Installation guidelines System: Cofraplus 220

Transcription

1 Edition: February 2012 Installation guidelines System: Cofraplus 220 ArcelorMittal Construction International Industriestrasse Otelfingen / Zürich Switzerland

2 Summary 1. Basic principles Documentation Building site conditions Lifting the material Packaging and storage on site Un-packaging Protective film Safety General rules Inspection of existing works Inspection of installation work Structure alignment Installing the profiles sheets Cutting and drilling during installation Cutting Drilling Anchoring, fixing and connecting the profiles sheeting during installation General Fixations and how to fix Screws Cartridge-fired pins Blind rivets Considerations System fixation description Handling bundles and sheets Installation Installation on wings Wings type Wings type Installation on Connectors* (slim floors) Connectors with tubes Connectors without tubes Modular connectors Width of support Propping Fixings and connections Overlaps Side laps End lap Direction of installation Securing for uplift Design of flashings Disclaimer note ArcelorMittal Construction International Page 2 of 20

3 1. Basic principles Every project has requirements according with national and local regulations. These regulations must be taken in consideration for the calculations in order to select the thickness of the profile and slab, and defining the reinforcements. Safety may fail if not properly selected. Before ordering any material, it must be checked that the selected system performances are in accordance with the requirements for the project Load bearing of the system 1.2. Fire behaviour 2. Documentation For any project it is necessary to prepare a basic documentation to verify that the building can be erected in accordance with client s performance requirements: Installation drawings with the layout of the floors and indications about the position of any profile and the direction of installation should be a must before starting the erection. Details showing how flashings should be positioned, sealed, and fixed. Cutting list to have a reference of the materials we have ordered and ease following of the layout 3. Building site conditions A necessary task that can save time and money during the erection of the building is to do a visit to check: Site is in conditions to receive and storage the materials properly Free space to place and move the cranes, platforms, scaffoldings, etc. Safety measure can be installed ArcelorMittal Construction International Page 3 of 20

4 3.1. Lifting the material Bundles must be handled properly to avoid damaging the material. Bundles can be handled with: Sling belts. They must be properly placed to avoid sliding on the bottom of the bundle; pallet can be used for this issue, and edge protection on the top of the bundle. See image Sling belts and spreader beam for bundles longer than 10 meters can be used. The sling belts must be secured to the bundle reinforcements to lift the panels. Fork lift 3.2. Packaging and storage on site It is recommended to install the materials as soon as the bundles arrive to the works site. However, some rules must be taken in consideration to keep them at job site since the time they arrive till installation. Avoiding the retention of water between sheets and panels is a must to avoid corrosion. ArcelorMittal Construction International Page 4 of 20

5 Bundles must be stored with a slop of 1% to facilitate the evacuation of the water. Bundles must be covered with a tarpaulin to reduce the accumulation of sand and dirty that can scratch the profiles when they are handled. This cover can not be used for long term storage. The tarpaulin must be air-permeable and it must be secured against wind. Under no circumstances must the bundles be covered with just a plastic sheet and left outside. The materials must be distributed on site as close as possible to the area where they will be installed. Bundles can not be stacked on top of each other on the construction site. They can be delivered stacked but they must be unloaded and stored separately When lifting the bundles to the roof, you must secure them to avoid sliding sheets or panels. Before leaving bundles on the roof, you must check with the contractor that the structure can support the bundled weight Un-packaging When you unpack the materials you have to take care about the risk of displacements of the materials or up-lifting them due to the wind action. Waste material has to be taken to the proper place to avoid dirty and risk of accidents Protective film Coated products are supplied with a removable protective film to prevent mechanical damage during transport and assembly. This film must be removed 15 days after outside storage exposed to weather and/or immediately after installation, whichever is soonest. Of course, it can be also removed just before installing the product if it facilitates the work. ArcelorMittal Construction International Page 5 of 20

6 4. Safety The work site must have the collective protective measures installed properly before starting the works; as safety net fall arrest system and access points. These protections must be defined according with the requirements of the safety project (risk assessment) created by the General contractor. Employees must be equipped with the individual protections appropriated for the job that they are doing. Some of the protections are: helmets, gloves, boots, harness, etc. Sheets can be used as a work platform once they have been fixed. It is forbidden to circulate on sheets that have not been fixed. 5. General rules 5.1. Inspection of existing works Before starting the installation, it is necessary to check the works and analyze if there are deviations in the existing works (structure alignment, dimensions, etc.) that could concern your own works and stop you installing materials properly Inspection of installation work Your own works must be inspected regularly to verify that all the works are being developed according with the manufacturer s instructions and the construction rules. When works are done professionally, we all will get the customer satisfaction and reducing the claims. The checking list documents provided in this document can help to do it Structure alignment If the structure is not properly aligned, the floor will not be flat or concrete will not be properly spread. When defects in the alignment, etc. the contractor should correct the defects or installing a substructure prior starting our works. ArcelorMittal Construction International Page 6 of 20

7 5.4. Installing the profiles sheets Profiles have to be installed according with the layout drawing prepared for this job. It must be done in the direction indicated in the drawings. Before interrupting the day works, profiles must be secured to avoid uplift due to the wind action. 6. Cutting and drilling during installation 6.1. Cutting Sheets can not be cut with abrasive tools. Most kinds of saws are suitable to cut steel sheets and panels if they don t burn the material as abrasive tools. Metal shavings have to be removed from the area to avoid adverse optical and warranty issues. During the cuts, the area where the saw tool can scratch the sheet must be protected Drilling Metal shavings from these operations have to be removed to avoid optical and warranty issues. 7. Anchoring, fixing and connecting the profiles sheeting during installation 7.1. General Depending on the final use of the sheet/panel, its dimension and the supporting structure, several fixings systems can be used. Fasteners must have an appropriate corrosion protection for the environment where the buildings are located. Installation and dimension of the fasteners is described in the next points ArcelorMittal Construction International Page 7 of 20

8 7.2. Fixations and how to fix The next points will describe the possible fasteners, how they must be fitted and the field of application Screws Screws can be used to fix cladding sheets or panels, composite floors, decking roofs. Two types of screws are acceptable: Self-drilling Self-tapping Tools, power and speed must be fitted according with the technical recommendations of the screw manufactures. In the case of self-tapping screws, the diameter of the hole must be in concordance with the instruction of the screw manufacturer to keep the loadbearing capacity. If the screws have a sealing washer, it is recommended to use a depth stop to keep the waterproof properties. No water tight Correct Too tight Oblique Cartridge-fired pins Cartridge-fired pins can be used to fix composite floor decks, decking profiles or trays. These elements are not recommended for cold roofs due to water tightness These pins can be used if the steel structure has a minimum thickness of 6 mm. Gun and the colour code of the cartridge must be selected taking in considerations the structure thickness and the recommendations of the cartridge manufacturer. Check of protusion Correct ArcelorMittal Construction International Page 8 of 20

9 Blind rivets Blind rivets can be used for stitching two sheets together for side laps, flashings, etc. Load-bearing capacity and diameter of the drilled hole must be considered from the recommendations of the rivets manufacturer Considerations Expansion and contraction of the materials due to the changes of temperature must be taken in consideration when the type of fixation is decided. Our technical assistance can support you to choose the right fastener and indications about how to install it properly. ArcelorMittal Construction International Page 9 of 20

10 8. System fixation description 8.1. Handling bundles and sheets Bundles must be positioned as close as possible to the place where sheets will be fixed. Distribution of bundles on the steel structure As sheets use to be shorter than the distance between beams, packing timbers can be use as supported elements when necessary. Sheets are packed at reverse position as they will be positioned. Prior installation, decking operative will turn back every profile while they stand on the top flange of the beam at either end of the first bundle of decking. Turning sheets on site Once the sheet is turn back, it will be positioned onto the beam Installation Every system has its own way of installation. In this case, you must follow the recommendations below: Fixation of the steel sheet with the necessary fasteners according with calculations There are two possible ways of installation, each of them with some variances. ArcelorMittal Construction International Page 10 of 20

11 Installation on wings Wings are used when the depth of the beam is much higher than the depth of the profile. Installation on wings Once consecutive profiles are adjusted, they are fixed from underside (optical reasons) with screws type SFS SD5 H15 of 5.5 x 25 (or equivalent) at each wing foot 1 fastener (e.g. drill screw type SFS SD5 H x 25 mm at each wing foot) To ensure the resistance of the profile two additional fasteners must be fixed at each side of the wing. 1 fastener: drill screw SFS SD5 H x 25 mm at each side of the Wing fixed at the mid of the stiffener must be obligatory used ArcelorMittal Construction International Page 11 of 20

12 There are two types of wings. Difference will be the relative position versus top flange of the beam. The selection of each type depends on the necessary concrete slab thickness on the beam to create a composite beam Wings type 1 When wing type one a Z sealing profile must be installed at the top end of the sheets to close the gap Wings type 2 When Wing type 2 is used, Z sealing profile is changed by a Sealing strip Sealing strip ArcelorMittal Construction International Page 12 of 20

13 8.3. Installation on Connectors* (slim floors) Connectors are used to create slim floors. In these cases, profiles and beams have similar depth and Cofraplus 220 will lay on the bottom flange of the beam. We can supply 3 types of connectors Connectors with tubes This connector must be fixed to the bottom flange of the beam before installing Cofraplus 220. Each connector must be fixed with 3 heavy duty shot-fired nails type Hilti X-ENP-19 L15 (or equivalent) per connector Heavy duty shot-fired nails e.g. Hilti X-ENP-19 L15 Number of fixing: 3 Once connector is fixed, the three sheets will be adjusted as indicated for wings and fixed with similar shot-fired nails to the flange of the beam. The nominal bearing width is indicated further. Cofraplus 220 will also be fixed to the connector as indicated in the next two images. * Connector will be the denomination for the end diaphragms in this document ArcelorMittal Construction International Page 13 of 20

14 If possible, connectors can be installed onto the steelwork in advance of its erection. This method must be discussed with the Contractor. e.g. drill screws SFS SD5- H x 20mm First, it is fixed on its rib crown on each tube of the connector with the indicated screws. Immediately after it, Cofraplus 220 is fixed on its rib crown to the upper lip of the connector as indicated in next image e.g. 2 drill screws SFS SD5 - H x 20mm per rib crown at third Top lip ArcelorMittal Construction International Page 14 of 20

15 Connectors without tubes As previous connector, it must be fixed to the bottom flange of the beam with similar shot-fired nails Once the three consecutive sheets are adjusted as previously indicated, they are fixed with a shot-fired nail to the bottom flange of the beam. Next step is fixing Cofraplus 220 to the top lip as indicated in the next image. e.g. 2 drill screws SFS SD5 - H x 20mm per rib crown at third Modular connectors We recommend fixing these connectors before turning sheets to the right position. This work can be done on the floor, before lifting the bundle to the floor or on a work platform once some profiles have already been fixed. As it is indicated in the next images, we must follow the next steps: Installation of the sealing tape to Cofraplus 220 Fixation of the connector with 6 screws as indicated in the image Turning down Cofraplus 220 to the right position of installation Lifting or moving to its position on the floor Fixation of the elements with shot-fired nails ArcelorMittal Construction International Page 15 of 20

16 Sealing tape e.g. 6 drill screws SFS SD5 - H x 20mm Turned down Adjusting 8.4. Width of support Width of the support must be confirmed according with the product we are using and, material of the structure and the wind loads In general, you can consider that for steel structure we need a nominal bearing of 50 mm with a minimum of 35 mm 8.5. Propping Cofraplus 220 has been designed to support high loads on high spans. However, some times it is required by the project larger spans or higher loads than for standard projects. ArcelorMittal Construction International Page 16 of 20

17 In such cases, the use of props can be required after calculating the floor. For these cases, we have designed a special template that can be sold or hired per project. These templates are screwed to the timber elements that will be used for propping and positioning under Cofraplus 220 as showed in the next images. Placing the supporting templates in zigzag to equilibrate the bearing timbers 8.6. Fixings and connections The number of fixings has been calculated to ensure the resistance of the floor to wind actions before pouring the concrete and the actions when concrete is being poured. ArcelorMittal Construction International Page 17 of 20

18 The selection of the fasteners has to be done according with the thickness of the structure and the grade of steel if the indicated fixations are not being used. All the fixings must be protected against corrosion, stainless steel or bichromium protection Overlaps Side laps Profile is asymmetric. There is a small and a big side. Small side is indicated with a tape as showed in the photo. Small side will lay on the big side when installing. Small Stitching is necessary. For aesthetical reasons, we recommend to stitch from underside. Stitching fastener (e.g. screw SFS SL2-S 4.8 x 20mm) ArcelorMittal Construction International Page 18 of 20

19 End lap End lap is not applied on these profiles. They are installed as single span configuration. See Installation on wings and connectors Direction of installation Even if it is not a must for this product we recommend that installation must be done in the direction of the predominant winds. Every product has its own direction of installation and must be consider before starting installing it. Design span length Design span length H005 Standard edge abutment H006 H007 H008 H003 Edge trimmer beam H003 H010 H004 External support beam H011 Internal support beam External support beam H004 Standard end abutment H009 H012 Standard end abutment Edge trimmer beam H005 Standard edge abutment H006 H007 H008 ArcelorMittal Construction International Page 19 of 20

20 8.9. Securing for uplift Products must be fixed as soon as they are placed on the roof or façade to avoid any uplift due to the action of the wind. Before interrupting the work, it is necessary to check that all the products are properly fixed and the bundles are also fixed with some straps to avoid risks of falling materials Design of flashings Flashings must be designed to keep the poured concrete on site. The size of the flashings depends on the slab thickness. As it will vary depending on the main frame, consult us for the right design in every case. 9. Disclaimer note This document is a standard-guideline for the handling and installation of our product and may be subject to revision for each individual project. ArcelorMittal Construction International Page 20 of 20