Abu Dhabi Airports Company PJSC Specification, Section 076200

SECTION 076200

SHEET METAL FLASHING AND TRIM

1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Contractor shall provide all labour, Materials, Contractor’s Equipment and Plant to fully
execute the requirements to furnish, deliver, and install the Works as expressly described in
the Drawings and Specification, or implied therefrom, and in accordance with the Contract.
It is the intent of this Specification section that the work performed pursuant hereto be
complete and acceptable in every respect for its intended purpose. It is further required that
the provisions of this Specification section shall be complementary to, and shall be
correlated with, the requirements of the Contract. Nothing in this Specification section shall
limit the scope of work as required by the Contract.
B. Section Includes:

1. Formed low-slope roof sheet metal fabrications.

a. Metal roof edge flashing (ref SMF-01).
C. Related Sections include, but are not limited to, the following. This paragraph cross-
references requirements a reader might expect to find in this Section but are specified in
another section. It is not intended to be, and shall not be interpreted as, a listing of every
other section that has a relationship to this Section.

1. Division 07 Section "Thermoplastic Membrane Roofing" for installing sheet metal

flashing and trim integral with membrane roofing.

1.3 PERFORMANCE REQUIREMENTS

A. General:

1. Contractor is responsible for the design of sheet metal flashing and trim and related
elements, including interfaces and coordination with work of adjoining trades, to
satisfy aesthetic effects and performance requirements in accordance with the
Contract Documents.
2. The Specification together with the Drawings establish requirements for aesthetic
effects and performance requirements. As scope and performance documents, the
Drawings and Specifications do not necessarily indicate or describe in detail all work
required for the full performance and completion of the Works. Contractor is
responsible for developing and completing the design in accordance with the Contract
Documents, and shall provide all items required for proper completion of the Works
without adjustment to the Contract price.

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a. Aesthetic effects are as indicated on Drawings by dimensions, arrangements,

alignment, and profiles of components and assemblies as they relate to
sightlines, to one another, and to adjoining construction.
b. Performance requirements are specified by criteria, conformance with which
may be subject to verification by preconstruction testing, field testing, or in-
service performance as determined by Engineer. Scheduling and procedures
for such testing that may be required to verify that the design complies with
performance requirements shall be agreed with Engineer prior to commencing
Work.
c. Do not revise intended aesthetic effects, as judged solely by Engineer, except
with Engineer's approval. If revisions are proposed, submit comprehensive
explanatory data to Engineer for review.
B. General: Sheet metal flashing and trim assemblies shall withstand wind loads, structural
movement, thermally induced movement, and exposure to weather without failure due to
defective manufacture, fabrication, installation, or other defects in construction. Completed
sheet metal flashing and trim shall not rattle, leak, or loosen, and shall remain watertight.
C. Fabricate and install roof edge flashing capable of resisting uplift pressures calculated in
accordance with Division 07 Section "Thermoplastic Membrane Roofing", for perimeter
uplift force, corner uplift force, and outward force.
D. Thermal Movements: Provide sheet metal flashing and trim that allows for thermal
movements from temperature changes as follows.
1. Provide for thermal movements resulting from ambient temperature range between
0 deg C and 70 deg C, and surface temperature range between 0 deg C and 85 deg C.

1.4 PRECONSTRUCTION TESTING

A. Fire Mockup Testing: Provide Metal roof edge flashing SMF-01, for fire testing of external
wall assemblies and roof assemblies of Hotel building. See Division 07 Section “Internal
Buildings Fire Testing.”

1.5 SUBMITTALS
A. Product Data: For each type of product specified. Include construction details, material
descriptions, dimensions of individual components and profiles, and finishes for each
manufactured product and accessory.
B. Shop Drawings: Show fabrication and installation layouts of sheet metal flashing and trim,
including plans, elevations, expansion-joint locations, and keyed details. Distinguish
between shop- and field-assembled work. Include the following:

1. Identification of material, thickness, weight, and finish for each item and location in
Project.
2. Details for forming sheet metal flashing and trim, including profiles, shapes, seams,
and dimensions.
3. Details for joining, supporting, and securing sheet metal flashing and trim, including
layout and spacing of fasteners, cleats, clips, and other attachments. Include pattern
of seams.
4. Details of termination points and assemblies, including fixed points.
5. Details of expansion joints and expansion-joint covers, including showing direction
of expansion and contraction.
6. Details of edge conditions, including eaves, ridges, valleys, rakes, crickets, and
counterflashings as applicable.
7. Details of special conditions.

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8. Details of connections to adjoining work.

9. Detail formed flashing and trim at a scale of not less than 1:5.

C. Samples for Initial Selection: For each type of sheet metal flashing, trim, and accessory
indicated with factory-applied color finishes involving color selection.
D. Samples for Verification: For each type of exposed finish required, prepared on Samples of
size indicated below:

1. Sheet Metal Flashing: 300 mm long by actual width of unit, including finished seam
and in required profile. Include fasteners, cleats, clips, closures, and other
attachments.
2. Trim, Metal Closures, Expansion Joints, Joint Intersections, and Miscellaneous
Fabrications: 300 mm long and in required profile. Include fasteners and other
exposed accessories.
3. Accessories and Miscellaneous Materials: Full-size Sample.
E. Certification: Signed and sealed by Contractor, certifying that products and systems to be
provided comply with performance requirements in the Contract Documents. Include
calculations and structural analysis including comprehensive engineering analysis (limited
to the extent of the defined Performance Requirements in this Section) signed and sealed by
the qualified professional engineer responsible for their preparation.
1. Should there be proposed deviations from specified requirements, submit
calculations, loads, standards and other factors used to establish compliance with
performance requirements, for review and acceptance by Engineer.
2. Should there be proposed deviations from aesthetic effects, submit drawings
indicating such proposed deviations, for review and acceptance by Engineer.
F. Qualification Data: For qualified fabricator.
G. Maintenance Data: For sheet metal flashing, trim, and accessories to include in
maintenance manuals.
H. Warranties: Sample of special warranties.

1.6 QUALITY ASSURANCE

A. Fabricator Qualifications: Shop that employs skilled workers who custom fabricate sheet
metal flashing and trim similar to that required for this Project and whose products have a
record of successful in-service performance.
B. Sheet Metal Flashing and Trim Standard: Comply with SMACNA's "Architectural Sheet
Metal Manual" unless more stringent requirements are specified or shown on Drawings.
C. Preinstallation Conference: Conduct conference at Project site.

1. Meet with Employer, Engineer, Employer's insurer if applicable, Installer, and

installers whose work interfaces with or affects sheet metal flashing and trim
including installers of roofing materials, roof accessories, and roof-mounted
equipment.
2. Review methods and procedures related to sheet metal flashing and trim.
3. Examine substrate conditions for compliance with requirements, including flatness
and attachment to structural members.
4. Review special roof details, roof drainage, roof penetrations, equipment curbs, and
condition of other construction that will affect sheet metal flashing.
5. Document proceedings, including corrective measures and actions required, and
furnish copy of record to each participant.

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1.7 REFERENCES
A. Product manufacture, testing and installation shall comply with the following references
unless otherwise stated in the specification or otherwise approved by the Engineer.
B. American Architectural Manufacturers Association
1. AAMA 620-2002: Voluntary Specification High Performance Organic Coatings on
Coil Coated Architectural Aluminum
2. AAMA 621-2002: Voluntary Specification for High Performance Organic coatings
on Coil Coated Architectural Hot Dipped Galvanized (HDG) and Zinc-Aluminum
Coated Steel Substrates
C. ASTM International
1. ASTM A 653/A 653M-05: Specification for Steel Sheet, Zinc-Coated (Galvanized) or
Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process
2. ASTM A 755/A 755M-03: Specification for Steel Sheet, Metallic Coated by the Hot-
Dip Process and Prepainted by the Coil-Coating Process for Exterior Exposed
Building Products
3. ASTM A 792/A 792M-05: Specification for Steel Sheet, 55% Aluminum-Zinc Alloy-
Coated by the Hot-Dip Process
4. ASTM B 32-04: Specification for Solder Metal
5. ASTM B 209M-04: Specification for Aluminum and Aluminum-Alloy Sheet and
Plate [Metric]
6. ASTM C 920-02: Specification for Elastomeric Joint Sealants
7. ASTM D 1187-97 (Reapproved 2002): Specification for Asphalt-Base Emulsions for
Use as Protective Coatings for Metal
D. Sheet Metal and Air Conditioning Contractors' National Association
1. Architectural Sheet Metal Manual. 2003.

1.8 DELIVERY, STORAGE, AND HANDLING

A. Do not store sheet metal flashing and trim materials in contact with other materials that
might cause staining, denting, or other surface damage. Store sheet metal flashing and trim
materials away from uncured concrete and masonry.
B. Protect strippable protective covering on sheet metal flashing and trim from exposure to
sunlight and high humidity, except to the extent necessary for the period of sheet metal
flashing and trim installation.

1.9 WARRANTY

A. Special Warranty: Warranty form in which Installer agrees to repair or replace components
of sheet metal flashing that fail in materials or workmanship within specified warranty
period.

1. Failures include, but are not limited to, the following:

a. Structural failures, including but not limited to rupturing, cracking, or

puncturing.
b. Wrinkling or buckling.
c. Loose parts.
d. Failure to remain weathertight, including uncontrolled water leakage.

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e. Deterioration of metals, metal finishes, and other materials beyond normal

weathering, including non-uniformity of color or finish.
f. Galvanic action between sheet metal flashing and dissimilar materials.

2. Warranty Period: Five years. See Division 01 Section “Warranties” for

commencement date of warranty period.

B. Special Warranty on Finishes: Manufacturer's standard form in which manufacturer agrees

to repair finish or replace sheet metal flashing and trim that shows evidence of deterioration
of factory-applied finishes within specified warranty period.

1. Exposed Panel Finish: Deterioration includes, but is not limited to, the following:

a. Color fading more than 5 Hunter units when tested according to

ASTM D 2244.
b. Chalking in excess of a No. 8 rating when tested according to ASTM D 4214.
c. Cracking, checking, peeling, or failure of paint to adhere to bare metal.

2. Finish Warranty Period: 20 years. See Division 01 Section “Warranties” for

commencement date of warranty period.

2 - PRODUCTS

2.1 SHEET METALS

A. General:
1. Provide sheet metal fabrications of coil-coated aluminum sheet, or coil-coated
metallic-coated steel sheet.
2. Protect mechanical and other finishes on exposed surfaces from damage by applying
a strippable, temporary protective film before shipping.

B. Aluminum Sheet: ASTM B 209M, alloy as standard with manufacturer for finish required,
with temper as required to suit forming operations and performance required.

1. Surface: Smooth, flat.

2. Exposed Coil-Coated Finish:

a. Two-Coat Fluoropolymer: AAMA 620. Fluoropolymer finish containing not

less than 70 percent PVDF resin by weight in color coat. Prepare, pretreat, and
apply coating to exposed metal surfaces to comply with coating and resin
manufacturers' written instructions.
b. Colors: Special colors to be selected by Engineer. Multiple colors will be
required.

3. Concealed Finish: Pretreat with 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 0.013 mm.

C. Metallic-Coated Steel Sheet: Restricted flatness steel sheet, metallic coated by the hot-dip
process and prepainted by the coil-coating process to comply with ASTM A 755/A 755M.

1. Zinc-Coated (Galvanized) Steel Sheet: ASTM A 653/A 653M, G90 (Z275) coating
designation; structural quality.

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2. Aluminum-Zinc Alloy-Coated Steel Sheet: ASTM A 792/A 792M, Class AZ50

coating designation, Grade 40 (Class AZM150 coating designation, Grade 275);
structural quality.
3. Surface: Smooth, flat.
4. Exposed Coil-Coated Finish:

a. Two-Coat Fluoropolymer: AAMA 621. Fluoropolymer finish containing not

less than 70 percent PVDF resin by weight in color coat. Prepare, pretreat, and
apply coating to exposed metal surfaces to comply with coating and resin
manufacturers' written instructions.
b. Colors: Special colors to be selected by Engineer. Multiple colors will be
required.

5. Concealed Finish: Pretreat with 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 0.013 mm.

2.2 MISCELLANEOUS MATERIALS

A. 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 and recommended by manufacturer of primary sheet metal.
B. Fasteners: Wood screws, annular threaded nails, self-tapping screws, self-locking rivets and
bolts, and other suitable fasteners designed to withstand design loads and recommended by
manufacturer of primary sheet metal.

1. General: Blind fasteners or self-drilling screws, gasketed, with hex-washer head.

a. Exposed Fasteners: Heads matching color of sheet metal using plastic caps or
factory-applied coating.
b. Blind Fasteners: High-strength stainless-steel rivets suitable for metal being
fastened.

2. Fasteners for Aluminum Sheet: Series 300 stainless steel.

3. Fasteners for Zinc-Coated (Galvanized) or Aluminum-Zinc Alloy-Coated Steel Sheet:
Series 300 stainless steel.
C. Solder:

1. For Zinc-Coated (Galvanized) Steel: ASTM B 32, Grade Sn50, 50 percent tin and 50
percent lead or Grade Sn60, 60 percent tin and 40 percent lead.

D. Sealant Tape: Pressure-sensitive, 100 percent solids, gray polyisobutylene compound

sealant tape with release-paper backing. Provide permanently elastic, nonsag, nontoxic,
nonstaining tape 1/2 inch (13 mm) wide and 1/8 inch (3 mm) thick.
E. Elastomeric Sealant: ASTM C 920, elastomeric silicone polymer sealant; low modulus; of
type, grade, class, and use classifications required to seal joints in sheet metal flashing and
trim and remain watertight.
F. Bituminous Coating: Cold-applied asphalt emulsion complying with ASTM D 1187.

2.3 FABRICATION, GENERAL

A. General: Custom fabricate sheet metal flashing and trim to comply with recommendations
in SMACNA's "Architectural Sheet Metal Manual" that apply to design, dimensions,

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geometry, metal thickness, and other characteristics of item specified. Fabricate items at the
shop to greatest extent possible.

1. Fabricate sheet metal flashing and trim in thickness or weight needed to comply with
performance requirements, but not less than that specified for each application and
metal.
2. Obtain field measurements for accurate fit before shop fabrication.
3. Form sheet metal flashing and trim without excessive oil canning, buckling, and tool
marks and true to line and levels indicated on Drawings, with exposed edges folded
back to form hems.
4. Conceal fasteners and expansion provisions where possible. Exposed fasteners are
not allowed on faces exposed to view.
B. Fabrication Tolerances: Fabricate sheet metal flashing and trim that is capable of
installation to a tolerance of 6 mm in 6 m on slope and location lines as indicated on
Drawings and within 3-mm offset of adjoining faces and of alignment of matching profiles.
C. Sealed Joints: Form nonexpansion but movable joints in metal to accommodate elastomeric
sealant.
D. Expansion Provisions: Where lapped expansion provisions cannot be used, form expansion
joints of intermeshing hooked flanges, not less than 25 mm deep, filled with butyl sealant
concealed within joints.
E. Fabricate cleats and attachment devices from same material as accessory being anchored or
from compatible, noncorrosive metal.
F. Fabricate cleats and attachment devices of sizes as recommended by SMACNA's
"Architectural Sheet Metal Manual", but not less than thickness of metal being secured.
G. Seams: Fabricate nonmoving seams with flat-lock seams. Tin edges to be seamed, form
seams, and solder. Do ot solder aluminum.

2.4 LOW-SLOPE ROOF SHEET METAL FABRICATIONS

A. Roof-Edge Flashing: Fabricate in minimum 2400-mm-long, but not exceeding 3-m-long,
sections. Furnish with 150-mm-wide, joint cover plates.

1. Joint Style: Butt, with 300-mm- wide, concealed backup plate.

2. Fabricate from one of the following materials:

a. Galvanized Steel: Thickness as determined by fabricator to comply with

performance requirements but not less than 1.5 mm thick.
b. Aluminum-Zinc Alloy-Coated Steel: Thickness as determined by fabricator to
comply with performance requirements but not less than 1.5 mm thick.
B. Counterflashing: Fabricate from one of the following materials:
1. Aluminum: Thickness as determined by fabricator to comply with performance
requirements but not less than 0.90 mm thick.
2. Galvanized Steel: Thickness as determined by fabricator to comply with performance
requirements but not less than 0.60 mm thick.
3. Aluminum-Zinc Alloy-Coated Steel: Thickness as determined by fabricator to
comply with performance requirements but not less than 0.60 mm thick.
C. Flashing Receivers: Fabricate from one of the following materials:
1. Aluminum: Thickness as determined by fabricator to comply with performance
requirements but not less than 0.90 mm thick.

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2. Galvanized Steel: Thickness as determined by fabricator to comply with performance

requirements but not less than 0.60 mm thick.
3. Aluminum-Zinc Alloy-Coated Steel: Thickness as determined by fabricator to
comply with performance requirements but not less than 0.60 mm thick.

3 - EXECUTION

3.1 EXAMINATION
A. Examine substrates, areas, and conditions, with Installer present, to verify actual locations,
dimensions and other conditions affecting performance of the Work.

1. Verify compliance with requirements for installation tolerances of substrates.

2. Verify that substrate is sound, dry, smooth, clean, sloped for drainage, and securely
anchored.
B. For the record, prepare written report, endorsed by Installer, listing conditions detrimental to
performance of the Work.
C. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 INSTALLATION, GENERAL

A. 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 other miscellaneous items as
required to complete sheet metal flashing and trim system.

1. Install sheet metal flashing and trim true to line and levels indicated on Drawings.
Provide uniform, neat seams with minimum exposure of solder, welds, and sealant.
2. 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
fabricating sheet metal.
3. Space cleats not more than 300 mm apart. Anchor each cleat with two fasteners.
Bend tabs over fasteners.
4. Install exposed sheet metal flashing and trim without excessive oil canning, buckling,
and tool marks.
5. Torch cutting of sheet metal flashing and trim is not permitted.
B. Metal Protection: Where dissimilar metals will contact each other or corrosive substrates,
protect against galvanic action by painting contact surfaces with bituminous coating or by
other permanent separation as recommended by SMACNA.

1. Coat back side of stainless-steel sheet metal flashing and trim with bituminous
coating where flashing and trim will contact wood, ferrous metal, or cementitious
construction.
C. 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 expansion provisions cannot be used or would not be
sufficiently watertight, form expansion joints of intermeshing hooked flanges, not less than
25 mm deep, filled with sealant concealed within joints.
D. Fastener Sizes: Use fasteners of sizes that will penetrate wood not less than 32 mm for
nails and not less than 19 mm for wood screws.
E. Seal joints as required for watertight construction.

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1. 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 ambient
temperature at time of installation is between 10 and 21 deg C, set joint members for
50 percent movement each way. Adjust setting proportionately for installation at
higher ambient temperatures.
2. Prepare joints and apply sealants to comply with requirements in Division 07 Section
"Joint Sealants."
F. Soldered Joints: Clean surfaces to be soldered, removing oils and foreign matter. Pre-tin
edges of sheets to be soldered to a width of 38 mm, except reduce pre-tinning where pre-
tinned surface would show in completed Work.

1. Do not solder aluminum sheet.

2. Do not use torches for soldering. Heat surfaces to receive solder and flow solder into
joint. Fill joint completely. Completely remove flux and spatter from exposed
surfaces.

3.3 ROOF FLASHING INSTALLATION

A. General: Install sheet metal flashing and trim to comply with performance requirements and
SMACNA's "Architectural Sheet Metal Manual." Provide concealed fasteners where
possible, set units true to line, and level as indicated on Drawings. Install work with laps,
joints, and seams that will be permanently watertight and weather resistant.

B. Roof Edge Flashing: Anchor to resist uplift and outward forces according to
recommendations in SMACNA's "Architectural Sheet Metal Manual" and as indicated by
Contractor on final Shop Drawings. Interlock bottom edge of roof edge flashing with
continuous cleat anchored to substrate at staggered 75-mm centers.
C. Pipe or Post Counterflashing: Install counterflashing umbrella with close-fitting collar with
top edge flared for elastomeric sealant, extending a minimum of 100 mm over base flashing.
Install stainless-steel draw band and tighten.
D. 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 sealant. Secure in a waterproof manner by means of anchor and
washer at spacing determined by Installer to comply with performance requirements but not
more than 900-mm centers.

3.4 ERECTION TOLERANCES

A. Installation Tolerances: Shim and align sheet metal flashing and trim within installed
tolerance of 6 mm in 6 m on slope and location lines as indicated on Drawings and within
3-mm offset of adjoining faces and of alignment of matching profiles.

3.5 CLEANING AND PROTECTION

A. Clean and neutralize flux materials. Clean off excess solder.
B. Clean off excess sealants.
C. Remove temporary protective coverings and strippable films as sheet metal flashing and
trim are installed unless otherwise indicated in manufacturer's written installation
instructions. On completion of installation, remove unused materials and clean finished
surfaces. Maintain in a clean condition during construction.

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D. Replace sheet metal flashing and trim that have been damaged or that have deteriorated
beyond successful repair by finish touchup or similar minor repair procedures.

END OF SECTION

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