PART 1 - GENERAL 1.1 SUMMARY SECTION 06 40 00 A. Provide architectural woodwork as shown and specified. Work includes: 1. Providing plastic laminate finished casework. 2. Providing plastic laminate clad countertops and trim. 3. Providing standing and running wood trim. 4. Installing wood doors furnished under Section 08 14 00. 5. Installing door hardware furnished under Section 08 71 00. B. Related Sections: 1. Section 09 90 00 Paints and Coatings: Field applied painted finishes. 1.2 REFERENCES A. Reference standards: 1. American National Standards Institute (ANSI): a. ANSI A115 Series "Door and Frame Preparation for Hardware." b. ANSI A208.1-1999 Particleboard 2. Architectural Woodwork Institute (AWI): a. AWI 2003 "Architectural Woodwork Quality Standards, 8th Edition, Version 1.0." b. AWI Section 100 "Lumber." c. AWI Section 200 "Panel Products." d. AWI Section 300 "Standing & Running Trim" e. AWI Section 400B "Architectural Cabinets (Laminate Clad Cabinets)." f. AWI Section 400C "Architectural Cabinets (Tops)." g. AWI Section 500 "Paneling & Related Wood Doors." h. AWI Section 1500 "Factory Finishing" i. AWI Section 1700 "Installation" 3. National Electrical Manufacturers Association (NEMA): a. NEMA LD3-2000 "High-Pressure Decorative Laminates, Part 1-4." 4. National Institute of Standards and Technology (NIST) Product Standards: a. NIST PS 1-95 "Construction and Industrial Plywood." b. NIST PS 20-99 "American Softwood and Lumber Standard." 1.3 DEFINITIONS A. Exposed Surfaces: Casework surfaces visible after installation with doors and drawers closed. Other locations considered to be exposed include wall hung casework bottoms more than 40 inches above the floor and visible members in open cases or behind clear glass doors. B. Semi-Exposed Surfaces: Casework members behind opaque doors, including shelves, divisions, interior faces of ends, case backs, drawer sides, backs and bottoms and back face of doors. Tops of cases 6'-6" or more above the floor shall be considered semi-exposed. C. Concealed Surfaces: Sleepers, web frames, dust panels and other surfaces not usually visible after installation. 06 40 00-1
1.4 SUBMITTALS A. Submit shop drawings for casework, countertops, paneling and trim. 1. Provide large scale details. Indicate materials, component profiles, fastening and jointing details, hardware, finishes and accessories. 2. Show relationship to adjacent work. Indicate countertop methods of edging and location and construction of joints. 3. Provide manufacturer's product data for hardware, accessory and specialty items. B. Submit samples of the following: 1. Plastic laminate manufacturers full color range of plastic laminate samples for color selection. 2. Submit one sample of each type of casework hardware for review and approval. Accepted samples will be returned to the Contractor. Accepted samples may be used in the work. C. Submit product certificates signed by the woodwork fabricator certifying products comply with specified requirements. D. Submit manufacturer's maintenance data for plastic laminate products. Include a list of approved cleaning materials and recommended cleaning procedures. Provide instructions for stain removal and surface finish restoration. 1.5 QUALITY ASSURANCE A. Architectural woodwork fabricators qualifications: A firm specializing in the fabrication of architectural woodwork with a satisfactory record of performance on projects of comparable size and quality. Fabricator shall be acceptable to the Architect/Engineer. B. Installation: Performed only by the architectural woodwork fabricator or experienced skilled finish carpenters approved by the fabricator and acceptable to the Architect/Engineer. C. Quality Standards: Comply with AWI 2003 "Architectural Woodwork Quality Standards, 8th Edition, Version 1.0." except as otherwise indicated. D. Provide lumber and plywood factory grade-marked on concealed surfaces. Omit marking and submit mill certificates for materials that cannot be marked on a concealed surface. E. Pre-installation meeting: Meet at project site before delivery of architectural woodwork and review coordination and controls required for proper installation in areas to receive work. Include in meeting the Contractor, Architect/Engineer, installers of millwork, other finishes, painting, and when applicable mechanical and electrical work. 1.6 DELIVERY, STORAGE AND HANDLING A. Protect architectural woodwork materials during delivery, storage and handling to prevent damage, soiling and deterioration. B. Do not deliver architectural woodwork materials until concrete, masonry and other similar wet work has been completed and is thoroughly dry, outside door and window openings are permanently watertight, and, in case of temperature dropping below 60 degrees F, until temporary heating and ventilating systems are in operation. C. Store materials in dry well-ventilated spaces with constant minimum temperature of 60 degrees F and maximum relative humidity of 55 percent. 06 40 00-2
1.7 PROJECT CONDITIONS A. Provide and maintain a constant temperature and humidity before, during and after installation as required to maintain optimum moisture content of installed materials. B. Field Measurements: Where architectural woodwork items are indicated to be fitted to other construction, verify dimensions of other construction by accurate field measurements before manufacturing architectural woodwork; show recorded measurements on final shop drawings. Coordinate manufacturing schedule with construction progress to avoid delay of Work. PART 2 - PRODUCTS 2.1 GENERAL A. Materials used in finished work shall be clear, free of cracks, checks, knots, and other imperfections that may interfere with proper completion of the work. Warped or otherwise imperfect work shall be removed and replaced by responsible Contractor. B. Lumber and panel product materials: Comply with AWI Quality Standards. 1. Section 100: Lumber. 2. Section 200: Panel Products. C. Provide lumber surfaced four sides (S4S) and worked to profiles and patterns shown. Nominal sizes are as shown, except where detailed dimensions are indicated. D. Moisture content: Provide materials kiln-dried to moisture content complying with AWI Standards, Section 100-S-11. E. Hardwood lumber: Comply with National Hardwood Lumber Association (NHLA) "Rules for Measurement and Inspection of Hardwood Lumber and Cypress." F. Softwood lumber: Comply with PS-20 "American Softwood and Lumber Standard" and with applicable grading rules of grading and inspection agency for species indicated. 1. Douglas Fir, Western Red Cedar, Ponderosa Pine, White Pine: Western Lumber Grading Rules, 91 published by Western Wood Products Association (WWPA), or Standard Grading Rules, No. 16, 1989, published by West Coast Lumber Inspection Bureau (WCLIB). G. Plywood: Provide each softwood plywood panel grade-trademarked, identifying type, grade and conformance with NIST Product Standard PS 1 for Construction and Industrial Plywood. 1. Thickness and application details as shown on the drawings. H. Particleboard: Comply with ANSI A208.1 "Particleboard, Mat-Formed Wood." I. Plastic laminate: Comply with NEMA Publication No. LD3 "High-Pressure Decorative Laminates, Part 1-4" requirements for high-pressure laminated materials. 1. Plastic laminate: Formica Corp., "Formica" or an Architect/Engineer approved equal by Nevamar Corp., Pioneer Plastics Corp., or Wilsonart International. Satin finish, color selected by Architect/Engineer based on manufacturer's full line of solid colors and patterns. J. Cabinet construction: Comply with AWI Section 400C and AWI publication "Architectural Casework Details" for Custom Grade architectural woodwork. K. Paneling construction: Comply with AWI Section 500. 06 40 00-3
L. Factory finishing: Comply with AWI Section 1500 and publication "Factory Finishing of Architectural Woodwork." M. Hardware preparation: Comply with ANSI A115 Series "Specifications for Door and Frame Preparation for Hardware." N. Fasteners: Provide fastener type, size, material and finish as required by conditions of use, substrate material and adequate anchorage for the work. O. Cast Plastic - Solid surface materials: DuPont Corian Corian or an Architect/Engineer approved equal integrally colored solid surface, non-porous, homogenous polyester and acrylic components with filler by Formica Corp. "Surell", Nevamar Decorative Surfaces "Fountainhead" or Wilsonart International Gibraltar. 2.2 MATERIALS A. Plastic laminate countertops and trim: AWI Custom Grade, Section 400C. 1. Face sheets: General purpose grade, GP50, minimum.050" thick. 2. Cores: Minimum 3/4" thick 5-ply exterior grade hardwood faced plywood or ANSI A208.1 phenolic resin particleboard type 2-M-2 or 2-M-3. 3. Adhesive: AWI 100-S-5 Type I waterproof type as recommended by plastic laminate manufacturer. 4. Color and Finish: As selected by the Architect/Engineer. 5. Joint sealants: One-component silicone rubber elastomeric sealant complying with Section 07 92 00 requirements, color matched to plastic laminate color. 2.3 CAST RESIN PANELS A. Cast Resin, Lumicor: high performance resins, including acrylic, coss-linked acrylic. 1. Lumicor Tiki Grass or Design Tex Tiki Stalk 2. Cross Linked Acrylic ¼ thickness 3. Matte Finish 4. Fire Rating ASTM D635-03 5. Smoke Density ASTM D2843-99 6. Rate of Ignition ASTM D1929-96 2.4 STANDING AND RUNNING TRIM A. Standing and running trim and plywood paneling, site applied transparent stained finish: AWI Custom Grade, Section 300, Clear plain sawn Oak hardwood, sizes and profiles shown. 1. Install standing and running trim 2.5 PLASTIC LAMINATE CASEWORK A. Plastic Laminate Clad Casework: AWI Sections 400, Custom grade. 1. Casework Construction: Flush overlay design. 2. Casework Bodies, Countertops and Splashes: High pressure plastic laminate and cabinet liner on particle board, minimum 3/4 inch thick except where otherwise indicated. Provide exterior grade plywood instead of particle board for countertops and backsplashes with sinks. 3. Casework Shelving: Cabinet liner on particle board, except provide high pressure plastic laminate matching casework at open cases. Finish four edges, top and bottom face of shelves in open cases. a. Shelving under 30 inches wide: 3/4 inch thick. b. Shelving over 30 inches wide: 1 inch thick. c. Adjustable shelving standards: Metal, recessed flush with applicable clips. 4. Concealed Framing: Sound material of any species. 5. Casework Backs: Melamine on particle board, minimum 1/4 inch thick. 06 40 00-4
6. Drawer Bottoms, Sides, Backs and Semi-Exposed Fronts: Melamine on particle board, minimum 1/2 inch thick with color matched PVC edging. 7. Casework Doors and Drawer Fronts: High pressure plastic laminate and casework liner on particle board. a. Doors 30 inches wide x 60 inches high or smaller: 3/4 inch thick. b. Larger doors to a maximum of 36 inches wide x 72 inches high: 1 inch thick. 8. Wood Cleats: Hardwood, used with wall supported shelves or countertops. 9. Edge Treatment: PVC or same laminate as horizontal surfaces. 10. Wall cabinets shall have exposed bottoms finished to match face material and color when bottom is 40 inches above floor line. B. Finishes and Laminates: 1. Laminate Cladding Colors, Patterns, Finishes: As selected by the Architect. 2. Exposed Surfaces: General Purpose 0.050 inch high pressure plastic laminate including four edges and back face of doors and applied drawer faces. 3. Semi-Exposed Surfaces: Except as otherwise indicated, provide melamine on particle board. 4. Provide 0.020 inch phenolic backing sheet to underside of plastic laminate faced countertops and exposed particle board edges of all cutouts for sinks and to concealed backsplash faces which are not an integral part of the casework unit and are adhered to the wall. 5. Concealed surfaces require no laminate finish unless specifically noted otherwise. C. Casework hardware: 1. Finish: US32D, satin stainless steel finish, unless otherwise indicated. 2. Hinges: Julius Blum Inc., Stanley, NC (800) 438-6788 Maxus Institutional Hinges, concealed 170 degree swing. a. Subject to compliance with specified requirements, the following manufacturers are acceptable: 1) Grass America, Kernersville, NC (800) 334-3512. 2) Hafele America, Archdale, NC (800) 334-1873. 3) Mepla Inc., High Point, NC (800) 456-3752. 3. Pulls: Wire pulls, 4 inch projecting type. Finish: Dull chrome. 4. Catches: Magnetic type catches with aluminum case. Provide 30 lb. double catches for double doors and full height case doors; 12 lb. single catches used for single doors of base and wall-hung casework. Provide extruded aluminum dead bolt on left-hand door for locked double doors. 5. Drawer Slides: Steel 2-section drawer slides with nylon ball-bearing rollers for standard drawers and steel 3-section full extension drawer slides with ball bearings and nylon rollers for file drawers. All metal parts to be plated. Slide lengths and ratings shall suit particular application. 6. Provide plated #8 or #10 Pan head or Phillips head self-tapping high-low thread screws and washers for casework installation. 2.6 FABRICATION A. Field verify dimensions and installation conditions affecting the work. B. Shop fabricate casework in accordance with AWI Quality Standards. 1. Where details are not shown, comply with applicable Quality Standards or with alternate details acceptable to Architect/Engineer as fabricator's option. 2. Fabricate exposed edges of casework panels and shelving, including edges of casework doors and drawers, with matching materials. 3. Provide casework hardware, including hinges, pulls, adjustable shelving standards, brackets and clips, drawer slides, and accessories as indicated or required. Finish as selected by Architect/Engineer. 06 40 00-5
C. Shop fabricate plastic laminate countertops and trim in accordance with AWI Quality Standards and drawing details. Bond plastic laminate to substrate in accordance with plastic laminate manufacturer's requirements. Keep joints to a minimum, no exposed metal accessories acceptable. 1. Provide exposed plastic laminate edges self-edged and built up to edge thickness detailed or accepted on final shop drawings. 2. Shop cut sink cutouts. Coordinate work with plumbing work. Obtain fixture templates as required to perform the work. 3. Protect exposed core surfaces that will be concealed after installation with two coats of sanding sealer. D. Fabricate finished work properly framed, closely fit and accurately set to required lines and levels and rigidly secured in place. E. Fabricate work straight, plumb, level and in true alignment; neatly and accurately fit, scribed and thoroughly secured. Miters and other joints shall be planed and sanded. All work shall be left clean and free from warp, twist, open joints and other defects. F. Provide finished woodwork dressed and sanded free from machine and tool marks, abrasions, raised grain or other defects on surfaces exposed to view in finished work. Exposed wood surfaces shall be uniform in color and grain. G. Assemble casework, countertops and similar items at the shop in largest possible sections and deliver to the site ready for installation. Shop fit work that cannot be shop assembled. H. Provide metal fabrications, brackets, supports as indicated on the drawings to support various millwork components. 2.7 FINISHING A. Quality Standard: Comply with AWI Section 1500 "Factory Finishing" for finishing preparation, including sanding, filling countersunk fasteners, and dealing with concealed surfaces and other preparations applicable to each unit of work. PART 3 - EXECUTION 3.1 PREPARATION A. Condition architectural woodwork materials and products for not less than 48 hours to average prevailing humidity conditions in installation areas before installing. B. Install blocking and anchoring devices built into substrates for anchorage of architectural woodwork items. C. Before installation, examine shop fabricated architectural woodwork for completion. Complete work as required, including back priming and removal of packing. 3.2 INSTALLATION A. Install architectural woodwork materials and products plumb, level, true and straight with no distortion. Shim as required using concealed shims. Install to a tolerance of 1/8" in 8'-0" for plumb and level (including countertops) and with 1/16" maximum offset in flush adjoining surfaces, 1/8" maximum offsets in revealed adjoining surfaces. B. Scribe and cut work to fit adjoining work and refinish cut surfaces or repair damaged finish at cuts. 06 40 00-6
C. Anchor architectural woodwork items to built-in place blocking or directly attach to substrate framing. Secure to grounds, stripping and blocking with countersunk, concealed fasteners and blind nailing as required for a complete installation. Use finish nails for exposed nailing, countersunk and filled flush with woodwork and matching final finish where transparent finish is indicated. Plug and sand screw fastener holes. D. Install standing and running trim with minimum number of joints. Use full-length pieces, from maximum length of lumber available, to the greatest extent possible. Stagger joints in adjacent and related members. Cope at returns, miter at corners and comply with Quality Standards for joinery. Butt joints, except as detailed, are not acceptable. E. Install casework without distortion so that doors and drawers will fit openings properly and be accurately aligned. Adjust hardware to center doors and drawers in openings and to provide unencumbered operation. Complete the installation of hardware and accessory items as indicated. F. Install plastic laminate countertops and trim. Provide work level, true to alignment, accurately fit to wall conditions and securely fastened to base units and other support systems as indicated. 1. Seal intersection of countertops and applied splashes with bead of color matched silicone sealant. G. Install wood doors furnished under Section 08 14 00. Provide pilot holes of proper size for screws in wood doors. Apply hardware in accordance with manufacturer's instructions. Adjust doors to provide uniform clearance and to contact stops uniformly. Remove and replace doors which are warped, bowed or otherwise damaged and cannot be properly fit. H. Install door hardware furnished under Section 08 71 00. Apply door hardware in accordance with manufacturer's instructions. Fit door hardware before application of finish. Remove or protect during finishing operations. 3.3 CLEANING AND PROTECTION A. Repair damaged and defective architectural woodwork to eliminate functional and visual defects. Where not possible to repair properly, replace architectural woodwork items as directed by Architect/Engineer. B. Clean architectural woodwork items on exposed and semi-exposed surfaces. Touch-up shop applied finishes when required to restore damaged or soiled areas. 1. Clean hardware, lubricate and make final adjustments for proper operation. C. Provide temporary covers and protect installed work until final acceptance. END OF SECTION 06 40 00 06 40 00-7