Architecturally

Exposed
Structural
Steel

a supplement to

MAY 2003

hile exposed structural steel was once the

select province of a few noteworthy projects,
architects today are increasingly using
transparency in their design. The current
trend may have started with Helmut Jahns
United Airlines Terminal in Chicago, but it has now spread
to everything from small retail stores to office lobbies.
Unfortunately, existing codes and standardseven
AISCs Code of Standard Practicedo not fully address the
unique level of detail needed to successfully design, detail,
fabricate and erect Architecturally Exposed Structural Steel
(AESS). Further, because AESS costs more to fabricate than
standard structural steel, it is critical that these designs are
properly budgeted. The repercussion of not properly budgeting AESS is often the need for redesign, project delays, and
ultimately even higher project costs. In addition, the members requiring special handling and finish are often poorly
identified in the contract documentsand, since the EOR
often specifies the steel while the architect specifies the paint
and appearance, there is sometimes a built-in conflict or
compatibility issue. Finally, the lack of acceptance criteria for
AESS members often leads to disputes between the design
team and the contractor over what is desired versus what
was bid.
In response to these issues, the Steel Liaison Committee
of the Structural Engineers Association of Colorado and the
Rocky Mountain Steel Construction Association, with input
from local contractors and architects, developed guidelines
to assist in the specification of AESS. According to the Committee: The goal of these tools is to allow the designer to
communicate the desired appearance in a format that Contractors can price/budget/bid more appropriately.
The guidelines include three key elements:
Sample Board: The sample board includes small pieces
of fabricated structural steel that indicate a range of finish
surfaces that can be expected from structural steel fabricators. The board includes bare steel with fabrication defects
and pieces with typical finish coats. The samples are intended to allow the designer to see how various fabrication
techniques affect the final product. The goal of the sample
board is to allow the designer to decide what features are
important for their project. Physical samples allow the designer to evaluate how imperfections in the finished surface
appear from various distances.
The photos printed here are taken from the sample board ,
but due to reproduction technology might not fully represent
the actual appearance on the sample board. However, design-

ers or contractors wishing to obtain an actual sample board

can purchase one from Zimkor Industries for $1,780 by contacting William Zimmerman at wgzimmerman@zimkor.com
or 303.791.1333.
Cost Matrix: Of course, knowing appearance of the final
steel is only half the story. Equally important is knowing the
budget impact of AESS. The cost matrix is designed to provide the designer with the cost premium associated with
specifying the desired techniques to achieve the final appearance of an AESS project. The cost of producing work to
a higher appearance standard varies greatly from fabricator
to fabricator, depending on the equipment in the shop and
the experience of the staff. This variation is indicated in the
cost matrix as a range of cost premiums for each desired fabrication technique or finish coat item specified.
The cost premiums noted apply to the total weight of
AESS for that particular line item, fabricated and erected.
While the cost matrix was prepared initially by surveying
fabricators in the Rocky Mountain region, the figures have
been further checked through surveying a select group of
national fabricators. The idea behind the cost matrix is to
allow a designer to balance a project budget with the desired
project scope. As a result, several design iterations might be
required. Also, it is imperative that a designer contacts a
local fabricator for more detailed pricing as the project becomes more defined.
Specification: SEAC/RCSCA has prepared a generic
specification that includes many common fabrication and
erection techniques to help communicate a designers expectations to the fabricator. The specification includes a
number of editors notes to provide guidance. The headings
in the specification are coordinated with the line times from
the cost matrix and sample board. The intent of the specification is to provide a consistent mechanism to define appearance quality requirements that were selected with the
sample board and budgeted with the cost matrix. The primary scope of the project was to offer a common language to
address the appearance issues of structural steel used in exposed locations.
Although many of the finish issues are common to miscellaneous metals, stairs and railings, the specification is not
written to cover all of these items. Furthermore there are numerous performance topics such as jointing for thermal movements, waterproofing and fire resistance which this document
does not address. Any comments or suggestions on how the
Specification can be improved or modified should be sent to
Jack Petersen at jpetersen@martin/martin.com.

Supplement cover: the recent expansion of the Austin, TX convention center includes a spectacular atrium space that features exposed
structural steel framing and a cobalt-blue art-glass wall on the exterior of the building.

2 AESS Supplement Modern Steel Constrution May 2003

SAMPLE BOARD
Closeup photos of the AESS sample board are used thorughout this supplement to illustrate the visual appearance of
many conditions encountered when designing exposed structural steel. A photograph of the complete board appears below.

SAMPLE AESS SPECIFICATION

2.

SECTION 05125
ARCHITECURALLY EXPOSED STRUCTURAL STEEL

Editors Note: Address alignment and location of bridging

where joists are visible in Division 5 Section Open Web Metal
Joists

PART 1 GENERAL
1.1 RELATED DOCUMENTS

3.

A. Drawings and general provisions of the Contract,

including General and Supplementary Conditions
and Division 1 Specification Sections, apply to the
Section.

Editors Note: It is critical to define to the bidders what members will be considered as Architecturally Exposed Structural
Steel (AESS). Furthermore the degree to which the requirements of the AISC Code of Standard Practice apply must be
spelled out.
A. This Section includes requirements regarding the
appearance and surface preparation of Architecturally Exposed Structural Steel (AESS).
Refer to Division 5, Section Structural Steel for all
other requirements regarding steel work not included in this section.
This section applies to any members noted on Architectural [and Structural] drawings as AESS [and
in the areas defined as AESS below].

Division 5 Section Steel Joists

Editors Note: Address fastener spacing and weld showthrough in areas where decking is visible in the finished structure. Coordinate paint system requirements with that of AESS

1.2 SUMMARY

B.

Division 5 Section Structural Steel

7.

1.3

4.

Division 5 Section Metal Decking for erection requirements relating to exposed steel
decking and its connections

5.

Division 5 Section Metal Fabrications for

loose steel-bearing plates and miscellaneous
steel framing.

6.

Division 9 Section Special Coatings for finish

coat requirements and coordination with
primer and surface preparation specified in
this section.

Division 9 Section Painting for finish coat requirements and coordination with primer and surface preparation specified in this section.

SUBMITTALS

Related Sections: The following Sections contain requirements that relate to this Section:

A. General: Submit each item below according to the

Conditions of the Contract and Division 1 Specification Sections.

1.

B.

Product Data for each type of product specified.

C.

Shop Drawings detailing fabrication of AESS components.

Division 1 Section Quality Control for independent testing agency procedures and administrative requirements.

May 2003 Modern Steel Constrution AESS Supplement 3

The sample on the left shows the appearance of typical structural welds. On the right, the welds have been ground smooth.

1.

Provide erection drawings clearly indicating

which members are considered as AESS members.

2.

Include details that clearly identify all of the

requirements listed in sections 2.3 Fabrication and 3.3 Erection of this specification.
Provide connections for exposed AESS consistent with concepts shown on the architectural
or structural drawings.

3.

Indicate welds by standard AWS symbols, distinguishing between shop and field welds, and
show size, length and type of each weld. Identify grinding, finish and profile of welds as defined herein.

4.

Indicate type, size, finish and length of bolts,

distinguishing between shop and field bolts.
Identify high-strength bolted slip-critical, direct-tensioned shear/bearing connections. [Indicate to which direction bolt heads should be
oriented.]

5.

Clearly indicate which surfaces or edges are

exposed and what class of surface preparation
is being used.

6.

Indicate special tolerances and erection requirements as noted on the drawings or defined herein.

D. Qualification data for firms and persons specified

in the Quality Assurance Article to demonstrate
their capabilities and experience. Include lists of
completed projects names and address, names and
addresses of architects and owners, and other information specified.
[For each project, submit photographs showing detail of installed AESS.]
1.4 QUALITY ASSURANCE

4 AESS Supplement Modern Steel Constrution May 2003

A. Fabricator Qualifications: In addition to those qualifications listed in Division 5 Section Structural

Steel, engage a firm experienced in fabricating
AESS similar to that indicated for this Project with
a record of successful in-service performance, as
well as sufficient production capacity to fabricate
AESS without delaying the Work.
B.

Erector Qualifications: In addition to those qualifications listed in Division 5 Section Structural

Steel, engage an experienced Erector who has completed AESS work similar in material, design, and
extent to that indicted for this Project and with a
record of successful in-service performance.

C.

Comply with applicable provisions of the following specifications and documents:

1.

AISC Code of Standard Practice, latest edition,

Section 10 as amended herein.

The connection on the left shows a connection with the typical blocking tolerance. The connection on the right shows the same connection
with tolerances minimized.

6.

Editors Note: The following section should be edited to define

how many mockup pieces are required. The Architect must define the size and extent of the pieces which are required and
what specific finishes must be demonstrated.
D. Mockups: At least four weeks prior to fabricating
AESS, the contractor shall construct mockups to
demonstrate aesthetic effects as well as qualities of
materials and execution. A mockup for each of the
following elements shall be constructed:

a.

E.

Build mockups to comply with the following requirements, using materials indicated for final unit
of Work.
1.

Locate mockups on-site or in the fabricators

shop as directed by Architect. Mockups shall
be full-size pieces unless the Architect approves smaller models.

2.

Notify the Architect one week in advance of

the dates and times when mockups will be
available for review.

3.

Demonstrate the proposed range of aesthetic

effects regarding each element listed under the
fabrication heading below.

4.

Mockup will have finished surface (including

surface preparation and paint system).

5.

Obtain Architects approval of mockups before

starting fabrication of final units.

Retain and maintain mockups during construction in an undisturbed condition as a

standard for judging the completed work.
Approved mockups in an undisturbed
condition at the time of Substantial completion may become part of the completed
work.

Pre-installation Conference: The General Contractor shall schedule and conduct conference at the
project site to comply with requirements of Division 1 Section Project Meetings. As a minimum,
the meeting shall include the General Contractor,
Fabricator, Erector, the finish-painting subcontractor, and the Architect. Coordinate requirements for
shipping, special handling, attachment of safety cables and temporary erection bracing, touch up
painting and other requirements for AESS.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Deliver AESS to Project site in such quantities and
at such times to ensure continuity of installation.
B.

Store materials to permit easy access for inspection

and identification. Keep steel members off ground
by using pallets, platforms, or other supports. Protect steel members and packaged materials from
erosion and deterioration. Use special care in handling to prevent twisting or warping of AESS members.

May 2003 Modern Steel Constrution AESS Supplement 5

On the left, the field-welding aid (the backing bar) has been left in place. On the right, the field-welding aid has been removed and the weld
ground smooth.

C.

Erect pre-painted finish pieces using padded slings

or other methods such that they are not damaged.
Provide padding as required to protect while rigging and aligning members frames. Weld tabs for
temporary bracing and safety cabling only at points
concealed from view in the completed structure or
where approved by the Architect during the pre-installation meeting. Methods of removing temporary erection devices and finishing the AESS
members shall be approved by the Architect prior
to erection.

cated on drawings and approved on final shop

drawings.]
PART 2 PRODUCTS
2.1 MATERIALS
A. General: Meet requirements Division 5 Section
Structural Steel as amended below.
B.

1.6 PROJECT CONDITIONS

A. Field Measurements: Where AESS is indicated to
fit against walls and other 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.
1.7

COORDINATION
A. Coordinate installation of anchors for AESS members that connect to the work of other trades. Furnish setting drawings, templates, and directions for
installing anchors, including sleeves, concrete inserts, anchor bolts, and items with integral anchors,
that are to be embedded in concrete or masonry.
Deliver such items to the project site in time for installation. [Anchorage concepts shall be as indi-

High-Strength Bolts, Nuts, and Washers: Per section 05120 heavy hex heads and nuts [Provide
rounded bolt heads with twist-off bolts]. Provide
standard carbon steel [Cadmium plated] [Mechanically galvanized] finish.

2.2 PRIMERS
Editors Note: The primer specified in section 05120 must be
coordinated with the finish coat system listed in section 09900
to ensure coating compatibility. The use of the Federal Specification System (i.e. FS TT-P-6664) is obsolete since many of
these specs do not address current VOC regulations and other
environmental standards such as lead & chromates. Primers
for steel come in a variety of resins such as alkyd, waterborne,
epoxy, and zinc rich
Alkyd Primers-Typically referred to as shop coat primer, this
product can come in many different levels of quality depending
on the level of corrosion protect required. This would include
keeping the steel from flash rusting prior to being covered by in
an interior wall up to long-term corrosion protection. They are
fast drying, enabling the fabricator to quickly deliver product to

6 AESS Supplement Modern Steel Constrution May 2003

The left half of this sample shows a typical groove weld. The right
half shows the same weld ground smooth.

This sample shows atypical weld-access hole.

the job site. Standard alkyd primers can be finish coated with an
alkyd or waterbased enamel. Universal alkyd primers can be
used under high-performance coatings such as epoxies or urethanes. In general, for exterior exposure, a high-quality, universal, rust-inhibitive primer should be used. The increase in
cost over a standard Shop Coat primer is on the order of
$5.00 to $10.00 per gallon. The material cost of the paint represents a small portion of the total painting cost, while the higher
quality provides greater corrosion protection to the steel.

be cured prior to top-coating. Although a urethane finish coat

can be applied directly over an organic zinc, it is suggested that
an intermediate epoxy coating be used to prevent pin holing
in the urethane coating, promote adhesion of the system, and
increase film build to hide imperfections in the steel. Alkyd finish coats should not be specified over zinc primers. For galvanizing repair, an organic zinc with not less than 90% zinc by
weight in the dry film should be used for regalvanizing welds
and damage due to erection.

Acrylic Primer: Acrylic primers are corrosion resistant and

water-soluble, often providing a lower VOC. They are available
in shop-coat quality up to a universal primer for use under high
performance coatings such as epoxies and urethanes.

FINISHES

Epoxy Primer: Epoxy primers provide excellent corrosion protection for steel and can be top coated with a variety of finishes.
Epoxy primers can be applied in the shop and typically have a
high film build that will hide minor imperfections.
Zinc Rich Primer: Zinc rich primer provides superior corrosion
protection by providing cathodic protection to the steel. Zinc
rich coatings can be specified as either organic zinc or inorganic
zinc. Both inorganic and organic will meet class B slip coefficients for bolted connections. In arid regions (such as the Rocky
Mountain Region) organic epoxy/zinc primers should be specified, as they do not rely on an outside source (humidity) for
cure. Inorganic zinc requires a constant humidity of no less
than 40% RH for proper cure. If an intermediate and finish coat
are to be completed in the shop, the lack of humidity can cause
delays in both the painting process and project as the zinc must

When possible, finish coating should be done in the field after

erection. Finish coats applied in the shop almost always incur
damage from handling in shipping and erection. This often results in applying an additional finish coat in the field or completing costly touch up which often does not blend in with the
original finish. *Note: If finish painting is to be done prior to
delivery of the steel, special sections should be added to ensure
proper handling and minimize damage.
Finish coatings for commercial projects with AESS fall into the
following categories
Alkyds (Oil based): Acceptable finish coat for interior applications and some exterior application. Dries to hard durable finish. When applied specified for exterior use, alkyds will chalk
and fade with UV exposure in a relatively short period. Can be
brush, roll, or spray applied.
Acrylics (Waterborne): Acceptable finish coat for both interior
and exterior service. Acrylics provide good color and gloss re-

May 2003 Modern Steel Constrution AESS Supplement 7

On the left, the fillet weld is continuous. On the right, the fillet weld
is intermittent.

This sample shows the visibility of typical shop marks.

C. Primer: Acrylic water-soluble shop coat with good

resistance to normal atmospheric corrosion. Primer
shall comply with all federal standards for VOC,
lead and chromate levels.

tention under UV exposure. Can be easily applied by brush,

roller, or spray. Low odor and VOC for interior application.
Epoxy: Can be applied as a finish for interior use where abrasion resistance is required. High-build nature of film can help
cover imperfections in the steel. Will chalk and fade with UV
exposure. 4. Polyurethane: Provides high performance protection with excellent color and gloss retention. A higher film
build than alkyd or acrylic helps cover imperfections in the
steel. Should be sprayed applied for best appearance.

D. Primer: Fast-curing two-part epoxy. Primer shall

comply with all federal standards for VOC, lead
and chromate levels.
E. Primer: Organic, epoxy/zinc-rich, meeting class B
surface requirements for slip-critical connections.
Primer shall comply with all federal standards for
VOC, lead and chromate levels.

A. Compatibility: The General Contractor shall submit

all components/procedures of the paint system for
AESS as a single coordinated submittal. As a minimum, identify required surface preparation,
primer, intermediate coat (if applicable) and finish
coat. All of the items shall be coordinated with the
finish coat specified in Division 9.

F.

G. Galvanizing Repair Paint: High-zinc-dust-content

paint for galvanizing welds and repair-painting
galvanized steel, with dry-film coating not less
than 90-percent zinc dust by weight.

Editors Note: The primers below are listed in order of cost from
lowest to highest. Coordinate requirements with the surface
preparation and finish-coat sections of the specification.
A. Primer: Fabricators standard alkyd red oxide, rustinhibiting primer.

Primer: Inorganic zinc-rich meeting class B surface

requirements for slip-critical connections. Primer
shall comply with all federal standards for VOC,
lead and chromate levels.

2.3 FABRICATION

B. Primer: Fast curing, universal modified alkyd, rust

inhibiting shop coat with good resistance to normal
atmospheric corrosion. Primer shall comply with
all federal standards for VOC, lead and chromate
levels

8 AESS Supplement Modern Steel Constrution May 2003

A. Fabricate and assemble AESS in the shop to the

greatest extent possible. Locate field joints in AESS
assemblies at concealed locations or as approved
by the Architect. Detail AESS assemblies to minimize field handling and expedite erection.

This sample shows typical weld show-through from welding the connection on the far side of the piece.

B.

C.

Fabricate AESS with exposed surfaces smooth,

square and of surface quality consistent with the
approved mock up. Use special care in handling
and shipping of AESS both before and after shop
painting.

Weld show-through has been minimized.

4. Continuous Welds: Where welding is noted on

the drawings, provide continuous welds of a
uniform size and profile.
5.

Minimize Weld Show Through: At locations

where welding on the far side of an exposed
connection occurs, grind distortion and marking of the steel to a smooth profile with adjacent material.

6.

Coping and Blocking Tolerance: Maintain a

uniform gap of 1/8 1/32 at all copes and
blocks.

7.

Joint Gap Tolerance: Maintain a uniform gap

of 1/8 1/32.

8.

Piece Marks Hidden: Fabricate such that piece

marks are fully hidden in the final structure or
made with such media to permit full removal
after erection.

In addition to special care used to handle and fabricate AESS, employ the following fabrication techniques.

Editors Note: The following is a list of special fabrication methods that may impact the final appearance of the AESS. Many of
these items have significant cost premiums and should not be
used indiscriminately. Refer to the cost matrix for anticipated
range of added cost associated with each line item.
1.

Fabrication Tolerance: Fabricate steel to one

half the normal tolerance as specified in the
Code of Standard Practice Section 10.

2.

Welds ground smooth: Fabricator shall grind

welds of AESS smooth. For groove welds, the
weld shall be made flush to the surfaces each
side and be within +1/16, -0 of plate thickness.

3.

Contouring and blending of welds: Where fillet welds are indicated to be ground-contoured, or blended, oversize welds as required
and grind to provide a smooth transition and
to match profile on approved mock-up.

10. Mill Mark Removal: Fabricator shall deliver

steel with no mill marks (stenciled, stamped,
raised etc) in exposed locations. Mill marks
shall be omitted by cutting of mill material to
appropriate lengths where possible. Where not
possible, the fabricator can fill and/or grind to
a surface finish consistent with the approved
mock up.

May 2003 Modern Steel Constrution AESS Supplement 9

A typical mill mark.

The appearance of sheared edges that have been ground.

weld built-up sections by methods that will maintain alignment of members without warp exceeding the tolerance of this section.

11. Grinding of sheared edges: Fabricator shall

grind all edges of sheared, punched or flamecut steel to match approved mockup.
12. Rolled Members: Member specified to be
rolled to a final curved shape shall be fully
shaped in the shop and tied during shipping to
prevent stress relieving. Distortion of the web
or stem, and of outstanding flanges or legs of
angles shall be visibly acceptable to the Architect from a distance of 20 under any lighting
condition determined by the Architect. Tolerances for the vertical and horizontal walls of
rectangular HSS members after rolling shall be
the specified dimension +/- .
13. Seal weld open ends of round and rectangular
hollow structural section with 3/8 closure
plates. Provide continuous, sealed welds at
angle to gusset-plate connections and similar
locations where AESS is exposed to weather.
2.1 SHOP CONNECTIONS
A. Bolted Connections: Make in accordance with Section 05120. Provide bolt type and finish as noted
herein and align bolt heads as indicated on the approved shop erection drawings.
B.

2.2 SHOP PRIMING

A. Shop-prime steel surfaces, except the following:

B.

1.

Surfaces embedded in concrete or mortar. Extend priming of partially embedded members

to a depth of 2.

2.

Surfaces to be field welded.

3.

Surfaces to be high-strength bolted with slipcritical connections, if primer does not meet
the specified AISC slip coefficient.

Surface Preparation: Clean surfaces to be painted.

Remove loose rust, loose mill scale, and spatter,
slag, or flux deposits. Prepare surfaces according to
SSPC Specifications as follows:

Editors Note: Surface preparation is the most important (and

often the most costly) step in providing a good finish on AESS.
A level of surface preparation is associated with each type of finish coat. It is critical that the correct level of preparation be specified on the contract documents to avoid change orders during
construction. Each level of SSPC specification includes the levels below (i.e., SSPC-6 includes the requirements of SSPC-3).

Weld Connections: Comply with AWS D1.1 and

Section 05120. Appearance and quality of welds
shall be consistent with the mock up. Assemble and

10 AESS Supplement Modern Steel Constrution May 2003

1.

SSPC-SP 1 Solvent Cleaning

Interior environment, low-end primer/finish coating: alkyd (oil-based)

finish coat with a shop-coat primer over an SSPC-3 surface preparation.

2.

SSPC-SP 2 Hand Tool Cleaning. (This level

of surface preparation will not be adequate for
most paint systems for AESS construction.)

3.

SSPC-SP 3 Power Tool Cleaning. (This level

of surface prep is the minimum for most AESS
projects. It may be acceptable for alkyd
primers and acrylic or alkyd finish coats, particularly in interior applications.)

4.

5.

C.

SSPC-SP 6 Commercial Blast Cleaning. (This

level of surface prep adds significantly to the
total cost of the steel. It is required for epoxy
primers to allow adequate bonding to the steel.
Recommended for locations where a rust inhibitive primer will be used in an exterior application. It is also required where
polyurethane finish coats will be used over the
primer.)
Coordinate the required blast profile with the
approved paint submittal prior to beginning
surface preparation.

Priming: Immediately after surface preparation,

apply primer according to manufacturers instructions to provide a dry film thickness of not less than
1.5 mils (0.038 mm). Use priming methods that result in full coverage of joints, corners, edges, and
exposed surfaces.

Interior environment, high-end primer/finish coating: epoxy finish

coat with an epoxy or zinc rich primer, over an SSPC-3 surface
preparation.

1.

Stripe paint corners, crevices, bolts, welds, and

sharp edges.

2.

Apply two coats of shop primer to surfaces

that are inaccessible after assembly or erection.

Editors Note: Finish painting in the shop is not recommended

by either the fabrication or painting community that contributed to this specification. If finish painting is to be done
prior to delivery of the steel, special sections should be added
here.
2.3 GALVANIZING
Editors Note: Galvanized steel should not be painted with
alkyd top coats as loss of adhesion will occur. An intermediate
coat of high-build epoxy should be used if an alkyd paint is described as the finish coat. Zinc coatings produced by the hot-dip
galvanizing process are excellent corrosion-protection systems.
When the coating becomes very thick or dull gray, the coating
might not be suitable for architectural applications. The appearance can become blotchy with sections of dull finish and
sections with bright finish. Almost all of these surface effects
last for the first couple of years and then the coating becomes
uniformly dull gray as the protective layer of corrosion products is formed on the surface of the galvanized steel. The cause
of the irregular surface finishes is the variation in steel chemistry of the parts to be hot-dip galvanized. ASTM A 385 describes the effects of steel chemistry on the hot-dip galvanized
finish. The two elements with the most influence are silicon and
phosphorus. If these elements are controlled to recommended

May 2003 Modern Steel Constrution AESS Supplement 11

Exterior environment, low-end primer/finish coating: acrylic (waterbased) finish coat with a shop coat primer over an SSPC-6 surface
preparation.

Exterior environment, high-end primer/finish coating: polyurethane

finish coat with an epoxy intermediate coat and zinc rich primer over
an SSPC-6 surface preparation.

levels, the finish will be bright and shiny. Many steel makers
control the overall impurity content but not these two specific
elements, so there might be some parts that are bright and shiny
and some that are dull gray. Care should be taken when specifying a particular steel for hot-dip galvanizing if an architectural finish is expected.

view in the final structure or as approved by the

Architect. Handle, lift and align pieces using
padded slings and/or other protection required to
maintain the appearance of the AESS through the
process of erection.

A. Hot-Dip Galvanized Finish: Apply zinc coating by

the hot-dip process to AESS indicated for galvanizing according to ASTM A 123. Fabricate such that
all connections of assemblies are made in the field
with bolted connections. Provide galvanized finish
or members and assemblies within the range of
color and surface textures presented in the mock
ups.
PART 3 EXECUTION
3.1 EXAMINATION
A. The erector shall check all AESS members upon delivery for twist, kinks, gouges or other imperfections which might result in rejection of the
appearance of the member. Coordinate remedial
action with fabricator prior to erecting steel.
3.2 PREPARATON
A. Provide connections for temporary shoring, bracing and supports only where noted on the approved shop drawings. Temporary connections not
shown shall be made at locations not exposed to

3.3 ERECTION
A. Set AESS accurately in locations and to elevations
indicated, and according to AISC specifications referenced in this Section.
B.

In addition to the special care used to handle and

erect AESS, employ the following erection techniques:

Editors Note: The following is a list of special erection issues

that can impact the final appearance of the AESS. Many of
these items have significant cost premiums and should not be
used indiscriminately. Refer to the cost matrix for anticipated
range of added cost associated with each line item.
Editors Note: The AISC Code of Standard Practice specifies
that AESS framing shall be constructed to one-half the tolerance of typical structural steel frames. This requirement is intended to improve fit up when the exposed steel interfaces with
other materials such as curtain wall masonry, etc. If this is not
the case, standard tolerances are more economical. The variations permitted under the standard frame tolerances noted in
Chapter 7 will typically be acceptable when viewed by eye
(without instruments).

12 AESS Supplement Modern Steel Constrution May 2003

1.

AESS Erection tolerances: Erection tolerances

shall meet the requirements of standard frame
tolerances for structural steel per Chapter 7 of
the AISC Code of Standard Practice.

E.

Obtain permission for any torch cutting or field

fabrication from the Architect. Finish sections thermally cut during erection to a surface appearance
consistent with the mock up.

OR

F.

Do not enlarge unfair holes in members by burning

or by using drift pins. Ream holes that must be enlarged to admit bolts. Replace connection plates
that are misaligned where holes cannot be aligned
with acceptable final appearance.

1.

AESS Erection Tolerances: Erection Tolerances

shall meet the requirements of Chapter 10 of
the AISC Code of Standard Practice.

2.

Welds ground smooth: Erector shall grind

welds smooth in the connections of AESS
members. For groove welds, the weld shall be
made flush to the surfaces of each side and be
within + 1/16, -0 of plate thickness.

3.

Contouring and blending of welds: Where fillet welds are indicated to be ground contoured, or blended, oversize welds as required;
grind to provide a smooth transition and to
match profile on approved mock-up .

4.

Continuous Welds: Where noted on the drawings, provide continuous welds of a uniform
size and profile.

5.

Minimize Weld Show Through: At locations

where welding on the far side of an exposed
connection occurs, grind distortion and marking of the steel to a smooth profile with adjacent material.

6. Bolt Head Orientation: All bolt heads shall be

oriented as indicated on the contract documents. Where bolt-head alignment is specified,
the orientation shall be noted for each connection on the erection drawings. Where not
noted, the bolt heads in a given connection
shall be oriented to one side.
7.

8.

C.

Removal of field connection aids: Run-out

tabs, erection bolts and other steel members
added to connections to allow for alignment,
fit-up, and welding in the field shall be removed from the structure. Field groove welds
shall be selected to eliminate the need for backing bars or to permit their removal after welding. Welds at run-out tabs shall be removed to
match adjacent surfaces and ground smooth.
Holes for erection bolts shall be plug welded
and ground smooth.
Filling of weld access holes: Where holes must
be cut in the web at the intersection with
flanges on W shapes and structural tees to permit field welding of the flanges, they shall be
filled. Filling shall be executed with proper
procedures to minimize restraint and address
thermal stresses in group 4 and 5 shapes.

3.4 FIELD CONNECTIONS

A. Bolted Connections: Install bolts of the specified
type and finish in accordance with Division 5 section Structural Steel.
B.

Welded Connections: Comply with AWS D1.1 for

procedures, and appearance. Refer to Division 5
section Structural Steel for other requirements.
1.

Assemble and weld built-up sections by methods that will maintain true alignment of axes
without warp. Verify that weld sizes, fabrication sequence, and equipment used for AESS
will limit distortions to allowable tolerances.

2.

Obtain Architects approval for appearance of

welds in repaired or field modified work.

3.5 FIELD QUALITY CONTROL

A. Structural requirements: The Owner will engage an
independent testing and inspecting agency to perform field inspections and tests and to prepare test
reports. Refer to Division 5 section Structural
Steel for detailed bolt and weld testing requirements.
B.

AESS acceptance: The Architect shall observe the

AESS steel in place and determine acceptability
based on the mockup. The Testing Agency shall
have no responsibility for enforcing the requirements of this section.

3.6 ADJUSTING AND CLEANING

A. Touchup Painting: Cleaning and touchup painting
of field welds, bolted connections, and abraded
areas of shop paint shall completed to blend with
the adjacent surfaces of AESS. Such touch up work
shall be done in accordance with manufacturers
instructions as specified in Division 9, Section
Painting.
B.

Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas and repair galvanizing
to comply with ASTM A780.

Field Welding: Weld profile, quality, and finish

shall be consistent with mock-ups approved prior
to fabrication.

D. Splice members only where indicated.

May 2003 Modern Steel Constrution AESS Supplement 13

ARCHITECTURALLY EXPOSED STRUCTURAL STEEL (AESS)

FABRICATION, ERECTION, AND COATING RELATIVE COST
MATRIX

Specification
Section
(Fabrication)

Specification
Section (Erection)

AISC Code of
Standard Practice
Section

PROCESS

STANDARD

CATEGORY 3

CATEGORY 2

CATEGORY 1

NOTES

AISC Code of
Standard Practice
Section 10 for AESS
(pre-set)

High profile
conditions that are
out of reach to touch
and can be viewed
from a distance 20
feet or more (pre-set)

High profile
conditions that are
out of reach to touch
and can be viewed in
close proximity
within 20 feet (preset)

High profile
conditions that are
within reach to touch
and can be viewed in
close proximity (preset)

USER

Custom selected by
the user
(interactively input)

ADDED COST
RANGE TO AESS

FABRICATION AND ERECTION CLASSIFICATIONS

2.2

2.2

10.4.1

SPECIAL CARE IN PROCESSING AESS

2.2.1

3.3.1

10.2.1, 10.4.2

TOLERANCES: ONE-HALF STANDARD

2.2.2

3.3.2

10.2.5

WELDS GROUND SMOOTH

2.2.3

3.3.3

---

WELDS CONTOURED & BLENDED

2.2.4

3.3.4

---

CONTINUOUS WELDS

2.2.5

3.3.5

10.2.3

WELD SHOW THROUGH MINIMIZED

2.2.6

---

---

COPING AND BLOCKING TOLERANCES MINIMIZED

10%

to

20%

5%

to

10%

10%

to

20%

20%

to

30%

5%

to

10%

5%

to

10%

5%

to

10%

5%

to

10%

1%

to

5%

1%

to

5%

1%

to

5%

2.2.7

---

10.2.4

JOINT GAP TOLERANCES MINIMIZED

2.2.8

---

10.2.6

PIECE MARKS HIDDEN

2.2.9

---

10.2.8

SURFACE DEFECTS MINIMIZED

2.2.10

---

10.2.7

MILL MARKS REMOVED

X
X

2.2.11

---

---

GRINDING OF SHEARED EDGES

2.2.12

---

---

ROLLED MEMBERS: MINIMIZE DISTORTION

2.2.13

---

---

SEAL WELDS TO CLOSE OPEN GAPS

---

3.3.6

---

BOLT HEAD ORIENTATION DICTATED

2%

to

10%

10%

to

15%

5%

to

10%

1%

to

5%

5%

to

10%

5%

to

10%

---

3.3.7

---

FIELD WELDING AIDS REMOVED

---

3.3.8

---

CLOSE WELD ACCESS HOLES AT FULL PEN WELDS

RANGE IN COST INCREASE OVER STANDARD STRUCTURAL STEEL

27%

TO

60%

22%

TO

45%

67%

TO

125%

96%

TO

195%

10%

TO

20%

SURFACE PREPARATION CLASSIFICATIONS

POWER TOOL CLEANING CLEANING (SSPC-SP3)

COMMERCIAL BLAST CLEANING (SSPC-SP6)

RANGE OF COST INCREASE OVER POWER TOOL CLEANING (SSPC-SP3)

CLASSIFICATION, SSPC-SP# =

10%

TO

20%

10%

TO

20%

10%

TO

20%

10%

TO

20%

10%

TO

0%

to

0%

10%

to

20%

20%

PRIMER AND FINISH COATING CLASSIFICATIONS

A

CLASSIFICATION, FINISH =

FINISH A: INTERIOR ENVIRONMENT - LOW END FINISH

5%

to

10%

FINISH B: INTERIOR ENVIRONMENT - HIGH END FINISH

35%

to

50%

FINISH C: EXTERIOR ENVIRONMENT - LOW END FINISH

10%

to

20%

FINISH D: EXTERIOR ENVIRONMENT - HIGH END FINISH

45%

to

60%

FINISH E: GALVANIZING

10%

to

20%

RANGE OF COST INCREASE SHOP PRIMED WITH NO FINISH COAT

5%

TO

10%

5%

TO

10%

5%

TO

10%

5%

TO

10%

5%

TO

10%

ACCUMULATED RANGE OF COST INCREASE

42%

TO

90%

37%

TO

75%

82%

TO

155%

111%

TO

225%

25%

TO

50%

COST MATRIX NOTES:

1. THE ABOVE COST INCREASE PERCENTAGES APPLY TO THE ARCHITECTURAL EXPOSED
POSED STRUCTURAL STEEL PORTIONS OF THE FRAME ONLY.
2. THE ABOVE COST INCREASE PERCENTAGES ARE INTENDED TO GIVE THE DESIGNER
IN
NER INFORMATION
TO MAKE PRELIMINARY COST ESTIMATING JUDGEMENTS.
THEY ARE ESTIMATES AND WILL VARY
FOR EACH PROJECT. CONTACT A FABRICATOR TO OBTAIN SPECIFIC PRICING FOR
EAC PROJECT.
R EACH
BLUE DESIGNATES USER INPUT CELLS.
GREEN DESIGNATES RESULTS CELLS.

14 AESS Supplement Modern Steel Constrution May 2003

May 2003 Modern Steel Constrution AESS Supplement 15

COST MATRIX NOTES

Special Care in Processing AESS: Upgraded care in the process of fabrcating, trucking, handling, storing, and erecting the material is required to
obtain minimally acceptable AESS. This classification is required whenever AESS is specified.

Tolerances: One-Half Standard: The tolerances for structural steel frames

are set by AISC Code of Standard Practice. If AESS is specified, these tolerances are required to be one-half of those of a standard structural steel.
These reduced tolerances should be carefully reviewed to see if they are
required, as they add significant cost to the project.

Welds Ground Smooth: In a standard structural steel frame, the welds

are left in an as welded condition with the slag and weld spatter removed.
For AESS frames, the process is the same. Should smooth grinding of the
welds be required, this classification should be specified. It is important to
note that in many cases, grinding the weld will leave a blemish that is more
obvious than the unground weld.

Welds Contoured and Blended: The comments under item k. apply here,
but the requirements of contoured and blended welds add an additional
complexity. If transitions of smoothly ground welds are required to contoured and blended, this process will be done by hand and will leave blemishes around the weld area that may be more noticeable than the
as-welded condition. Samples of this process should be submitted for review prior to fabrication.
Continuous Welds: Many welds in standard structural steel and AESS
frames are specified for strength to be intermittent. Some AESS structures may require that these welds be continuous for aesthetic reasons.
Special care is required to avoid distrotion of the member. If this is the
case, this classification should be specified.
Weld Show Through Minimized: In standard structural steel frames,
there is no attempt to minimize the show through on the back face of the
welded element caused by the welding process. Typically in AESS frames,
the weld show through is left the same as a standard frame. If minimized
show through is required, this can be done by hand grinding the backside
of the weld. It is important to note that this process may leave a blemish
that in most cases is more objectionable than the show through.
Coping and Blocking Tolerances Minimized: The AISC Code of Standard Practice Section 10.24 requires all copes, miters, and cuts in AESS
material are to be made with a uniform gap of 1/8. This tolerance is more
stringent than the tolerances that fabricators are held to for standard structural steel material. In many cases, this requires the fabricator to custom
cut and fit each member, adding significant cost to the project. This classification is not recommended for standard AESS. It is recommended to
specify this classification only where joints are within a close viewing proximity and only if completely necessary.
Joint Gap Tolerances Minimized: This classification is similar to item b.
above. A clear distance between abutting members of 1/8 is required.
Again, this is more stringent than the tolerances that fabricators are held
to for standard structural steel. This classification is difficult to achieve
both in the shop and field due to material size consistency and erection fit
up tolerances, adding significant cost to the project.
Piece Marks Hidden: During the fabrication and erection processes,
members are marked with specific piece numbers. These numbers are
usually left on the piece after erection is complete. AESS pieces are
marked in inconspicuous places whenever possible, but there are many
cases where these marks will be seen. If removal of these marks is required for aesthetic reasons, this classification should be specified.

Surface Defects Minimized: In the process of handling the materials, the

flanges of the beams and columns will inevitably be deformed and scarred.
If this classification is specified, these deformities and scars will be removed.

Mill Marks Removed: All steel mills mark their material with heat numbers
and producer information to identify the material chemistry and strength
and the producer. These marks can be stenciled, stamped or taped on to
the member. Most mills now stamp the markings on the piece. Removal
of the stenciled or taped marking is a simple process, but removing the
stamped marking is a difficult process. The common method to remove a
stamped mark is to grind it out, leaving a large blemish where the marking
was. This blemish is more obvious to the viewer than the mill mark. It is

important to note that whenever the mill marks are removed, the traceability for those pieces is usually lost.
l

Grinding of Sheared Edges: In the process of fabrication, some types

(plate and sheet specifically) of material are sheared. The sheared edge
leaves a rough surface with burrs, which is not usually ground for standard
structural steel pieces, except where it interferes with the fit-up. AESS requirements may demand that the rough surface be deburred and ground
smooth for aesthetic reasons.

m Rolled Members: Minimize Distortion: In the process of fabrication,

some members may be rolled into various shapes. When rolling the member, it will distort. If AESS requirements dictate that the distortion shall be
minimized, this classification should be specified. The added cost range
percentages noted assume that 10% of the AESS tonnage is to be rolled.
n

Seal Welds To Close Open Gaps: In standard structural steel frames,

seal welding to close joints and gaps is normally not required. AESS
frames may require welds to seal gaps from environmental implications or
for aesthetic reasons. Should seal welding be required, this classification
should be specified. It is important to note that seal welding of members
can distort them.

Bolt Head Orientation Dictated: For standard structural steel frames, the
orientation of the bolt heads is left up to the erector. Ease of access for
placing and tightening the bolt will dictate the bolt head orientation. Should
the bolt heads be required to all be on the same surface, special attention
is required in the shop and field.

Field Welding Aids Removed: In a standard structural steel frame, the

aids used in the process of field welding are not removed. Often times
they are not removed due to structural integrity issues. Should they be removed from AESS frames due to aesthetic concerns, special attention is
required in the shop and in the field.

Close Weld Access Holes at Full Pen Welds: The comments under item
q. above also apply here. Weld access holes are the holes in the web of
beams and columns to allow the welder to weld in the areas of the members web. If they are required to be closed for aesthetic reasons, special
attention is required in the shop and in the field.

Power Tool Cleaning (SSPC-SP3): Power tool cleaning removes all loose
mill scale, loose rust, loose paint and other loose detrimental foreign matter using power tools. This process requires that Solvent Cleaning (SSPCSP1) be performed prior. It is not intended that adherent mill scale, rust
and paint be removed by this process. Mill scale, rust and paint are considered adherent if they cannot be removed by lifting with a dull putty knife.

Commercial Blast Cleaning (SSPC-SP6): A commercial blast cleaned

surface, when viewed without magnification, shall be free of all visible oil,
grease, dust, dirt, mill scale, rust, coating, oxides, corrosion products, and
other foreign matter.

Interior Environment - Low End Primer/Finish Coating: Alkyd (oilbased) finish coat with a shop coat primer.

Interior Environment - High End Primer/Finish Coating: Epoxy finish

coat with an epoxy or zinc rich primer.

Exterior Environment - Low End Primer/Finish Coating: Acrylic (waterbased) finish coat with a shop coat primer.

w Exterior Environment - High End Primer/Finish Coating: Polyurethane

finish coat with an epoxy intermediate coat and zinc rich primer.
x

Galvanizing (ASTM A385): Care should be taken when specifying hot

dip galvanizing for AESS. Zinc coatings produced by the hot dip galvanizing process are excellent corrosion protection systems, but when the
coating becomes very thick or dull gray, the coating may not be suitable for
architectural applications. The appearance can become blotchy with sections of dull finish and sections with bright finish. Almost all of these surface effects last for the first couple of years and then the coating becomes
uniformly dull gray as the protective layer of corrosion products is formed
on the surface of the galvanized steel. ASTM A385 describes the effects
of steel chemistry on the hot dip galvanized finish, and also states that experienced galvanizers can in many instance exercise some control over
coating structure. If cosmetic (aesthetic) appearance is of concern, the
purchaser should select an experienced galvanizer and discuss any concerns about aesthetics (surface appearance) prior to any galvanizing.

16 AESS Supplement Modern Steel Constrution May 2003