Installation Guide. This installation guide is furnished as a supplement to the project specific panel installation drawings.

Transcription

1 Installation Guide This installation guide is furnished as a supplement to the project specific panel installation drawings. Note: Variations from the contents of this guide can occur because of project specific requirements and subsequent engineering changes. Always refer to the panel installation drawings, supplied with your order, governing specific part and assembly procedures and applicable installation details.

2 TABLE OF CONTENTS SAFETY GUIDELINES 1 HANDLING PANELS 1 Unloading and Storage 1 HANDLING MATERIALS 2 Hardware, Fasteners and Foam Storage 2 TOOLS AND RELATED MATERIALS 2 FASTENERS 3 Panel Fasteners and Tools 3 Shiplap Fasteners 3 Panel-to-Structural Fasteners 3 Panel-to-Track Fasteners 3 HARDWARE 5 WALL SYSTEM GENERAL INFORMATION 6 The tekr Panel 6 PANEL INSTALLATION 7 Track Installation 7 Installation Procedure 8 Track Connection 12 Girt Connection 13 Installation of Panels on Multiple Levels (Stack Joint) 14 Roof Connections 15 DOOR AND WINDOW INSTALLATION 16 Door and Window Openings 16 Sealing and Damp Proofing 18 Wiring and Plumbing Installation 18 FINISHING 20 Exterior Finishing 20 Interior Finishing 21 GENERAL INFORMATION 22 Load Bearing Buildings 22 Load Bearing Panel Installation 22 Support 22

3 SAFETY GUIDELINES Safety must be a concern throughout the installation process. This guide contains safety information that is important for all workers to know, understand and follow. It is not possible to present complete and comprehensive safety instructions in this guide. All local, state and O.S.H.A. safety regulations must be followed at all times. The installation contractor has the ultimate responsibility for the safely of workers and must comply with all applicable safety regulations. The Occupational Safety and Health Act regulations, applicable to the erection of this or any other building, are identified as Part 1926, Safety and Health Regulations for Construction. They are available online or from a government bookstore. The O.S.H.A. Regulations should be recognized as a job site requirement. Failure to do so may result in death, injury or substantial fines. This is the safety alert symbol. When you see this symbol in this guide be alert to the potential for personal injury. Follow all recommended precautions and safe practices to avoid injuries. Follow Safety Instructions and Warnings. Carefully read all applicable installation drawings and follow all safety and warning messages in this guide. HANDLING PANELS Unloading and Storage Your material is carefully inspected, loaded and accepted by the transport company before leaving the tekr manufacturing plant. It is the carrier s responsibility to deliver the shipment damage free. It is the consignee s responsibility to inspect the shipment for loss, damage and shortages when it is delivered. Instructions for material inspection and handling are supplied with the consignment. Panels arrive on wrapped pallets that are 50 wide, 8 tall and up to 18 long. When loading or unloading panels from a truck use a forklift with a minimum fork length of 60 and a fork separation of at least 60. Lifting capacity should be at least 4,000 lbs. If panels need to be removed from a stack, use a load distribution device, such as a pallet or sheet of plywood, to avoid damage to the panels. Do not allow tekr panels to rest directly on the ground. When installing the panels, handle the panels by the exposed metal stud at the top and bottom to avoid damage to the polystyrene insulation. Do not use the side ship-laps to lift the panels as this can cause the internal EPS bond to break causing localized delamination of the panels. CAUTIONS: Always wear gloves when handling panels. WARNING: Carrying a panel in windy conditions is extremely hazardous. Panels may act as a sail throwing workers off balance and result in possible injury. Always secure loose panels to prevent wind damage. 1

4 HANDLING MATERIALS Hardware, Fasteners and Foam Storage All building materials used for the wall installation should be checked, separated, and stored in a dry protected area to ensure they are not damaged, stolen or lost. Each tekr panel is labeled with a unique panel number on the bottom stud for a specific location. Be sure to place materials so they are near the area of intended use to with the panel labels facing the structure to eliminate unnecessary handling. Always ensure that the label on the bottom of the panel is placed down in the base track during installation. TOOLS AND RELATED MATERIALS Ensure that proper tools, in good repair, are on hand before starting panel installation. An inefficient drill motor, lack of tools, inadequate power source or other equipment deficiency will slow down the entire crew and increase the time required to install the panels. The cost of lost time is greater than the cost of providing proper well-maintained equipment. The installation procedures shown in this guide require the following tools and materials: Adjustable clutch electric screw gun with 3 /8 hex sockets and a 6 or 8 extension Self-drilling fasteners (#14 x ¾ ) supplied with your order Self-drilling fasteners (off-set girt fastener) (2 ½ or 3 ½ ) supplied with your order Powder actuated nail gun or hammer drill for base track installation. 4 level Chop saw Reciprocating saw Hand held band saw Steel tape measure Hand Laser Chalk line Gloves Foam Hot Knife Appropriate safety equipment 2

5 FASTENERS The shipping manifest will list the quantity and type of wall fasteners supplied with your order. The fastener locations are shown on the wall panel layout drawing details. Always check the type and quantity of supplied fasteners against the shipping manifest. Panel Fasteners and Tools Shiplap Fasteners (supplied with your order) Part # 420 Type: Self drilling fasteners (#16 x 1 ¼ ) Required tool: Adjustable clutch electric screw gun with appropriate hex head drive & extension Note: Use a depth locating or torque control electric screw gun to drive self-drilling screws. High RPM ( RPM) drivers are necessary to attain optimum speeds and high tool amperage (4 to 7 amps) is required to achieve the proper torque to secure the fasteners. Panel-to-Structural Fasteners (supplied with your order) Part # 405 and 410 Type: Self drilling screw or other offset screw (# ½ or 3 ½ ) Required tool: Adjustable clutch electric screw gun with appropriate hex head drive & extension Panel-to-Track Fasteners (supplied with your order) Part # 415 Type: Self drilling screw or other offset screw (#14 x ¾ ) Required tool: Adjustable clutch electric screw gun with appropriate hex head drive & extension Note: Use a depth location or torque control electric screw gun to drive self-drilling screws. High RPM ( RPM) drivers are necessary to attain optimum speeds and high tool amperage (8 to 10 amps) is required to achieve the proper torque for securing fasteners. 3

6 FIGURE 1 Fasteners Do not overdrive fasteners! Use drivers with the torque control set to function properly for the combination of fastener size and material thickness. 4

7 HARDWARE The shipping manifest will list the quantity and type of hardware supplied with your order. The hardware locations are shown on the wall panel layout drawing details. Always check the type and quantity of supplied hardware against the shipping manifest. FIGURE 2 Hardware 5

8 WALL SYSTEM GENERAL INFORMATION The tekr Panel The 4 wide tekr panel is the standard building block of the system. The panel has a shiplap on each side of the panel. The orientation of the panels is alternated to mate the metal of the shiplaps together enabling a positive steel-to-steel connection. The panels are connected together using #16 x 1 ¼ self-drilling screws on 2 centers. White diamonds are located at 2 intervals on the panels to allow for quick screw spacing. In some cases local conditions may require the structural engineer to specify less than 2 screw spacing. Custom width panels are often required for a project. Custom width panels are made to specific widths greater than 2-0 and less than the standard 4 wide panels. The panels are marked with a unique panel number on the bottom stud and must be installed in the designated location and orientation marked on the installation drawings. The face of each panel is marked to locate the high and low ribs of the structural corrugation (see figure 3 below). This allows fast installation of cladding materials. For special width panels the corrugation pattern will vary from the surface indication. A simple probe of the panel with a screwdriver will accurately locate the high and low ribs in this condition. FIGURE 3 Panel Markings 6

9 PANEL INSTALLATION Track Installation The method of track installation is dependent on the engineering requirements and design of each project. However, the general steps outlined below are applicable in most situations. It is critical to ensure the footing for the track is level for proper installation of the panels. However, the panel design allows for minor field adjustments if required. Install the 18 gauge galvanized steel base track (color-coded yellow) specified by the project s engineering specification. Secure the track using fasteners as specified by the engineer of record for the project. Note: Fasteners for the track to foundation attachment are not provided by tekr in your order. Continuous beads of water resistant sealant are recommended between the concrete and track. Note: Sealant is not provided by tekr in your order. 7

10 Warning: Always wear protective clothing and eye and ear protection when using powder actuated nailing or other fastening systems. The objective of OSHA Standards is to protect the worker from injury or illness. Identification of specific requirements for installation is beyond the intent of this guide. Safe installation practices may be further defined and made mandatory by state and local ordinances. Maintenance of good housekeeping on the jobsite is recognized as being most important to both OSHA compliance and to successful job completion. Installation Procedure tekr installation drawings often reference the Structure Line (SL) of a building. Accurately locating this structure line and transferring it to your footing or slab is required to determine bottom track location. tekr recommends the use of a single axis hand laser for quickly and accurately locating your structure line. tekr construction drawings include a Builder s Check Dimension to speed up panel installation. Builder s Check Dimensions must be marked on the inside center of the track to assure proper spacing of the panels after the track is installed. The dimensions are shown on the installation drawings and correspond to the centerline of the panel s shiplap joint. Typically, installation starts at the corner of the building. There are four standard corner orientations (see figure 5). It is critical to use the corner orientation called for in the details (circled detail) on the installation drawings. 8

11 FIGURE 4 Corner Isometric Detail FIGURE 5 Corners Detail 9

12 Install the short leg of the corner connector angle to the shiplap of one of the panels while lying on a flat surface and then tilt it into place. Check the panel for true and plumb after the panel is in position. Secure the panel to the base track. Then tilt the adjacent corner panel into the base track and slide it into position. Check the panel for plumb and secure it to the corner angle and then to the track. The base track is designed to allow for play so that panels are easily slid into place. To assure a coplanar wall surface the panel to track connection should always be made from the same side. tekr recommends that these fasteners be installed on the outside of the track where possible. tekr panels are wrapped onto the structural steel to avoid surface irregularities and to compensate for minor variances of the structural steel components. The screw sequence shown below is critical to properly install the panels. Most post installation surface irregularities are due to improper screw sequences. The standard 4 panels have a mark at the edge of the panel on 2 centers to help locate screw locations without having to measure the centers (see figure 6). Install the next wall panel in from the corner by sliding it into place. Check the panel for level and spacing then stitch the panel-to-panel connection beginning at bottom of the panels and work towards the top. Always start the stitching procedure at the bottom of the panel. Never start the stitching procedure in the middle of the panel, as it will result in a shiplap screw not making a solid connection with the opposite panel s shiplap. Do not make a connection to the base track until the next panel is set in place and connected from the bottom to top of the shiplap. This method allows the panels to be slid into place without fighting the track connection. Typically a misalignment of the panel face is due to the shiplap screw not being properly installed and blocking the panel joint from proper alignment. Once the panel is attached at the shiplap, panel-to-panel fasteners at base track, girt and eave strut may be completed (in that order) on the corner panel. This eliminates any misalignment of the surface from one panel to the next. Always start at the end of the panel and work in the direction of installation. Do not fasten the second panel to the structure until the third panel is stood and fastened to the shiplap of second panel. Note: Remove any screw that fails to successfully connect panels before installing any additional fasteners. Failure to remove these fasteners will lead to a misalignment of the panels. Note: Use adequate temporary bracing to avoid wind damage and to make sure the walls are plumb if used in a self-supporting load bearing situation. 10

13 FIGURE 6 Fastener Sequence 11

14 Track Connection Attach the bottom of the first panel installed to the base track using self-drilling screws on the outside of the building at a maximum spacing of 1-0 on center. This step must be done at least one panel behind the one being installed. All screw sizes and patterns require verification by the project engineer to meet local conditions. Always attach the panels to the track from the outside. The track is oversized relative to the panel bottom stud allowing the panels to slide easily in the base track for installation. The wall will not stay flush if the connection is made from alternating sides. A top track similar to the base track is used in load bearing situations or on walls with parapets. The top track is attached to the top of the panels using the same recommended screw size and spacing for the project. FIGURE 7 Base Detail (N.B.T.) Not By tekr 12

15 Girt Connection tekr panels, using the supplied offset fasteners, are attached to all girts or structural members with a minimum of 4 fasteners in each 4 wide panel section. FIGURE 8 Girt Detail In order to locate the optimum positions for the screw installation follow the simple instructions below: 1. Mark the outside of the panel with a chalk line centered on the midpoint of the girt face and chalk line on the previous panel. 2. Locate the panel makings on the face of the panel. 3. Horizontal lines indicate the location of the high rib of the corrugation (for special width panels the high rib is located with a screw driver or other probe) 4. Vertical lines indicate the location of the deep rib of the corrugation pattern. Please note that the vertical lines also include the diagonal section of the corrugation pattern. The diagonal rib of the corrugation is always 1 ½ wide starting at the end of the horizontal markings. For ease of location the line spacing for both horizontal and vertical is ½. Simply move in 3 vertical lines from either side to locate the flat segment of the deep rib (for special width panels the high rib is located with a screw driver or other probe). 5. Using a screw gun, with the supplied hex head extension, push the screw through the foam until it locates the steel core. Once the core is located, drive the screw through the panel and into the girt. Make sure that the clutch setting on the gun is set to stop when the offset screw is seated in the girt. To avoid burning off the tips girt screws require extra force and lower speed drivers to allow for thicker steel connection points. 13

16 Installation of Panels on Multiple Levels (Stack Joint) Where walls are greater than 18 high the tekr panels can be stacked using the factory supplied H track. The following installation sequence is recommended: Install the lower panels and attach to the girt (as described previously). The H track (supplied in 12 foot lengths) is attached to the top of the lower panel using #14 x ¾ hex head screws at 1 foot on center (sealant can be applied if required). The upper panel is lifted into position and secured at the girt using the supplied offset fasteners (using the same spacing as a normal girt connection) and to the H track from the outside of the building. Warning: Ensure that suitable precautions are taken for the weight, size and prevailing wind conditions during installation of panels on multiple levels. FIGURE 9 Stack Joint Detail 14

17 Roof Connections Below are examples of typical panel connections and roof trim details. FIGURE 10 Gable Detail FIGURE 11 Eave Detail FIGURE 12 Parapet Detail 15

18 DOOR AND WINDOW INSTALLATION Door and Window Openings All door, window, and utility rough openings are pre cut at the factory eliminating field modifications and jobsite waste. Should a change be required after panels are shipped, modifications can be made. For field modifications we recommend you contact tekr directly to review the proposed changes. We can then send our recommended details for the modifications described. Note: Load bearing buildings will require a local engineer to approve the panel design. Based on local conditions the engineer may require the adaptation of headers and/or structural support. Panel sizes and locations are detailed on the installation drawings supplied. Details for weatherproofing and finishing the door and window openings are available on the Senergy website FIGURE 13 Type A Door Installation 16

19 FIGURE 14 Type A Window Installation FIGURE 15 Type B Door Installation 17

20 FIGURE 16 Type B Window Installation Sealing and Damp Proofing Always apply a waterproof sealer prior to backfilling in any below grade applications. A local coating applicator can advise you on the types and installation of suitable sealing materials. Wiring and Plumbing Installation tekr panels are designed to simplify the installation of chases for wiring and plumbing. There are no restrictions on the number or size of channels that can be cut into the face of the panels. The structural integrity of the panel is not compromised by the removal of small sections of foam for wiring or small box installation. The majority of plumbing is run in interior walls where insulation is less critical. However, the foam insulation can be removed to accommodate the piping should it be necessary to run plumbing in the exterior wall. 18

21 FIGURE 17 Electrical Detail FIGURE 18 Plumbing Detail 19

22 FINSHING Exterior Finishing The tekr system is designed to accept any type of exterior finishing. Acrylic stucco systems can be direct applied to tekr panels reducing the wall preparation time, and installation cost, making stucco and acrylic finishes cost competitive with the more traditional finishes. The lack of a cavity in the tekr system reduces the possibility of mold growth within the wall. Direct applied stucco systems are not considered EIFS. FIGURE 19 Cutaway For metal skins or other non-stucco claddings a Z-strip is often specified to make applications of those systems more efficient while maintaining a thermal break. 20

23 FIGURE 20 Z-Strip Detail Important note: Acrylic finishes when applied to the tekr panel are not classed as an EFIS assembly. Therefore, tekr is not subject to the same insurance restrictions as EFIS finished on stud framed walls. Consult your local Senergy coatings representative to provide correct installation details and answer any coating application questions. Foam fillers are necessary at certain locations after panels have been installed. These areas include the exterior base and top track face, exterior stack joint face, and exterior corner connections. These foam fillers are not supplied as a part of the panel order. This is usually handled by your insulation installer. When installing windows and doors, some exterior infill may be necessary based on the type of finish being applied to the panel. Interior Finishing Fire codes require EPS foam to be covered to protect personnel during a fire. Gypsum Board (½ thick) is a cost effective covering in many cases. FRP is often used in high moisture environments. Panels are marked to easily locate the high rib of the corrugation pattern for the interior cladding installers. 21

24 GENERAL INFORMATION Load Bearing Buildings When tekr panels are used for load bearing applications, engineering of the building is the responsibility of the customer s structural engineer. Load Bearing Panel Installation Installation of load bearing panels follows the same fastening sequence as earlier described in this guide. In lieu of fastening the panel to structure, fasten panel to wood or metal plate, to which you fasten temporary braces. Braces must remain in place until roof trusses are on and roof sheeting (OSB or decking that is transferring load from roof to wall) is installed. Top track, similar to base track, must be installed on top of panels prior to nailer plate and truss installation. FIGURE 21 Temporary Bracing Detail For both wall and roof applications consult the provided load tables to make sure the panels are able to carry the wind and snow (live) loads. Support For additional information contact tekr (208) info@tekr.com 22