet, rising stem, solid
wedge, with normally open supervisory/tamper switch with double wire leads.
2.4.2 Gate Valves - 65 mm and Larger: outside screw and yoke gate valves, 1,200 kPa
(12 bar), cast iron body, flanged or grooved ends, bronze mounted, bolted
bonnet, rising stem, solid wedge, with normally open supervisory/tamper switch
with double wire leads and rising stem.
2.4.3 Swing Check Valves - 50mm and smaller Bronze body, threaded end, Y-pattern,
regrindable bronze seat, renewable bronze disc, 1,200 kPa (12 bar), suitable for
installation in a horizontal or vertical line with flow upward.
2.4.4 Swing Check Valves - 65mm and larger Cast or ductile iron body, flanged or
grooved ends, bronze trim, bolted. cap, renewable bronze seat and disc, 1,200
kPa (12 bar), suitable for installation in a horizontal or vertical line with flow
upward.
2.4.5 Butterfly Valve - 50mm and smaller: Bronze body butterfly valve, 1,200 kPa (12
bar), geared operator, visible position indicator, normally open
supervisory/tamper switch with double wire leads, stainless steel disc and stem.
2.4.6 Butterfly Valve - 65mm and larger: Cast or ductile iron body butterfly valve, lug
style, 1,200 kPa (12 bar), geared operator, visible position indicator, normally
open supervisory/tamper switch with double wire leads, EPDM resilient seat,
EPDM seals, nickel plated ductile iron disc. Valve assembly to be bubble tight to
12bar with no downstream flange/pipe attached. Use cap screws for removal of
downstream piping while using the valve for system shutoff.
2.4.7 Globe Valves: Cast bronze body and screwed bonnet. Rubber, bronze or teflon
disc, silicon bronze alloy stem, teflon-impregnated packing with bronze nut.
Threaded or soldered end connections, and with aluminum or malleable-iron
hand wheel.
2.5 SPECIALTY VALVES
2.5.1 Interior Automatic Air Vent: Float type hot pressed brass MS58 consists of two
halves screwed together and fitted with O-ring seal, with rubber valve seal, plastic
float, vacuum breaker complete with automatic self-sealing spring loaded brass
check valve stainless steel spring and catch ring rated for 1200 KPa working
pressure.
2.5.2 Alarm Check Valve: UL Listed, FM approved, 1200 KPa working pressure,
designed for vertical or horizontal installations and have cast iron body, flanged
inlet and outlet, bronze grooved seat with “O” ring seals, single hinge pin and
latch design. Provide trim sets for bypass, drain, electric sprinkler alarm switch,
pressure gauges, precision retard chamber, 6” water motor alarm, drip cup
assembly piped without valves separate from main drain line, and fill line

attachment with strainer.
The alarm check valve assembly shall be installed with upstream with supervisory
switch in addition to a downstream flow switch. The assembly shall be provided
with upstream and downstream pressure gauges and test and drain valve. The
assembly shall be installed upstream each fire water supply riser. The tamper
switch and flow switch shall be connected to the main fire alarm panel and
building management system.
2.5.3 Zone Control Station: The zone control station shall include outside screw &
yoke gate valve with supervisory/tamper switch, downstream flow switch, test
and drain valve and pressure gauge. The valve and supervisory/tamper switch can
be replaced by a butterfly valve with built in supervisory/tamper switch. The
tamper switch and flow switch shall be connected to the main fire alarm panel
and building management system.
2.5.4 Hose Valves: hose valve outlets should be of a type acceptable to the civil
defense authority and should comprise a valve 65mm bore constructed in gun
metal with a 65mm instantaneous female coupling (to match the requirements
and equipments of the civil defense authority) and a blank cap secured by a
suitable length of chain. The valve gate should lift clear of the waterway and the
valve cover should be securely fitted to the valve body so that it does not
unscrew when operated. The valve spindle should not be less than 22mm
diameter and fitted with a gun metal hand wheel about 150mm in diameter
which should be marked with OPEN and SHUT directions; openings should be
anti-clockwise. The whole fitting should be of sound construction and shall be
suitable for a working pressure of 12.1 bar.
The valve must have an in-built integral pressure-reducing device for adjusting
the water outlet pressure to 6.9 bars regardless of the inlet water pressure.
Fire department valves should be installed inside the fire cabinets. The valve shall
be installed with a clearance not less than 200mm above the hand wheel.
2.5.5 Deluge Valve: UL Listed, FM approved, 1,200 kPa (12 bar) working pressure,
designed for vertical or horizontal installations and have cast iron body, flanged
inlet and outlet, bronze grooved seat with “O” ring seals, single hinge pin and
latch design. Provide trim sets for bypass, drain, electric sprinkler alarm switch,
solenoid valve, pressure gages, drip cup assembly piped without valves separate
from main drain line, and fill line attachment with strainer.
The deluge valve assembly shall be installed with upstream gate valve (outside
screw and yoke) with supervisory switch in addition to a downstream flow switch.
The assembly shall be provided with upstream pressure gauge. The deluge valve
assembly shall be complete with a UL listed and FM approved control panel,
which shall be monitored at the main fire alarm control panel.
2.6 SPRINKLERS
All sprinkler heads used within the fire protection systems shall be UL listed, FM

approved, quick response type rated for 1200 kPa working pressure, designed to
comply with NFPA requirements.
2.6.1 Upright Sprinkler: Automatic upright sprinkler head, quick response type,
frangible bulb type, 79 degree C. temperature rating, bronze frame and deflector,
15 mm orifice and 15 mm thread with not less than 5.6 K-factor.
2.6.2 Concealed Pendent Sprinkler: Automatic pendent sprinkler head, quick response
type, frangible bulb type, 68 degree C. temperature rating, bronze frame and
deflector, 15 mm orifice and 15 mm thread with not less than 5.6 K-factor in all
finished areas except corridors and public areas. The sprinkler shall be provided
with a cover plate of temperature rating of not less than 57 degree C. The cover
plate color shall meet the requirements of the interior designer and to match the
ceiling color.
2.6.3 Sprinkler Head Cabinet and Wrench: Finished steel cabinet suitable for wall
mounting, with hinged cover and space for spare sprinkler heads plus sprinkler
head wrench. Provide separate cabinets and spare sprinklers for each style of
sprinkler heads on the project. The quantity of spare sprinkler heads shall be in
accordance to NFPA 13.
2.7 SIGHT TEST AND DRAIN CONNECTION
Smooth bore non-corrosive orifice gives flow equivalent to one nominal 15 mm

orifice sprinkler with test and drain valves.
2.8 FIRE HOSE REELS
Fire hose reel shall be slim type, to be mounted inside fire cabinets, swinging type
to comply or exceed with BS 5274/EN 671.
All the internal parts used shall be made of material according to BS 1490 LM
16/24. The hose tubing should be 25mm internal diameter rubber reinforced with
double braiding and 30mtr long to comply with BS 3169 type 1 class B or EN 694.
The hose reel nozzle to comply with EN 671 -PN 16/DN 25/6.
The unit shall be complete with lock shield valve and 25mm pressure reducing
valve to maintain pressure of 4.6 bar at outlet.
For testing and maintenance drain line with non return valve to be used. Brief
operating instructions should be clearly displayed on each hose reel in both
languages, Arabic and English.
2.9 FIRE DEPARTMENT INLET CONNECTION
Fire department inlet connection shall be fitted with a twin inlet brass or bronze
fire department inlet connection for fire brigade use in case that is no water in
the fire water network. The fire department inlet connection shall be protected
provided by a non-return (check) valve (system side). The outlet shall be 150mm
to BS 4504. The fire department inlet connection shall be rated for 12.1 bars

working pressure.
The fire department inlet connection shall comprise 2 inlets consisting of a 65mm
instantaneous male coupling and one outlet of 150mm. The connection shall be
of double clapper type and shall be protected by a cap secured by a suitable
length of chain. The coupling shall comply with BS 336.
Each fire department inlet connection shall be provided with a swing check valve
on connection with the system supply risers.
Inlet Box
The fire department inlet connection shall be housed in an inlet box with a glass
fronted door and to be coordinated for location with the exterior of each
building. The location shall be accessible to the fire trucks. The door should be as
follows:
Glazed with wired glass and conspicuously indicated by the words: "FIRE BRIGADE
- WET MAIN INLET" or "WET RISER INLET" in block letters on the inner face of the
glass, both in English and Arabic.
Fastened only by means of a spring lock which can also be operated from inside
without the aid of a key after the glass has been broken.
Made large enough for hose to be connected to inlets even if the door cannot be
opened and the only means of access is by breaking the glass.
The box should be constructed in accordance with BS 3980 with minimum

dimensions 610mm x 400mm x 305mm.
The box shall be built into the structure with a fall of one in 12 from the rear of
the base to the front of the base. Construction material for the cabinet shall be
brushed / polished stainless steel as required by Architect/ Engineer.
2.10 FIRE HOSE AND DISCHARGE NOZZLE
65mm diameter hose of 30 meters length, red color fire hose with efficient
density rubber lining, sealed pin holes, reinforced with synthetic nylon jacket as
integral part with minimum working pressure of 12.1 bar.
Robust alloy coupling should be bound and tested in factory. Binding should be
with corrosion resistant material. Hose to comply with BS 6391 type 3 or Din
standards. Discharge nozzle shall be made to aluminum alloy to BS 1490 and
fitted with instantaneous adaptor as per BS 336 and should have settings as
diffuser / jet / spray / on / off.
2.11 FIRE HOSE COUPLINGS
Fire hose couplings shall be 65 mm diameter, cast brass finish, double pin lug,
with two expansion rings, two tail and one swivel gasket. The couplings shall be
polished chrome plated.

2.12 ALARM AND WATER FLOW DETECTION DEVICES
2.12.1 General: Types and sizes shall mate and match piping and equipment connected
with. All equipment shall be UL listed and FM approved. All alarm and fire
detection devices shall be monitored at the fire alarm panel. The fire alarm
system shall be coordinated with the building management system BMS.
2.12.2 Water Flow Indicators: Electrical-supervision, vane type water flow detector,
rated to 1700 kPa; designed for horizontal or vertical installation; have 2-SPDT
circuit switches to provide isolated alarm and auxiliary contacts, 7 ampere 125
volts AC and 0.25 ampere 24 Volts DC; complete with factory-set, field-adjustable
retard element to prevent false signals, and tamper-proof cover which sends a
signal when cover is removed.
2.12.3 Supervisory Switches: Electrical-supervision type, 2 SPDT, normally closed

contacts, with switching component enclosed in submersible, weatherproof, and
oil resistant NEMA Type 4 and P 6 enclosure, designed to signal valve in other
than full open position.
2.13 DETECTORS
2.13.1 Optical Smoke Detector: Refer to section 13967.
2.13.2 Collective Heat Detector: : Refer to section 13967.
2.14 SIGHT TEST AND DRAIN CONNECTION
Smooth bore non-corrosive orifice gives flow equivalent to one nominal 15 mm

orifice sprinkler with test and drain valves.
2.15 TEST AND DRAIN VALVE
The test and drain valves shall be smooth bore non-corrosive orifice gives flow
equivalent to one nominal 15 mm orifice sprinkler. Each valve shall be complete
with sight glass and can be operated with two directions TEST and DRAIN.
2.16 FIRE CABINET
FHC Fully Recessed The back box / cabinet shall be constructed from 16 SWG zinc
powder coated steel, shall have the knockouts for pipe entry. The cabinet shall be
fully recessed divided into 2 sections, top section shall accommodate the 25mm *
30 meter hose reel while the lower section shall accommodate the 30 meters of
the 65 mm hose, hose valve, discharge nozzle, portable fire extinguisher as shown
on the drawings. Dimension shall be as per drawings.
Architrave shall be 20 SWG zinc powder coated steel.
Door shall be 18 SWG zinc powder coated steel , as per the Architect requirement.
Door shall be fixed to the cabinet by concealed hinges left or right as required to
facilitate the hose reel pull direction.

Identification of the fire cabinet equipment shall be as per the Architect
requirement in compliance to NFPA Standards and shall be lettered on the
cabinet in both Arabic and English languages.
Fire equipment’s shall be provided as specified elsewhere.
2.17 FIRE EXTINGUISHERS
General: Provide fire extinguishers for each extinguisher cabinet and other
locations indicated, in colors and finishes approved by the Engineer from
manufacturer's standard, which comply with requirements of governing
authorities.
Mounting Brackets: provide manufacturer's standard brackets designed to

prevent accidental dislodgment of extinguisher, of sizes required for type and
capacity of extinguisher indicated, in manufacturer's standard plated finish.
Provide brackets for extinguishers not located in cabinets and for those located in
cabinets, where indicated or required.
Fire Extinguisher Type FE-1: Stored pressure Dry Powder Type, 6 kg capacity
containing nonconductor Mono-Ammonium Phosphate and Ammonium Sulphate
for a working temperature range of -20C to 60C in cylinder of 16 SWG mild steel
and zinc die-cast operating head with Acetal and stainless steel fittings and
components. The minimum discharge range is 5 meters and stored pressure is
134 KPa at 21°C.
Fire Extinguisher Type FE-2: CO2 type, 6 kg capacity, red glossy polyester coated
aluminum cylinder with discharge horn, pressurized at approximately 5000 Pa at
21°C.
Fire Extinguisher Type FE-3: UL listed, stored pressure foam type, 9 liter capacity,
containing AFFF foam in stainless steel shell, to be provided with a pressure
gauge.
Fire Extinguisher Type FE-5: Stored pressure dry powder type, 12 kg capacity
containing non conductor mono-ammonium phosphate and ammonium sulphate
in a container of 16 SWG mild steel. The container shall be provided with an
automatic release head consisting of release sprinkler head, manometer and an
overpressure valve.
2.18 IDENTIFICATION SIGNS
Drain valves, test valves, control valves, alarm check valves and zone control
station shall be fitted with approved enameled signs indicating their use.

PART 3 EXECUTION
3.1 GENERAL
Cooperate with other trades to insure adequate space for equipment and piping
placement.
Review plans, specifications and shop drawings of other trades to coordinate

work.
Install in strict accordance with approved shop drawings.
Do not begin installation until local authority approval is submitted to the

Engineer.
3.2 EXAMINATION
Examine rough-in for fire cabinets and sprinklers to verify actual locations of
piping connections prior installing.
Examine walls for suitable conditions where cabinets are to be installed. Examine
ceiling pattern, air diffusers and grills, light fixtures, for suitable conditions where
sprinkler are to be installed.
Do not proceed until unsatisfactory conditions have been corrected.
3.3 PIPING INSTALLATIONS
Drawings (plans, schematics and diagrams) indicate the general location and
arrangement of piping systems. So far as practical, install piping as indicated.
Deviations from approved "Working Plans" for piping require written approval of
the Engineer.
Install sprinkler piping to provide for system drainage in accordance with NFPA
13.
Use approved fittings to make all changes in direction, branch takeoffs from
mains and reductions in pipe sizes.
Install unions in pipes 50 mm and smaller adjacent to each valve. Unions are not
required on flanged devices.
Install flanges or flange adapters on valves, apparatus and equipment having 65

mm and larger connections.
Provide hangers and supports in Compliance with the requirements of NFPA 13,
NFPA 14 and Section 15145.
Make connections between underground and above-ground piping using an

approved transition piece strapped or fastened to prevent separation.
Install mechanical sleeve seal at pipe penetrations in walls and floors.

Provide pressure gauges with a connection not less than 6 mm and having a soft
metal seated globe valve, arranged for draining pipe between gauge and valve.
Paint piping with two (2) coats of red lead and three (3) coats of red paint.
3.4 PIPE JOINT CONSTRUCTION
3.4.1 Welded Joints: AWS D10.9, Level AR-3
3.4.2 Threaded Joints: Conform to ANSI B1.20.1, tapered pipe threads for field cut
threads. Join pipe, fittings, and valves as follows:
Note the internal length of threads in fittings or valve ends, and proximity of
internal seat or wall, to determine how far pipe should be threaded into joint.
Align threads at point of assembly. Apply appropriate tape or thread compound
to the external pipe threads. Assemble joint to appropriate thread depth. When
using a wrench on valves place the wrench on the valve end into which the pipe is
being threaded. Do not use pipe with threads which are corroded, or damaged. If
a weld opens during cutting or threading operations, that portion of pipe shall not
be used.
3.4.3 Flanged Joints: Align flanged surfaces parallel. Assemble joints by sequencing bolt
tightening to make initial contact of flanges and gaskets as flat and parallel as
possible. Use suitable lubricants on bolt threads. Tighten bolts gradually and
uniformly to appropriate torque specified by the bolt manufacturer.
3.4.4 Push-on Joints: AWWA C111-90.
3.4.5 Grooved-end Pipe and Grooved-end Fitting Joints: Use UL listed and FM
approved grooved-end fittings and grooved-end couplings that are made by the
same manufacturer and that are listed to be used together.
Groove pipe and assemble joints with grooved coupling, gasket, lubricant, and
bolts according to coupling and fitting of manufacturers written instructions.
3.5 VALVE INSTALLATIONS
Install fire protection specialty valves, fittings, and specialties in accordance with
the manufacturer's written instructions, NFPA 13, 14 and the Engineer
requirements.
Where there is more than one control valve, provide permanently marked
identification signs indicating the portion of the system controlled by each valve.
3.6 SPRINKLER INSTALLATIONS
Use proper tools recommended by the manufacturer to prevent damage during

installation.

Sprinkler Style Location
Upright, brass finish Non finished areas
Pendent, Concealed, chrome plated or Finished areas
painted
3.7 FIRE CABINET INSTALLATIONS
Examine walls for thickness and framing for cabinets to verify cabinet depth and
mounting prior to cabinet installation. Cabinets shall be built into walls unless
otherwise indicated on Drawings.
Install items included in this section in locations and at mounting heights

indicated, or if not indicated, at heights to comply with applications of governing
authorities.
Prepare recesses in walls for fire cabinets as required by type and size of cabinet
and style of trim and to comply with manufacturer's instructions.
Securely fasten mounting brackets and fire cabinets to structure, square and
plumb, to comply with manufacturer's instructions.
3.8 INSTALLATION OF ZONE CONTROL STATION
Provide UL listed zone control station comprising indicating type floor control
valve with supervisory switch, pressure gauge, water flow switch, one piece test
and drain valve with sight glass. Make connection to fire alarm control panel.
3.9 FINAL ELECTRICAL CONNECTIONS
Make connections of electric wiring to the electric equipment.
3.10 FIRE PROTECTION BLOCK PLAN
Provide a frame and glazed block plan showing the areas protected and positions
of alarm valve. Locate the block plan as directed by the Engineer.
3.11 REMOTE ALARM
Ensure that the components of the systems include for the necessary provisions
to transfer visual and audible remote alarm signals. Carry out connections to the
remote alarm contacts.
Flush, test, and inspect sprinkler and hose reel piping systems in accordance with
NFPA 13.
Test and inspect wet stand-pipes in accordance with NFPA 14.
Replace piping system components which do not pass the test procedures
specified, and re-test repaired portion of the system.

3.13 FLUSHING AND DRAINAGE
Provision shall be made for flushing the firewater sprinkler system.
All piping shall be provided where necessary or where shown on the drawings and
at all sectional valves with a draining facility to help draining the major part(s) of
the system.
On all risers 100mm diameter or larger, the drain valve shall be 50mm diameter
size.
On 65mm diameter and 80mm diameter risers, the drain valve shall be 32mm
diameter size.
On smaller risers, the drain valve shall be 20mm diameter size.
No direct interconnections shall be made between sewers and sprinkler

drainpipes.
3.14 SPARE PARTS
As recommended by the manufacturer to cover a working period of three years,

submit to the Employer, for approval, a priced list of the recommended spare
parts and tools to cover the above mentioned working period. The list should
nominate the above-required items and shall be provided for approval during the
bidding stage. The approved list shall be part from the operation and
maintenance manuals.
3.15 MAINTENANCE OF THE SYSTEM
A maintenance schedule showing site visit and system testing shall be submitted
to the owner for approval.
Maintenance shall be as per the conditions of the contract.
The system shall be maintained accordingly for a period of one year from the date
of initial handing over and Owner’s acceptance.
3.16 WARRANTY
The system shall be warranted for parts and labor for not less than a period listed
in the contract conditions from date of initial handing over of the work and
Owner’s acceptance.
A system-checking schedule showing site visits shall be submitted to the owner

for approval.
The contractor shall be responsible for operation and maintenance of the

complete fire protection systems until the end of contract defect’s liability period
including all required spare parts, maintenance equipment, tools, aluminum
ladder, all labor and supervision in carrying out all routine operational
maintenance and full preventive maintenance activities during such period.

3.17 TRAINING
The contractor shall provide technical training issue as one of the most essential
points for the buildings dedicated facility staff who will be capable of doing a day
to day operation and management of the buildings and keep its valuable systems
efficient.
The concerned training should:
Include the equipments factory tests.
Be performed by the manufacturers technical staff (mother company).
Be for efficient time.
Be for dedicated enough people of the facility staff (number of trainee shall be
defined by the owner).
Consider using all the practical tools and instruments during the training.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
CLEAN AGENT FIRE EXTINGUISHING SPECIFICATION REV.

ECG ENGINEERING CONSULTANTS GROUP S.A.
CAIRO - EGYPT SYSEM
13967 – 2039 0

CONTENTS
SECTION 13967
CLEAN AGENT FIRE EXTINGUISHING SYSTEM
Page
PART 1 GENERAL 2
1.2 Description 2
1.4 Submittals 2
1.5 System Description And Operation 3
1.6 Approvals 4
1.9 Delivery, Storage And Handling 6
1.10 Scheduling 6
PART 2 PRODUCTS 6
2.1 Piping 6
2.2 Storage Containers And Distribution System 7
2.3 Discharge Nozzles 7
2.4 Detection System 8
2.6 Control Panel 9
2.7 Manual Release Switch 10
2.8 Abort Station 10
2.9 Audible And Visual Alarms 10
2.10 Caution / Advisory Signs 10
2.11 Fire Doors To Protected Areas 10
2.12 Fire Curtains 10
2.13 Wall Penetration 11
2.14 Wiring And Conduits 11
PART 3 EXECUTION 11
3.1 Installation 11
3.2 System Inspection And Checkout 11
3.3 Training Requirements 12
3.4 Operation And Maintenance 12
3.5 Record Drawings 12
3.6 Acceptance Tests 12
3.7 System Inspections 13
3.8 Warranty 13
3.9 Spare Parts 13
Clean Agent Fire Extinguishing System Section 13967

Renovation and Refurnishing Unilever Factory 6th October , Sheet 1 of 14
SECTION 13967
CLEAN AGENT FIRE EXTINGUISHING SYSTEM
PART 1 GENERAL
Drawings and general provisions of Contract, including General Conditions,

Conditions of Particular Application and Division-1 specification sections, apply to
this section.
1.2 DESCRIPTION
This section covers the automatic clean agent fire extinguishing systems.
Comply with the applicable requirements set forth in the latest edition of the
listed standards for the design, equipment, installation, testing and maintenance
of extinguishing agent:
National Fire Protection Association

NFPA No.
70 National Electrical Code

72 National Fire Alarm Code
75 Electronic Computer System
2001 Clean Agent Systems
1.4 SUBMITTALS
Submit the following in accordance with Conditions of Contract and Division-1

specification sections:
1.4.1 Product Data: submit product data for approval prior to installation.
1.4.2 The installing contractor shall submit the following design information to the local
Fire Prevention Agency, owners Insurance Underwriter, Architect/Engineer, and
all other Authorities Having Jurisdiction before starting installation:
Field installation layout drawings having a scale of not less than 1:100 detailing
the location of all agent storage tanks, pipe runs including pipe sizes and lengths,
control panel(s), detectors, manual pull stations, abort stations, audible and visual
alarms, etc.
Auxiliary details and information such as maintenance panels, door holders,

special sealing requirements and equipment shutdowns.
Separate layouts, or drawings, shall be provided for each level, (i.e.; room, sub-
floor, and above reflected ceiling) and for mechanical and electrical work.
A separate layout or drawing shall show isometric details of agent storage

containers, mounting details and proposed pipe runs and sizes.
Electrical layout drawings shall show the location of all devices and include point-
to-point conduit runs and a description of the method(s) used for detector
mounting.
Internal control panel wiring diagram shall include power supply requirements
and field wiring termination points.
Graphic annunciator wiring schematics and dimensioned display panel illustration

shall be provided. (Optional device)
Complete hydraulic flow calculations, from a UL listed computer program, for all
engineered Clean Agent systems. Calculation sheet(s) must include the
manufacturers name and UL listing number for verification. The individual
sections of pipe and each fitting to be used, as shown on the isometrics, must be
identified and included in the calculation. Total agent discharge time must be
shown and detailed by zone.
Provide calculations for the battery stand-by power supply taking into
consideration the power requirements of all alarms, initiating devices and
auxiliary components under full load conditions.
A complete sequence of operation shall be submitted detailing all alarm devices,

shutdown functions, remote signaling, damper operation, time delay and agent
discharge for each zone or system.
System component datasheets.
1.4.3 Record Drawings: At project close-out, submit drawings of installed systems in

1.4.4 Operation and Maintenance Manual for the systems and equipment.
1.4.5 Sequence of operation detailing alarm devices, shutdown functions, remote

signaling, damper operation, time delay and agent discharge for each system.
1.5 SYSTEM DESCRIPTION AND OPERATION
Total flooding clean agent extinguishing systems. The system shall provide 7.5%
by volume minimum design concentration at 21 degree C. with flooding factor of
3
0.5887 kg/m for each protected room. The header shall be equipped with a
pressure relief valve. The systems shall include required mechanical and electrical
installation, detection and control equipment, agent storage cylinders, nozzles,

pipe and fittings, weighing device, manual release and abort stations, audible and
visual alarm devices, auxiliary devices and controls, shut down, alarm interface,
caution/advisory signs and functional checkout and testing.
The systems shall be actuated by an optical smoke/heat detectors installed at a

maximum spacing of 25 m2 per detector. If air flow exceeds one air change per
minute, optical detectors only shall be installed at spacing not exceeding 12.5 m 2
per detector. Detectors shall be wired to provide double knock signal using
verified detection method of operation.
1.5.1 The automatic operation of each protected area shall be as follows:
 Actuation of one (1) detector, within the system, shall:

 Illuminate the related "ALARM" lamp on the control panel,
 Energize an alarm bell and visual indicator located inside protected area,
 Activate two (2) sets of 10 Amp rated auxiliary contacts which shall operate
door holders/activate fire curtains, transmit a signal to fire alarm panel and
to shutdown HVAC equipment/dampers.
 Actuation of a second detector, within the system, shall:
 Illuminate a related "PRE-DISCHARGE" lamp on the control panel,
 Energize an alarm horn/strobe device located outside protected areas,
 Start time-delay sequence (not to exceed 30 second),
 Enable system abort sequence,
 Shut down the HVAC system and/or close dampers.
 After completion of the time-delay sequence, the agent shall be discharged
and the following shall occur:
 Illuminate a related "SYSTEM FIRED" lamp on the control panel,
 Shut down of all power to equipment.
 The system shall be capable of being actuated by manual discharge device
located at exit of each protected area. Operation of a manual device shall
duplicate the "Verified Detection" sequence described above except the time
delay and abort functions shall be by-passed. The manual discharge station
shall be of the electrical actuation type and shall be supervised at the main
control panel.
1.6 APPROVALS
All equipment shall be approved and listed by at least one international

recognized testing laboratory such as: VDS, CNPP, LPC, and UL/FM.
The following sections include requirements which relate to this sections:

16050 Basic Electrical Materials and Methods
1.8.1 QUALIFICATIONS:
Manufacturer:
The manufacturer of the Suppression System hardware and detection

components shall have a minimum of 10 years experience in the design and
manufacture of similar types of suppression systems and can refer to similar
installations providing satisfactory service.
The name of the manufacturer, part numbers and serial numbers shall appear on
all major components.
All devices, components and equipment shall be the products of the same
manufacturer.
All devices, components and equipment shall be new, standard products of the
manufacturer’s latest design and suitable to perform the functions intended.
Locks for all cabinets shall be keyed alike.
Installer:
The installing contractor shall be trained by the supplier to design, install, test and
maintain Suppression Systems.
The installing contractor shall be an experienced firm regularly engaged in the

installation of automatic Clean Agent, or similar, fire suppression systems in strict
accordance with all applicable standards.
The installing contractor must have a minimum of five (5) years experience in the
design, installation and testing of Clean Agent, or similar, fire suppression
systems. A list of systems of a similar nature and scope shall be provided on
request.
The installing contractor shall maintain a Clean Agent system.
The installing contractor shall be an authorized stocking distributor of the Clean

Agent system equipment so that immediate replacement parts are available from
inventory.
The installing contractor shall show proof of emergency service.

1.8.2 Regulatory Requirements:
Conform to the applicable building codes for the requirements specified herein.
Codes and Permits: Conform to the local code requirements applicable to this
section. Obtain and pay any necessary permits prior to beginning work involved in
this section.
1.9.1 Acceptance at Job Site:
Deliver materials to job site in a sealed, original containers bearing the

manufacturer’s labels.
Materials arriving at the job site without labels, opened or damaged shall not be
accepted for use.
1.9.2 Storage and Protection:
Store, protect and handle the products at the job site under provision of Contract,
including General Conditions.
Materials shall be stored in a well ventilated areas.
1.10 SCHEDULING
Coordinate work performed under this section with other works and disciplines.
PART 2 PRODUCTS
2.1 PIPING
Comply with NFPA 2001.
Piping material and dimensions shall be as mentioned below.
Pipes: Seamless steel pipes schedule 40 to ASTM A 53 Grade B. Nonmetallic

pipes are not allowed.
Fittings: Malleable iron fittings rated 2000 kPa (300 lb class) to ASTM A 197.
Fittings rated 1000 kPa are not allowed.
Jointing: Threaded, welded, flanged and grooved as long as they conform to the
above requirements. Do not use hole-cut fittings.
All piping must be galvanized.
Welding on pipes and fittings shall be cold dip coated following installation.

Pipe hangers and supports shall be to MSS SP-58, MSS SP-69 and MSS SP-90 and
shall be hot-dip galvanized and listed for fire protection service.
2.2 STORAGE CONTAINERS AND DISTRIBUTION SYSTEM
Each system shall have its own supply of clean agent.
Systems shall be designed in accordance with the manufacturer's guidelines.
Each supply shall be located within the hazard area, or as near as possible.
The clean agent shall be stored in Agent Storage Containers. Containers shall be
super-pressurized, with dry Nitrogen, to an operating pressure of 360 psi @ 70° F.
(2482 kpa at 21° C). Containers shall be of high-strength alloy steel construction
and conform to NFPA 2001.
Containers shall be actuated by gas cartridge actuator wired to a an agent release

module (ARM) located at each agent container. Using a solenoid valve for
container actuation shall also be accepted.
Each container shall have a pressure gauge, liquid level indicator and low pressure
supervisory switch to provide visual and electrical supervision of the container
pressure. The low pressure supervisory switch shall be wired to the control panel
to provide an audible and visual "Trouble" alarm in the event the container
pressure drops below 288 psi (1986 kPa). The pressure gauge shall be color coded
to provide an easy, visual indication of container pressure.
Each container shall have a pressure relief provision that automatically operates
when the internal temperature exceeds 150°F. (66°C).
Distribution piping, and fittings, shall be installed in accordance with the

manufacturer's requirements, NFPA 2001 and approved piping standards and
guidelines. All distribution piping shall be installed by qualified individuals using
good, accepted practices and quality procedures. All piping shall be adequately
supported and anchored at all directional changes and nozzle locations.
All piping shall be reamed, blown clear and swabbed with suitable solvents to
remove burrs, mill varnish and cutting oils before assembly.
All pipe threads shall be sealed with Teflon tape pipe sealant applied to the male
thread ONLY.
2.3 DISCHARGE NOZZLES
Engineered discharge nozzles of gray anodized aluminum shall be provided,

within the manufacturers guidelines, to distribute the agent throughout the
protected spaces. The nozzles shall be designed to provide proper agent quantity
and distribution.

Nozzles shall be available in pipe sizes 10 mm thru 50mm. Each size shall be
available in 180° and 360° distribution patterns.
Ceiling plates shall be used to conceal pipe entry holes through ceiling tiles.
2.4 DETECTION SYSTEM
2.4.1 Detection System, Single Zone
The control panel used where an automatic control system is required to activate
the fixed clean agent system.
The control system shall be used to operate a single fixed fire suppression or
alarm system based on inputs received from approved detection devices.
Detection circuits to be configured using cross-zone, verified detection or single

input release concepts.
System shall have an adjustable pre-discharge time delay circuit to allow

evacuation of the protected area prior to the discharge of clean agent.
System shall be of listing as mentioned in part 1 GENERAL and comply with all
requirements of NFPA Standards 2001, 71, 72A and 72D.
2.4.2 Detection System, Multi-Zone:
The control system used shall be multi-zone control system where an automatic
system is required to activate and coordinate multiple zones of fixed clean agent
systems.
All inputs shall be analog or addressable; configured as cross-zone, verified

detection or single input release concepts.

evacuation of the protected area prior to the discharge of clean agent.
System shall be microprocessor based and field programmable using a computer

/ software interface.
System shall be capable of remote site status reporting via fiber-optic or modem
communication means.
System shall be capable of providing addressable output functions.

2.5 DETECTORS
Provide optical smoke / heat detectors in protected areas.
Detectors shall be documented compatible with the control equipment to which

it is connected. The detectors shall obtain their operating power from the control
panel.
To minimize nuisance alarms, voltage and RF transient suppression techniques

shall be employed as well as an insect screen. All detector designs shall provide
full solid-state construction.
Each detector base or the detector itself shall have a flashing status indicating LED
for visual supervision. When the detector is activated, the flashing LED will latch
on steady and at full brilliance until it is reset by the reset switch, from the control
panel.
Detectors shall be plug-in lockable with separate base.
The optical smoke detectors shall be sensitive to visible and invisible products of
combustion.
2.6 CONTROL PANEL
The control panel shall be listed as mentioned in part 1 GENERAL as a "Releasing

Device" to perform the functions necessary to operate the systems detections,
actuation and auxiliary functions as per NFPA requirements and outlined here
below.
Provide wall mounted, 18 gauge metal cabinet suitable for electrical circuits with
a hinged, locked door painted with approved finish, 220 VAC, 50 Hz, audible and
visual "Trouble" sign in the event of a loss of A/C, rectified or battery power
occurred, self-contained 24 VDC emergency power supply including a battery
charger and rechargeable batteries with a minimum rating of 6 Amp hours.
Include in addition to the above the following features in a single enclosure:
 Audible circuits - each rated 24 VDC, 0.25 A

 Audible silence switches
 Sets of 10 A auxiliary contacts
 Diagnostic LED's for easy trouble shooting
 Solid-state, field programmable time delay 0-60 seconds
 abort options
 Protective covers over high voltage terminals
 Connections to power a remote annunciator
 Incoming power circuit breaker. Not a fuse

 Agent cylinder isolating switch for facilitating the testing. Operation of the
switch cause a trouble signal
 Verified detection
 Parallel wired agent release modules
 Class "A" wiring of detection and agent release circuits.
The supplied control panel shall be microprocessor base and capable of

integration to a fire alarm system. All software and hardware required for the
integration must be included in the package. Coordinate with fire alarm system
installer.
2.7 MANUAL RELEASE SWITCH
Dual action device for manual discharge of the agent. The manual actuation shall
bypass the time delay and abort functions, shall cause the system discharge and
shall cause all alarm and shutdown devices to operate in the same manner as if
the system had operated automatically.
2.8 ABORT STATION
Locate next to each manual release switch and shall be supervised and shall
indicate a trouble condition at the control panel if depressed.
2.9 AUDIBLE AND VISUAL ALARMS
Provide 150mm diameter alarm bell, alarm horn and visual alarm strobe with
label attached to strobe lens.
2.10 CAUTION / ADVISORY SIGNS
Provide, in Arabic and English, signs as required to comply with NFPA

recommendations at entrance to each protected area, for manual discharge
stations, for flashing light over each exit from a protected space.
2.11 FIRE DOORS TO PROTECTED AREAS
Fit automatic self-closing doors at all entrances to protected areas. Provide each
door / leaf with electrically actuated magnetic door holder to close the door
automatically upon receiving a signal from the control panel. The doors shall also
close manually.
2.12 FIRE CURTAINS
Roll up type, fiber glass installed in such a manner that upon receiving a signal
from the control panel, in case of fire, the holding mechanism will let loose the
curtain to fall through a "U" channel guide.

2.13 WALL PENETRATION
Seal all openings in walls, floors or ceilings within the protected areas with 2
hours rated fire-proof sealant.
2.14 WIRING AND CONDUITS
As specified in Sections 16050 and 16721.
PART 3 EXECUTION
3.1 INSTALLATION
All installation shall be in accordance with manufacturer's written instruction, and

NFPA Standards and shall be earthed.
3.2 SYSTEM INSPECTION AND CHECKOUT
3.2.1 Check the entire system after the system installation has been completed by
qualified, trained personnel in accordance with the manufacturer's recommended
procedures and NFPA standards:
 Check for proper mounting and installation all containers and distribution
piping.
 Test for proper connection, continuity and resistance to ground all electrical
wiring.
 Functionally test the complete system in the presence of the Engineer or his
representative and all functions, including system and equipment interlocks,
must be operational at least five (5) days prior to the final acceptance tests.
 Test each detector in accordance with the manufacturer's recommended

procedures, and test values recorded.
 All system and equipment interlocks, such as door release devices, audible
and visual devices, equipment shutdowns, local and remote alarms, etc.,
shall function as required and designed.
 Test each control panel circuit for trouble by inducing a trouble condition
into the system.
 The piping shall be pneumatically tested in a closed circuit for a period of
10 minutes at 150 PSI. At the end of 10 minutes, the pressure drop shall
not exceed 20 percent of the test pressure.
 When pressurizing the piping, pressure shall be increased in 50-PSI
increments.
 A flow test using nitrogen (or air) shall be performed on the piping network
to verify that flow is continuous, and the piping and nozzles are
unobstructed.

3.3 TRAINING REQUIREMENTS
The contractor shall provide technical training issue as one of the most
essential points for the buildings dedicated facility staff who will be capable of
doing a day to day operation and management of the buildings and keep its
valuable systems efficient.
The concerned training should:
Include the equipments factory tests.
Be performed by the manufacturers technical staff (mother company).
Be for efficient time.
Be for dedicated enough people of the facility staff (number of trainee shall be
defined by the owner).
consider using all the practical tools and instruments during the training.
3.4 OPERATION AND MAINTENANCE
Prior to final acceptance, provide complete operation and maintenance

instruction manuals for each system, to the Engineer. Detail all aspects of system
operation and maintenance, including piping isometrics, wiring diagrams of all
circuits, a written description of the system design and sequence of operation,
drawing(s) illustrating control logic and equipment used in the system. Include in
the manual checklists and procedures for emergency situations, troubleshooting
techniques and maintenance operations and procedures.
3.5 RECORD DRAWINGS
Upon completion of each system, provide a copy of "Record" drawings for each
system to the Engineer. The drawings shall show actual installation details
including all equipment locations (i.e. control panel(s), agent container(s),
detectors, alarms, manual and abort release stations, etc.), as well as piping and
conduit routing details. Show all room or facilities modifications, including door
and / or damper installations completed. Provide a copy of reproducible
engineering drawings plus a copy of electronic files reflecting all actual installation
details.
3.6 ACCEPTANCE TESTS
At the time "Record" drawings and maintenance / operations manuals are

submitted, submit a "Test Plan" describing procedures to be used to test the
clean agent system(s). The Test Plan shall include a step-by-step description of all
tests to be performed and shall indicate the type and location of test apparatus to
be employed. The tests shall demonstrate that the operational and installation
requirements of this specification have been met. All tests shall be conducted in
the presence of the Engineer and shall not be conducted until the Test Plan has
been approved.

The tests shall demonstrate that the entire control system functions as designed
and intended. All circuits shall be tested: automatic actuation, manual actuation,
HVAC and power shutdowns, audible and visual alarm devices, manual override
of abort functions and agent container pressure supervision. Supervision of all
panel circuits, including AC power and battery power supplies, shall be tested and
qualified.
Upon acceptance by the Owner, the completed system(s) shall be placed in

normal service.
3.7 SYSTEM INSPECTIONS
Provide two (2) inspections of each system, installed under this contract, during
the one-year warranty period. The first inspection shall be at the six month
interval, and the second inspection at the twelve month interval, after system
acceptance. Inspections shall be conducted in accordance with the
manufacturer's guidelines and shall comply with the recommendations of NFPA
2001.
Documents certifying satisfactory system(s) operation shall be submitted to the

Employer upon completion of each inspection.
3.8 WARRANTY
The system shall be warranted for parts and labor for not less than a period listed
in the contract conditions from date of initial handing over of the work and
Owner’s acceptance.
A system-checking schedule showing site visits shall be submitted to the owner

for approval.

complete fire protection systems until the end of contract defect’s liability period
including all required spare parts, maintenance equipment, tools, aluminum
ladder, all labor and supervision in carrying out all routine operational
maintenance and full preventive maintenance activities during such period.
3.9 SPARE PARTS


The contractor shall also provide the necessary spare parts as per the
manufacturer's recommendations for a working period of three years for all fire
protection systems.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. CARBON DIOXIDE EXTINGUISHING
CAIRO - EGYPT SYSTEMS
13968 - 2039 0

CONTENTS
SECTION 13968
CARBON DIOXIDE EXTINGUISHING SYSTEMS
Page
PART 1 GENERAL 3
1.2 Description 3
1.4 Submittals 3
1.5 System Description and Operation 4
1.6 Approvals 5
1.9 Delivery, Storage And Handling 6
1.10 Scheduling 6
PART 2 PRODUCTS 6
2.1 Pipes And Fittings 6
2.2 Carbon Dioxide Agent 7
2.3 Gas Cylinders 7
2.4 Cylinder Assembly 7
2.5 Discharge Nozzles 7
2.6 Solenoid Actuator 7
2.7 Manual Actuator 8
2.8 Cylinder Straps And Racking 8
2.9 Stop / Maintenance Valve 8
2.10 Detection System 8
2.12 Control Panel 10
2.13 Manual Release Switch 10
2.14 Abort Station 11
2.15 Audible And Visual Alarms 11
2.16 Caution / Advisory Signs 11
2.17 Fire Doors To Protected Areas 11
2.18 Fire Curtains 11
2.19 Wall Penetration 11
2.20 Wiring And Conduits 11
2.21 Selector (Directional) Valves 11
PART 3 EXECUTION 12
3.1 Installation 12
3.2 System Inspection and Checkout 12
3.3 Training Requirements 13
3.4 Operation And Maintenance 13
3.5 Record Drawings 13
Carbon Dioxide Extinguishing Systems Section 13968

Egypt Phase 1&2 (Cost Reduction) (Prj. 2039) Sheet 0 of 7
3.6 Acceptance Tests 13
3.7 System Inspections 14
3.8 Warranty 14
3.9 Spare Parts 14

SECTION 13968
CARBON DIOXIDE EXTINGUISHING SYSTEMS
PART 1 GENERAL
Drawings and general provisions of Contract, including General Conditions,

Conditions of Particular Application and Division-1 specification sections, apply
to this section.
1.2 DESCRIPTION
This section covers the automatic carbon dioxide fire extinguishing systems in
the main electric rooms.
Comply with the applicable requirements set forth in the latest edition of the
listed standards for the design, equipment, installation, testing and
maintenance of extinguishing agent:
National Fire Protection Association

NFPA No.
12 Carbon dioxide Extinguishing Systems

70 National Electrical Code
72 National Fire Alarm Code
75 Electronic Computer System
1.4 SUBMITTALS
Submit the following in accordance with Conditions of Contract and Division-1

specification sections:
1.4.1 Product Data: submit product data for approval prior to installation.
1.4.2 Field installation layout detailing the location of agent storage tanks, sectional
valves (if any), pipe runs including pipe sizes and lengths, control panel(s),
detectors, manual pull stations, abort stations, audible and visual alarms, etc.
1.4.3 Auxiliary details and information such as maintenance panels, door holders,
special sealing requirements and equipment shutdowns.
1.4.4 Separate layouts and isometric details for each protected area.
1.4.5 Electrical layout drawings showing the locations of devices and include point-
to-point conduit runs.

1.4.6 Internal control panel wiring diagram including power supply requirements
and field wiring termination points.
1.4.7 Graphic annunciator wiring schematics and dimensioned display panel

illumination.
1.4.8 Complete hydraulic flow calculations, using a UL listed computer software.
1.4.9 Calculations for battery standby power supply taking into consideration the
power requirements of alarms, initiating devices and auxiliary components
under full load conditions.
1.4.10 Record Drawings: At project close-out, submit drawings of installed systems in

1.4.11 Operation and Maintenance Manual for the systems and equipment.
1.4.12 Sequence of operation detailing alarm devices, shutdown functions, remote

signaling, damper operation, time delay and agent discharge for each system.
1.5 SYSTEM DESCRIPTION AND OPERATION
Total flooding carbon dioxide extinguishing systems. The system provides 50%
by volume minimum design concentration with flooding factor of 1.33 kg/m3
for the electrical substations. The system for each room shall consist of a CO2
cylinders set (number of cylinders as shown on the drawings), each of the
same capacity and as indicated on the drawings. The header shall be equipped
with a pressure relief valve. The systems shall include required mechanical and
electrical installation, detection and control equipment, agent storage
cylinders, nozzles, pipe and fittings, weighing device, manual release and abort
stations, audible and visual alarm devices, auxiliary devices and controls, shut
down, alarm interface, caution/advisory signs and functional checkout and
testing.
The systems shall be actuated by an optical smoke / heat detectors installed at

a maximum spacing of 25 m2 per detector. If air flow exceeds one air change
per minute, optical detectors only shall be installed at spacing not exceeding
12.5 m2 per detector. Detectors shall be wired to provide double knock signal
using verified detection method of operation.
The automatic operation of each protected area shall be as follows:
1.5.1 Actuation of one (1) detector, within the system, shall:
Illuminate the related "ALARM" lamp on the control panel,
Energize an alarm bell and visual indicator located inside protected area,
Activate two (2) sets of 10 Amp rated auxiliary contacts which shall operate

door holders/activate fire curtains, transmit a signal to fire alarm panel and to
shutdown HVAC equipment/dampers.
1.5.2 Actuation of a second detector, within the system, shall:
Illuminate a related "PRE-DISCHARGE" lamp on the control panel,
Energize an alarm horn/strobe device located outside protected areas,
Start time-delay sequence (not to exceed 30 second),
Enable system abort sequence,
Shut down the HVAC system and/or close dampers.
1.5.3 After completion of the time-delay sequence, the agent shall be discharged
and the following shall occur:
Illuminate a related "SYSTEM FIRED" lamp on control panel,
Shut down of all power to equipment.
The system shall be capable of being actuated by manual discharge device

located at exit of each protected area. Operation of a manual device shall
duplicate the "Verified Detection" sequence described above except the time
delay and abort functions shall be by-passed. The manual discharge station
shall be of the electrical actuation type and shall be supervised at the main
control panel.
1.6 APPROVALS
All equipment shall be formally approved and listed by at least one

international recognized testing laboratory such as: VDS, CNPP, LPC, UL / FM.
The following sections include requirements which relate to this sections:
16050 Basic Electrical Materials and Methods

1.8.1 QUALIFICATIONS:
Manufacturer: The manufacturer of the system components shall have a

minimum of 10 years experience in the manufacture and design of specialized
fire suppression systems and related fire detection and control equipment.
Installer: The installer shall be authorized and trained by the manufacturer to

design, install and maintain carbon dioxide fire suppression systems.
1.8.2 Regulatory Requirements:
Conform to the applicable building codes for the requirements specified

herein.
Codes and Permits: Conform to the local code requirements applicable to this
section. Obtain and pay any necessary permits prior to beginning work
involved in this section.
1.9.1 Acceptance at Job Site:
Deliver materials to job site in a sealed, original containers bearing the

manufacturer’s labels.
Materials arriving at the job site without labels, opened or damaged shall not
be accepted for use.
1.9.2 Storage and Protection:
Store, protect and handle the products at the job site under provision of
Contract, including General Conditions.
Materials shall be stored in a well ventilated areas.
1.10 SCHEDULING
Coordinate work performed under this section with other works and
disciplines.
PART 2 PRODUCTS
2.1 PIPES AND FITTINGS
2.1.1 Pipes: Comply with NFPA 12, seamless steel pipes to ASTM A53 Grade B. Sch.
40 for ¾" and smaller, Sch. 80 for 1" and larger. Non-metal pipes are not
allowed.
2.1.2 Fittings: Comply with NFPA 12, fittings up to 2" shall be malleable iron fittings
rated for 2000 kPa (300 lb class) to ASTM A-197. Fittings rated for 1000 kPa
are not allowed. Forged steel fittings shall be used for larger sizes.
2.1.3 Jointing: Threaded, welded and flanged as long as they conform to the above
requirements. Do not use hole-cut fittings.

2.2 CARBON DIOXIDE AGENT
A clean, dry, non-corrosive, non-damaging, non-deteriorating chemical

meeting the requirements outlined in NFPA Standard No. 12.
2.3 GAS CYLINDERS
High-strength alloy steel to comply with the Department of Transportation

Regulation DOT 3A 1800 or 3AA 1800 for refillable pressure vessels and
conform to NFPA 12.
Locate on each cylinder agent release module and a weighing device with
remote alarm switch for visual and electric supervision of the cylinder weight.
Wire the low weight switch to the control panel to provide an audible and
visual "Trouble" alarm in the event the cylinder weight drops of 10%.
2.4 CYLINDER ASSEMBLY
Seamless steel construction with a red enamel or epoxy finish and equipped
with pressure differential discharge valve.
Valve constructed of brass and anodized aluminum capable of withstanding a

maximum pressure of 6,000 PSI
Valve to accommodate a “straight-through” discharge without any directional
changes for maximum discharge efficiency.
Valve to contain a safety pressure relief device
Cylinder shipped with maintenance record card and shipping cap attached.
Cylinder serial number, full and empty weight capacities and part number
recorded on a cylinder identification label attached to the cylinder.
2.5 DISCHARGE NOZZLES
Discharge nozzles shall be designed to direct the discharge of carbon dioxide

agent in a liquid or gaseous state.
Orifice sizes to be determined by a UL listed hydraulic calculation software

based on flow rate and the system design requirements.
Nozzles to be constructed of natural brass or zinc plated aluminum for

maximum corrosion resistance.
Nozzles to be equipped with flange mounting kits and sealing discs where
necessary.
2.6 SOLENOID ACTUATOR
Electrical actuation of agent cylinder to be accomplished by an electric

solenoid actuator interfaced through a compatible control panel by the system
manufacturer.

The actuator must be capable of being used in hazardous or non-hazardous
environments.
The actuator shall not require a special re-arming tool to reset the actuator
after operation.
2.7 MANUAL ACTUATOR
Manual actuation of the system shall be accomplished by pulling the hand

lever on the actuator.
A manual actuator must be provided when the solenoid actuator does not
include a manual operator.
2.8 CYLINDER STRAPS AND RACKING
Cylinder straps shall be supplied for all single cylinder systems as a minimum.
Straps may be used on any number of cylinders.
Cylinder racking shall be supplied for multiple cylinder systems. Racking shall
be available in single row, double row and back-to-back arrangements.
Provisions for weighing the cylinders in place shall be available.
2.9 STOP / MAINTENANCE VALVE
A Stop / Maintenance Valve shall be included on each system to provide a

manual shut-off means for the system during maintenance operations.
The Stop / Maintenance Valve will prevent the discharge of carbon dioxide
from the nozzles, thus providing fail-safe protection for the service technician.
Stop Valves shall be constructed of stainless steel and be capable of

withstanding pressures of up to 5000 psi.
Valve shall of UL listed / FM approved limit switch as part of the assembly to

annunciate a trouble signal to the control panels whenever the valve is closed.
Valve handle shall be lockable in either the open or closed positions for
security purposes.
2.10 DETECTION SYSTEM
2.10.1 Detection System, Single Zone: The control panel used where an automatic
control system is required to activate the fixed carbon dioxide system.
The control system shall be used to operate a single fixed fire suppression or
alarm system based on inputs received from approved detection devices.
Detection circuits to be configured using cross-zone, verified detection or

single input release concepts.

evacuation of the protected area prior to the discharge of carbon dioxide.
2.10.2 Detection System, Multi-Zone: The control system used shall be multi-zone
control system where an automatic system is required to activate and
coordinate multiple zones of fixed carbon dioxide systems.
All inputs shall be analog or addressable; configured as cross-zone, verified

detection or single input release concepts.

evacuation of the protected area prior to the discharge of carbon dioxide.
System shall be microprocessor based and field programmable using a

computer / software interface.
System shall be capable of remote site status reporting via fiber-optic or

modem communication means.
System shall be capable of providing addressable output functions.
2.11 DETECTORS
Provide optical smoke/heat detectors in protected areas.
Detectors shall be documented compatible with the control equipment to

which it is connected. The detectors shall obtain their operating power from
the control panel.
To minimize nuisance alarms, voltage and RF transient suppression techniques
shall be employed as well as an insect screen. All detector designs shall
provide full solid-state construction.
Each detector base or the detector itself shall have a flashing status indicating
LED for visual supervision. When the detector is activated, the flashing LED will
latch on steady and at full brilliance until it is reset by the reset switch, from
the control panel.
Detectors shall be plug-in lockable with separate base.
The optical smoke detectors shall be sensitive to visible and invisible products
of combustion.

2.12 CONTROL PANEL
The control panel shall be listed as mentioned in part 1 GENERAL as a

"Releasing Device" to perform the functions necessary to operate the systems
detections, actuation and auxiliary functions as per NFPA requirements and
outlined here below.
Provide wall mounted, 18 gauge metal cabinet suitable for electrical circuits
with a hinged, locked door painted with approved finish, 220 VAC, 50 Hz,
audible and visual "Trouble" sign in the event of a loss of A/C, rectified or
battery power occurred, self-contained 24 VDC emergency power supply
including a battery charger and rechargeable batteries with a minimum rating
of 6 Amp hours.
2.12.1 Include in addition to the above the following features in a single enclosure:
 Audible circuits - each rated 24 VDC, 0.25 A

 Audible silence switches
 Sets of 10 A auxiliary contacts
 Diagnostic LED's for easy trouble shooting
 Solid-state, field programmable time delay 0-60 seconds
 abort options
 Protective covers over high voltage terminals
 Connections to power a remote annunciator
 Incoming power circuit breaker. Not a fuse
 Agent cylinder isolating switch for facilitating the testing. Operation of the
switch cause a trouble signal
 Verified detection
 Parallel wired agent release modules
 Class "A" wiring of detection and agent release circuits.
The supplied control panel shall be microprocessor base and capable of

integration to a BMS system (and / or) fire alarm system. All software and
hardware required for the integration must be included in the package.
coordinate with BMS (and / or) fire alarm system.
2.13 MANUAL RELEASE SWITCH
Dual action device for manual discharge of the agent. The manual actuation
shall bypass the time delay and abort functions, shall cause the system
discharge and shall cause all alarm and shutdown devices to operate in the
same manner as if the system had operated automatically.

2.14 ABORT STATION
Locate next to each manual release switch and shall be supervised and shall
indicate a trouble condition at the control panel if depressed.
2.15 AUDIBLE AND VISUAL ALARMS
Provide 150 mm dia alarm bell, alarm horn and visual alarm strobe with label
attached to strobe lens.
2.16 CAUTION / ADVISORY SIGNS
Provide, in Arabic and English, signs as required to comply with NFPA

recommendations at entrance to each protected area, for manual discharge
stations, for flashing light over each exit from a protected space.
2.17 FIRE DOORS TO PROTECTED AREAS
Fit automatic self-closing doors at all entrances to protected areas. Provide

each door / leaf with electrically actuated magnetic door holder to close the
door automatically upon receiving a signal from the control panel. The doors
shall also close manually.
2.18 FIRE CURTAINS
Roll up type, fiber glass installed in such a manner that upon receiving a signal
from the control panel, in case of fire, the holding mechanism will let loose the
curtain to fall through a "U" channel guide.
2.19 WALL PENETRATION
Seal all openings in walls, floors or ceilings within the protected areas with 2
hours rated fire-proof sealant.
2.20 WIRING AND CONDUITS
As specified in Sections 16050 and 16721.
2.21 SELECTOR (DIRECTIONAL) VALVES
Valves in sizes 1/2" to and including 2" shall be ball type approved for low
pressure carbon dioxide service. Valves in sizes 3" and larger shall be high
performance butterfly style suitable for low pressure carbon dioxide service.
In the standby condition, the master valve or selector valve shall not fail open.
The valves shall not open automatically in the event of any electric or pneumatic
failure.
Valves provided with spring return pneumatic actuators shall not require CO2
vapor pressure to hold these valves closed. A manually operated pneumatic

override valve shall be mounted on each valve actuator for emergency manual
operation and shall be installed in an easily accessible location.
Valves provided with double acting actuators shall not require CO2 vapor
pressure to keep the valve closed. A manually operated pneumatic override valve
shall be mounted on each valve actuator for emergency manual operation and
shall be installed in an easily accessible location.
The use of remote mounted pilot cabinets to provide emergency mechanical

operation shall not be permitted.
PART 3 EXECUTION
3.1 INSTALLATION
All installation shall be in accordance with manufacturer's written instruction

and NFPA Standards.
3.2 SYSTEM INSPECTION AND CHECKOUT
3.2.1 Check the entire system after the system installation has been completed by
qualified, trained personnel in accordance with the manufacturer's
recommended procedures and NFPA standards:
3.2.2 Check for proper mounting and installation all containers, directional valves
and distribution piping.
 Test for proper connection, continuity and resistance to ground all electrical
wiring.
 Functionally test the complete system in the presence of the Engineer or his
representative and all functions, including system, equipments and
interlocks. The system shall be operational. The function test shall be
provided at least five days prior to the final acceptance tests as follows:
 Test each detector in accordance with the manufacturer's recommended

procedures and test values recorded.
 All system, equipment and interlocks such as door release devices, audible,
visual devices, equipment shutdowns, local and remote alarms, etc., shall
function as required and designed.
 Test each control panel circuit for trouble by inducing a trouble condition
into the system.
 The piping shall be pneumatically tested in a closed circuit for a period of
10 minutes at 150 PSI. At the end of 10 minutes, the pressure drop shall
not exceed 20 percent of the test pressure.
 When pressurizing the piping, pressure shall be increased in 50-PSI
increments.

 A flow test using nitrogen (or air) shall be performed on the piping network
to verify that flow is continuous, and the piping and nozzles are
unobstructed.
3.3 TRAINING REQUIREMENTS
3.3.1 The contractor shall provide technical training issue as one of the most
essential points for the buildings dedicated facility staff who will be capable of
doing a day to day operation and management of the buildings and keep its
valuable systems efficient.
3.3.2 The concerned training should:
 Include the equipments factory tests.

 Be performed by the manufacturers technical staff (mother company).
 Be for efficient time.
 Be for dedicated enough people of the facility staff (number of trainee shall
be defined by the owner).
 consider using all the practical tools and instruments during the training.
3.4 OPERATION AND MAINTENANCE
Prior to final acceptance, provide complete operation and maintenance

instruction manuals for each system, to the Engineer. Detail all aspects of
system operation and maintenance, including piping isometrics, wiring
diagrams of all circuits, a written description of the system design and
sequence of operation, drawing(s) illustrating control logic and equipment
used in the system. Include in the manual checklists and procedures for
emergency situations, troubleshooting techniques and maintenance
operations and procedures.
3.5 RECORD DRAWINGS
Upon completion of each system, provide a copy of "Record" drawings for

each system to the Engineer. The drawings shall show actual installation
details including all equipment locations (i.e. control panel(s), agent
container(s), detectors, alarms, manual and abort release stations, etc.), as
well as piping and conduit routing details. Show all room or facilities
modifications, including door and/or damper installations completed. Provide
a copy of reproducible engineering drawings plus a copy of electronic files
reflecting all actual installation details.
3.6 ACCEPTANCE TESTS
At the time "Record" drawings and maintenance / operations manuals are

submitted, submit a "Test Plan" describing procedures to be used to test the
carbon dioxide system(s). The test Plan shall include a step-by-step description
of all tests to be performed and shall indicate the type and location of test

apparatus to be employed. The tests shall demonstrate that the operational
and installation requirements of this specification have been met. All tests
shall be conducted in the presence of the engineer and shall not be conducted
until the Test Plan has been approved.
The tests shall demonstrate that the entire control system functions as
designed and intended. All circuits shall be tested: automatic actuation,
manual actuation, HVAC and power shutdowns, audible and visual alarm
devices, manual override of abort functions and agent container weight
supervision. Supervision of all panel circuits, including AC power and battery
power supplies, shall be tested and qualified.
Upon acceptance by the Employer, the completed system(s) shall be placed in

normal service.
3.7 SYSTEM INSPECTIONS
Provide two (2) inspections of each system, installed under this contract,
during the one-year warranty period. The first inspection shall be at the six
months interval, and the second inspection at the twelve month interval, after
system acceptance. Inspections shall be conducted in accordance with the
manufacturer's guidelines and shall comply with the recommendations of
NFPA 12.
Documents certifying satisfactory system(s) operation shall be submitted to

the employer upon completion of each inspection.
3.8 WARRANTY
The system shall be warranted for parts and labor for not less than a period
listed in the contract conditions from date of initial handing over of the work
and Owner’s acceptance.
A system-checking schedule showing site visits shall be submitted to the

owner for approval.

complete fire protection systems until the end of contract defect’s liability
period including all required spare parts, maintenance equipment, tools,
aluminum ladder, all labor and supervision in carrying out all routine
operational maintenance and full preventive maintenance activities during
such period.
3.9 SPARE PARTS


The contractor shall also provide the necessary spare parts as per the
manufacturer's recommendations for a working period of three years for all fire
protection systems.


ISSUED FOR
PURCHASE
CONSTRUCTION
REV. PREPARED REVIEWED APPROVED

DATE PAGES REMARKS
NO. BY BY BY
A Apr. 2015 A.M. 24 ISSUED FOR CLIENT REVIEW
0 Apr. 2015 A.M. 24 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. ELECTRIC TRACTION ELEVATORS
CAIRO - EGYPT 14210 – 2039 0

CONTENTS
SECTION 14210
ELECTRIC TRACTION ELEVATORS
Page
PART 1 GENERAL 2
1.1 Summary 2
1.2 Codes and Standards 4
1.3 Life Safety 5
1.4 Requirements of Regulatory Agencies 5
1.5 Submittals and Samples 6
1.7 Coordination 8
1.8 Testing And Commissioning 8
1.9 Approval By Local Authorities 8
1.10 Product Delivery, Storage and Handling 8
1.11 Guarantee 8
1.12 Warranty 9
1.13 Maintenance and After-Sale Service 9
1.14 Hoisting 9
PART 2 PRODUCT 10
2.1 Summary of Common Elevator(S) Specifications 10
2.2 Acceptable Manufacturers 10
2.3 Elevator System 11
2.4 Elevator(S) Equipment 14
2.5 Power Supply 18
2.6 Control and Signal Fixtures 19
2.7 Elevator Seismic Designs and Emergency Operations 20
2.8 Particular Requirement For Service / Freight Elevators 20
PART 3 EXECUTION 20
3.1 Examination 20
3.2 Installation of Elevator System 21
3.4 Acceptance Inspections and Test 23
Electric Traction Elevators Section 14210

[[
SECTION 14210
ELECTRIC TRACTION ELEVATORS
PART 1 GENERAL
Specifications and general provisions of the Contract, including General

and Supplementary Conditions and Division 1 Specification Sections, apply
to this Section.
1.1 SUMMARY
New system of one bank incorporating one electric elevators, operating on Sim-
plex Selective Collective system as applicable per each bank. The project consists
of six stories factory building. Generally the total shall be:
 1 Freight type elevators, 2500 kg, 1.5 m/sec, (Front and Rear) entrances
( as per attached drawing) .
Complete electric traction elevators shall be provided including fire and

general safety requirements inside elevator cars, landing doors, elevator
well, escape doors, pit ladders, compensating ropes and weights, shock
absorbers, machine room, electrical installations, safety devices, over
speed stopping devices and governors, name plate etc. as per manufactur-
er's standards.
The specialized elevator's supplier/manufacturers shall perform complete

site survey. and submit a report and detailed drawings including all related
parameters to traffic analysis study and report required for a complete
and integrated work.
The traffic analysis shall be based on the project data and operation re-
quirements, and on the proposed trade Elevator(s) operating parameters
to assure complying with contract requirements.
Work shall be in accordance with the latest manufacturer’s standard pro-

duction and the latest technologies complying with this specification and
with the Codes and standards, as mentioned in this specification. Where
components are not otherwise indicated, provide standard components
published by manufacturer as included in standard pre-engineered eleva-
tor systems and as required for complete system.
The Specialized Elevator’s supplier/ manufacturers shall be responsible to

furnish, install, test and service, during the guarantee period all the inte-
grated work of the Elevators.
The work will cover, but not limited to the complete design, supply, con-
struct and install the Elevator(s) in accordance with the contract details

and specification, schedules and drawings.
This includes on site and off site all labor, materials, tools and equipment,
services and operations that are necessary to accomplish this installation
in a complete and workmanship.
1.1.1 Number of elevators:
 One electric traction elevators.
1.1.2 Capacity and Speed:
 One elevators x 2500 kg , 1.5 m/s .
1.1.3 Traction Type:
 AC 3 phase- 380 V, 50 Hz closed loop Variable Voltage, Variable Fre-

quency (ACV3F) converter/inverter to drive the Permanent Magnet (PM)
gearless, energy saving, Regenerative Braking (Regenerative current),
reduced KW, traction type elevator(s).
1.1.4 Elevator(s) Work:
 Traction equipment including related electrical service.

 Control system equipment including related electrical service
 Elevator cars and related equipment and accessories such as car operat-
ing panels and position indicator controls, sound-powered telephone
jack or according to manufacturer’s standard product, car telephones/
intercoms and service panels and any material and work of the elevators
car(s) such as interior finishes, the ceiling and interior lighting.
 Counter weight(s) and ropes.
 Guide rails for car(s) and counter weight(s)
 Over speed equipment and emergency breaks

 Hoist way work equipment and devices such as hoist way entrance (s),
Buffer(s), elevator well(s), compensating ropes.
 Machine room(s) work: (as applicable in architectural drawings) Electri-
cal installations, safety devices, over speed stopping devices, name
plates etc.
 Hardware and software interfacing with the fire alarm system of the
building, and with the BMS, CCTV, LAN and MFAP of the project.( if any)
 Structural Steel Framing for Attachment plates, angle brackets, and other
preparation of structural steel for fastening guide-rail an and counter weight
guide rail brackets.

 Decorative metal and field painting
 Hoist way division steel work for guide support
1.1.5 Power Supply: The specialized Elevator’s supplier/manufacturer shall pro-

vide:
 Main and standby power supply protection and disconnect isolator

switch per set, in the machine room
 Protected electrical feeders for main and standby power
 Phase sequence, Phase corrector and over/under voltage protection
 Battery-Powered Lowering system
1.1.6 Building Work:
 Coordinate the following building works with the main contractor’s

scope of work:
 Fire alarm detectors in hoist way and machine room (if any) including
hardware and software interfacing the control system of elevators
with the fire alarm system of the building.
 Conduit and wiring of lighting, ventilating and fire alarm systems.
 Temporary power and lighting to the hoist way and machine room
 Pit/Hoist way lighting as required by codes
 Machine room-( if any )-lighting and small power
 Earthing
 Cast-in-Place Concrete and Masonry for setting sleeves, openings in
the structure, inserts, and anchoring devices in concrete and for
grouting elevator entrance frames in walls.
 Concrete work to elevator openings (Sills), car door headers, tracks
and threshold, car door hangers etc.
 Water proofing of the elevator pit.
 Metal work within the machine room(s) such as beams, hooks etc.
 Warning signage
 Temporary works
 Ventilation and cooling to machine room (if any)
1.2 CODES AND STANDARDS
All work in these specifications shall comply with the latest edition of the
codes including revisions and authorized changes in effect on the date of
these specifications.

Codes shall include:
 Applicable Local Building Laws and Codes

 Local Code for Elevators
 Local Codes for safety of buildings.
 The requirements of Local codes that govern the installation.
 EN81: Safety rules for the construction and installation of elevators
 National Fire Protection Code NFPA 70
 ANSI/ASME A-17.1
 NFPA 252, UL 10B
 BS 5655
 IBC (international building code) chapters 6 & 7
 IEC standards for Electrical materials and installations
 EN 81-70: accessibility to lifts for persons including persons with disabil-
ity.
 EN 81-72: Safety rules for the construction and installation of lifts-Particular
applications for passenger and goods passenger lifts- Part 72: Firefighters
lifts.
 EN 81-73: Safety rules for the construction and installation of lifts-Particular
applications for passenger and goods passenger lifts- Part 73: Behavior of lifts
in event of fire.
 BS 9999 : Code of practice for fire safety in the design, management and
use of buildings
1.3 LIFE SAFETY
The following are the requirements for life safety, which should be includ-
ed inside the elevators cars and machine room, as per manufacturer’s
standards and civil works scope of application:
 A sound powered fire-fighters' telephone jack (when applicable)

 Elevator hoist way and machine room(if any )fire safety provisions (es-
cape door, ladders etc.)
(1) fireman’s elevator, as part of the elevator system.
1.4 REQUIREMENTS OF REGULATORY AGENCIES
Ensure that, where applicable, the work and any materials used in the exe-
cution of the work in accordance with the contract, comply with the re-
quirements of the particular Local Authority.

Comply with the most stringent requirements of the Applicable Local Build-
ing and Ordinances and Laws.
Permits: Obtain and pay for all local construction permits and the first
year’s elevator operating permits.
1.5 SUBMITTALS AND SAMPLES
1.5.1 Submittals for Bid Evaluation:
 Full compliance schedules attached to tender documents.

 The specialized Elevator’s supplier/ manufacturers shall perform traffic
analysis based on the project data and his Elevator(s) operating parame-
ters to assure complying with contract requirements and submit a full
report.
 The specialized Elevator’s supplier/ manufacturers shall select the ap-
propriate complete elevators and submit catalogs, schedules equipment
details, brochures of his standard advertised products, having enough
technical information, necessary for evaluation.
 List of Deviations (if any)
 Country of origin list and certificates of elements of the system for simi-
lar project.
 Time Schedule.
 Provide a work schedule for each functional unit or group, fully coordi-
nated with the overall construction schedule, containing sufficient de-
tails to allow complete monitoring of work progress. Include activities
such as: engineering, design approval, manufacturing, transportation
and delivery, as well as individual installation events, related construc-
tion activity by other divisions, and the completion date for each eleva-
tor.
 Two years spare parts list (quantity only).
1.5.2 Submittals For Construction:
The specialized Elevator’s supplier/manufacturer shall submit shop draw-

ings elevator equipment details, brochures; car, entrance, and signal fixture
finish samples proposed along with a full technical specification for the
equipment to be provided and highlighting any deviations from this tender
specification, but is not limited to as follows:
 3 Copies of CDs for files of the shop drawings and required material for
review within 60 days after receipt of Notice to Proceed.
 Drawings for equipment arrangement, car enclosures hoist way sections
1:50; hoist way details 1:33-1/3; hoist way and machine room plans

1:20; elevator cars and hoist way entrances 1:20; fixtures 1:10.
 Design Information for reactions, guide rail loads, weights, heat emis-
sions, seismic loads (zone 2).
 Electrical data sheets including motor horse power or Kilo Watts (KW),
starting current, full load running current demand factor, IP, insulation
class, power factor and regenerative loads for applicable motors and
power conversion units.
 Finishing Material samples for entrance frame finishes, car sill and inte-
rior car ceiling panel.
 Shop drawings and samples of all fixtures including external lantern; ex-
ternal pushbutton; light fixture; car operating panel, etc.
 Certificate signed by Elevator Manufacturer stating that the equipment
and controls provide the specified level of elevator performance with
the contract final acceptance after adjustments, test, and inspections
are performed. Certificate should include the elevator hoist way doors,
frames, hardware and accessories.
 As-built wiring diagrams, parts ordering information, operating instruc-
tions, maintenance instructions, and lubrication chart.
 Two years spare parts list.
1.6.1 Supplier/installer Qualifications approved by the elevator manufacturer

and who has completed elevator installations similar in material, design,
and extent of work with a record of successful performance and approved
by Local Authorities.
1.6.2 Source Limitations: Obtain elevators through one source from a single
manufacturer.
 Provide major elevator components, including machines, controllers

door operators, car frames, cabs, and entrances, manufactured by a sin-
gle manufacturer.
1.6.3 Regulatory Requirements: Comply with ASME A17.1[ and elevator design
requirements for earthquake loads].
 Provide earthquake equipment required by ASME A17.1.

 Ensure that, where applicable, the work and any materials used in the
execution of the work in accordance with the contract, comply with the
requirements of the particular Local Authority.
 Comply with the most stringent requirements of the Applicable Local
Building and Ordinances and Laws.
 Permits: Obtain and pay for all local construction permits and the first

year’s elevator operating permits.
 Where necessary, obtain from the Local Authority written approval that
may be required.
1.7 COORDINATION
Coordinate installation of sleeves, block outs, elevator equipment with in-

tegral anchors, and other items that are embedded in concrete or masonry
for elevator equipment. Coordinate locations and dimensions of other
work relating to the elevator(s) including pit ladders and electrical service,
electrical outlets, lights, and switches in pits.
1.8 TESTING AND COMMISSIONING
1.8.1 Trial tests shall be performed on completion of installation work. Correc-

tions, adjustments, etc, the as necessary for the specified and required per-
formance including any labor, materials, instruments, tools and equipment
required for carrying out the tests.
1.8.2 Certificate of completion that the entire installations of all parts of the ele-
vator installations covered by this specification are in perfect working or-
der.
1.8.3 Certify that works have been executed as per the latest international
standards, specifications, approved shop drawings and materials including
performance requirements and that the elevators are safe for public usage.
1.9 APPROVAL BY LOCAL AUTHORITIES
1.9.1 The work and materials used should comply with the requirements of the
particular Local Authority.
1.9.2 Where necessary, obtain from the Local Authority written approval that
may be required.
1.10 PRODUCT DELIVERY, STORAGE AND HANDLING
1.10.1 Delivered materials should be in the Manufacturer's original, unopened

protective packaging.
1.10.2 They should be stored in their original packaging and protected from soil-
ing, physical damage or wetting.
1.10.3 Equipment and exposed finishes should be protected against damage and
stains during transportation, installation and construction period.
1.11 GUARANTEE
1.11.1 The Manufacturer shall guarantee the equipment and workman ship by a

certificate for 5 years operation and service of the elevators With condition
that:
 The elevator to be under the pre-paid maintenance of the specialized

elevator’s supplier/manufacturer
1.12 WARRANTY
1.12.1 Special Project Warranty, signed by specialized Elevator’s suppli-

er/manufacturer, agreeing to replace, repair, or restore defective materials
and workmanship of elevator work during warranty period.
1.12.2 This warranty shall be in addition to, and not a limitation of, other rights
the Owner may have against the Contractor under the Contract Docu-
ments.
1.12.3 Warranty period is 24 months starting on date of Substantial (final) Com-

pletion.
1.13 MAINTENANCE AND AFTER-SALE SERVICE
1.13.1 All maintenance during specified maintenance period.
1.13.2 Preventative maintenance on all equipment described herein for a period

of 24 months commencing on date of final acceptance. The maintenance
shall include periodical examinations, adjustment, cleaning and lubrication
of all equipment.
1.13.3 Repair or replace electrical and mechanical parts whenever required and
shall use only genuine, standard parts produced by the Manufacturer of
the equipment installed. Maintain elevator machine rooms, hoist way, and
pits in clean condition.
1.13.4 Providing maintenance service, including adequate local parts inventory.
1.13.5 Providing 24-hour-a-day emergency service and respond to trouble calls

within 1 hour and passenger entrapments within 30 minutes of notifica-
tion. Personnel shall be experienced and certified in elevator maintenance.
1.13.6 All maintenance work shall be performed by direct employers and under
his supervision
1.14 HOISTING
All required hoisting and movement of elevator equipment, shall be the re-
sponsibility of the specialized Elevator’s supplier/manufactures, Machine
room ceiling mounted hoist way hooks or beams of suitable capacity for el-
evating and positioning of the hoist machines shall be included.

PART 2 PRODUCT
2.1 SUMMARY OF COMMON ELEVATOR(S) SPECIFICATIONS
Control system : Simplex Selective Collective for the men-

tioned elevator, Generally namely as fol-
lows:
 E1.
Power Supply – 380 Volts, 3-Phase, And 50 hertz
st th
Stops – G, 1 till 6 As per attached drawings .
Served repeated Floors : 6 floors
Buffers : Oil Buffers using fire-resistant hy-
draulic fluid.
Car Enclosure : Stainless steel
Hoist way Entrances : 1.5 hours fire rated doors and frames,
according to BS or EN-81 Codes .
Motor : 240 start/ hour- insulation class “ F”
Temperature rise class ”B”
The driving motor shall have sufficient

capacity to operate continuously at
100% of its nominal load and 100% of
contract speed and for a 10 minute pe-
riod at 110% of its nominal load and
100% of its nominal speed in both direc-
tions without overheating, and will be
capable to operate at ± 10% of normal
feeder voltage and ± 3% of normal
feeder frequency value, without dam-
age of insulation, or over heat, or inter-
ruption of elevator service.
2.2 ACCEPTABLE MANUFACTURERS
Manufacturers, including but are not limited to, the manufacturer listed
below shall offer their up to date product. For the different from source
origin of the same trade, submit a manufacturer certificate to verify that
this mentioned origin is one of his pre-engineered assembling factory un-
der his trade and quality system.
Any unlisted manufacturer/country of origin cannot be submitted inside

the Bid without complete detailed verifying demonstration and registration
to the local authorities for similar project requirements, specifications and
maintenance capabilities mentioned herein, and shall be subject to the En-
gineer's acceptance.
Approved manufacturers list:
 Schindler
 ThyssenKrupp
 Otis
 Mitsubishi
 Kone
2.3 ELEVATOR SYSTEM
Provide manufacturer's standard elevator(s).
Where components are not otherwise indicated, provide standard compo-

nents published by manufacturer as included in his standard pre-
engineered elevator systems and as required for complete system, in com-
pliance with the specifications and standards.
2.3.1 Performance:
Speed : 3% variation of the nominal speed under any load-

ing condition or travel direction.
Capacity : Safely travel, stop and hold up to 125% of the rated

load.
Stopping Accuracy: Automatic 2-way stopping and leveling device shall

be provided, designed to govern the stopping accu-
racy of the car 5 mm above or below the landing sill.
This operation shall be effective regardless of the
load in the car, direction of travel, rope slippage or
stretch.
Door Times : The door opening time shall be measured from the
instant the doors start to open until they are in the
fully open position.
The door closing times shall not be less than those

permitted by the Codes.
Floor- to- Floor Time: Floor -to- Floor time for up or down travel shall be
measured from time the doors start to close until
the time the car is level and stopped at the next
floor.
Noise and Vibration : All elevator equipment shall be mechanically isolat-

ed from the structure and electrically isolated from
the building power supply to prevent mechanical
and electrical noise and vibration being transmitted
to occupied areas of the building.
Measured noise levels relating to elevator equip-

ment and its operation shall not exceed 40-45 dBA
in the elevator machine rooms and lobbies and 55
dBA in elevator cars under any condition including
door operation and car exhaust blower on highest
speed, or as per manufacturer’s standard products
and governing code .
 Acceleration and deceleration shall be constant and shall be at least

.9m/sec2 and not exceed 1.0m/sec2 with an initial ramp between 0.5
and 0.75 second or as per governing code.
 Sustained jerk shall be a minimum of 1.0m/sec3 and not exceed
1.6m/sec3 or as per governing code.
2.3.2 Control system and operation:
 Provide manufacturer's standard microprocessor operation system.

 The control system shall be adaptive to meet continually changing traf-
fic conditions to assign the "best" car to the call.
 Automatic control system reprogrammable Selective Collective Micro-
processor-Based control system shall operate without attendants from
buttons in each car and at each floor.
 The control system will assign cars to external calls based on an optimiz-
ing program designed to minimize passenger waiting time. The control
system automatically responds to changes in demand for different traf-
fic conditions such as morning peaks, two-way, outgoing, peaks and light
off-peak two-way traffic.
 The system shall be equipped with terminal emergency stopping fea-
ture.
 The car load weighing device for the passenger load in elevator(s) shall
tell the control if the car is near to full capacity. It will bypass landing
calls until some people have gotten off. The control system will not close
the doors until some of the weight is removed.
 Emergency recall and emergency stop functions shall be initiated by the
fire alarm system in elevator lobby/lobbies, hoist way(s) and machine
room(s).
 Automatic Operation (Refer to elevator banks as per drawings).
Automatic control system Selective Collective Microprocessor-Based con-

trol system shall operate without attendants from buttons in each car and
at each floor.
When a car has been started, it shall respond to calls registered for the di-
rection of its travel in the order in which the floors are reached. Once the
direction of travel has been established, the car will not reverse direction
until all car calls have been answered or until all main service floor calls,
ahead of the car and corresponding to the direction of car travel, have
been answered.
Cars shall stop automatically at floors corresponding to registered calls, in

the order in which they are approached in each direction of travel.
The cars shall only answer calls corresponding to the direction in which the
car is traveling except that it may answer a call in the opposite direction if
that call is the highest (or lowest) call registered.
When the free car is clearing calls, the home car shall respond to:
 A call registered on the home car buttons.

 An up external call registered below the free car while the free car is
traveling up.
 An up or a down call registered above the free car while the free car is
traveling down.
 A main service floor call registered and the free car is delayed in its
normal operation for a predetermined period.
When cars are clearing calls, only one car shall stop in response to any reg-
istered external call. The first car to clear its calls shall return to the main
floor and become the home car. Should the last service required bring cars
to the main lobby floor, the car that arrived first shall become the free car.
Registration of a call shall cause the appropriate button to illuminate.

When the call is answered, the light shall go out.
Auxiliary Operations:
 Stand by power:
 In the event of main power failure, adequate standby power will be
supplied through normal feeders if exists, to start and run one eleva-
tor full time at rated speed.
 The standby power will be Sufficient to run the designated elevators,
the intercom system and all lights, exhaust blowers and emergency
call bells.
 The control system will then automatically start and run the cars

nonstop to the designated main lobby, one car at a time and park
with doors open.
 In addition to primary operation system features, provide the follow-
ing operational features for elevators where indicated, and as per
manufacturer’s standard products.
 Battery-Powered System : If main and emergency power fails and car is
at a floor, it remains at that floor, opens its doors, and shuts down. Cars
that are between floors are moved one at a time to the nearest upper or
lower floor, opens its doors, and shuts down. System includes re-
chargeable battery and automatic recharging system.
 Automatic Dispatching of Loaded Car: When car load exceeds 80 per-
cent of rated capacity, doors will begin closing and car will be released
for dispatching.
 Nuisance Call Cancel: When car calls exceed a preset number while car
load is less than a predetermined weight, after one run, all car calls are
canceled. Number of calls and weight can be adjusted.
 Car Call Cancellation : A passenger accidentally calling the wrong floor
may press the incorrect destination twice. Then the call will be can-
celled.
 VIP Operation : N/A.
 Parking Operation : a parking switch may be used to put the elevator
out of service during nights and holidays .
 Independent Service: N/A.
 Loaded-Car Bypass: When car load exceeds 80 percent of rated capaci-
ty, car will respond only to car calls, not to hall calls.
 Distributed Parking: When cars are not required for response to calls,
after a field adjustable time, they are parked with doors closed, distrib-
uted in predetermined zones throughout the building. One zone shall
include the main floor and adjacent floors; remaining floors shall be di-
vided into approximately equal zones.
 Emergency Firefighter Service: Interfacing between control system of
the elevators and the fire alarm system will be provided to recall the
cars during a fire or other emergency condition as required by the
standards and the Local Fire Authority. Visual/audible signal shall oper-
ate until return is complete or automatic operation restored. Provide
the designated level and alternate return level return switches.
 Emergency Car Lighting: Car- mounted rechargeable battery unit includ-
ing solid state charger and testing, enclosed in common metal container
and sufficient intensity bulbs. Alternately, emergency lights can be pro-
vided as a part of the car design.
2.4 ELEVATOR(S) EQUIPMENT

2.4.1 Traction: The traction equipment shall include the following, and as per
manufacturer’s standard products and provisions:
 Ac-type hoisting Elevator machine(s): Programmable and monitored sol-

id-state power converter/inverter and regulation unit(s), required to
drive of speed and torque for ACV3F traction system.
 The units shall be designed to limit current, suppress noise and prevent
transient voltage feedback into the building power supply.
 Hoist machine 1:1 or as per manufacturer standards, brake; drive
sheave equipped with rope guards, and deflector sheave, if required
mounted in proper alignment on an isolated bedplate. The machine,
and/or bedplate and the deflector sheave are to be Isolated from the
building structure.
 Single-wrap traction hoist machine drive sheaves with “V” grooves, pro-
vided with friction reducing liners or be equipped with a minimum of 6
each 13mm or according to manufacturer standards diameter or larger
hoist ropes.
 Machine shall have ball or roller bearings, without external cooling.
 Traction machine brake: Traction machine shall be fitted with a brake
drum which is securely installed and keyed to the motor’s shaft. Spring
actuated brake action shall be provided using electrically released self-
aligning mechanism. In case of power failure, the brake shall be applied
automatically to stop the car instantly.
 Reference signal:
 Digital reference signal tacho generator, belt or direct driven mount-
ed to each hoist machine.
 Encoder: solid- state, optical, digital- count type encoder shall be
provided and mounted in the machine room. The encoders shall be
mechanically coupled to the car via a slotted tape with drive sheaves
and a pit-tensioning sheave.
Mechanical cam-type tape encoders or rail friction encoders mount-
ed in the hoistway shall not be used on the passenger elevators.
 Over Speed Governor: The over-speed sensing governor safety
mechanism shall be installed in the equipment room and connected
to the car in order to monitor its speed, stop the traction motor and
actuate the brake system in the car if its speed exceeds a preset limit.
Centrifugal type for car and counter weight, with pull-through jaws
and 2 bi-directional electrical shutdown switches and overhead sup-
ports required.
Pit-Tensioning shall be mounted and provided with guides to enable

free vertical movement.

2.4.2 Elevator Car: Car door hangers, tracks, sills, edges, finishes and safety pro-
visions shall be according to the manufacturer’s standard products, in con-
formity with the codes, and guided by the following:
 Construction: Steel channel construction car frame and steel platform

with floor covering (as approved), and Car Sill flushed with the finished
car flooring.
 Dimensions: To be proposed by the Specialized Elevator’s suppli-
er/manufacturer in accordance to his design to suit available hoist way
dimensions.
Guide Shoes: Manufacturer standard low noise rollers type, appropriate

for speed and load
Door Operator: Closed loop high-speed ACV3F operator shall be provided

to open and close the car and hoistway doors simultaneously.
Doors shall open automatically when the car has arrived at the respective
landings.
Limits of travel Door travel shall be limited at both.
Interlock shall be provided at each hoistway entrance to prevent operation

of the elevator unless all doors are closed and locked.
The door operator shall be arranged so that, in case of interruption or fail-

ure of electric power, the doors can be readily opened by hand from within
the car if it is within the hoistway door unlocking zone, in accordance with
applicable codes.
Car Door Safety: The electronic protective device shall be capable of detec-
tion of obstructions anywhere within the opening.
Solid-state door safety infrared proximity device shall be installed across

car entrance. The device shall detect, through the breaking of any of light
beams, objects that in its path.
When activated, this sensor shall prevent the doors from closing or cause
them to stop and reopen if they are in the process of closing.
The doors shall remain open as long as the flow of traffic continues and
shall close shortly after the last person passes through the door opening
for a predetermined interval before closing.
Door Edges Protective Devices: Retractable edge shoe on leading edges of

elevator entrance doors that causes doors to stop and reopen upon con-
tacting an obstruction in entrance.

Nudging Action: If the door opens button is continually activated or the
door safety proximity device is continually obstructed a sounder shall acti-
vate and the doors shall begin to close at reduced kinetic energy when the
re-opening device is deactivated.
Reversal Device: If the door proximity device is interrupted while the door
is closing, the door shall stop and reopen.
Car top Inspection Station
Car Control Stations: Car control station with faceplate containing the op-
erating fixtures, to be mounted in the car front panels.
Ventilation: Exhaust blower with a diffuser and exhaust and intake port
protective screens.
Lighting: LED fixtures including integral emergency car lighting
Emergency Breaks (Safety Gear): The stopping mechanism of cars (and

counterweight as required per code) shall be a friction type with self
alignment friction jaws to grip the guide rails, if actuated due to over-speed
of the car, or if the control system fails to stop the car electrically. The grip
force of this system shall be proportional to the over-speed of the car, in
order to stop it gradually and smoothly.
2.4.3 Hoist way Equipment:
Hoist way Entrance(s): Hoist way entrances shall be Fire-Rated steel doors
(1.5 hours) and frames assemblies complying with NFPA 80,BS or EN81 that
are listed and labeled by a testing and inspecting agency acceptable to au-
thorities having jurisdiction, for fire-protection ratings indicated according
to (NFPA 252, UL 10B).
Sills, struts, headers and unit frames shall be constructed in proper relation
to the car guide rails. Material and finish shall be in accordance with the el-
evator contractor standards.
 Center opening Closed loop high-speed ACV3F operator

 Guide Rails of T-section Steel: Guide Rails of T-section Steel structural
members with brackets and cast iron rail clips for each elevator car and
counterweight, suitable for travel, car and counter weights, dimensions
and forces to be supported at floors, as per mentioned codes.
 Oil Buffers: Buffers are required for the car and counter weight
 Oil Buffers with spring return with supports, platforms and access lad-
ders.
 Oil used in Buffer(s) should be fire-resistant free from additives.

 Buffer shall be provided with a switch to stop the drive system, when-
ever the oil buffer is compressed.
 Safety protection if the oil in the buffer is less than allowable level.
 Counter weight: Counter weight made of steel channel frame with metal
filler guard around counter weight in pit.
 Hoist and over speed governor Ropes:
 Traction steel type ropes for all hoist ropes to suit Manufacturer's speci-
fication. Hoist and governor ropes fastened with adjustable shackles.
 Dead-end hitches shall be provided with dampening springs.
 Free rope Compensation as per manufacturer’s specification .
Sheaves:
 Sheaves with ball or roller bearings, mounted to car and counter weight
structural members.
 Governor and encoder pit tensioning sheaves
2.4.4 Life Safety:
Provide the following as per manufacturer’s standard and civil works scope
of application:
 Smoke Detectors (NFPA No. 72D) to be installed in elevator machine

room(s) to initiate alarm and to activate elevator fire return feature to
the main terminal (grade level) floor.
 Elevator hoist way(s) and machine room(s) fire and general safety provi-
sions as required by the followed codes (ventilation, sprinklers, fire rat-
ed door(s) etc, as per building civil works scope of application or equiva-
lent manufacturer’s standards.
 Sound Powered Telephone Jack as per building civil work scope or
equivalent manufacturers’ standards of application and wiring in each
elevator car. The system shall provide for 2-way communications be-
tween all of the stations with the wiring terminating at machine room(s)
junction box.
 Emergency car lighting with battery packs, chargers and test button
2.5 POWER SUPPLY
2.5.1 Main Power Supply: Electrical feeders for normal and standby mainline
power shall be through circuit breaker devices. There will be enough
standby power to run one elevator(s) including disconnect switches at ma-
chine room(s), as per building civil works scope of application.
Power switching off delay timer, coordinated with elevator(s) control sys-

tem to allow them to come to a complete stop before power off.
All main line wiring and conduits to run from the machine room disconnect
switches to the elevator(s) controllers/power conversion panels shall be
provided.
2.5.2 Electrical Wiring:
 Copper Conductors with 10% spare conductors throughout, individual

wires coded and all connections on identified studs or terminal blocks.
 Painted, galvanized steel Conduits and ducts.
 Traveling cables having 10% spare conductors shall be flame; moisture
and rodent resistant outer cover including shielded communication
wires and car lighting circuits from machine room to car connection
points.
 Traveling cables should be protected from hoist way or car items.
 Long traveling cables shall include steel tension wires.
 Earthing arrangements and protective conductors.
2.6 CONTROL AND SIGNAL FIXTURES
2.6.1 Car Control Stations:
 Manufacturer’s standard, flush mounted(2 COP to be mounted in both

sides of car door) car control stations to be mount in panel adjacent to
car door, unless otherwise indicated with stainless steel faceplates
 Call buttons for each direction of travel will light when activated and
remain lit until call has been fulfilled.
 LCD-type car position indicator, located above car door or above car
control station and audible signal
 Two-way voice Emergency Communication System without a handset
and with visible signal when activated.
 Flush-mounted cabinet telephone jack for Firefighters Two-Way Tele-
phone Communication Service.
2.6.2 Hall Push-button Stations: Hall push-button stations with flat faceplate at
each landing as indicated and buttons for calling elevator at desired direc-
tion. Stations will include direction indicating units and audible signals.
2.6.3 Card-Reader Operation: N/A
2.6.4 Key switches Operation: Push buttons are activated and deactivated by a
security key switch at car control stations. Key shall be removable in both
activated and deactivated positions.

2.6.5 Position Indicator(s): N/A
2.6.6 Hall Lantern: N/A.
2.7 ELEVATOR SEISMIC DESIGNS AND EMERGENCY OPERATIONS
Seismic Designs: The Main Contractor shall prepare and submit all required
equipment seismic design calculations, reactions, and supporting infor-
mation on the shop drawing per ASME A17.1 – 2000. Provide all required
protection, provisions, seismic designs, restraints, guards, tie downs and
operations for Seismic Zone 2, according to manufacturer’s standard prod-
ucts.
Calculations shall indicate the vertical and horizontal seismic design loads,
for all operating and control equipment and the rail loads.
2.8 PARTICULAR REQUIREMENT FOR SERVICE / FREIGHT ELEVATORS
2.8.1 Car inside dimensions: as per manufacturers standards dimensions

according to required capacity
2.8.2 Hoist way door size: as per manufacturers standards dimensions according
to required capacity)
2.8.3 Hoist way door type: Side opening (telescopic) with high speed VVVF
operation .
2.8.4 Car inside finishing:
 Floor finish made of granite.

 Side walls & panels: painted steel sheet
 Car door & side panels: painted steel sheet.
 landing doors: painted steel sheet.
 Ceiling: painted steel sheet
 Handrail: 3.8 cm diameter stainless steel, mount 82 cm above cab floor
(omit for freight).
 Bumper rail: Stainless steel flat bar, mount 33 cm to center of rail from
cab floor.
 Operating side panel: Convenience electric outlet.
PART 3 EXECUTION
3.1 EXAMINATION
Prior to beginning the installation of equipment, examine the hoist way

and machine room areas, for compliance with requirements for installation
tolerances and other conditions affecting performance.
Examine hoist way, openings, pit, and machine room and examine sup-
porting structure and other conditions under which elevator work is to be
installed.
A written report should be made including dimensional discrepancies and

conditions affecting performance or indicating that dimensions and condi-
tions were found to be satisfactory.
Installation should only start after unsatisfactory conditions have been cor-
rected.
3.2 INSTALLATION OF ELEVATOR SYSTEM
3.2.1 General: Comply with manufacturer's written instructions.
Install each equipment item in accordance with accepted work practices,

referenced codes and specifications.
Do all installation and execution works with competent mechanical tools

and provide senior personnel (adjuster or field engineer ) to assist engineer
with acceptance testing and subsequent re-testing (if required due to fail-
ure to meet all specified performance factors).
Install machine room equipment with clearances complying with refer-

enced codes and specifications.
Install items so that they may be removed by portable hoists or other

means for maintenance and/or repair.
Install items and equipment so that access for maintenance is safe and as-
sure continuity of operation.
3.2.2 Welded Construction: Provide welded connections for installation of ele-

vator work, adjustment, inspection, maintenance and replacement of worn
parts. Comply with the standards, as listed in Civil and Architectural Speci-
fications, for workmanship and for qualifications of welding operators.
3.2.3 Coordination: Coordinate elevator work with work of other trades for
proper time and sequence to avoid construction delays. Use benchmarks,
lines and levels designated by the Contractor to ensure dimensional coor-
dination of the work.
3.2.4 Sound Isolation: Mount rotating and vibrating elevator equipment and
components on vibration-absorption mounts, designed to effectively pre-
vent transmission of vibrations to structure and thereby, eliminate sources
of structure-borne noise form elevator system.

3.2.5 Leveling Tolerance: 3 mm up or down, regardless of load and direction
travel.
Set sills flush with finished floor surface at landings. Coordinate with other
trades to facilitate and ensure proper grouting of sills.
3.3.1 Work at the site will be checked during the installation and corrective work
shall be done prior to further installation.
Acceptance Authority should be completed, all corrective work accom-

plished and installation approved for issuance of a permit to operate.
Coordinate installation of hoist way entrances with installation of elevator

guide rails for accurate alignment of entrances with car.
3.3.2 Alignment: Coordinate installation of hoist way entrances with installation

of elevator guide rails for accurate alignment of entrances with cars.
Where possible, delay final adjustment of sills and doors until car is opera-
ble in shaft. Reduce clearances to minimum, safe workable dimension at
each landing. Align guide rails vertically within a tolerance of 1.6 mm in 30
m. Secure joints without gaps and file any irregularities to a smooth sur-
face.
Balance cars after the final car installations to equalize pressure of roller
guide shoes on rails
3.3.3 Doors: Adjust motors, power converters, brakes, and controllers, leveling
switches, limit switches, stopping switches, door operators, interlocks and
safety devices to achieve required performance levels.
3.3.4 Cleanup and Touchup: Keep work areas orderly and free from debris dur-
ing progress of project.
Remove all loose materials and filings resulting from this work from hoist
way surfaces.
Clean machine room equipment and floor of dirt, oil and grease.
Clean hoist way, car, car enclosures, entrances, operating and signal fix-
tures, and trim of dirt, oil, grease and finger marks.
Touchup all minor scratches, dents or imperfections in finished materials

and painted surfaces that are exposed to public view.

3.4 ACCEPTANCE INSPECTIONS AND TEST
Prior to acceptance testing as per manufacturer’s standards, a copy of this

testing standard shall be given to the engineer for review
In all test conditions speed and performance times specified shall be met,
stopping accuracy shall be maintained without re-leveling and general rid-
ing quality shall be acceptable to the Engineer.
3.4.1 Final acceptance of the installation shall be made only after all field quality
control inspections and tests by the Engineer are complete, all submittals
and certificates have been received and the Engineer is satisfied that the
following have been satisfactorily completed:
 Workmanship and equipment comply with specification.

 Contract speed, capacity and floor-to-floor performance comply with
specification.
 Satisfactory performances of starting, accelerating, decelerating, run-
ning, leveling, stopping, door operation and closing force.
 Insulation Resistance Test at 500 volts with minimum resistance to
ground shall be 4 Mega ohm for door lock circuit, loop circuit, motor,
field circuits etc.
 Check floor-to-floor performance time, speed, stopping accuracy and
general ride of elevator with no load, balanced load and full load in car.
 Run fully loaded car continuously with equipment ambient machine
room temperature 40ºc for a period of one hour with a minimum of 240
starts-stops at each floor in both directions for a period of 10 seconds.
Temperature rise in windings shall not exceed 50º C above ambient
room temperature.
 At the end of the test, again check floor-to-floor performance time,
stopping accuracy and general ride with full load, balanced load and no
load in car.
3.4.2 Testing Equipment and Instruments: Furnish the following equipment and
instruments, but is not limited to, to perform required tests.
 Test weights (larger weights with dollies or wheels are acceptable if

weight is certified).
 Multi meter.
 500-volt Megger.
 Alternating-current voltmeter and ammeter.
 Stop watch.
 Celsius-calibrated thermometers.

 Precision tachometer.
 Spring scale for door-force test.
 Decibel meter for noise test.
 3-axis recording accelerometer for vibration, car sway and car ride test
or according to manufacturer’s standard provisions and practices.
3.4.3 Submittals: Provide written information for the testing procedures and
equipment necessary for proper maintenance and adjustment of the
equipment prior to acceptance, as follows, but not limited to:
 As built single-line wiring diagram of elevator circuits with index of loca-

tion and function of all components.
 Installation diagrams and shop drawings as built elevator components.
 Final corrected sets on CD ROMs
 Detailed catalogs for all replaceable parts including ordering forms and
instructions.
 Complete operating and maintenance instructions for all controls and
switches provided.
 Any special maintenance or trouble shooting tools or devices required
for maintenance on all elevators, as per manufacturer’s standard provi-
sions and practices.
3.4.4 Examination certificate: a copy of each relevant type examination certifi-

cate shall be provided for :
 Locking device.
 Landing doors (i.e. fire test certificate).
 Safety gear.
 Over speed governors.
 Ascending car over speed protection means.
 Buffers.
 Safety circuits containing electronic component.
3.4.5 Owner’s Personnel Training: Provide add number training sessions at the
site for the designated Owner’s elevator operating,, safety and security
personnel for operations, emergencies and car operating panel controls.
Provide all required training tools and information (videos, CD ROMs, man-
uals, etc) and training personnel to provide knowledge on how to operate
the elevator(s) and interface functions and controls.
3.4.6 Warranty Inspection: Final inspection and test should be made prior (at

least 15 days) to warranty expiration.
Replace, repair and/or adjust any equipment found totally or partially de-
fective.
Stopping accuracy shall be measured under all load conditions.

Variance from rated speed, regardless of load, shall not exceed 3%.

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UNILEVER FACTORY

6th OF OCTOBER - EGYPT

RENOVATION AND REFURNISHING UNILEVER FACTORY

PROJECT No. 2039

THE NATURE OF THE REVISION IS BRIEFLY NOTED UNDER REMARKS BUT

REV. DATE PREPARED REVIEWED APPROVED PAGES REMARKS

A Apr. 2015 R.E. 4 ISSUED FOR CLIENT REVIEW

0 Apr. 2015 R.E. 4 ISSUED FOR TENDER

ECG Form No. E409 Rev. 5/03 Sheet 0 of 4

MEASUREMENT AND PAYMENT,

00010 Table of Contents

DIVISION 1: GENERAL REQUIREMENTS

01270 Measurement and Payment

00160 Finishing Schedules

TECHNICAL SPECIFICATIONS - PART A

DIVISION 1: GENERAL REQUIREMENTS

01732 Selective Demolition

DIVISION 2: SITE CONSTRUCTION

03300 Cast-In-Place Concrete

Table of Contents Section 00010

04810 Unit Masonry Assemblies

05120 Structural Steel

DIVISION 6: WOOD AND PLASTIC

DIVISION 7: THERMAL AND MOISTURE PROTECTION

07115 Bituminous Damp-Proofing

DIVISION 8: DOORS AND WINDOWS

08114 Steel Doors and Frames

09220 Portland Cement Plaster

Table of Contents Section 00010

10200 Louvers and Vents

DIVISION 13: SPECIAL CONSTRUCTION

13916 Fire Protection

DIVISION 14: CONVEYING SYSTEMS

14210 Electric Traction Elevators

TECHNICAL SPECIFICATIONS - PART B

DIVISION 15: MECHANICAL WORKS

15030 Electrical Requirements for Mechanical Equipment

Table of Contents Section 00010

16050 Basic Electrical Materials And Methods

Bms Point Schedule

Table of Contents Section 00010

THE NATURE OF THE REVISION IS BRIEFLY NOTED UNDER REMARKS BUT

REV. DATE PREPARED REVIEWED APPROVED PAGES REMARKS

A Apr. 2015 E.F. 7 ISSUED FOR CLIENT REVIEW

0 Apr. 2015 E.F. 7 ISSUED FOR TENDER

ECG Form No. E409 Rev. 5/03 Sheet 0 of 7

Selective Demolition Section 01732

1.1 RELATED DOCUMENTS

1.2.1 This Section Includes the Following:

 Demolition and removal of selected site elements.

1.4.1 Qualification Data: For demolition firm.

1.4.2 Schedule of Selective Demolition Activities: Indicate the following:

Selective Demolition Section 01732

1.4.4 Predemolition Photographs and Videotapes: Show existing conditions of

1.4.5 Landfill Records: Indicate receipt and acceptance of hazardous wastes by a

1.5 QUALITY ASSURANCE

1.5.1 Demolition Firm Qualifications: An experienced firm that has specialized in

1.5.2 Regulatory Requirements: Comply with hauling and disposal regulations of

1.5.3 Standards: Comply with ANSI A10.6 and NFPA 241.