INTRODUCTION The Erection Procedures Manual is designed to provide Mammut Builders and / or Erectors with some fundamental, good and safe practices. It will help the key-field people to control building quality and to develop the crafismanship of their laborers. Erection of Pre-engineered Buildings is a straightforward operation, provided some basic principles are followed and common sense used. Erection process is not one to be taken lightly. In fact, no matter how good the design and the fabrication of Steel Buildings may be, it is the erection and the finishing of the building which will stand for all to see. Sincerely, MAMMUT BUILDING SYSTEMS _P.0, Box: 41668, Sharjah, UAE, Tel: +971 4 801 2222, Fax: +971 4 801 2223 _ Page #1TABLE OF CONTENTS SECTION DESCRIPTION PAGE NO GOOD ERECTION PRACTICES... UNDERSTANDING MAMMUT ERECTION DRAWINGS. ERECTION. GENERAL NOTES / PRECAUTIONS. ERECTION CHECKLISTS... P.O. Box: 41668, ShiErection Procedures SECTION 1: GOOD ERECTION PRACTICES 1. GOOD ERECTION PRACTICES ‘The first priorities in erecting any building should be quality and safety, the reputation of the company (manufacturer or builder) depends on both. Likewise if the quality of erection is poor, the building will be judged by that finish. Quality and safety begin by having well trained and supervised personnel, the correct equipment for the job, and proper techniques. Site check: Prior to arranging delivery, the site should be checked to ensure that a suitable lay down area is available where materials will be safe and can be stored in the recommended manner. Notes of any obstructions, overhead cables etc., which could cause a safety hazard for the operation of erection equipment, should be taken,Materials will be delivered by trailers. A solid compacted site access is required for the trucks. Anchor bolts should be checked for tolerance in dimension and elevation before and after the pouring of concrete by using a dumpy level and / or a theodolite, Any bolts not complying with details and tolerances should be corrected. The foundation level should be checked as well. In buildings requiring grout, shim packs are placed in the centre of the bolt pattern. Checking of Anchor Bolts Buildings without crane systems generally do not require grout, but the use of shims is required if the concrete outside the stated tolerances. In other case, double nuts may be used in place of shim plates, 1.2 Preparation: The supervisor and erection foreman should study the drawings and bills of materials care fully. ‘They should review all erection drawings and notes. The commencement point may be dictated by site conditions, but it must start at a braced bay. From the study the weight and size of main frame members will be determined, and from that, the type and size of equipment as well as the procedures and methods used for erecting the main frame. Not all erection crews have the correct tools for particular job. The supervisor should ensure that equipment is prepared, considering the length and weight of individual or assembled components. MAMMUT BUILDING SYSTEMS 1668, Sharjah, U.A.E._ Tel: +971 4 801 2222, Fax: +971 4 801 2223Equipment should include mobile crane, forklift, spreader bar, wire, chain or nylon slings, guy wires, ratchet pullers, ropes and other erector hand tools. For small buildings up to 6m eave height, one or two forklifts can be used, For larger buildings cranes are required. Non Standard buildings should receive particular attention, keeping an eye out for things like nested purli / girts, - jack beams, - strut beams if they are not erected at the correct time, it may be impossible to install them later. 1.3 Unloading and Storage: Unloading of trailers should be conducted in an orderly and organized manner so that materials can be properly checked against lists. The operation should take place as near as possible to the place of erection, A Telescopic Handler truck is ideal for unloading, but a mobile crane is equally suitable, Also, care should be taken when handling sheets. When handling individual panels from the stack, each panel should be lifted clear to avoid scratches. If using a crane then nylon slings should be used to avoid damage to the edges of sheets. Unloading Materials Galvanized cold formed purlins, girts and channels as well as bundles of sheets should be stored in a safe area, clear of the ground and elevated at one end to allow water drainage, Preferably, the bundles should be loosely covered with tarpaulin to improve the protection and to allow the air circulation. Does not use polythene sheet cover, this will cause condensation. If moisture is trapped between galvanized items, stains will develop into white rust. Insulation rolls should not be stored on end, MAMMUT BUILDING SYSTEMS 1668, Sharjah, U.A.E.__ Tel: +971 4 801 2222, Fax: +971 4 801 2223Erection Procedures SECTION 2: UNDERSTANDING MAMMUT ERECTION DRAWINGS 2. UNDERSTANDING MAMMUT ERECTION DRAWINGS Prior to commencement of erection work, it is essential to have a clear understanding of the Engineering Documents. In the case of erection we refer specifically to Erection Drawings and Bills of Material. Erection Drawings to be used at site should be “Issued for Construction” and be the latest revision . Approval Drawings should never be used for site works. The revision boxes at the bottom right comer of each sheet indicate the latest status, i.e, for approval, issued for Construction, Revised as noted, etc. 2.1 Anchor Bolt Layout ‘This drawing shows the layout of all anchor bolts, normally on one sheet, but for very large buildings, could be on 2 of more sheets. Erection drawings are not to scale, so never attempt to scale any dimensions. The drawings are proportioned, although sometimes this can be misleading, as in the case of the 40mm, conerete notch, see example. (Note, all dimensions a imeters), The A/B layout contains the anchor bolt schedule, which is in the form of a table showing quantities and sizes, etc. MAMMUT BUILDING SYSTEMS P.O. Box: 41668, Sharjah, U.A.E._ Tel: +971 4 801 2222, Fax: +971 4 801 2223‘The key plan shows out to out dimensions, bay spacing dimensions, bolt setting details and critical dimensions forthe span, The details show if grout is required under columns, this applies to fixed base columns and crane columns. ‘The grout thickness is shown, also the bolt projection Adherence to dimensions is important, we recommend not more than Smm tolerance. 2.2 Cross Section The cross section is one of the most important drawings as it contains a lot of vital information. Columns and rafter references, connection details, bolt schedules, flange brace schedules and other details as applicable such as strut tubes and flange brace details. In conjunction with the Bill of Materials it is possible to determine the weight of individual members, or combination of members, this being essential during the planning or erection, and the capacity of the crane to be used in erection. ‘The cross section may be typical throughout in standard buildings, or in more complex jobs, there may be several cross sections identified by grid numbers. 2.3 Roof Framing Plan The roof fiaming plan show all the purlins, bracing and details applicable. Part numbers for purlins and bracing are shown, also sag rods where applicable, plus strut tubes. The drawings should be carefully studied otherwise iti possible to overlook details such as nested purlins, strut purlins and strut clips 2.4 — Roof Sheeting Layout All roof panels are shown by length and part number. Panel laps are shown, also skylight and downspout positions. Standard details of fasteners, rims and insulation are included. An important point to check is the starting ension of the sheeting, from the steel line. 2.5 Sidewall Sheeting & Framing Depending on the job, sidewall framing and sheeting may be on one drawing or more. MAMMUT BUILDING SYSTEMS _P.O. Box: 41668, Sharjah, U.A.E._ Tel: +971 4 801 2222, Fax: +971 4 801 2223‘The framing elevation shows the position and part numbers of girts, eave struts, bracing and sag rods. The sheeting elevations show the panel positions with length and part number. Eave trims, Gutters and downspouts are shown with part number rd details are included to indicate faste and trimming details. End walls are treated similarly. 2.6 Other Drawings Other drawings may include crane beam layouts and details, Mezzanine layouts and details, Accessories such as Sliding Doors, Roll-up doors, Personnel doors, Windows, Louvers and Ventilators. 2.7 Bill of Materials The BOM supplied with the Erection Drawings is the Customer BOM. The other BOM is for internal use only. ‘The BOM comprises a cover sheet which indicates job number, Building number, phase number, Customer name, location and building size. The cover sheet also shows the number of phases in the building, any revisions plus any special notes. ‘The second page indexes the various sub-areas, each sub-area then has its BOM on the remaining sheets. ‘The BOM has 7 columns indicating 1 - Part number 2- Quantity 3 External Size 4- Profile 5—Unit Weight 6—Total Weight 7 - Description The sub total of weight is shown at the end of each sub-area also the total number of items. The last page indicates the total BOM quantity of items and weight. The BOM is a reference to the items shown on the Erection Drawings and can be used to double check items against the packing list. It is also used to identify frame weights for crane capacities. MAMMUT BUILDING SYSTEMS P.O. Box: 41668, Sharjah, U.A.E._ Tel: +971 4 801 2222, Fax: +971 4 801 2223Erection Procedures Section, 3: Erection e ERECTION With pre-engineered steel buildings, bracing is vital for stability, especially during the erection stage. Erection always commences at the braced bay, which should be completed entirely with cable bracing, flange bracing, purlins, eave struts and temporary guy wires: This first bay should be plumbed and aligned before progressing to the next bay. Correct alignment is achieved by adjusting the cable bracing and the temporary bracing ( this cannot be achieved with nylon ropes). For buildings with eave height not exceeding 6m the plumbing and leveling could be done by using plumb bob and spitit level. For higher buildings, use theodolite Low tise PEB has a tolerance of1:300 for plumbing and alignmet. MAMMUT BUILDING SYSTEMS Fax: +971 43.1 Preparation Prepare all materials for the first bay erection. Identify the rafter sections required by part number assemble the rafter sections as near as possible to their lifting positions. The splice connections are made with high strength bolts; the sizes are shown on the drawing cross section, identified as $1, $2, 3, etc. Tighten the splice bolts and check for correct torque value using a calibrated torque wrench, or by turn of nut method. Attach eave strut clips using high strength bolts. Fix flange braces to the rafter using machine bolts, the flange brace positions and part numbers are shown on the drawing cross section. Flange braces are fitted on one side of the rafter only. For uniformity it is preferable to maintain the same side throughout the building. Temporary guy wires are attached to the rafler, manila or nylon ropes are not recommended for temporary guying, they can stretch and break. They are also unsuitable for aligning purposes. Prepare the mobile crane and Forklift for erection. 3.2. Erection Main Frames Erect the first four columns at the braced bay, verify the part number and orientation, and position over the anchor bolts. Ereetion of the Ist Column Adjust the columns for plumb by tightening or loosening the anchor bolts. Fix the wall girts to the columns for additional stability. Positions the crane for lifting the assembled rafier sections. Check that slings, chain and shackles are in good condition and or adequate capacity for the weight. The chains or slings should be long enough to provide sufficient spread at an angle of not less than 45 degrees. The spread of the slings is normally calculated by dividing the member length by! he lifting ps MAMMUT BUILDING SYSTEMS P.O. Box: 41668, Sharjah, U.A.E._ Tel: +971 4 801 2222, Fax: +971 4 801 2223,adjustment depending on rafter weight and configuration. Flange clamps are a safe lifting device which minimizes damage to paint. When using clamps, always install temporary bolts in the purlins holes, or use “G” clamps to prevent sliding. If clamps are not available, conventional slings may be used, in which case timber or other protection should be used on the flanges. Erection of the 1st Braced Bay, ‘Commence lifting the rafter. Previously attached hand ropes will help to guide the rafier to its po Carefully lower the rafter to the column cap plates, and position using spud wrenches. Spud wrenches are an invaluable tool for aligning members and holding in position whilst bolting up. Install the high strength bolt nuts and washers in the knee connection, K1. The bolt is nommally placed from the top, with the nut and washer on the underside. Hand tighten the bolts. Ratchet pullers are attached to the guy wires, and connected to suitable stable objects. Anchor bolts are most suitable for this purpose. The rafier is now aligned by means of the guy wire s and ratchet pullers, once all guy wires are in place itis safe to release the crane, Erect the second rafter and hold in place with the crane, at the same time position the purlins and bolt up. Connect the previously attached flange braces to the purlins with the bolts. ‘Complete the purlin installation and then install the diagonal bracing in the roof. Before tightening the diagonal bracing, ensure that the lip ofthe hillside washer is correctly seated in the web slot. ‘Adjust the tension of the bracing, at the same time check the rafter alignment. The completed braced bay should now be aligned. A theodolite should be used for plumbing, ifavailable. If not, for buildings of low eave height, a spirit level may be sufficient. A tolerance of | in 300 is allowable. MAMMUT BUILDING SYSTEMS P.O. Box: 41668, Sharjah, U.A.E.__ Tel: +971 4 801 2222, Fax: +971 4 801 2223Temporary Bracing After completing the first bay alignment the high strength bolts at the knee connection are fully tightened to their respective torque values. Times spent on correct alignment of the first bay will reap benefits as work proceeds with the remaining bays. The remaining bays are erected following the same procedure. All components are installed as work progresses including crane beams. Multi-span frames provide a degree of flexibility in erection in that partial spans may be erected if site conditions dictate When the main frames are all completed, the end wall framing can be crected. Pre-assembly of columns and girts on the ground saves time and is more efficient. End wall posts are connected to the purlins by post spanners using high strength bolts ‘The complete frame should now be checked for plumb and alignment. Adjustments can be made by tightening or loosening bracing, or by ratchet puller, if necessary, to pull a misaligned frame into plumb. After completion of all checking, bolt tightening can commence. Air or electric impact wrenches may be used and checked with a torque wrench, or they can be tightened manually using the “Tum of Nut Method”. The Turn of Nut Method is achieved by bringing all the bolts in the pattem to a snug tight position, using a normal spud wrench. Match mark the nuts against the connection plate, and then apply aPrior to sheeting framed openings for sliding doors are being installed, this includes door jambs, brackets and header. Completion of the Main Frames 3.3 Sheeting - Preparation The base angle is fixed to the concrete slab by means of masonry nails. Power actuated tools are preferred for fixing. The fixings for the base angle are provided by the erection contractor, to ensure compatibility of nails and fixing tools. The base angle should be set 200mm from the Props between Girts ‘There is a tendency for wall girts to sag under their own dead load, spec ~ially in bays over 7.5m. The girts are temporarily supported in a horizontal line with timber props from floor to girt, gir to git, girt to eave strut. The props remain in place until the wall panels are screwed, they can then be removed and relocated MAMMUT BUILDING SYSTEMS P.O, Box: 41668, Sharjah, U.A.E._ Tel: +971 4 801 2222, Fax: +971 4 801 2223to the next bay. The girts will remain straight and horizontal, Before commencing with sheeting, check the sheeting details on the drawings, a starting position will be given in relation to the stee! line, ‘mark the starting position, and then mark out the gauge of the sheets along the concrete notch. This will provide a check against” creep” or “bunching” of the panels, an important point in order for the comer trims to fit as detailed, Insulation is more convenient to handle if unrolled on the ground and pre-cut to the required lengths, a full length piece is used from eave to floor, with an allowance top and bottom. 3.4 Sheeting - Walls Sandwich panels & Single skin panels without insulation are to be started in compliance to Mammut Erection drawings, to ensure the start point of the sheet. This is mandatory in order to ensure the proper fixation of trims. Double face tape is applied to the eave strut and the base angle; this is used to hold the insulation in place. The insulation must be kept vertical, and pulled tight. Remove the fibers from the allowance at top and bottom and fold the white facing before placing the wall panel. Place the panel in the pre-marked position, plumb it and screw. A chalk line is a good idea for marking the girt position and thus maintaining a straight screw line. All screws are self drilling and require an electric screw-gun with a speed of 2000 to 2500 RPM. Depth sensitive or torque regulated screw-guns should be used to control the screw tightness. The EPDM washer should be compressed Imm wider than the steel washer when correctly tightened. ‘Wall Sheeting The second “drop” of insulation is fixed to the double faced tape and then the side tabs are stapled together 300mm centers, folded and stapled again in between the previous staples, thus providing a closed joint and vapor barrier. MAMMUT BUILDING SYSTEMS : 41668, Sharjah, U. ‘Tel: +971 4 801 2222, Fax: +971 4 801 2223‘The second panel is installed and so on. End wall panels are pre-cut in the factory, and no further cutting is necessary. The panels are stepped, the steps being covered by the gable trim. The preferred procedure is to complete all wall sheeting before starting the roof, as the eave trim covers the top of the wall panel and fits under the roof panel. Outside foam closures are placed between the wall panel and the eave trim to provide a dust fiee junction. 3.5. Sheeting - Roof Prepare the roof panels by segregating to the lengths shown on the roof sheeting plan. The sequence of roofing is from ridge to eave on both slopes finishing with the ridge panel. To commence, itis advisable to temporarily fix one run of panels to walk on. The insulation can then be unrolled on the“walkway”. Sheeting —Roof Double faced tape is applied to the eave struts, or an intermediate purlin if the roll does not cover the full width of the building. The insulation is lifted into place and is retained in place by the double faced tape. Before placing the roof panel, the insulation end should be folded over to be concealed, it is necessary to scrap away the fibers on the folded portion. The inside foam closure is placed on the fold, and the panel is then positioned. Adjust the line of the panel to avoid “saw-toothing” at the eave line. Use a nylon line projected from the eave strut by 70mm to give the correct distance and line. Screw the panel and move progressively panel by panel up to the ridge. After completing several runs of panel, the temporary “walkway” can be lifted, insulated, and re-fixed. cend-laps require bead mastic. This should be carefully unrolled from the release paper, over MAMMUT BUILDING SYSTEMS Box: 41668, Sharjah, U.A-E._ Tel: +971 4 801 2222, Fax: +971 4 801 2223the panel corrugations, do not stretch the bead, and otherwise it may break when the panel is nested over it. Make sure that the panel ribs are kept in a straight line from eave to ridge. Use a chalk fine to mark the purlin location and maintain a straight line of screws, thus avoiding mis-drilling and possible leakage. End-laps have additional screws as detailed on the drawing. Proceed with the next run of insulation, stapling the side tabs together, before placing the next run of panels. When both slopes of the roof panel have been fixed, the ridge panel or ridge cap is then laid, connecting both slopes. If a ridge cap is used then outside foam closures are used to fill the panel profile, if a ridge panel is used, it nests without foam closures. As work proceeds, itis important to keep the roof area clean, a soft brush should be readily avail able to sweep off, drill burrs or chips which if left will cause light surface corrosion, Stitch screws are fixed at panel side-laps at 500mm centers, as detailed. 35 Miscellaneous Having completed the roofing, gable trims are installed, outside foam closures are used against the end- wall panel, the stitch screws securing the gabie trim also keep the foam closures in place. Eave gutters are spliced using two runs of flowable mastic and pop-rivets, the gutter is then hung by means of gutter straps which are screwed through the roof panels. Sliding Door and Ventilators Down spout connections are cut with aviation snips, in locations shown on the roof plan. The down spouts are assembled in straight sections and a shoe, the complete unit is then attached to the gutter by pop rivets and to the wall panel by straps and rivets MAMMUT BUILDING SYSTEMS P.O. Box: 41668, Sharjah, U.A.E. 71 4 801 2222 01 2223,Personnel doors are supplied in knock down form and are generally field located. The frame is assembled and positioned, the wall panel is carefully cut using an electric nibbler Final cutting and fitting of head trim should be done with aviation snips. The powder-coated threshold support is fitted and screwed to the jambs & headers, Check that the frame is plumb and square before final fixing Head trim, jamb trims and the door leaf are now fitted. Personnel doors have the option of standard hardware or panic hardware. Interior liner panel is fitted, inthis example up to 3 metres above floor level. A base angle is fixed to the floor as for the extemal panel, positioned 200mm away from the exterior base angle. The liner panels, are pre cut to length, but may require cutting vertically at columns, depending on the bay width, Closure trims are fitted at columns, and a head trim along the top of the panel. Trims are fixed with 4.8 x 20 stitch screws, the panels with 5.5 self drilling screws. Sliding doors leafs are assembled on the floor, the framing members are connected by machine bolts and clips. The sheeting is also fixed before hanging the door. The trolley trucks are located in the top member of the door leaf, the adjusting nuts on the trolley trucks should be set equally, final adjustments can be made after hanging the doors. Once the doors are hung and positioned over the bottom door guide, the stoppers are installed, also the handles and the door hood trims, note that there isan inner and outer hood trim, complete details are on the drawing. 3.7. Mezzanine Floors When mezzanine floors are provided, they are erected with the main frames, generally prior to sheeting.The mezzanine beams are first installed by connecting to the columns with clips and high strength bolts as indicated on the drawing details. The joists are then placed between the beams and connected with clips and bolts. An edge angle is then placed and fixed atthe perimeter of the mezzanine area, prior to laying and screwing the decking Mezzanine Floors ‘The decking panels are attached by 5.5 x 40mm self drilling fasteners without washers. Openings for stairs and penetrations are framed before fixing the reinforcement. Itis important to advise the concreting crew about placement of concrete, particularly if a pump is to be used. The concrete should be evenly spread; concentrated piles of wet concrete could cause deflection in joists or decking. MAMMUT BUILDING SYSTEMS Box: 41668, Sharjah, U.A.E. Tel: +971 4 801 2222, Fax: +971 4 801 22233.8 Fascia Fascia posts are bolted to the brackets, fascia girts are then attached to the posts. The girts consist of “C” and “Z” sections, which must be correctly aligned and leveled before commencing sheeting the fascia, Prepare forthe sheeting by installing the sill rim on the bottom girt. Check the starting dimension from the corner of the framing, offer up the first panel, mark the git with a chalk line and then serew the panel to the girt, Continue installing panels on each elevation until complete. The back-up panels are installed next; they are attached to the top girt, and overlap the valley gutter at the base. The extemal comer trims are installed using 4.8 x 20 self drilling screws. The Cap flashing can now be installed using 4.8 x 20 self drilling screws, make sure that the flashing slopes into the building as shown on the detail. The overlapping joints of the flashing should be sealed with flow able mastic. ‘The soffit panel edge trim is fitted to the wall panel, make sure that itis evel with the sill trim, and is leveled around the building, Starting the soffit in the correct place is important, ifthe soffit panel and wallfascia sheets, are the same type, the ribs should be aligned. Align the ribs, and fix the panels as shown in the detail. Corner panels should be mitered equally. MAMMUT BUILDING SYSTEMS : 41668, Sharjah, U.A.E. Tel: +971 4 801 2222, Fax: +971 4 801 2223 _3.9 Crane Beams Special care should be taken in case of buildings with crane runways, the column supporting runway beams should be erected on shims provided, to zero tolerance. If not, the performance of the over head crane will be very poor. Alignment of crane beams is very important, the centers of the crane beam webs should be the equal to the centers of the crane wheels, and the maximum tolerance is 10mm. Alignment is achieved by setting each end of the beam to the correct dimension as shown on the drawing, and stretching a line from end to end, alternately, a theodolite can be used if available. The crane beam brackets are having slotted holes to assist in ease of alignment, if the building has been carefully plumbed, adjustment will be minimal, During alignment install the “T” brackets and shim plates, and install the angle braces from column to beam. Once final alignment is confirmed, fully tighten all high strength bolts to the required torque. Fixing Crane Beams MAMMUT BUILDING SYSTEMS P.O. Box: 41668, Sharjah, U.A.E._ Tel: +971 4 801 2222, Fax: +971 4 801 2223Erection Procedures CTION 4: General Motes and, Precautions 4.1 Care & Handling of Mammut Sheeting Unloading Sheets are packed in bundles, and may be unloaded by a suitable forklift truck or crane. Care must be taken not to “break the back” of the sheets when unloading. Do not use chains or cable slings for unloading, unless good protection is provided for the comers of the bundle. 2. Storage Packs of sheets should be store in a safe area of the site. They should be stored clear of the ground and elevated at one end to allow for water drainage should they become wet. Preferably, the bundles should be loosely covered with a tarpaulin; this will afford protection and air circulation. 3. Handling Care should be taken when handling sheets. rectors should use clean gloves to avoid dirty marks, oil or grease stains on sheets. When handling vidual panels from the stack, each panel should be lifted clear, not dragged along, which cause scratches, 4. Cutting and Fixing Only proper tools should be used for cutting profiled sheets. An electric nibbler should be used for cutting across the ribs, an electric shear for cutting longitudinally, and aviation snips for small detail work. Correct Standing of the operator /, MAMMUT BUILDING SYSTEMS __P.O. Box: 41668, Sharjah, U.A.E. Tel: +971 4 801 2222, Fax: +971 4 801 2223A grinding disk should not be used for cutting sheeting. It is important to use correct sized drill bits and screws for secure fastening of panels. During fixing, the panel should be correctly aligned and temporarily clamped to ensure the holes are drilled correctly. Drilling of holes produces very hot metal chips ( burrs ), which should be removed from the panel by brushing, This should be done immediately if possible and the work area should be swept with a soft broom at the end of each day work Care should be taken in walking on roof panels. Workers or visitors should use soft footwear. Metal studs or heel tips will cause severe damage to the panels. It is important to walk in the correct place on roof panels. Always step on the low portion ofthe panel, \hich is in contact with the purlin, Standing on the high corrugations may result in deformation of the panel Other useful tips in achieving a quality job are: Use a screw gun with a depth locator, this will ensure correct fixing of fasteners and avoid sheet damage.When drilling use a rubber or leather thimble on the drill bit to prevent the chuck of the drill damaging the panel when the drill goes through the material. 5. Completion and Inspection On completion, the sheeted area should be inspected. Any ferrous objects such as pop-tivet, stalks, bolts, nails, serews etc. left on the roofing should be removed. ‘Any accidental scratches, minor damage or cutting should be touched-up with the appropriate paint. The area should be left clean. 6. Paint Repair For minor scratches, a small brush can be used to apply Alkyd touch-up paint of matching color to the damaged area. MAMMUT BUILDING SYSTEMS 1668, Sharjah, U.A.E. Tel: +971 4 801 2222, Fax: +971 4 801 2223If damage has affected the galvanized coating, then the damaged area should be coated with special primer followed by a special polyurethane finish coat 4.2 Water test procedures for Roofing ‘There is really no better way of water testing a roof than actual rainfall, as to simulate even fall or wind blown rain is impossible. If medium to heavy rain has fallen after completion of roofing, and no leakage is visible then the roof should be considered tested and satisfactory. If the roofing has been completed during a dry season, and testing is required, then the following test can be cartied out: ‘A.25 to 30mm diameter hose will be required with sufficient mains pressure, or a tank and electrical pump. ‘Two tests can be done. 1. The hose should be positioned on the ridge, or highest point of the roof. The water should then cascade down each slope, down each valley between panel ribs. The hose should not be deliberately directly at the panel end laps and side laps. ‘The second and longer test can be carried out if desired by attaching a rotary garden sprinkler to the hose and allow the whole roof to be systematically “watered “. This is the nearest method of stimulating rainfall as the sprinkler system causes the water to bounce, thus finding any weakness in lap conditions. MAMMUT BUILDING SYSTEMS arjah, U, 4 801 2222, Fax: +971 4 801 2223Points to wateh out To respect the starting position for roof panels. Panels should be plumbed and held in place by Vice Grips before screwing. The panel gauge should be marked on the sheeting notch. 3 yi a4 Held in place by Vice Grips before screwing Straight line at the eave A line should be used to maintain a straight sheeting line at the eave. A chalk line should be used to ensure the screws are installed in a straight line, and avoid misdrilling. Roof sheets should be undamaged End lap mastic must be carefully placed over the Insulation should be neatly folded at the base angle and eave. It can never be neatly cut off afterwards. | fiid ‘Usage of Chalk Line MAMMUT BUILDING SYSTEMS P.O. Box: 41668, Sharjah, U.A.E._ Tel: +971 4 801 2222, Fax: +971 4 801 2223Cause of leakage 1. Careless handling and foot traffic cause deformation on panels, resulting in poor side lapping and end lapping. Closing gaps in side laps and end laps with silicone sealant is untidy and will not provide a long-term solution. ‘The non-installations of end lap bead mastic at all the skylight locations. Side lap stitch screws are not installed as detailed in the erection drawing i.e. greater spacing than detailed End lap mastic is stitched over the rib, thus it will break and become ineffective. The use of wrong screws. Mixing roof and wall screws. Foam closures are not well fitted. ‘The screws are loose. Roof panels are not fully screwed. Screws are over tightened. The wrong hanging of fiberglass roof insulation. In such case, the fiberglass insulation will act as a sponge, eventually becoming waterlogged ‘The flowable mastic sealant is not placed between the overlapping gutter sections. It is not enough to place the sealant at the edge of the lap. The overhang of panels inserted at the eave into the gutter is insufficient since the foam closure could not be felt. MAMMUT BUILDING SYSTEMS P.O. Box: 41668, Sharjah, U.A-E. Tel: +971 4 801 2222, Fax: +971 4 801 22:Erection Procedures Section 5: Erection Cheeklists ERECTION CHECK LIST 1. CIVIL WORKS: Does anchor bolt size comply with drawings requirement? Is the orientation correct? Are the dimensions correct bolt to bolt on the base? ‘Are the dimensions correct center to center of grid lines (or with allowable tolerance) Is the edge distance from bolt to concrete correct? Is the sheeting notch in the concrete correct? Are the bases or edge beams within acceptable levels? Is the concrete quality sound and adequate? ll, FRAME ERECTION : Is the roof and wall bracing in place? Are black up plates fitted where required, at bracing locations? Is the bracing tight? Are the flange stays fixed on columns & rafters? Are the high strength bolts installed in correct location? Is the washer installed with the HSB? 1s the HSB thread projection correct? Are the HSB's correctly tightened? Are all purlins bolts installed? MAMMUT BUILDING U.A.E, Tel: +971 4 801 2222, Fax: +971 4 801 222310 Are all purlins clips fitted where required? 11 Are eave strut plates fitted where required? 12 Are purlins straight abnd aligned? 13 Are the main frames plumbed and aligned within allowable tolerance? 14 Are crane beams braced and aligned? 15 Are stopped fitted on crane beams? 16 Have crane columns been levelled and grouted? 17 Are all bolts (HSB & MB) in place on mezzanine (before concreting)? 48 Is touch-up painted completed? 19 20 Ill, SHEETING AND TRIMMING; 1 Is the base angle securely fastened to concrete? 2. Are the girts and purlins temporarily supported during sheeting? 3 4 IV. INSULATION: 1. Is the fiberglass insulation cut to length and fixed correctly with double faced tape’ Has the insulation been properly staped at the side tabs? Has the insulation been correctly joined (wide spans)? Is the insulation taught and not sagging? Have any tears in insulation been repaired with patching tape? MAMMUT BUILDING SYSTEMS P.O. Box: 41668, Sharjah, UAE, Tel: +971 4 801 2222, Fax: +971 4 801 2223V. SHEETING - VERTICAL: Are sheets correctly lapped? Are the sheets plumb? Are the sheets fastened in the correct location? Are the sheets fastened with the correct of fastener? Have side lap fasteners been fitted as indicate on drawings? Have corner trims been correctly fitted with correct number of fasteners? ern Panrona VI. SHEETING - ROOFING: Are the sheets correctly lapped lapped-sides and ends? Is the tailline of sheeting straight? Has endlap mastic been installed? Has roof been cleaned? Have correct fasteners been used? Ate the fasteners in the correct location? Are the Hi-ib panels double screwed at end laps? Are foam closures installed where shown? Is the gable trim correctly fixed and aligned? 1 2 3 4 5 6 7 8 9 a3 Vil. GUTTERS - EAVE: 1 Hava cave gutters been sealed at overlaps and correct number of rivets installed at the joint? Have end caps been sealed and fitted? Have down pipe outlets been sealed and riveted? Are the down pipes plumb and correctly fastened? MAMMUT BUILDING SYSTEMS P.O. Box: 41668, Sharjah, U.A.E. Tel: +971 4 801 2222, Fax: +971 4 801 2223Vill, GUTTERS - VALLEY: 1 Are the splices correctly sealed and bolted? 2 Are the outlets sealed? 3 IX. GUTTERS - VALLEY: Are double sliding doors operating smoothly? Are fall up doors correctly tensioned and operation freely (manually and electrically)? Are personnel dogrs opening correctly including locksets, panic devices Gnd auto-closers PS _ 2 : Are windows sliding freely and locking correctly? ‘Are all trims around accessories and framed openings fixed? Are skylights installed and framed (if roof insulated)? Are ridge vents fastened according to drawing? Are vents in fine? 9 Have foam closures been fitted under ridge vents? 10 Has the roof sheets been crimped upwards at the ridge vent? 11 Have end flashing been fitted at ridge vents? 42 On continuous ridge vents has the connection flashing been installed? 13. Have pipe flashing been installed on pipe penetration? 14 X. GENERAL : Has the work been cleaned-off, specially roof sheeting & gutters? Is sheeting straight, plumb and aligned? Are sheet ribs aligned where appropriate (e.g... Soffit to wall)? Has all touch-up been done on frame and sheets? Are all trims installed according to details? MAMMUT BUILDING SYSTEMS +9714