SAFBUILD®

INSTALLATION MANUAL
 DISCLAIMER
This manual is provided to assist with the erection of your steel
building. Any person constructing the building needs to be competent
in general construction processes. You may also need a license to
construct the building (consult your state building authority). You
should also ensure that construction insurance has been taken out.

The building is fully engineered and MUST be built in accordance

with the Procedure & Sequence described in the Manual and
Drawings for the engineering to be valid.

If there are any discrepancies between the Drawings, and Bill of

Materials please contact your Customer Service Representative for
clarification.

2.
ACKNOWLEDGEMENT
This manual is the invaluable efforts
made by the following team

Content Review / Contributor

Sarah Ong’wen
Simon Omenda
Oscar Nyabenge
Steve Kiruhi
Santosh Kumar Panda

Additional Contributor

3.
 1. INTRODUCTION

1.1 About this manual

Erection refers to the assembling of the various component parts that make up the pre-
engineered steel building. The erection process entails much more than merely installing
the fabricated steel for the building. It actually begins with the foundation and building
anchorage and continues to cleaning the job site upon completion.

The methods and procedures suggested by this Erection Manual represent basic, safe
erection practices. They can, and should, be modified when necessary to adapt to special
conditions or circumstances.

1.2 About SAFBUILD®

SAFBUILD® the world-class pre-engineered steel building solutions are prefabricated cold-
formed steel structures from Safal Building Systems, that are easily assembled on site.
Therefore, reducing overall costs of construction and project duration.

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2. PREPAREDNESS

2.1 Understand the Engineering Documents

The following are some basic building components:

5.
2.2 Understand the Engineering Documents

Prior to beginning the erection work, it is essential to have a clear understanding of the
Engineering Documents, especially the Erection Drawings and Bill of Materials.

2.2.1 Anchor Bolt Setting Plan:

This drawing shows the layout of all anchor bolts. The Anchor Bolt layout also includes an
anchor bolt schedule, in table form, showing the, quantities and sizes of the anchor bolts
required.

The key plan specifies out-to-out the dimensions, bay spacing dimensions, bolt setting details
and critical dimensions for the span. Critical distances on the drawing should be respected at
all times. The details specify whether grout is required under the columns. The grout thickness
will be shown on the drawings, as well as the bolt projection. Adherence to anchor bolt setting
tolerance is important.

2.2.2 Cross-Section:

The cross-section drawing indicates columns and rafter references, connection details, bolt
schedules, flange brace schedules and other information as applicable, such as strut tubes
and flange brace details.

When reviewed in conjunction with the Bill of Materials it is possible to determine the weight
of individual members, or a combination of assembled members. This data is essential during
the planning of erection, needed in order to determine the capacity of the erection crane to be
used.

2.2.3 Roof Framing Plan:

The roof framing plan illustrates the purlins, bracing and related miscellaneous details. Part
numbers are indicated on this drawing for purlins, bracing, sag rods (where applicable), etc. The
drawings should be studied very carefully, otherwise it is possible to overlook critical details.

2.2.4 Roof Sheeting Layout:

The roof sheeting plan displays all the panels including their length and part numbers. It
also shows the sky light distribution and downspout positions. Standard details of panel lap,
fasteners, trims and insulation are also included. It is very important to note the starting
dimension of the sheeting from the steel line.
2.2.5 Sidewall & Endwell Sheeting & Framing:

Depending upon the drawing and erection requirements, sidewall framing and sheeting may
be represented on one drawing or more. 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 numbers. Wall lights
eave trims, gutters and downspouts are also shown along with part numbers. Related standard
details are included which indicate the number, size and position of fasteners. Additional
trimming details are also included in the drawing. It is important to check the starting
dimension of the sheeting from the steel line.

2.2.6 Other Drawings:

Other drawings may include accessories such as Sliding Doors, Roll-up doors, Staircase Cage
Ladders, Personnel doors, Windows, Louvers and Ventilators.

2.2.7 Bill of Materials (BOM):

The BOM is a reference to the items shown on the Erection Drawings and can be used to verify
that all items have been received at the site

The BOM has a USAGE column and a MARKING column. The USAGE columns clearly indicate
what each item is to be used for. The MARKING column is to help you identify some of the
frame components and their location.

You also need to refer to the Layout Plan for Left and Right and the bay numbers. Portal
numbers start from the Left end.

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 The building components are prefixed with the
following codes for easier identification:

C Main Building Columns LEP Lean-to Eave Purlin

R Main Building Rafter LKB Lean-to Knee Brace
M Main Building End Wall Mullions KB Knee Brace
P Main Building Roof Purlins D Droppers
G Main Building Girts LC Lean-to Columns
EP Eave Purlin LR Lean-to Rafters
AB Apex Brace LM Lean-to End Wall Mullions
LG Lean-to-Girts LP Lean-to Purlins

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2.3 Know Installation Tools & Equipment’s

ITEM IMAGE

Telescopic boom Truck Mounted crane

Telescopic boom crane was mounted on a standard

truck chassis for the first time in 1979. Good range
of lifting capacity, good mobility & ease of operation
are some of the key features of its popularity. In
still construction cranes ranging from 20 Ton –
250 Ton are used. For selection of right crane refer
crane selection guide.

Pick-N- Carry Cranes

Pick-n-Carry which are widely used in construction

and infrastructure industry. These machines are
used for loading, unloading, moving, shifting and
erecting material. These cranes are available from
9 tons to 25 tons capacity.

Boom lifter

Boom lifter is used to work at height safely. A boom
lifter is really a machine that is enclosed with
hydraulically power boom which may be moved in
the in numerous directions by the operator.

Spreader Bars

A spreader bar is a type of below-the-hook lifting

device used to aid crane operators in picking up large
items. Most commonly used when the object being
lifted is too large to be lifted from a single point, and
not designed to take any adverse loading caused
from angled slings during the lift.

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 Web Slings

Webbing slings are flexible, lightweight and have a

wide bearing surface, which helps protect the load you
are lifting. Webbing slings are the most popular type of
slings, and their stretchy characteristics help minimize
shock loading problems. These are used for lifting all
structural material.

Wire rope Sling

Wire rope slings are assemblies of high-quality

steel wire ropes, used for lifting, hoisting, pulling,
rigging and other material handling activities.
Wire rope slings come in many types that each
have a variety of uses. They can be formulated
into various products to match the requirements
of multiple industries. For selection of the right
Sling refer Sling selection guide.

Steel Guy Ropes

A guy-wire, guy-line, or guy-rope, also known as simply

a guy, is a tensioned cable designed to add stability
to a free-standing structure. These are also used for
temporary life line during construction.

Turnbuckle Tensioner

A turnbuckle is a device for adjusting the tension or

length of ropes, cables, tie rods, and other tensioning
systems. It normally consists of two threaded eye bolts,
one screwed into each end of a small metal frame, one
with a left-hand thread and the other with a right-hand
thread. The tension can be adjusted by rotating the
frame, which causes both eye bolts to be screwed in
or out simultaneously, without twisting the eye bolts or
attached cables.

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Chain Pulley Block

Chain Pulley Blocks are widely used for lifting of loads

and for lifting and lowering of Heavy Loads without
Fatigue. This is usually used where there is no crane
access to the location.

Rope Pulley System

It is characterized by the use of a single continuous

rope to transmit a tension force around one or more
pulleys to lift or move a load—the rope may be a light
line or a strong cable.

Ratchet Tool

In a tool or machine, a ratchet is a wheel or bar with

sloping teeth, which can move only in one direction,
because a piece of metal stops the teeth from moving
backwards. This helps in tighten fasteners where the
space is less for the moment arm.

Torque Wrench

A torque wrench is a tool used to apply a specific

torque to a fastener such as a nut or bolt. It is usually
in the form of a socket wrench with special internal
mechanisms. A torque wrench is used where the
tightness of bolts is crucial.

Power Drill

A power drill is a tool that implements various-sized

drill-bit attachments to drill a hole into an object such
as Steel, wood. It is a motorized piece of machinery
that is commonly used in construction and for building
material needs. You should have a Right-angle
attachment to drill difficult to access area.

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 Hammer Drill

Hammer drill is a power tool used chiefly for drilling in

hard materials. It is a type of rotary drill with an impact
mechanism that generates a hammering motion If a
hammer drill’s impact mechanism can be turned off,
the tool can be used like a conventional drill to also
perform tasks such as screw driving.

Power Screwdriver

A power screwdriver is a screwdriver that uses some

form of power source to perform the work of driving
screws, rather than relying on human muscle. Power
screwdrivers generally operate under electric power,
and while they may use standard wall outlet current,
battery powered tools are by far more common.

Impact Wrench

An impact wrench is a socket wrench power tool

designed to deliver high torque output with minimal
exertion by the user, by storing energy in a rotating
mass, then delivering it suddenly to the output shaft.

Compound-action snips/ Aviation snips

Snips are hand tools used to cut sheet metal and

other tough webs. Standard compound-action snips
are designed for cutting steel or softer materials

Power Nibbler

These are used to easily cut a variety of profiles in sheet

metal, ejecting chips and ribbons downward for safety
of both operator and workpiece.

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Apart from the Erection & Tools mentioned above the crew is expected to have the following
for quality installation:

1. Steel Measuring Tape (at least one 5 Meter & one 30/50 Meter as per building size)
2. Magnetic Spirit Level (at least 1 meter Long)
3. Magnetic Plumb (at least 250g Magnetic Plumb Bob with 4.5m String)
4. Metal Roofing Square (at least 300 mm)
5. A full set of Spanner suitable for M12- M30 Bolts
6. Heavy duty ground anchoring steel pegs (for temporary anchoring of building)
7. Clamps (C Clamp, Bar Clamp, Spring Clamp)
8 Digital Laser Tape Measure with Bubble Level (Optional)

Note: The Installation Tools & Equipment’s mentioned above are bare minimum. There may
be site specific specialized tool requirements which the Installer & the site engineer should
discuss and arrange before start of work.

2.4 Kickoff Meeting

A kick-off meeting is the first meeting with the project team and the client of the project.
This meeting would follow definition of the base elements for the project and other project
planning activities. Apart from providing a structured start into the project execution, kick-off
meetings establish a positive atmosphere before the start of the project. The meeting is also
a good opportunity to get the project team to agree on common goals. In this way, the event
lays the foundation for a successful project implementation.

2.5 Resource Planning

Resource planning is a process of allocating tasks to human and non-human resources so

that they’re judiciously utilized. A well-crafted resource plan improves the speed, quality &
safety of work. Resource planning helps project managers manage resource utilization and
track resource capacity, to keep projects on budget. Resource planning is essential for India
as there is enormous diversity in the availability of resources.
To attend the speed, quality & safety in site execution of pre-engineered metal building
system, the construction team should focus on the following factors to prepare a good
resource plan:
• Location of work
• Type of Project- Greenfield/ Brown field
• Accessibility
• Criticalness of erection
• Project Schedule
• Season of work (Summer/ Winter/ Rainy)

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 It is recommended that safe working conditions and accident prevention practices be
the top priority on the job site. Safe and healthy work place improves the productivity &
quality. Though job site safety is a joint responsibility of all parties present on the job site,
including owners, architects, engineers, contractors, subcontractors, delivery personnel, and
employees of all the above, among others, Steel Erection being one of the riskiest activities,
EHS team should visit the site & understand the site condition, discuss with planning &
erection team to understand the erection plan. Then they should do Job Safety Analysis
(JSA) of each & every activity. Based on the JSA safe working plan should be developed.

All our Teams follow the following Basic PPE as per the Annexure

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3. PRE-INSTALLATION SITE WORK

3.1 Job Site Preparation

There are many benefits to a clean and orderly job site. Before mobilizing, the project team
should make a site visit to make a detail observation of the current site condition wrt to the
requirement. The following are some of the points to be checked:
• Accessibility for trucks/trailers and equipment
• Obstructions below ground, above ground & overhead
• Storage Location- It should be clean, level, compacted and preferable at a higher
level than the rest the site
• Availability of Water & power

Existing conditions should be considered in pre-construction planning.

3.2 Unloading & Storage

Pre-planning of receiving and unloading of materials is an important part of the Installation

procedures. This involves careful, safe and orderly storage of all material. Detailed planning
is required at the job site where storage space is restricted. Here a planned separation of
materials in the order of the installation process is necessary to minimize the costly double
handling of materials.

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 While set procedures are not possible in all cases, special attention should be given to the
following items:

• The lay-down area should be clean and levelled. It should be as near as possible to the
place of erection to minimize lifting, travel and re-handling during building assembly
• Trained manpower & suitable Pick N Carry should be available with lifting tools as
required for proper unloading
• Check materials against the Packing List and immediately report shortage or excess
material

Since the material are custom design & built, any loss/damage of a single material/ member
will affect the whole project. So care should be taken for Storage & Protection of Material.
Keep the bundles clear of the ground by providing suitable packing blocks. Protect members
from weather, by storing the bundles with an inclination to permit water drainage in case
of rain or condensation. It is advisable to lightly cover with a tarpaulin. Bundles of sheets
should be stored in the same way.

3.3 Pre-Erection Checks

Do a final check on your levels and bolt spacings.

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The following dimensions must be controlled:

• Steel Line to outer bolt row

• Diagonal distance between bolt groups
• Distance from axis centre line to bolt row
• Distance between bolts
• Distance between frame axis
• Levels of foundations & Anchor Bolt protrusion

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 4. INSTALLATION OF STRUCTURE

4.1 Typical details

Please get yourself acquainted with the following typical details before start of erection.
Incase of any confusion as the Safal Building representative for assistance

4.1.1 Knee Bracket Connection

Knee Bracket is a connecting member between the column & rafter. Refer to the Connection
Detail drawings for type and number of screws and bolts. Based on the types of portal
frames the knee brackets can be connected as follows:

Single Section
• Line up the top outside edge of the Rafter with the outside leading edge of the Column.
• Fit the Knee Bracket over the Column and Rafter web. The Knee Bracket is designed to fit
snugly on the column top with the return flange of the Knee Bracket folding neatly around
the Column and Rafter flange.

Back-to-Back

All back-to-back portals require one left and one right Knee Bracket to each Column / Rafter
(Knee) connection point.
• Line up the top outside edge of the Rafter with the outside leading edge of the Column.
• Fit the Left and Right Knee Brackets over the Column and Rafter web. The Knee Bracket
is designed to fit snugly on the column top with the return flange of the Knee Bracket
folding neatly around the Column flange.

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4.1.2 Apex Bracket Connection

Apex Bracket is a connecting member between the rafters at ridge/ apex.

Apex Bracket is designed to fit in line with the pitch of the Rafter. Refer to the
Connection Detail drawings for type and number of screws and bolts. Based on
the types of portal frames the apex brackets can be connected as follows:

Single Rafter

• The bottom leading flange of the opposing Rafters should just touch.
• The Apex Bracket aligns with the top flange edges of the Rafters.
• Place your Apex Bracket on the rafter joint so that the return flange
on the Apex Bracket faces down the same as the Rafters.
• Once you have followed the measurement sequence and are satisfied that your portal
is correctly positioned place 2 Tek screws through the Apex Bracket into the Rafters
each side to prevent movement whilst tightening your main connection bolts.

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 Back-to-Back Rafter

All back-to-back portals require two Apex Brackets.

Follow same steps as in single rafter system for one side
& repeat the same for the other side also.

4.1.3 Knee Brace Connection

The knee bracing is a new bracing system where the diagonal brace is anchored to a short
member instead of the beam-column joint. It includes relatively simple connections for ease
of construction but has a greater impact on the structural stability of the building. Based on the
type of frame the Knee Brace

Single Column- Rafter

Once you have determined that your first mid portal is square and of the correct height, it is
now time to locate your Knee Brace. These Knee Braces are fixed web to web. Please note
Knee Braces
are used only in mid portals unless the end portal is fully open.

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Keen Brace is fixed using following steps:

• Place the Knee Brace, web to web, on the portal Column and Rafter. Position the
top points of the Knee Brace to the top of the Rafter and to the outer edge of the
Column as shown above. The angle between the Knee Brace and the Column
and the angle between the Knee Brace and the Rafter should be equal.
• Recheck your measurements, clamp each end of the Knee Brace, place two
tek screws in each end to assist in maintaining correct placement.
• Drill two bolt holes each end in the inside web of the brace through
the brace and Column and Rafter respectively. Secure your bolts
tightly and then place the remaining tek screws required.

Back-to-Back Column-Rafter

It is easiest to make up your Knee Braces using the end portal as a template, so long as it is
the same size section. You should do this once you have determined that your first gable portal
is square and of the correct height.

The Knee Brace is made up of a back-to-back Cee section and fits to the Knee Brace Brackets on
the column and rafter. Ensure Knee Brace Bracket is installed on to the Columns and Rafter as
per connection detail. Place the Knee Brace section on to the Knee Brace Bracket on the portal
Column and Rafter. Continue your portal frame assembly including the other componentry,
which makes up the entire frame.

Fix with the required bolts & tek screws as specified.

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 4.1.4 Apex Brace Connection

Once you have determined that your first mid portal is square and of the correct height, it is
now time to locate your Apex Brace.

Apex Braces are used only in mid portals unless the end portal is fully open.

Apex Brace

For single rafter portal please follow the following steps:

• Place the Apex Brace web to web with the Rafter. As the portal is now square you can
obtain the position for the top two points of the Apex Brace by measuring from the centre
of the peak connection joint down the rafter to determine an equal measurement to both
points.
• Recheck your measurements, clamp the Apex Brace in position and attach with two Tek
screws. Be careful to maintain the correct position of the brace whilst affixing it to the
portal rafters.
• Drill two bolt holes each end in the inside web of the brace through the Apex Brace and
Rafter respectively. Secure your bolts tightly and then place the remaining Tek screws
required.

Apex Brace & Droppers Back-to-Back Rafters

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For Back-to-Back Rafters apex Brace is made up of double Cee sections fixed under the rafter.
It is connected to the rafters’ using brackets at each end, plus a dropper in the middle (if
supplied).

• Align the Apex Brace so as to determine the location of the Apex Brace to Rafter Web
Bracket.
• Ensure bolts and spacers are installed at the intermediate positions on the Apex brace, as
provided in the assembly drawings.
• Bolt and screw the Apex Brace and the Rafter to the Rafter Web Bracket.
• Measure the required length of the dropper and cut to length (if supplied).
• Using the Dropper Fixing Brackets fit the Dropper to the underside of the Apex Bracket and
the Flange of the Apex Brace.

4.1.5 Fly Bracing

The structural fly bracing consists of strap material and is fixed by the use of 14.20 x 22
structural screws.

Fly bracing should be fixed to the preceding bay after the adjoining bay has had all purlins and
girts fixed. The successful installation of fly bracing will assist greatly in firming up the main
structure.

The strap required for fly brace is supplied cut to length as per “Connection Details Plan”. The
strap needs to be fixed so that no lateral movement is achievable. (taut not sloppy).

4.1.6 Cross Bracing

Cross bracing are the members fixed diagonally to columns & rafters which restricts the
movement of the members under load.

Strap Bracing
The structural cross bracing where nominated in the Roof Plan is carried out with 32mm Strap.
It is fixed using 14.20x22 structural screws (number of screws as per Connection Details plan).

For location and position of cross bracing, refer to the Roof plan.

Following the installation of the fly bracing to the finished purlins and girts, fit the structural
cross bracing to the roof and wall bays. The strap is attached to the rafter close to the apex,
then either centre of rafter or close to the Knee bracket. If finishing centre of a rafter, then
another strap will continue to the Knee bracket. The strap is also fixed to the top and bottom
of the required columns as per Elevation drawings.

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 If double strapping is required there should be at least 5mm gap between the straps.
The steps are as follows:
• Measure the length required for the strap as per the Roof plan and add 300mm.
• Roll out the strap and cut to length.
• Fix the strap with 1 screw at the apex end of the rafter, or top of column.
• Bend the strap in a loop at the other end (reason for extra 300mm) and put a screw through
the strap.
• Using a claw hammer or rod place through loop and stretch tight, fix screw to rafter/column.
• Fit the required screws into each end as per Connection Detail drawings.
• Repeat other side.
• When both sides of a cross brace are finished fix 2 screws to each point where the strap
crosses the bottom of the purlins/girts.
• Repeat for each roof and wall bay requiring cross bracing.

4.1.7 Purlins and Girts

For correct connection details refer to Connection Details drawings.

Roof Purlins
The top (apex) Roof Purlin is fixed as close as possible to the apex end of the Rafter. The
bottom Roof Purlin is the Eave Purlin (See page 34).
Refer to the Assembly drawings for the Roof Purlin spacing.

Side Wall Girts

Where the walls are sheeted to ground level, the bottom girt around the building is fixed
200mm above the finished floor height. The top girt is the Eave Purlin
Refer to the Assembly drawings for the Wall Girt spacing.
Where Header Sheets are provided, a Side Girt (if supplied) should be fixed under the Eave
Purlin to suit the header sheet length.

End Wall Girts

The End Wall Girts attach to the inside of the corner Column (End Portal) and overlap on the

24.
flange of the End Wall Mullions.
To enable the End Wall Sheeting to be fixed at the corners, a small angle bracket (cut from the
Fixing Trim Angle - General Purpose or strap) is fixed to the Side Girt web.
Where the walls are sheeted to ground level, the bottom girt around the building is fixed
200mm above the finished floor height.

Eave Purlins
The Eave Purlin is mounted in position at the Rafter top by screwing directly through the web
to the Knee Bracket or screwed to an Eave Purlin Bracket.
The Eave Purlin Bracket projects past the Column outer flange by the required distance so that
this Eave Purlin is in-line with the Side Wall Girt projection. Or, if the whole side is open, this
projection distance is to be the thickness of the eave/header.
The Eave Purlin is fixed with the open C facing out of the building. The inside web of the Eave
Purlin fits to the Knee Bracket or Eave Purlin Bracket and is attached by way of 14.20 x 22
industrial Tek screws according to position and specification.

The Eave Purlins in the centre or middle bays of your building fit exactly to the centre of
Column according to the size of your bays.

The Eave Purlin on the end bays fit flush to the outside of the end girts.

The height to the top flange of the Eave Purlin is the same as the side wall shed height. The
top flange of the Eave Purlin will be in line with the tops of the Roof Purlins to give a straight
sheet line from apex to eave.

Gable Ends Raking Girts

Raking Girt is provided to allow for the End Wall Sheeting to be fixed at the top.
• For the sheeted end walls, fix the Raking Girt to the bottom exterior
edge of the Roof Purlins using two Tek screws per purlin.
• The Raking Girt extends from the apex to the Eave Purlin.

25.
 4.2 General Construction Notes

• Please note that your building may not be having all the components. Please read the
correct drawing to understand all building components. The drawings marked released for
construction issued with this manual overrides all earlier drawing.
• It is recommended that as much assembly of building components is completed while
the components are on the ground as opposed to in the air. An example of this would be
measuring and coping knee braces before columns are installed, or installing all necessary
clips or brackets to a column before raising and installing the column.
• Before drilling holes in concrete, ensure that location to drill is 100% correct. If incorrect,
building construction may need to be delayed
• The exact makeup of a bolt assembly can vary by building. Note that although washers are
illustrated as part of a bolt assembly, the bolts supplied may instead have a flanged head
and nut (washer/head or washer/nut combined). For exact makeup of the bolt assembly,
please refer to the building order.
• When installing trim, keep in mind how water will run. Trim should be installed so water
will not flow into the building during normal flow.
• Framing screws have various diameters and lengths. Make sure that when installing framing
screws, correct screw size, type and number per connection are used, per the engineering
drawings and building order. If you have been provided with screws of various length and
self drilling tip size, the correct use of screws should be listed on the building order. If not,
longer screws that can drill through more material should be saved for those connections

26.
 that require drilling through a significant amount of steel. Use a power screwdriver (no
Impact drivers) for Framing Screws.
• The building is not designed to withstand erection forces nor to stand up by itself when
it is partially complete. Please do not relay on the base plates alone to keep the portals
standing during construction. It is essential that there are temporary or construction
bracings as per requirement in place during Installation. Those bracing should remain in
place until the all building components are fixed as per drawing & specification
• Do not cut COLORPLUS® materials with abrasive cutters. Use electric/hand shears or
nibblers.
• When installing all screws that include rubber washers, such as wall and roof screws, care
must be taken to tighten these screws the proper amount. If screws are tightened too
much or too little, they will not seal properly. Screws should be tightened so that washer
has been compressed, but not to such a degree that the washer becomes deformed. If
washer becomes deformed, a screw with a fresh washer will need to be re-installed.

4.3 Assembly of Structure

There are two types of portal frames. The specific sequence of assembling the specific type of
portal must be followed.

4.3.1 Single Section Portal:

Steps to be followed while assembling a Single Section Portal

27.
 • Lay out the Columns (C) flange down in line with your foundation bolts according to the
location determined by the Mark. Place on timbers to allow access for structural frame
bolt placement.
• Fit the Knee Bracket (D) into place at column top using structural frame bolts and hand
tighten
• Fix the Base Plates (B) to the footing.
• Place the Rafters in position flange down to the column top. Loosely fit the Apex Bracket to
the Rafters (E) using your structural frame bolts and hand tighten.
• Follow the “Portal Measurement Sequence” guide ( Annexure-1) and align the main part of
the frame (columns and rafters).
• With the main frame correctly aligned, place frame screws in the Knee Bracket and Apex
Bracket to prevent movement while securing bolts. Tighten all bolts securely.

NOTE: End wall (Gable) portals unless exposed are always single section without knees and
apex braces (refer to your specification sheet and BOM).

• Locate the Apex Brace (H) in position web to web. The ends should be equal distances from
the apex. Fix screws/ bolts as per the connection details drawing.
• Locate and fix the Knee Braces (G) into position web to web. An approximately equidistant
triangle between the Columns and Rafters should be formed. Fix screws/ bolts as per the
connection details drawing.
• Check the final measurement and remove and extraneous matter such as drill swarf,
filings, spare bolts and screws from the completed portal.

4.3.2 Back to Back Section Portal

28.
“Back-to-back” refers to C sections being fixed together to form an I section. This is done by
assembling the C section web to web. The Columns, Rafters and all brackets are “back-to-
back”.
The position of back-to-back portals can be determined from the Specification sheet. e.g.,
2C25024 represents a back-to-back section.

In the BOM Rafters are not specified as left or right, therefore you will always have either 2 or
4 Rafters.
2 x Rafters = Single section portal (refer previous section)
4 x Rafters = Back-to-back portal
e.g., If you have 4 x R2 Rafters, then your portal 2 will be back-to-back.

Following steps to be followed to assemble a Back to Back Section Portal:

• Lay out the Columns in line with your foundation bolts. Place on timbers to allow access
for bolt placement.
• Place back-to-back columns together web side to web side. Check that you have back-to-
back column pairs not corner columns. Back-to-back columns will have additional holes
punched in the web where they are bolted together and filled with packing plates for the
frame to act as one.
• Back-to-back portals have double brackets. Fix your Knee Brackets in opposing pairs (Left
and Right) and slide them into place between the web faces of the Columns.
• Insert your Structural Column Frame Bolts and hand tighten.
• Proceed down the column length putting Intermediate Column Frame Bolts loosely in the
web holes until the base. At the base fix the Base Plates inside the columns and secure
with Structural Column Frame Bolts.
• Check that the columns line up top and bottom and the flange sides are parallel, similarly
the Knee Brackets should be correctly aligned with the column side.
• Fix the Base Plates to footing.
• Place the lower of the back-to-back Rafters in position flange down. Loosely fix the first
Apex Bracket and the Rafter to the Knee Bracket on the Column, so the portal is close to
its final dimensions.
• You need to slightly bend the inner lip of the Column top to allow the Rafter to sit neatly in
position.
• Locate the Apex Brace in position. The ends should be equal distances from the apex.
(Refer to the section “Apex Brace”).

29.
 NOTE: Ensure the entire portal and braces have sufficient timbers under it to prevent
distortion by sagging.

• Fix the Knee Braces in position. (Refer to knee brace detail below)
• Fix the top Rafters (flange up) and place all Structural Rafter Frame Bolts (hand tight) in
the Knee Brackets and Apex Brackets.
• Follow the “Portal Measurement Sequence” guide (Annexure-1) and align the main part of
the frame (Columns and Rafters).
• With the main frame correct, place Frame screws in the Knee Bracket and Apex Bracket
to prevent movement while securing the bolts. Tighten the Structural Column Frame Bolts
securely.
• Fix the Knee Braces snugly into their correct placement (an approximately equidistant
triangle between the Columns and Rafters should be formed). You will need to drill bolt
holes for fixing the Structural Knee Brace Bolts. Refer to connection detail for final fixings.
• Ensure that all flange edges on Knee Braces fit together square and tight.
• Insert all other Intermediate Rafter Frame Bolts into Rafters. Tighten these and all
Structural bolts securely.
• Place the Apex Brace and Dropper carefully into their correct position. Hold with screws
prior to final fixing. You will need to drill bolt holes for fixing the Structural Apex Brace
Bolts. Refer to connection detail for final fixings.
• Do a final measurement check and remove and extraneous matter such as drill swarf,
filings, spare bolts, screws etc from the completed portal.

4.4 Erection of Structure

Before start of the Portal Erection make sure you have the following things in place:

1. Right type & size crane (You must go through the load chart of the crane & take support
from the qualified professional for finding the right size. Please take a note for these cold-
formed steel structures, reach is the most important factor for crane selection, not weight.
2. Proper arrangement for working at height
3. Availability of temporary bracing & anchoring arrangement for the same
4. Proper lifting gears (Web Slings are preferred over wire rope slings)
5. Guiding Ropes

30.
Following procedure to be followed for a quality installation:

• Starting from one end, lift the end portal into place.
• Two lifting points are required on the Rafters with the attachment points being
approximately where the Apex Brace attaches to the Rafter.
• Where the two lift chains divide at the crane lift point, the angle between the two chains
should not exceed 60°.
• Ensure the sling knot with weight applied is sitting on the top of the rafter - not on the
side.
• When lifting the portal, the crane needs to lift smoothly without stopping until the
Columns completely clear the ground and the entire frame is suspended by the crane.
• Do not allow the Columns to come in contact with the ground until such time as they are
placed directly on the footing bolts.
• Do not release the Portal. The crane must continue to retain enough weight to keep the
portal vertical until such time as the portal frame is properly secured and braced.
• Tighten your base bolts.
• Place the End Wall Mullions. The best way of doing this is to use a scissor lift to assist in
the placement of your End Wall Mullions.
• Fit fixed bracing to the top of the columns plus to the rafter near the apex

• Use a spirit level against the side of the Columns to ensure that they are level. Adjust
accordingly.
• After the fixed bracing has been fixed undo the slings.
• Stand portal number 2, attach it to your hold down bolts and fix fixed bracing to the columns
as previously described.
• To both sides of the roof, fit the Roof Purlins and Eave Purlin.

31.
 • Final fixing should be applied to the end portal. Temporary fixing should be applied to portal
number 2 to allow the adjoining Roof Purlins to be fixed later.
• Stand portal number 3, attach it to your hold down bolts and fix fixed bracing to the columns
and rafters. Remember every 3rd portal must be braced as per the ends.
• To both sides of the roof, fit the roof and eave purlins.
• Final fixing can now be applied to portal number 2 and temporary fixing to portal number 3.
• Continue this procedure until all portals are stood, ensuring that the fixed bracing, Roof
Purlins and Eave Purlins are fixed to every portal as it is erected.
• Fit the Fly Bracing and Cross Bracing to the roof. (Refer to Bracing Drawing and the sections
relating to the Fly Bracing and Cross Bracing
• After all portals have been stood (as above), then fit all the side and end wall girts to the
building.
• Fit the Fly Bracing and Cross Bracing to the walls. (Refer to Bracing Drawing and the
sections relating to the Fly Bracing and Cross Bracing)

4.5 Erection of Other Building Components

4.5.1 Wall Mullions

Wall Mullions are positioned as shown in the layout plan, consider any openings. The Wall
Mullions lay at 90 degrees to the Column direction and may need to be cut and fixed into the
correct position - generally spaced evenly between the inside edge of the Columns (End Portal).
Mullions may need to be moved or removed to allow for openings and or Doors positions.
Mullions are also positioned in any dividing walls.

For fixing details of Mullions please refer to the connection detail drawing.

32.
4.5.2 Install of door, windows & rolling shutters
Install all door, windows & rolling shutters per manufacturers’ instructions. For connection
details to the main frame refer the connection detail drawing.

5. Installation of Sheeting
Installation of sheeting can be done based on the site requirement. But it is preferable to
complete the wall sheet first followed by the roof sheet. This gives an additional bracing for
partial finished building.

5.1.1 Install trim around framed openings

Install necessary head/jamb cover, which is installed only on the overhead door jambs and
header. After installing head/jamb cover, install head/jamb trim. Note that head/jamb trim is
installed on all three sides of doors and all four sides of windows.

5.1.2 Install base trim

If your building includes base trim, install that before proceeding with installation of wall
sheeting.

5.1.3 Side Wall Sheeting

After completing any base trim, install insulation & sidewall sheets

33.
 Always place wall screws through the pan, adjacent to the crest. Five (5) wall screws per full
sheet per purlin are fixed at each girt line.

The edge of the sheeting with the capillary groove is always the underlap. For maximum
weather tightness, start laying sheets from the end of the building that will be in the lee of
the worst anticipated or prevailing weather. Put the edge of the sheet as close to the edge of
the wall girts as possible, starting with your cover lap first and proceed along the long wall.

Place the sheeting just below the top of the eave purlin so as not to interfere with the roof
sheeting. Do not put the sheet past the top of the eave purlin as this will impede placement
of the roof sheet. This will bring the sheeting 50mm below the slab / column.

Take particular care to level your first and second sheets, and then check every couple of
sheets from there on with a spirit level to maintain correct level.

Screws should be fixed in straight lines using a level. Continue along the wall with the
sheeting, until such time as you reach an opening. Stop one sheet before the opening,
measure and cut the next sheet and to fit accordingly beside and over the opening.

Header Sheets MUST be screwed in the pan to each side of the peak at the top and bottom (5
screws per purlin per sheet)

Take care to install any Drip or Soffit Flashings before continuing the sheeting, otherwise
you will have to go back and redo those. All other flashings are done at a later stage.
Take particular care with your wall sheeting that your cover laps
are correctly positioned, a neat fit and seal correctly.

5.1.4 End Wall Sheeting

On your gable ends, the increment rise per meter is -

• 87mm per metre for a 5 degree roof;

• 176mm per metre for a 10 degree roof;
• 268mm per metre for a 15 degree roof;
• 364mm per metre for a 20 degree roof;
• 466mm per metre for a 25 degree roof;
• 577mm per metre for a 30 degree roof.

34.
Check your wall sheeting width to determine the rake to cut your sheets.

You will need to cut your End Wall Sheeting at the appropriate roof angle. You can either
pre-cut your End Wall Sheeting on an angle on the ground or once it’s up there, use
your nibblers to follow the roof sheet line just below the level of the roof sheet line.

The Raking Girt is Tek screwed onto the bottom of the overhanging roof purlins. The End Wall
Sheeting is then screwed to the Raking Girt.

Ensure you maintain your level carefully as you go across the end wall with a spirit level and
make sure your screw lines are straight.

5.1.5 Roof Sheeting

Roof foot traffic must be limited to “Controlled Foot Traffic”. Extreme care should be
exercised when roofs are installed to prevent any unsightly aesthetic imperfections.

In the event of roof sheeting being loaded onto the frame, then the delivered packs must be
broken down into bundles no larger than the number of sheets required to fit over one side of
one bay.

Spread the bundles of roof sheets on both sides of the building and only directly over a rafter
(not midspan). Only one bundle per rafter.

35.
 The frame is not designed to take the dead load of excessive bundles of roof sheets in the one location.

Before lifting sheets onto the roof, check that they are the correct way up and that the
overlapping side is towards the edge of the roof from which the installation will start.

Once the side walls are installed the roof sheeting can be installed. It pays to place a couple
of sheets on the roof first and get them exactly in the right position before proceeding further.
Ensure that the sheet protrudes 50mm past the wall sheet ridge into the gutter to avoid any
drainage problems.

Always place roof screws through the crest, perpendicular to the sheeting and in the centre of
the crest.

Depending on the profile of the roof sheet install screws as per the sheeting layout drawing.

Fix a screw on every rib on the Eaves Purlin.

Do not fix the apex screws until fixing the flashing. (Apex and headwall flashings)

The edge of the sheeting with the capillary groove is always the underlap.

36.
For maximum weather tightness, start laying sheets from the end of the building that will be
in the lee of the worst anticipated or prevailing weather.

Ensure that screws are not over tightened, and that sheeting is exactly aligned at the lower
end. This provides a far better finished product.

Always take care after sheeting the roof that you Bend Up and Bend down
the sheets at the top (apex) and the bottom (gutter end) respectively.

Any swarf, filings etc left from putting Tek screws in should be removed with a soft broom.
Take care that there is no moisture on the roof, as it is extremely slippery.

5.1.6 Install of Flashing

It is essential that everything aligns up correctly to provide a very neat, finished product. So,
some care and a lot of thought must be taken when applying the flashings.

Barge Flashing
Always start from the bottom (the gutter line) and protrude the barge flashing at the same
level as the roof sheet (about 60mm into the gutter). Start from that point and go to the peak.
Remember if it is several pieces for a large building always start from the bottom and work up.
Cut the overhanging top face so there is a vertical joint line showing at the peak of the building.

Ridge Flashing
The ridge flashing should be fixed in a direction so that the joins do not allow rain to be driven
into them. The overlaps of the ridge cap should be sealed using a sealant and screwed down.
The ridge cap fits over the roof sheets and is screwed to the roof sheeting and into the apex
purlin. Fix with standard roof screws to match the roof sheeting profile screws.

Corner Flashings
The main corner flashings fit up behind the barge capping and gutter. Fix with stitching
screws on the same line as the wall-girt screws.

37.
 Drip Flashings
Any drip flashings are fixed using wall screws. The number of fixings is the same as the number
fixed to the side cladding

5.1.7 Installation of Gutter and Rainwater Goods

The gutters come in a standard length of 3m, an overlap of 100mm for a join. Also supplied
will be stop ends/end caps, gutter brackets, downpipes, shoes, downpipe straps and
downpipe cleats. Requirements for water tanks can be available upon request.

Gutter straps are attached to the top of the roof sheet on the sheet’s ribs and on the upper
lip of the box gutter. The gutter straps supplied will be sufficient to allow placement evenly
spaced along each side of the building. Avoid placing a bracket at the same juncture of a
down pipe spout/outlet. Straps are attached by frame screws.

The level of the gutter may be slightly varied from one end to the other or may go from the
middle of the building at the same degree of slope to each end. Depending on the position
and number of down pipes it may also be placed at the same level as the building.

To make the outlet of the gutter turn your gutter upside down with the bottom flat showing.
Take the downpipe and trace the outline of the downpipe on the bottom of the gutter. Create
an X within the traced line and cut along the X. Push the cut pieces down to create an outlet
for the downpipe to fit over.

Now fit the stop end to the gutter end with four Aluminium Pop Rivets. Seal the inside of the
stop end with suitable silicone to prevent leakage. Be sure that the stop ends of the gutter fits
neatly under the barge cap at the end of the building.

You are now ready to place the next section of gutter on your building. Allow for a suitable
overlap, cut back 100mm on the top lip of the gutter and slide the second piece of gutter
around the cut piece and place two lines of silicone in the new section at the overlap
point. Ensure the overlap is in the direction of the water flow. Join the gutters with Three
Aluminium Pop Rivets. Follow the same procedure for fixing along the building until the
entire wall is correctly guttered.

38.
Install the downpipe strap on to the top of the ribs of the wall cladding where the downpipe
is placed using frame screws.

Fix the side of the Downpipe to the created outlet with Two Aluminium Pop Rivets. When
joining two downpipes or a downpipe to a shoe. Cut away the corners of the upper most
downpipe by 75mm. Fit the Downpipe/Shoe over the cut pieces and fasten the sides of the
Downpipe/shoe with Two Aluminium Pop Rivets. Ensure the seam is always facing the wall
cladding.

Place the downpipe cleat over the downpipe and secure it onto the downpipe strap
using frame screws. Use a plumb line to ensure the downpipe is sitting straight.

39.
 6. Occupational Health and Safety

Whilst the building is under construction, then the site is a construction site and under no
circumstance should the building be used for storage or any other use. Only construction
personnel properly trained and authorized should be allowed on the site at any time.

You should be familiar with the current workplace health and safety requirements in relation
to acceptable workplace procedures. It is recommended that you check with the appropriate
Authority in your area as to your responsibilities.

The minimum required Personal Protective Equipment (PPE) is mentioned in annexure-3.

For further details please refer SBS EHS Manual.

40.
 Annexure 1 | Portal Measurement Sequence
The set out of your portals requires a five-measurement system. The portal is laid out on your
building site with the Columns in line with your foundation bolts. This gives you a parallel base
point to start from. With your Rafters, Knee Brackets and Apex Bracket attached the portal can
now be measured for height and square. Do NOT over tighten your bolts at this stage, as you
will need to be able to move your frame to achieve accuracy.

Use steel measuring tapes only as nylon tapes stretch.

measurement No 1 = Apex height – sheeting profile height – purlin web height (e.g., 3500mm
+ 25mm – 100mm = 3375mm)

This height is achieved by extending a string line across the bottom of your Columns. From the
middle of the string line measure to your highest point at the apex. This measurement should
be the specified apex height less the height of your roof purlins.

measurement No 2 = Open span c/c + Column web size (e.g., 6000mm + 250mm = 6250mm)
As your columns have been laid out on the ground parallel you now need to check the overall
measurement of your columns outside flange to outside flange. Start at the column base and
measure to the same spot on the opposite column base.

measurement No 3 = Open span c/c + Column web size (e.g., 6000mm + 250mm = 6250mm)
Measurement No 3 is a repeat of Measurement No 2 except that it is made just below the Knee

41.
 Bracket.
measurement No 4 = measurement No 5

To complete the square on your portal you now must measure the diagonals of the basic frame.

Measurements should be made from the furthest points to enable the greatest degree of accuracy.

Mark these points for future reference.

Note the measurement that you have achieved to compare with Measurement No 5.
measurement No 5 = measurement No 4

Measurement No 5 is a repeat of Measurement No 4. but for the opposing diagonal.

NOTE:

Measurement No 4 and 5 must be equal for the portal to be square (assuming the slab is level).

To be valid, the diagonal measurements being taken must be from the same opposing points.

Minor adjustments can be made by moving the Columns and Rafters up or down as required.

If any adjustment is made you must repeat the five measurement system as a final check
before tightening your fastenings or attaching any Knee Braces or Apex Braces.

42.
 Annexure 2 | Glossary
Please note that these terms are only a guide to industry terminology used throughout the
construction kit. Some items may not be applicable to your specific building.

Apex
The highest point being the peak of building.

Apex Brace
Horizontally positioned C-Section used below peak of rafters to assist in rafter section strength.

Apex Brackets
Plate used to join rafters at peak of building.

Back-to-Back - B2B - B/B

This refers to when two C-Sections are joined web to web to form a “H” section.

Barge Flashing
Used to cover the gap between the roof and the end wall sheeting on gable ends. It extends
from over the edge of the roof sheet, and fixes to the face of the end wall or gable sheet, from
apex of building to gutter.

Base Plates - Column Base Plates, EWM Base Plates, PAD Base Plates - RD Base
Plates
Angle bracket used for fixing the columns to the footing/slab

Bays
Reference to the size of the spacing between Columns and/or End Wall Mullions Reference to
bays is end or middle for both the sides and ends.

BOM
Bill of Materials. This contains the quantities, lengths, usage and component descriptions

Sag Rods
Mid Span Bracing fixed to the underside or inside of either purlin, girts or both. Position noted
on the Specification Plan, which bays are required and number of rows.

Columns
The vertical C section of the portal frame that makes up the side walls.

Corner Flashings
Cover material in an ‘L’ shape placed vertically in corner situations.

43.
 Downpipe
Rectangular or round section formed as a conduit for the disposal of rainwater collected in the
gutters to the ground. Each length of downpipe has one end larger than the other to allow for
joining of different lengths.

Eave Purlins
C-Section either C100 or C150. Attached to Rafter top by way of Eave Purlin Bracket. The
brackets project out from the outside Column flange the distance of the Side Girt projection.

Eave Purlin Brackets

Brackets used to attach the Eave Purlins to the Rafter tops. The brackets project out from the
outside Column flange the distance of the Side Girt projection at the eave point

End Wall Girts

These girts are fixed to the outside web of the corner Columns and to the outside flange of the
End Wall Mullions

End Wall Mullions (EWM)

C section used for supporting the gable / dividing wall Rafters and fixing the End Wall Girts to.

End Wall Sheeting

Gable End Wall Sheets (non-gutter side). These need to be cut at the angle to suit the roof
pitch. They are supplied long enough to enable the sheeting to extend past the finished floor
line by 50mm. End Wall Sheets are fixed with Wall Screws in the lower pans of the sheeting to
the End Wall Girts and to the Raking Girt at the top.

Fixing Brackets
A general-purpose bracket for attachment of girts, mullions, headers and other components.

Flange
This term describes the shorter of the two main folded sections.

Hold Down Bolts

Threaded bolts embedded into the slab/footings or Dynabolts. Used to fix (via a base plate) the
columns and/or mullions to the footings/slab.

Footings
Foundations formed with reinforced concrete and placed under each column and mullion.
Footings are placed regardless of whether a slab is being installed but vary in size accordingly.

Frame Screws
Two types – 14.20 x 22 for up to 5mm thickness and 12.24 x 32. for up to 12mm thickness.
These are vital in the building for overall strength.
44.
Gable
The end wall that is peaked. It does not have the gutter attached but is finished off with the
Barge Capping.

Girt (Side Wall Girt, End Wall Girt)

Folded section fixed horizontally to the Columns and Mullions.

Gutter
Fixed to the top of the side walls to collect the roof water.

Gutter Brackets
Fixed to the peak of the wall sheeting or beams to enable the gutter to be fixed in place.

Header Purlin
Double C-Section. Attached to Rafter top by way of Eave Bracket. The brackets project out
from the outside Column flange by the distance of the Side Girt projection. The two C-Sections
are bolted together, with a bracket fastened to the bottom flange.

Knee Brackets
Used for connecting the Columns and Rafters. They are left - handed and right - handed.

Knee Brace
C-Section connecting the Column and Rafters to strengthen the connection.

Mark
A reference marked on some materials to assist with the identification and placement.

Outlet/Spout
Cut into the bottom of the Gutter. Downpipes are fixed over.

Parapet Sheeting
Sheeting on the side wall of the central building above the lean-to roof and below the main
building roof.

Raking Girt
Channel screwed to the bottom exterior edge of the Roof Purlins from the apex to
Gutter. It is placed to allow for the End Wall Sheeting to be fixed at the top.

Rafter
The C-section connected to the column tops both sides and joined at the apex of the building.
On larger building these may be back-to-back.

45.
 Roof Purlin
Folded section attached to the Rafters.

Ridge Flashing
This is the folded flashing, which covers the gap between the Roof Sheets at the ridge or peak
of the building.

Roller Door Jambs

C section used to support the door, fix the roller door brackets and track guides to.

Roof Screws
Fixed through the peaks (ridges) of the sheeting to the purlins. The type and number of screws
varies depending on the wind region, sheeting profile and position on the roof.

Roof Sheet
Sheeting for the roof. Fixed with roof screws through the peak (ridges) of the sheeting and into
the roof purlin/eave purlin. The sheeting extends halfway into the gutter.

Side Wall Sheeting

Long wall (gutter side) sheets. These are supplied approximately 50mm longer than the eave
height of the building to enable the sheeting to extend past the finished floor line. Wall sheets
are fixed with Wall Screws in the lower pans of the sheeting to the Side Wall Girts.

Slab
Refers to a concreted area of a minimum reinforced thickness on which to construct the
building. A slab can be a partial area or full sized. A partial slab can be combined with other
types of foundations for the remainder of the construction.

Stop Ends/End Caps

Fixed to the end of the gutter in opposing pairs.

Wall Screws
These are smaller screws and fixed in the lower pans of the sheeting.

Web
The largest exterior flat side of C-Section and Z-Section.

46.
 Annexure 3 | Personal Protective Equipment (PPE) Matrix

S. No. Activities PPE Requirements

1 2 3 4 5 6 7
Safety Safety Safety Reflection Hand Welding Goggles
Helmet Shoes Belt Jacket Gloves Shield

1 Anchor bolt Casting

verification by
engineer/supervisor
√ √
2 Unloading of Material
from trailer
√ √ √
3 Shifting of Material √ √ √ √
4 Assembly of Structure √ √ √ √
5 Structure Erection
(Person working
at Height)
√ √ √ √ √
6 Alignment of
building (Person
Working at Height)
√ √ √ √
7 Alignment of
building (Person
Working at Height)
√ √ √ √ √
8 Welding (Person
Working at Height)
√ √ √ √
9 Cutting (Flame/
Mechanical) (at Ground)
√ √ √ √ √
10 Cutting (Flame/
Mechanical) (Person
Working at Height)
√ √ √ √ √ √
11 Electrical Work
(at Ground)
√ √ √ √
12 Electrical Work (Person
Working at Height)
√ √ √ √ √

47.