SECTION 15515 BASIC HVAC SYSTEM MATERIALS AND METHODS

This spec was part of the Des Plaines, IL River WRF project that bid Feb 26, 2015.

SECTION 15515 BASIC HVAC SYSTEM MATERIALS AND METHODS

PART 1 -  GENERAL
1.1 SUMMARY
A. This Section includes the following:
1. Piping materials and installation instructions common to most piping systems.
2. Sleeves.
3. Escutcheons.
4. Pipe Penetrations
5. Duct Penetrations
6. Mechanical demolition.
7. Equipment installation requirements common to equipment sections.
8. Painting and finishing.
9. Concrete bases.
10. Supports and anchorages.
1.2 DEFINITIONS

A. Finished Spaces:  Spaces other than mechanical and electrical equipment rooms, furred spaces, pipe and duct shafts, unheated spaces immediately below roof, spaces above ceilings, unexcavated spaces, crawlspaces, and tunnels.

B. Exposed, Interior Installations:  Exposed to view indoors. Examples include finished occupied spaces and mechanical equipment rooms.

C. Exposed, Exterior Installations: Exposed to view outdoors or subject to outdoor ambient temperatures and weather conditions.  Examples include rooftop locations.

D. Concealed, Interior Installations: Concealed from view and protected from physical contact by building occupants. Examples include above ceilings and in duct shafts.

E. Concealed, Exterior Installations: Concealed from view and protected from weather conditions and physical contact by building occupants but subject to outdoor ambient temperatures.  Examples include installations within unheated shelters.
F. The following are industry abbreviations for plastic materials:
1. ABS:  Acrylonitrile-butadiene-styrene plastic.
2. CPVC:  Chlorinated polyvinyl chloride plastic.
3. PE: Polyethylene plastic.
4. PVC: Polyvinyl chloride plastic.
G. The following are industry abbreviations for rubber materials:
1. EPDM: Ethylene-propylene-diene terpolymer rubber.

2. NBR:  Acrylonitrile-butadiene rubber.
1.3 QUALITY ASSURANCE

A. Steel Support Welding:  Qualify processes and operators according to AWS D1.1, "Structural Welding Code--Steel."
1.4 DELIVERY, STORAGE, AND HANDLING

A. Deliver pipes and tubes with factory-applied end caps. Maintain end caps through shipping, storage, and handling to prevent pipe end damage and to prevent entrance of dirt, debris, and moisture.

B. Store plastic pipes protected from direct sunlight.  Support to prevent sagging and bending.
1.5 COORDINATION

A. Arrange for pipe spaces, chases, slots, and openings in building structure during progress of construction, to allow for mechanical installations.

B. Coordinate installation of required supporting devices and set sleeves in poured-in- place concrete and other structural components as they are constructed.

C. Coordinate requirements for access panels and doors for mechanical items requiring access that are concealed behind finished surfaces.

PART 2 -  PRODUCTS
2.1 MANUFACTURERS

A. In other Part 2 articles where subparagraph titles below introduce lists, the following requirements apply for product selection:
1. Manufacturers: Subject to compliance with requirements, provide products by the manufacturers specified.
2.2 PIPE, TUBE, AND FITTINGS – GENERAL

A. Refer to individual Division 15 piping Sections for pipe, tube, and fitting materials and joining methods.
B. Pipe Threads: ASME B1.20.1 for factory-threaded pipe and pipe fittings.
2.3 JOINING MATERIALS – GENERAL

A. Refer to individual Division 15 piping Sections for special joining materials not listed below.

B. Pipe-Flange Gasket Materials: Suitable for chemical and thermal conditions of piping system contents.

1. ASME B16.21, nonmetallic, flat, asbestos-free, 1/8-inch maximum thickness unless thickness or specific material is indicated.
a) Full-Face Type:  For flat-face, Class 125, cast-iron and cast-bronze flanges.
b) Narrow-Face Type: For raised-face, Class 250, cast-iron and steel flanges.
C. Flange Bolts and Nuts:  ASME B18.2.1, carbon steel, unless otherwise indicated.

D. Solder Filler Metals:  ASTM B 32, lead-free alloys.  Include water-flushable flux according to ASTM B 813.

E. Brazing Filler Metals:  AWS A5.8, BCuP Series, copper-phosphorus alloys for general-duty brazing, unless otherwise indicated; and AWS A5.8, BAg1, silver alloy for refrigerant piping, unless otherwise indicated.

F. Welding Filler Metals: Comply with AWS D10.12 for welding materials appropriate for wall thickness and chemical analysis of steel pipe being welded.
2.4 PIPE PENETRATIONS – GENERAL

A. Provide steel pipe sleeves with minimum wall thickness of 1/4 inch for pipes passing through beams and walls of concrete, brick, tile, or masonry, and 22 gage galvanized iron sleeves for pipes passing through other parts of construction. Provide steel pipe for all sleeves penetrating floors.  Furnish each sleeve having inside diameter 1 inch larger than outside diameter of un-insulated and insulated pipe, unless wall or floor is a firewall, in which case, only the pipe shall penetrate.

B. For pipes passing through floors, walls, and ceilings provide chrome-plated brass escutcheons having outside diameter to cover sleeved openings and inside diameter to fit pipe.
C. Fire and smoke-rated surfaces.
1. 3M CP 25N/S or CP 25S/L caulk, 3M FS 195 wrap/strip with restricting collar, 3M CS 195 composite sheet, Pipe Shields Inc. Series F fire barrier kits, Proset Systems fire rated floor and wall penetrations, Insta Foam Products Insta Fire Seal Firestop Foam, Dow Corning Fire Stop System.
2. UL-listed or tested by an independent testing laboratory, approved by the State or Local Code jurisdictions. Use a product that has a rating not less than the rating of the wall or floor being penetrated. Sleeves in concrete to be schedule 40 steel pipe with integral water stop unless the fire stop material used includes a sleeve that is an integral part of the rated assembly.
D. Non rated surfaces
1. Stamped steel, chrome plated, hinged, split ring escutcheons or floor-ceiling plates for covering openings in occupied spaces.
2. In exterior wall openings below grade, use a modular mechanical type seal consisting of interlocking synthetic rubber links shaped to continuously fill the annular space between the uninsulated pipe and the cored opening or a water stop type wall sleeve.

3. At interior partitions where pipe penetrations are sealed, use Tremco Dymonic, Sika Corp. Sikaflex 1a, Sonneborn Sonolastic NPI, or Mameco Vulken 116 urethane caulk to effect the seal. Use galvanized sheet metal sleeves in hollow wall penetrations.
2.5 DUCT PENETRATIONS – GENERAL
A. Fire and smoke-rated surfaces:
1. 3M CP 25N/S or CP 25S/L caulk, 3M FS 195 wrap/strip with restricting collar, Insta Foam Products Insta Fire Seal Firestop Foam, Dow Corning Fire Stop System.
2. UL listed or tested by an independent testing laboratory, approved by the State and Local Code jurisdictions.  Use a product that has a rating not less than the rating of the wall or floor being penetrated. Sleeves in concrete to be minimum 16 gauge galvanized steel sleeves.

B. Non-rated surfaces.  Fiberglass insulation fill at voids with galvanized steel sheet metal bank-off on both side of duct penetration through walls. Use fire resistant sealant for sealing and soundproofing.

PART 3 -  EXECUTION
3.1 PIPING SYSTEMS - COMMON REQUIREMENTS
A. Install piping according to the following requirements.

B. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems.  Indicated locations and arrangements were used to size pipe and calculate friction loss, expansion, pump sizing, and other design considerations. Install piping as indicated unless deviations to layout are approved on Coordination Drawings.

C. Install piping in concealed locations, unless otherwise indicated and except in equipment rooms and service areas.

D. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles or parallel to building walls.  Diagonal runs are prohibited unless specifically indicated otherwise.

E. Install piping above accessible ceilings to allow sufficient space for ceiling panel removal.
F. Install piping to permit valve servicing.
G. Install piping at indicated slopes.
H. Install piping free of sags and bends.
I. Install fittings for changes in direction and branch connections.
J. Install piping to allow application of insulation.

K. Select system components with pressure rating equal to or greater than system operating pressure.
L. Sleeves are required for core-drilled holes; see detail at end of this section.

M. Install sleeves for pipes passing through concrete and masonry walls, gypsum-board partitions, and concrete floor and roof slabs.
1. Cut sleeves to length for mounting flush with both surfaces.
a) Exception:  Extend sleeves installed in floors of mechanical equipment areas or other wet areas 2 inches above finished floor level.  Extend cast-iron sleeve fittings below floor slab as required to secure clamping ring if ring is specified.
2. Install sleeves in new walls and slabs as new walls and slabs are constructed.
3. Install sleeves that are large enough to provide 1/4-inch annular clear space between sleeve and pipe or pipe insulation. Use the following sleeve materials:
a) Steel Pipe Sleeves:  For pipes smaller than NPS 6.
b) Steel Sheet Sleeves:  For pipes NPS 6 and larger, penetrating gypsum- board partitions.
4. Except for underground wall penetrations, seal annular space between sleeve and pipe or pipe insulation, using joint sealants appropriate for size, depth, and location of joint.

N. Fire-Barrier Penetrations:  Maintain indicated fire rating of walls, partitions, ceilings, and floors at pipe penetrations.  Seal pipe penetrations with fire stop materials.
O. Verify final equipment locations for roughing-in.

P. Refer to equipment specifications in other Sections of these Specifications for roughing-in requirements.
3.2 PIPING JOINT CONSTRUCTION
A. Join pipe and fittings according to the following requirements.
B. Ream ends of pipes and tubes and remove burrs.  Bevel plain ends of steel pipe.

C. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly.

D. Soldered Joints:  Apply ASTM B 813, water-flushable flux, unless otherwise indicated, to tube end. Construct joints according to ASTM B 828 or CDA's "Copper Tube Handbook," using lead-free solder alloy complying with ASTM B 32.

E. Brazed Joints:  Construct joints according to AWS's "Brazing Handbook," "Pipe and Tube" Chapter, using copper-phosphorus brazing filler metal complying with AWS A5.8.

F. Threaded Joints: Thread pipe with tapered pipe threads according to ASME B1.20.1. Cut threads full and clean using sharp dies. Ream threaded pipe ends to remove burrs and restore full ID. Join pipe fittings and valves as follows:

1. Apply appropriate tape or thread compound to external pipe threads unless dry seal threading is specified.
2. Damaged Threads:  Do not use pipe or pipe fittings with threads that are corroded or damaged.  Do not use pipe sections that have cracked or open welds.

G. Welded Joints:  Construct joints according to AWS D10.12, using qualified processes and welding operators according to Part 1 "Quality Assurance" Article.

H. Flanged Joints:  Select appropriate gasket material, size, type, and thickness for service application.  Install gasket concentrically positioned.  Use suitable lubricants on bolt threads.
3.3 PIPING CONNECTIONS – GENERAL
A. Make connections according to the following, unless otherwise indicated:
1. Install unions, in piping NPS 2 and smaller, adjacent to each valve and at final connection to each piece of equipment.
2. Install flanges, in piping NPS 2-1/2 and larger, adjacent to flanged valves and at final connection to each piece of equipment.
3. Wet Piping Systems:  Install dielectric coupling and nipple fittings to connect piping materials of dissimilar metals.
3.4 EQUIPMENT INSTALLATION - COMMON REQUIREMENTS

A. Install equipment to allow maximum possible headroom unless specific mounting heights are not indicated.

B. Install equipment level and plumb, parallel and perpendicular to other building systems and components in exposed interior spaces, unless otherwise indicated.

C. Install mechanical equipment to facilitate service, maintenance, and repair or replacement of components.  Connect equipment for ease of disconnecting, with minimum interference to other installations. Extend grease fittings to accessible locations.
D. Install equipment to allow right of way for piping installed at required slope.
3.5 PAINTING

A. Damage and Touchup:  Repair marred and damaged factory-painted finishes with materials and procedures to match original factory finish.
3.6 CONCRETE BASES

A. Concrete Bases:  Anchor equipment to concrete base according to equipment manufacturer's written instructions.  Coordinate size and placement of concrete bases with the contractor responsible for placement of the concrete.
1. Construct concrete bases of dimensions indicated, but not less than 4 inches larger in both directions than supported unit.

2. Install dowel rods to connect concrete base to concrete floor. Unless otherwise indicated, install dowel rods on 18-inch centers around the full perimeter of the base.
3. Install epoxy-coated anchor bolts for supported equipment that extend through concrete base, and anchor into structural concrete floor.
4. Place and secure anchorage devices. Use supported equipment manufacturer's setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded.
5. Install anchor bolts to elevations required for proper attachment to supported equipment.
6. Install anchor bolts according to anchor-bolt manufacturers written instructions.
3.7 ERECTION OF METAL SUPPORTS AND ANCHORAGES

A. Cut, fit, and place miscellaneous metal supports accurately in location, alignment, and elevation to support and anchor mechanical materials and equipment.
B. Field Welding: Comply with AWS D1.1.

END OF SECTION