CIVIL WORKS

Metal Work

STANDARD TECHNICAL SPECIFICATIONS FOR ELECTRIC WORKS

CIVIL WORKS

( SPECIFICATION )

METAL WORK

ADWEA/ADDC/AADC STANDARD : S-AAA-CIV-METAL

(REV.0-2015)

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CONTENTS

1 GENERAL ....................................................................................................................... 3
2 TECHNICAL DESCRIPTION ...................................................................................... 3
2.1 Materials ............................................................................................................................ 3
2.2 Execution ........................................................................................................................... 4
2.3 Steel Requirements ............................................................................................................ 4
2.4 Gauges of Sheet Steel ........................................................................................................ 5
2.5 Aluminium Materials ........................................................................................................ 5
2.6 Metal Finishes ................................................................................................................... 6
2.7 Steel Doors Criteria ........................................................................................................... 6
2.8 Criteria for Fire Doors ....................................................................................................... 7
2.9 Criteria for the Construction of Doors, Windows and Walls of Aluminium Profile ......... 8
2.10 Master Key System ........................................................................................................... 9
2.11 Aluminium Windows ...................................................................................................... 10
2.12 Insect Protection Screening ............................................................................................. 10
2.13 Panic Device .................................................................................................................... 11
2.14 Sectional Doors or Hinged Wing Doors .......................................................................... 11
2.15 Entrance Gates (hinged) .................................................................................................. 11
2.16 External Sun Shields ....................................................................................................... 11
2.17 Louvers ............................................................................................................................ 12
2.18 Removable Fencing for Transformers/Reactor Bays/Enclosures .................................... 12
2.19 Suspended Ceilings ......................................................................................................... 13

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METAL WORK
1 GENERAL
This part of the Specification shall cover all items related to furnishing and installing the various
metal works in all structures of the Project. Works shall include all items required for the
tendered Project, as well as all auxiliary works.
All works shall further be carried out in full compliance with all local rules and regulations and
the Specification shall further be read, if applicable for the Project.
For applicable technical standards, tests, reference shall be made to:
 S-AAA-CIV-GEN - General Requirements
(Applicable Technical Standards, Tests, etc.)

2 TECHNICAL DESCRIPTION

2.1 Materials
All materials and structural components to be supplied, erected or installed and, therefore,
ultimately incorporated in the structure shall be new and unused. They shall be suitable for their
intended purpose and appropriately matched to each other.
They shall receive hot dipped galvanized and protective coating against corrosion as described in
this specification. Metal works shall also be interconnected to the Station earthing by an
approved method as per this specification.
The most important materials are to comply at least as follows:
a) Copper and copper alloys : BS. 1400
b) Aluminium / aluminium alloys : BS. 1471
c) Stainless steel : DIN 17440 or AISI type 316
d) Steel : DIN EN 10 025 or approved equivalent.
e) Connectors and filler metals
All connectors such as bolts, screws, rivets, adhesives and filler metals for welding and
soldering shall satisfy the stress demands and be adapted to suit the respective processing
methods.
f) Sealing, separating and coating materials
All sealing, separating and coating materials shall be weather and ageing resistant, non-
soldering, heavy inflammable and plastically or elastically permanent depending on stress
and shall not contain any constituents harmful to contiguous material.

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2.2 Execution
All work shall be executed by skilled workers in a workmanlike manner.
The structural components may be joined together by use of bolts, rivets and welds to the
strength required upon the static analysis. The static analysis shall be made by the
Bidder/Contractor.
For all the metal work the Bidder/Contractor shall furnish ADWEA/ADDC/AADC with working
drawings and an approved static analysis.
For parts of different materials to be joined together connectors of corrosion resistant material
shall only be used. Bi-metallic corrosion shall be avoided wherever possible.
Connections and fixings shall be located so that at temperature variations, the structural members
can expand, contract and move without restraint. All locations required to be tight shall remain
tight.
No structural components shall be installed before the structure can take the respective load.
Anchor arrangements shall be suitably provided to ensure safe transmission of the force into the
structure.
All prefabricated aluminium and stainless steel elements shall have a protective coating against
damage of the surfaces out of plastic, which has to be removed before work is accepted. The
various parts of the metal work, such as windows, doors, railings, gratings, louvers, gates, minor
steel structure, etc., shall be constructed as specified hereafter.
The joints between the structural components and the member of the structure shall be filled with
suitable filler and sealed as specified hereafter.

2.3 Steel Requirements

Steel shall conform to the following requirements or an approved equivalent:
 Hot rolled members shall conform to the Series of DIN 1024, DIN 1025, DIN 1026, DIN
1027, DIN 1028, DIN 1029. Grades shall be S235 or S355 as per DIN EN 10 027-1
 Cold finish steel: mild steel, rolled or drawn, free from scale, accurate to size or gauge
 Copper bearing steel: mild steel, containing 0.20 percent copper, minimum
 Stainless steel shall be DIN 17400 or AISI type 316 stainless steel. Exposed surfaces of all
stainless steel shall be matt finished
 Cast steel shall be a high-grade cast steel alloy produced in accordance with ASTM A 27
 Genuine wrought iron shall conform to the following:
- bolts, rods, bars : ASTM A 41
- plates : ASTM A 42
- sheets : ASTM A 62.

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 Cast iron shall be a soft grey iron, conforming to ASTM A 190

 Malleable cast iron shall be high-grade white iron castings, fully annealed and of uniform
ductile structure throughout, conforming to ASTM A 196 and A 47
 Other materials: all other materials covered under this section shall conform to the
requirements of EURONORM (EN), DIN, BS or other standards approved by
ADWEA/ADDC/AADC.

2.4 Gauges of Sheet Steel

Except where other gauges are indicated or specified, the gauges of sheet steel shall not be
lighter than the following gauges:
 Door frames in general 16
 Frames in hinged doors, having an inside height of more than 1.8 m 16
 Architrave, auxiliary frame, etc. 16
 Door saddle, rails, stile, panel plate, flush plate 16

2.5 Aluminium Materials

a) Aluminium materials shall conform to the following:
- aluminium sheet : alloy 5005 H14
- aluminium sheet : duranodic finish, Anoclad 11
- aluminium sheet : powder coated
- aluminium extrusions : alloy 6063 - T5 and T6
- aluminium extrusions : duranodic finish, Anoclad 11
- aluminium pipe handrails : alloy 6063 - T5.
b) Insulation
Jambs, heads, sills and exterior mullions, window units and exterior door frames shall be
completely insulated with fibreglass in place and of thickness as shown on the approved
drawings.
c) Connectors
Exposed screws and bolts for aluminium work shall be aluminium alloy or stainless steel,
lengths as required and chemically treated to match the bronze finish whenever used on
duranized items. Modified truss and pan heads may be used, if approved by
ADWEA/ADDC/AADC, in areas where counter-sinking is not practicable due to gauge of
finish material.

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2.6 Metal Finishes

Unless otherwise specified, aluminium surfaces shall conform to the following: Duranodic
finish, or equivalent:
 All exposed aluminium surfaces shall have a finish with standards and procedures
equivalent to the Bronze Natural Color applied to mill finish
 The coating shall be applied having a minimum thickness of 17 µm and have a minimum
weight of 5 mg/cm2. Color range samples shall be submitted to ADWEA/ADDC/AADC
for approval before commencing with the production
 Samples taken from production lots of finished material shall be tested in accordance with
ASTM
 Powder coated aluminium.

2.7 Steel Doors Criteria

All galvanised steel doors must meet the following minimum requirements under this contract as
specified hereafter:
 Material : Steel sheet of at least 1.0 mm thickness
Frames to be made at least of 2.0 mm thickness.
 Build-up : Steel doors shall be of double-skinned construction, fully filled with suitable,
approved fire resistant material.
 Hinges : Each door leaf shall be fixed at least 3 hinges. The fixing of the doors to the
walls shall be accomplished by means of flat steel anchor strips 40/4 mm and
8 to 10 mm diameter steel bolts, either cemented into walls where masonry or
concrete will be met, or welded to a steel substructure. On a length of 2.50 m,
a minimum of 3 anchors have to be provided. The lengths of the bolts shall be
such that they will stand the stresses to be expected.
 Hardware : All doors shall receive mortice locks for steel doors, with back sets of 65 mm;
the function of the locks shall be of the night latch type with one separate
dead bolt.
2 stainless steel lever handles. Alternatively, on one side a knob may be
requested by ADWEA/ADDC/AADC
2 stainless steel door handle plates or roses
1 cylinder lock for general master key system
2 stainless steel roses for the cylinder lock, unless covered by handle plate
1 stainless steel dust cover to locks at outside
1 door closer.

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The clearances for hinged doors shall be 3 mm at jambs and heads, 6 mm at meeting stiles of
pairs of doors and 6 mm at bottom, unless specifically indicated or specified otherwise.
Joints formed with mechanical fastenings shall be closely fitted and made permanently
watertight.
Top and bottom edges of all metal doors shall be closed to provide a weather seal. This seal may
be provided as part of the door construction or by the addition of inverted steel channels or other
suitable shapes welded to the face sheets.

2.8 Criteria for Fire Doors

Fire rated steel doors and frames shall be designed, manufactured/tested and installed in
according with NFPA 251/EN/BS.
Fire rating of door, frame, hardware and other accessories shall be at least 90 minutes for
stability/integrity and 20 minutes for insulation.
Fire door assembly (including hardware/ironmongery) test certificate from an independent,
internationally recognised laboratory confirming the above shall be submitted along with Vendor
/ Material submittal.
Fire door leafs shall be manufactured with double flush skins of galvanized steel sheet, edges
and welded to the case. The case to be stiffened with steel section frame. The door leaf shall be
filled with suitable fire resistance material to limit the transmission of heat on the unexposed side
of door.
The size of door shall be suitable for access of the largest items of the equipment to be installed
and to the satisfaction of ADWEA/ADDC/AADC.
Weather sealing gasket around the door leaf shall be provided to prevent the ingress of dust. The
sealing gasket shall be from non-combustible or limited combustible material of listed type.
Number of latches and hinges shall be according to NFPA 80 /DIN/EN/BS.
The door assembly shall be adequately reinforced for all hardware, lock and the cut outs for lock,
handle, knob etc. shall be made at the factory.
Complete, detailed drawings with sections, hardware, furniture etc. shall be submitted for
ADWEA/ADDC/AADC’s approval before manufacturing the door.
Painting of door and frame shall be according to the relevant section of these specifications. Two
shop coats protected against corrosion are required. The first coat to be applied before
assembling of the door starts.
The fixing of the door frame to the walls shall be carried out by means of flat steel anchor strips
either cemented into the masonry or concrete wall or to be screwed to the steel structure.
Three anchors shall be provided per 2.5 m length with a minimum of six anchors per door frame.

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Mortice locks to be installed for centre latch, fire-protected by suitable material, prepared to
insert a profile cylinder of the master key system, panic device, exit device, designed for trouble-
free operations.
Overhead surface mounted door closer, fully adjustable to spring power and closing speed.
For double winged doors: door selectors and lever bolts with rod and keep shall be applied.
Door stopper for each leaf shall be fixed according to the advise of ADWEA/ADDC/AADC.
All fire doors shall be arranged to remain in the normally closed position with suitable
self-closing device.
Application:
 Doors over viewing out side (external doors) as well as located in rooms not-protected by
automatic CO2 system shall not be required to be fire rated.
 Doors for basement shall be fire rated type.
 Shape and finish of fire rated and non-fire rated doors shall be similar to each other.

2.9 Criteria for the Construction of Doors, Windows and Walls of Aluminium Profile
General construction features:
Height/width : As shown on approved drawings
Material : Frames of extruded aluminium profiles of decorative duranodic or powder
coating finish; quality of aluminium alloy to withstand the adverse local
climatic conditions a 5-year guarantee has to given on all materials
Sections : Approx. 55 mm (deep) x 110 mm width, thickness not less than 2 mm, and
the bottom rail 125 x 55 mm
Glazing : Double Glazing, with glazing stops of square profile of the snap-in type,
with neoprene bedding for glass panes (glazing clips)
Fanlights : As per relevant description
Hardware : Security bolt lock with profile cylinder for master key system; 1 floor
mounted automatic door-closer with hold-open at 150 degrees with floor
stop, door-holder and cover-plate; top off-set pivots in aluminium;
aluminium cross- bars on both sides of each leaf as pull/push handle,
200/10 mm tubular section; all bolts and screws shall be concealed in the
frame of the top flush type; rose type fact plates for lock and cylinder; all
material stainless steel
Fixing : Fixing of aluminium frame to the structure shall be done as per the standard
and as approved by ADWEA/ADDC/AADC with anchor plates and bolts,
rigidly cemented into wall. Space between door construction and
concrete/masonry wall shall always be filled with rock-wool or other

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approved insulation.
Joints : Joints of doorframe to walls shall be covered with aluminium-angles
25/25/2 mm on each side, and the outside shall be sealed with permanent
elastic materials.

These construction features apply to single and double winged doors, fanlights, as well as to fix
side frame elements or any other exterior glass wall elements.
The components of the construction shall be sized to the stress required, but not less than
mentioned as follows:
 Built-in frame 30/110/2 mm
 Mullions 50/110/2 mm.
During application of grouts, the Bidder/Contractor shall give special attention to manufacturer's
written instructions and follow them carefully.
 Sidelights framing 50/50/2 mm
 Fanlight framing 50/50/2 mm
 For door stop, rubber seal required.
The hardware for the metal work shall be furnished and installed in the door by the
Manufacturer, and shall include standard items as follows:
 Mortice security lock, prepared for the profile cylinder of the master key system
 Door-o-matic floor spring, with backstop, consisting of fully hydraulic closer with
adjustments for spring tension plate closing and latching speed, cover-plate of stainless
steel
 Top offset pivot of stainless steel
 Push bars on each side of each wing as pull handle, height 200 mm, approx. 10 mm
thickness, aluminium tubular section, width same as door wing, securely fastened into
spacer, mounted by screws on the door sills
 Profile cylinders
 Weather shield of extruded aluminium profile
 Double glazing, safety glass.

2.10 Master Key System

An appropriate serviceable and functional master key system for the whole plant shall be
installed. Details of the system itself shall be defined in close co-ordination with
ADWEA/ADDC/AADC and only after obtaining ADWEA/ADDC/AADC's approval the order
shall be placed.

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Generally, following requirements shall be kept:

 ‘Grand Master’ key shall operate all locks of all stations covered under the system
 ‘Master Key’ shall operate all locks of the concerned station
 ‘Sub-Keys’ - if desired by ADWEA/ADDC/AADC - shall open all locks of a group within
the main compound, and
 ‘Single Key’ shall open the lock of a single room.
Necessary attention shall be paid to later extensions of the Grand Master Key System, which
shall be suitable for the entire plant including all final stages.
The profile cylinders shall be sea water resistive and shall suit all plant requirements and shall be
of types such as half, double, asymmetrical, short-cylinder, etc. The material of the cylinders
shall be of massive brass, nickel-plated with six security pawl studs.
 Hardware
Heavy security cylinder mortar lock, profile SNP cylinder, all in accordance with DIN 1825,
with 8 mm self-tensioned nut, hardened steel case enamelled, braked, fore end of stainless steel
quality, back set 60 mm.
 Keys
The keys shall be made of new silver material and shall have an engraved indication of the
applicable key system and the compound/group/ or door number. Keys shall be supplied in
accordance with the requirement of ADWEA/ADDC/AADC.
Suitable dust covers shall be provided for all outside doors.

2.11 Aluminium Windows

The construction features of aluminium profile windows shall be identical to those specified for
doors of aluminium profiles.
Sizes as per relevant design. All movable windows shall be bottom hung. Internal insect
protection screening shall be provided. All hardware shall be of concealed construction in the
aluminium frames; the parapet shall be covered with an aluminium sill. Double glazing as per
Specification. All fixings, screws, bolts, etc. shall be of stainless steel and of approved size and
type.

2.12 Insect Protection Screening

Consisting of a separate aluminium-frame (see window dimension) with an approved screen
material to be mounted removable on to the window with clips and angle fillers.
Application : at all aluminium windows that may be opened
Position : Internally (i.e. behind glass panels) and shall not be seen at external elevations.

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2.13 Panic Device

Panic devices shall be installed for all emergency exits and the switchgear hall exits, both for
single and double-winged doors with overlapping astragal. Simultaneous opening of double
doors shall be ensured by slight pressure on any part of the panic cross-bar.
The outside operation shall be made by lever handle with a dead locking mechanism.

2.14 Sectional Doors or Hinged Wing Doors

Generally, profiled galvanised steel doors of the overhead track type shall be installed. They
shall be of the polyurethane foam- filled type, preferably of the SPU type or an approved
equivalent.

2.15 Entrance Gates (hinged)

Side hinged entrance gates shall be of heavy galvanised profiles with adjustable hinges (height
and distance adjustment). All profiles shall be hot dip galvanised and coated in approved color.
Minimum dimensions shall be for:
 Main Double Gate wings : approximately 3.3 m x 3.0 m each (width x height)
 Pedestrian (side) Gates : approximately 1.2 x 3.0 m
 Side and top frame tubes : 100 x 50 x 4 mm
 Bottom tubes : 100 x 50 x 4 mm
 Verticals : 25 x 25 x 2.5 mm
 Intermediates : 100 x 50 x 4 mm.
For typical details of the gate installation, reference shall be made to the below listed drawing
provided in the Drawings Section:
Drawing No. Title
DWG CIV 13 02-01 Main Gate Details – Sheet 1 of 4
DWG CIV 13 02-02 Main Gate Details – Sheet 2 of 4
DWG CIV 13 02-03 Main Gate Details – Sheet 3 of 4
DWG CIV 13 02-04 Main Gate Details – Sheet 4 of 4

Alternatively, heavy duty cast aluminium gates may be proposed for approval.

2.16 External Sun Shields

GRP Sun Shields, minimum thickness 6 mm, supported on steel frames and resting on/being
fixed to concrete bases (tubular posts) shall be provided for car parking areas. External quality
material to the approval of ADWEA/ADDC/AADC shall be provided.

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2.17 Louvers
Openings in exterior walls for air inlet and outlet, shall be covered with louvers and dust filters.
The size shall be in accordance with the design. Louvers shall be constructed of horizontal
weather louvers made of pressed Robertson Versacor APM plates covering the design space.
Thickness of steel sheet shall be minimum 1.5 mm. The louvers shall be mounted on L-profile
steel frame, galvanised and of minimum thickness 50/50/ 4 mm. The opening behind the louvers
shall be covered by aluminium screen for protection against insects and birds.
The louvers shall be fixed to the walls. All fixing accessories such as screws, nuts, bolts, etc.,
shall be of stainless steel.
The joints between wall and steel frame shall be filled with mineral wool and shall be sealed
with permanent elastic sealing compound approved by ADWEA/ADDC/AADC.

2.18 Removable Fencing for Transformers/Reactor Bays/Enclosures

For Removable Fencing of Transformers / Reactor Bays / Enclosures, reference shall be made to
the below listed drawings, which are provided in the Drawings Section.
Drawing No. Title
DWG AAA CIV 08 01 Transformer Bay Fence Detail Sheet 1/5
DWG AAA CIV 08 02 Transformer Bay Fence Detail Sheet 2/5
DWG AAA CIV 08 03 Transformer Bay Fence Detail Sheet 3/5
DWG AAA CIV 08 04 Transformer Bay Fence Detail Sheet 4/5
DWG AAA CIV 08 05 Transformer Bay Fence Detail Sheet 5/5

Frames are to be made of a rigid design and appropriate size, vertically filled with
rectangular/square tubes at distances of approximately 125 mm (centre lines). A horizontal cross
bar of appropriate size shall run across the frame(s) at ~1.50 m above floor level. Further details
of the fencing for transformer bays shall be as follows:
 Width : as per transformer/reactor bay
 Height : > 3.0 m, or as required by transformer/reactor design
 Frames tube sizes :
- sides/ top : 100 x 50 x 4 mm
- bottom : 100 x 50 x 4 mm
- vertical fill : 25 x 25 x 2.5 mm
- intermediates : 100 x 50 x 4 mm.

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The supporting construction to the wall shall consist of vertical channels/sections fixed with
anchor plates into the concrete wall. A separate door passage of 120/250 cm shall be arranged,
consisting of an individual steel frame with adequate hinges and lock of master key system.
All steel parts shall be hot-dip galvanised and additionally corrosion protected according to this
specification. All parts shall be properly connected to the earthing system to the satisfaction of
ADWEA/ADDC/AADC.
Alternatively, powder coated heavy duty aluminium profiles for the construction of such
fences/gates may be proposed for ADWEA/ADDC/AADC’s approval.

2.19 Suspended Ceilings

Double-grid acoustic suspended ceilings shall be made from square type aluminium powder
coated panels of a type and color as approved by ADWEA/ADDC/AADC. Minimum panel
thickness shall be 0.70 mm. Adequate and integrated light fittings (including emergency
lighting) have to be provided as well.
Application: Control room, electrical room, corridors, entrances, and as indicated in the finishing
schedule.

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