Tata BlueScope Steel BUTLER INDIA Erection Manual

Metal Building - Erection, Installation

andMaintenance Manual

The Metal Building Erection, Installation and Maintenance

Manual has been prepared to assist builders in order to erect

buildings properly, quickly and safely.

This manual consists of brief outline of building terminology,

safety, tools required for installation of Pre- engineered building,

engineering documents, anchor bolt setting, material handling

and storage, and building maintenance. It also coves erection of

primary and secondary structures which includes column,

rafters, Purlin, grits, and roofing and walling sheeting.

The erection information presented in this Manual is provided as

a supplement to the erection drawings supplied with Building.

This Manual is intended as a guide, to be used in conjunction

with erection drawings, to help plan and organise installation

work at site. It will help to identify parts, establish a safe erection

sequence, speed up assembly and point out any areas or

procedures requiring special emphasis or attention. The building

erection drawings will always govern with regard to construction

details and specific building parts.

It is strongly recommended that before begin, familiarise with all

the building components and connection details as well as the

sequence of erection. This will help to plan the work and avoid

unnecessary delays during erection.

The builders who refer to the contents of this manual must pay

regard to current regulations for site safety. The builders are

responsible for maintaining strictly the current legal regulations

of labour safety during erection of buildings.

In line with quality objectives and quest for excellence,

Tata BlueScope Steel is now seeking long-term relationships

with qualified builders to provide the best & safest steel building

erection service to our customers.

Introduction

Part 1 - Tata BlueScope Steel

1. Metal Building Terminology 2

2. Built-Up Framing System 8

3. Roofing, Wall Cladding and Structural Decking 12

Part 2 - Metal Building Erection

4. PPE and Erection Tools & Equipments 15

Tools and Quantity

Erection Tools & Equipments

Mobile Equipments

Slings

Scaffolding

ELCB Box

Hand Tools

Tips on Gas Cutting, Welding and Grinding

5. Understanding Engineering Documents 30

Anchor bolt setting plan

Cross Section

Roof Framing Plan

Roof Sheeting Layout

Sidewall Sheeting and Framing

Other Drawings

Shipper List

6. Foundation and Anchor Bolts 32

Guidelines of Setting of Anchor Bolt

Diagonal method

Right angle (3-4-50 method)

Theodolite method

7. Material Management at Site 34

Procedure

Material Storage

8. Frame Erection Procedure 38

Pre Lift Check List and Meeting

Framing Sequence

Secondary Structural Connections

Part 3 Sheet Installation

9. Roof and Wall Cladding Panel Installation 59

Wall Cladding Installation

Roof sheeting installation

10. Installing Pierced fixed Cladding 65

General Installation Procedure

Side-lapping & Positioning Pierced-fixed sheets

Pierced-fixing on Valleys (for Walling only)

Pierced-fixing on side-laps

11. Installing Concealed fixed Cladding 68

Installing KLIP-LOK™ roofs

Installing KLIP-LOK™ walls

12. End of Sheets 71

13. Flashings 74

14. Insulation 76

Wall Insulation

Storage of Insulation Roll

15. General Care, Safety and Handling 78

Safety

Care and Storage before Installation

Handling Cladding on Site

Walking on Roofs

Marking out, Cutting and Drilling

Clean Up

Warn other Contractors

Sealants

Maintenance

Part 4 Building Maintenance and Recommendations

16. Claims 82

17. Tolerances 84

18. Building Maintenance 92

Safety

Maintenance of Building Exterior

Gutter Maintenance

Downtake Pipe Maintenance

Penetrations, Flashings, Cappings

Roof Sheeting Maintenance

Maintenance of Accessories

19. Annexure 96

Content

Manufacturing Facility: Tata BlueScope Steel, Bhiwadi

Manufacturing Facility: Tata BlueScope Steel, Chennai

Manufacturing Facility: Tata BlueScope Steel, Pune

Tata BlueScope Steel Limited is an INR 12 bn equal joint venture

between Tata Steel Limited and BlueScope Steel Limited. The

company has three manufacturing facilities consistently

delivering world class services and products. The Building

Solutions manufacturing facilities are based at Pune, Chennai

and Bhiwadi. With four regional offices and 20 sales offices the

Building Solutions Business is on a growth curve. The Building

Solutions facilities at Pune, Bhiwadi and Chennai have been

operational since August, December 2006 and January 2007. In

these facilities, top-of-the-line equipment from leading suppliers

all over the globe has been used. The Coated Steel

manufacturing facility will be operational from the first quarter of

2009 at Jamshedpur. The Jamshedpur facility will have an

annual metallic coating capacity of 250,000 tonnes and paint line

capacity of 150,000 tonnes.Tata BlueScope Steel Limited offers

a comprehensive range of branded steel products for building

and construction applications, including the premium

ZINCALUME® steel, COLORBOND® steel, LYSAGHT™

Cladding and BUTLER™ BUILDING SYSTEMS. All our facilities

are architecturally designed to showcase our leading product

brands. The plant building is a BUTLER™ BUILDING

SYSTEMS, truly representing 100 years of experience in

pre-engineered metal buildings. The LYSAGHT™ Roof and Wall

Cladding has been manufactured from COLORBOND® steel

and ZINCALUME® steel that adds to the aesthetic appeal of

these buildings. Tata BlueScope Steel Limited is annunciating a

revolution by “Creating Your New World”.

Tata BlueScope Steel

1

Administration Building, Tata BlueScope Steel, Pune

ACCESSORY: An extra building component added to a basic

BSL building, such as a door, window, ventilator, insulation, wire

mesh, translucent sheets etc.

ALUMINISED: Aluminum coated steel

ASSEMBLY: Two or more components bolted together

ASTRAGAL: A bent plate fixed at door leaf to cover gap

ANCHOR BOLTS: Bolts set in concrete, used to anchor

structural members to concrete foundation.

BASE ANGLE: A continuous angle secured to foundation to

support cladding

BASE PLATE: The end plate of a column which rests on the

supporting substructure surface

BASE CHANNEL: A light gauge cold formed channel which

replaces the base angle when liner or double cladding partitions

are required

BEAM: A horizontal structural member designed primarily to

resist moments

BAY: The space between the centre lines of frames or primary

supporting members in the longitudinal direction of the building.

Also called bay spacing or bay length

BEAD MASTIC: A sealant furnished in a continuous roll.

Normally used for sealing end laps of roof panels

BENT PLATE: A plate bent to form an angle.

BIRD MESH: Wire mesh used to prevent birds from entering the

building through the ventilators, louvers and roof monitors.

BRACE RODS/CABLES: Rods or cables placed diagonally in

the roof and walls for the purpose of transferring wind loads to

the foundation and longitudinally stabilising the building.

BRACED BAY: The bay where bracing is provided

BRACKET: A structural support projecting from a column or

rafter to which another structural member is fastened.

BUILT UP SECTIONS: A structural member usually an “I” shape

made from individual plates welded together.

“C” SECTION: A member formed into a “C” shape profile by cold

roll-forming from coils.

CANTILEVER: A projecting beam that is supported and

restrained at one end only.

CANOPY: An projecting roof structure, below the eave level,

supported at one end only.

CAP PLATE: A plate located at the top of a column or end of a

beam. Also refer to as End plate.

CAPILLARY ACTION: The action of water rising to a higher

level due to surface tension.

CAT WALK: A narrow walk way used to provide access to

mechanical equipment normally supported on roof platform.

CAULKING: A sealant used in making watertight joints.

CHECKERED PLATE: Flat hot rolled plate with raised

checkered design to prevent slipping; used for industrial

equipment platform, catwalks, stair treads, etc

CLEAR HEIGHT: The vertical dimension from the finished floor

level to the lowest underside point of the rafter.

CLEAR SPAN: A building without internal columns.

CLIP: A bent plate or angle used to fasten two or more members

together.

CLOSURE STRIP: Purpose-made from fillers to fit inside and

outside profiles of roof and wall panels providing a weather tight

seal.

COIL: A roll of steel sheet or wire.

COLD-FORMED MEMBER: A light gauge structural member

produced from coiled steel stock formed to desired shape at

room temperatures.

COLUMN: A vertical structural member used in a building to

transfer loads from the roof beams, trusses or rafters to the

foundation.

CONCRETE NOTCH: A rebate or notch formed along the edge

of the concrete floor slab or grade beam, allowing wall panels to

end below the floor level thus preventing ingress of dust or water.

CONTINUOUS RIDGE VENT: Two or more ridge ventilators

mounted on the building ridge that allows air circulation.

1Metal Building Terminology

2

CORNER COLUMN: A column at any corner of a building.

Corner column may be primary rigid frame column or light end

wall column.

CRANE BEAM: A beam that supports an overhead / underhung

travelling bridge crane.

CRANE CAPACITY: The maximum weight a crane can safely lift.

CRANE RAIL: Rail welded or bolted to a crane beam forming

the track on which the crane moves.

CRANE STOPPER: A small vertical member welded /bolted to a

crane beam to stop the crane bridge at the end of the crane run

area.

CURB: Raised flashing around the roof opening to form

waterproof opening.

CURVED EAVE: Curved panels provided at the eave.

DAMPER: Baffle plate in a ridge ventilator that can be opened

or closed using the cable catch assembly.

DEAD LOAD: The self weight of the pre-engineered building

structure including all its components such as frame, floors,

secondary members, sheeting, bolts, etc

DESIGN CODES: Regulation developed by recognised

agencies establishing design loads procedures, and

construction details for structure. Examples are, MBMA, AISI,

AISC, AWS, IS 800, IS 801 etc.

DOOR GUIDE: An angle, channel or proprietary product used to

restrain a door leaf or curtain during its opening and closing.

DOOR STOPPER: A clip bolted to the vertical door member to

prevent opening beyond the door limit.

DOUBLE CHANNEL: Double or back to back “C” sections

stitched / bolted together.

DOUBLE FACE TAPE: Used as an aid to fix fibreglass

insulation.

DOUBLE SLIDING DOOR: Sliding door with two leaves.

DOWNSPOUT: Cold formed sheet metal section or PVC pipe

used to carry water from the gutter of a building to the ground or

storm drainage system.

DOWNSPOUT ELBOW: Cold-formed sheet metal section or

PVC elbow used to carry out, matching the downspout profile,

attach to lower end of a downspout and curved in such a way as

to direct water away from a wall.

DOWNSPOUT STRAPS: Metal straps used to fix the

downspouts to the side walls.

EAVE: A line along the side wall formed by the intersection of

inside faces or planes of the roof and the side wall panels.

EAVE GUTTER: Gutter at eave of the building.

EAVE HEIGHT: The vertical dimension from the finished floor

level to the top of the eave strut.

EAVE STRUT: A structural member, located at the eave, used

for supporting the roof panels and the wall panels.

EAVE STRUT CLIP: A clip used to support the eave strut.

EAVE TRIM/ FLASHING: A sheet metal closure whose function

is primarily to provide weather tightness at the eave between the

eave gutter and the wall panels.

END BAY: The first or last bay in the building. It is spacing

between the outside face of the outer flange of the end wall

columns and the centre line of the interior column.

END LAP: A term used to describe the lap of roof sheet where

the end of the one sheet overlaps the end of the other sheet

below it.

END WALL: A term used to describe the entire frame structure

of a building at gable end.

END WALL COLUMN(S): A vertical member located at the

endwall which supports the end wall rafter and girts.

END WALL ROOF EXTENSION: Roof cantilevered beyond the

end wall steel line.

ERECTION DRAWINGS: Drawing and erection instructions

which identify all the individual components in sufficient detail to

permit the proper assembly of all parts of the metal building

systems.

EWDS: Non-expandable double slope endwall

EWSS: Non-expandable single slope endwall

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EWWX: Non-expandable WX endwall

EXDS: Expandable double slope endwall

EXPANSION JOINT: A joint of building allowing for expansion

and contraction

EXSS: Expandable single slope endwall

EXWX: Expandable WX endwall

FASCIA: An accessory whose function is to enhance the

appearance of a wall. Also used to cover the ridge or gable of a

building

FIELD WORK: Modification or rectification carried out on site.

FIN NECK BOLT OR ROUND HEADED BOLT: Flat dome

headed bolt used in framed openings, fascias, and the

mezzanines.

FINISHED FLOOR: Top of the concrete slab or finished surface

FIXED BASE: A column that is designed to resist rotational as

well as vertical and horizontal movement.

FLANGE BRACE: An angle member connecting to the inner

flange of columns / rafters to girt / purlin to provide them with

lateral support and stability.

FLASHING: A sheet metal closure used to provide

weather-tightness in a structure.

FLUSH MOUNTED: A girt system where the outside flanges of

girts and columns are flush. The girts are supported by the use

of girt clips bolted to the column webs.

FOUNDATION: The substructure which supports a building or

the other structure.

FRAMED OPENINGS: Framing (headers, sills and jambs) and

flashing which surround an opening of a building. Usually

provided to accommodate field installed accessories such as

sliding doors, roll up doors, etc

GABLE: The triangular portion of the endwall of a building

directly under the sloping roof and above the eave height line.

GABLE ANGLE: An angle fastened to the purlins at rake for the

attachment of end wall cladding.

GABLE FLASHING / BARGE FLASHING: A flashing designed

to close the opening between the roof panels and end wall

cladding.

GAGE OR GAUGE: The distance between holes along the

transverse axis of a plate.

GALVANISED: Steel coated with a layer of zinc for corrosion

resistance.

GIRT: Secondary horizontal member attached to the main frame

/ endwall columns. Girts support wall cladding.

GLAZING: Surface glass

GROUT: Non-shrinking sand and cement based mixture used

under base plates to obtain a uniform bearing surface.

GUSSET PLATE: Steel stiffner plate used to help distribute load

at a connection.

HAND RAILS: Horizontal and vertical pipes fixed to the

stringers, edges of mezzanine floors, openings in floors and

platform walkways.

HANGER DOOR: A large multi leaf door that is used in aircraft

hangars or similar buildings.

HAUNCH: Intersection of the column and rafter.

HEADER: A horizontal member over an opening in a wall.

HIGH STRENGTH BOLTS: Any bolt made from steel having a

tensile strength in excess of 690 megapascal (MPa). Some

examples are: ASTM A 325 etc

HILLSIDE WASHER: A washer having non parallel faces

normally used on brace cables or rods. Also known as bevel

washer.

IMPACT LOAD: A dynamic load resulting from the motion,

machinery, craneway, elevators and other similar moving forces

INSULATION: Any material used in building construction for

reduction of heat transfer.

INTERIOR BAY: The distance between the centre lines of two

adjacent interior rigid frame.

JACK BEAM: A primary horizontal member used to support

another beam, truss or rafter.

4

JAMB: Vertical member at the side of a wall opening.

JIB CRANE: A cantilever boom or horizontal beam with a hoist

and trolley.

JOIST: A horizontal member for supporting the decking of floors

or roofs.

LEAN TO OR WX: A structure dependent upon another

structure for lateral stability and having only one slope or pitch

LINER PANEL: Interior wall or roof sheeting attached to the

inside flanges of the girts or purlins.

LIVE LOAD: Any variable load that results from intended use of

structure during its life time.

LMSW: Uses truss purlins with 7 _-inch end seats.

LONGITUDINAL: The direction parallel to the ridge line.

LOUVER: A wall opening provided with slanted blades, fixed or

movable, to allow flow of air inside the building.

LRF: Clearspan double slope frame with tapered columns

LRDS: Clearspan double slope frame with straight columns

LRSS: Clearspan single slope frame with straight columns

LRST: Clearspan single slope frame with tapered columns

MACHINE BOLTS: Mild steel bolts conforming to ASTM A307

standard specification.

MEZZANINE: An intermediate floor within a building above the

ground floor that occupies all or part of the building floor area

and consists of columns, beam, joists, deck panels and edge

trims to receive reinforced concrete.

MRF: Modular double slope frame with tapered columns

MOMENT: The tendency of a force to cause rotation about a

point of axis.

MOMENT CONNECTION: A connection designed to transfer

moment as well as axial and shear forces, between connecting

members.

MONORAIL BEAM: A single beam support for a material

handling system. It is normally a hot rolled “I” beam.

MONO SLOPE: A building sloped in one direction.

MRDS: Modular double slope frame with straight columns

MRSS: Modular single slope frame with straight columns

MRST: Modular single slope frame with tapered columns

MULLION: A vertical bar or pier between panes or sections of

windows and screens.

MULTI-GABLE BUILDING: Buildings consisting of two or more

gables across the width of the building.

MULTI-SPAN BUILDINGS: Buildings with interior columns.

PART MARK: A number physically marked on a piece or

packing that identifies each component of the building for

erection and shipping purposes.

PEAK: The upper most point of a gable. Also called peak point

or ridge point

PEAK PANEL: Also known as RIDGE PANEL. Used to link and

weather-seal roof panels on opposite slopes.

PEAK SIGN: A sign attached to the peak of the building at the

endwall showing the name of the manufacture of building. Also

called as RIDGE SIGN.

PIN CONNECTION: A connection designed to transfer the axial

and shear forces between the connecting members but not

moments.

POP RIVET: Used for joining flashings and light gauge metal

trims & also called as blind rivet.

PORTAL FRAME (PORTF): Column and beam bracing used in

lieu of standard diagonal bracing rods to provide clear access.

PRIMARY FRAMING: The main load carrying members of a

structural system generally the columns, rafters, and/or other

main support members.

PRIMER PAINT: The initial coat of paint applied in the shop to

the structural framing of a building for protection against

environmental conditions during shipping and erection.

PURLIN: A horizontal secondary structural member, bolted to

the rafters, which transfers the loads from the roof covering to

the primary frames.

RAFTER: A primary beam member supported on columns.

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RAKE: The intersection of the plane of roof and the plane of the

gable.

REACTION: The resisting forces, at the column bases of a

frame, holding the frame in equilibrium under given loading

conditions.

REVISION: A change that is made to the building design,

component details, location of accessories.

RIDGE VENTILATOR: The ventilator used at the ridge line

RIGID FRAME: A structural frame consisting of members joined

together with rigid (or moments) connection as to render the

frame stable with respect to imposed loads, without the need for

bracing in its plane.

RIGID FRAME ENDWALL: A system of endwall framing where

the main interior frame is used at the end wall mostly for purpose

of future expansion.

RISERS: The vertical rise of the steps of a staircase.

ROLL UP DOOR: A door which opens vertically and supported

on a shaft or drum and runs along vertical tracks.

ROOF COVERING: The exterior roof skin consisting of panels or

sheets, their attachments, and weather sealant.

ROOF CURB: Weatherproof flashing used on roofs to support

power ventilators or ducting. Roof curbs can be of fibreglass or

sheet metal.

ROOF MONITOR: Raised gable, or portion of the main building,

located at the ridge, to allow lighting and ventilation.

ROOF SLOPE: The angle that a roof surface makes with the

horizontal usually expressed in units of vertical rise to 10 units of

horizontal run.

SAG ROD OR SAG ANGLE: A tension member used to limit the

movement of a girt or purlin in the direction of its weaker axis

before the installation of sheeting.

SECONDARY FRAMING: Members which carry loads to the

primary framing .In metal buildings this term includes purlins,

girts, eave strut, etc.

SEISMIC LOAD: The assumed lateral load acting in any

horizontal direction on the structural system due to earthquakes

SELF DRILLING SCREWS (SDS): Fasteners used for attaching

panels and trims to girts and purlins, which drill their own holes

and eliminate the pre drilling operation.

SELF TAPPING SCREWS: Have same functions as SDS but

need pre drilled holes.

SHEETING ANGLE: Angle used to support sheeting or cladding.

SHIMS: Small steel plates used for levelling base plates or for

packing between structural members.

SHIPPING LIST: A list that enumerates by part number or

description, each piece of material or assembly to be shipped

SHOP DETAILS: Drawing details for fabrication of parts and

assemblies.

SKY LIGHT: Translucent panels used at the roof to transmit

natural light. It is usually made of fibreglass or polycarbonate.

SLEEVE NUT: A long nut normally used to join two brace rods of

the same diameter together & is also known as coupling.

SLIDING DOOR: A single double leaf door which opens

horizontally by means of overhead trolleys or bottom wheels.

SLOT: An elongated hole.

SOFFIT: The underside covering of any exterior portion of the

metal building such as canopies, fascia and wall roof extension.

SOIL PRESSURE: The load per unit area a structure will exert

through the foundation.

SPACE SAVER: Building with single gable clear span and

straight column. Wall girts are flush mounted.

SPAN: Distance between the supports of beams, girders, or

trusses. In a pre-engineered building this is distance between

interior / exterior columns.

SPECIFICATION: A statement of particulars defining physical

dimensions, strength and other properties or a statement

defining performance expectations of material or devices.

SPLICE: The connection between two structural members.

STEEL LINE: The extreme outer limits of the structural framing

system of a building to which cladding is attached.

STIFFNER: Plate welded to a member to increase strength of

6

the web or to provide continuity at connections.

STILES: The vertical side members of a door frame / leaf.

STICH SCREWS: Fasteners used to fasten side laps of panels

and for attaching trims or flashings.

STRUT: A brace fitted into a framework to resist axial /

compressive force.

STRUT PURLIN: An additional purlin, in the braced bays,

located close to the normal purlin at intersection of roof brace

rods as required by the design.

THROAT: Minimum width of the ventilator air inlet.

THRUST: A horizontal component of a reaction.

TOLERANCE: A fractional allowance for variations from the

specified standard weight, dimension, etc. of mechanical

construction.

TRANSLUCENT: Allowing the passage of light, but not

permitting a clear view of any object. A translucent material is

semi transparent or semi clear.

TRANSVERSE: From sidewall to sidewall of a building.

TREAD: The horizontal step of a staircase.

TRIM: Pre-formed light gauge metal used as a cover to cut

edges, sides or junctions of sheeting.

TRUSS: A structural member, made up of several individual

parts welded or bolted together, designed to carry a tension or

compression force with the complete structure acting as a beam.

TUBE COLUMN: A vertical structural support member made of

a hollow square tube. Normally used as an interior support

column in multispan buildings or mezzanine floors.

TURN-OF-NUT METHOD: Method of tightening high strength

bolts in accordance with AISC: “Specification for structural joints

using ASTM A 325 BOLTS”

UNIFORM LOAD: Load that covers all or part of a beam or

surface where, throughout the portion covered, the intensity of

load per unit of length or area is the same.

UPLIFT: Wind load on a building which causes a load in the

upward direction.

VALLEY GUTTER: A channel used to carry off water, normally

from roofs of multigable buildings.

VAPOUR BARRIER: Material used to retard the flow of vapor or

moisture into walls and roofs and thus prevent condensation

within them.

VENTILATION: The process of changing the air within a

building.

VENTILATOR: A means of providing air changes within a

building.

WEB: The portion of a structural member between the flanges.

WHEEL BASE: The distance between the extreme wheels of a

crane along the crane beam.

WHEEL LOAD: The maximum load which is transferred through

the wheels of a crane to a crane beam

WIND COLUMN: A vertical member supporting a wall system

designed to withstand horizontal wind loads usually at end walls.

WIND LOAD: The pressure or reaction exerted on a structure by

a given wind velocity.

WX - Clearspan single slope frame with straight columns. Lateral

support provided by adjacent frame.

“Z” SECTION: A member formed from coiled steel stock into the

shape of block “z”. Usually used for purlins and girts.

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2Built Up Framing Systems

8

This basic framing illustration is designed as an aid in the

identification and location of the structural members and

components used in the construction of building structures.

There are a number of different types of structural systems

available from Tata BlueScope Steel to provide a large range of

space, support and protection possibilities and in light, medium

and heavy design loads. Generally, part references and usage

will follow a similar pattern for all buildings.

Main FrameMain frames consist of two or more columns spanned by roof

beam which support the roof structurals. All wide span buildings

are clear span structures with the exception of MRF buildings

which also require the use of interior columns.

Tata BlueScope Steel offers vide range of frame options to suit

the customers requirement at competitive rates. The following

options are available in frames to the customer as;

Clearspan

Clearspan frames are available in straight or tapered columns for

double slope and single slope profiles, and are used with single

slope width extensions (units supported by an adjacent unit, i.e.

WX frame).

Double Slope Profiles -

1. Frames - LRF

The LRF Envelope Frame has a clearspan double slope profile

with tapered sidewall columns. It offers almost total flexibility in

sizes within the limits of the envelope. Material used in this frame

is optimised to the specific width and height requirements.

Frame Specifications:-

LRF Columns: All columns are one piece tapered members with

the outside flange plumb. They can be ordered flush or with 8"

inset from the sidewall structural line as illustrated.

LRF Roof Beams: Roof beam profiles may vary. The top flange

of the roof beam will be straight to form the roof slope. The shape

of the web and bottom flange will vary as required to optimise the

material used to manufacture the beam.

2. Frames - LRDS

The LRDS Envelope Frame has a clearspan double slope profile

with straight sidewall columns. It offers almost total flexibility in

sizes within the limits of the envelope. Material used in this frame

is optimised to the specific width and height requirements.

LRDS Columns: All columns are one piece straight members

with the outside flange plumb. They can be ordered flush or with

an 8" inset from the sidewall structural line.

LRDS Roof Beams: Roof beam profiles may vary. The top

flange of the roof beam will be straight to form the roof slope. The

shape of the web and bottom flange will vary as required to

optimise the material used to manufacture the beam.

Single Slope Profiles -

1. Frames - LRST

The LRST Frame has a clearspan single slope profile with

tapered sidewall columns. Material used in this frame is

optimised to the specific width and height requirements.

LRST Columns: All columns are one piece tapered members


8" inset from the sidewall structural line.

LRST Roof Beams: Roof beam profiles may vary. The top

flange of the roof beam will be straight to form the roof slope.

The shape of the web and bottom flange will vary as required to


2. Frames - LRSS

The LRSS Frame has a clearspan single slope profile with

straight sidewall columns. Material used in this frame is


LRSS Columns: All columns are one piece straight members


an 8" inset from the sidewall structural line.

LRSS Roof Beams: Roof beam profiles may vary. The top




Multispan

Multispan frames are available in straight or tapered columns for

double slope and single slope profiles. Frame modules may vary

across the building width, independently by frame within the

building unit. Symmetry of modules is not required (i.e.: 60', 60',

50' would be an acceptable frame module combination for a 170'

wide MRF).

Double Slope Profiles -

1. Frames - MRF

The MRF Frame has a modular double slope profile with tapered

sidewall columns. Material used in this frame is optimised to the

specific width and height requirements.

MRF Columns: All columns are one piece tapered members



MRF Roof Beams: Roof beam profiles may vary. The top flange

of the roof beam will be straight to form the roof slope. The

shape of the web and bottom flange will vary as required to


Free Standing Single Slope Profiles -

1. Frames - MRST

THE MRST FRAME has a modular single slope profile with

tapered sidewall columns. Material used in this frame is


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MRST COLUMNS: All columns are one piece tapered members



MRST ROOF BEAMS: Roof beam profiles may vary. The top




2. Frames - MRSS

The MRSS Frame has a modular single slope profile with

straight sidewall columns. Material used in this frame is


The ratio of adjacent module widths cannot be less than 0.5 or

more than 2.0. For example, a 20' and 40' module set is allowed,

a 20' and 60' module set is not allowed.

MRSS Columns: All columns are one piece straight

members with the outside flange plumb.

They can be ordered flush or with 8" inset from the sidewall

structural line.

MRSS Roof Beams: Roof beam profiles may vary. The top




3. Frames - WX

The WX Frames has a clearspan single slope profile with a

straight sidewall column at the low side. WX frames are

designed to attach to the low eave of another unit so as to match

roof slope and eave elevation of the adjoined unit.

- WX frames must attach to a rigid frame such as an LRF for

structural stability.

- WX frames have all pinned joints while rigid frames have fixed

joints which make them "standalone" stable.

- WX frames with high side columns are not stable without the

support of the adjoined rigid frame because the high side column

has a pinned joint also. Since beam and post endwalls use

pinned joints, a WX intermediate frame cannot attach to a beam

and post endwall.

WX Columns: All columns are one piece straight members with

the outside flange plumb. They can be ordered flush or with 8"

inset from the sidewall structural line.

WX Roof Beams Roof beam profiles may vary. The top flange

of the roof beam will be straight to form the roof slope. The

shape of the web and bottom flange will vary as required to opti-

mise the material used to manufacture the beam.

4. Frames - ENDWALL

Endwall frames can be a pinned endwall frame or semi- rigid

endwall frame. In either case, the frames are designed only for

the loads on the endwall and are NOT designed for future expan-

sion. Both frames use an H-section roof beam.

10

Semi - Rigid Endwall Frames

The semi-rigid endwall frame uses a light Clearspan or Modular

rigid frame with straight columns and endwall posts rotated 90

degrees. This frame is NOT expandable in the future.

Expandable Endwall Frames

Utilises an interior frames located 2' inset from the endwall struc-

tural line (with pinned endwall posts) which allow for future

length expansion of the building. A building with possibility of

Future Expansion must be specified at the beginning of the proj-

ect in order to be considered in the design and highlighted on the

drawings.

5. Frames - MIXED

11


Bui

lt-U

p Fr

ames

3Roofing, Wall Cladding and Structural Decking

• First Launch in 1969

• 600 mm Wide Panel

• Cross Flutes

• Factory Punched Structurals and Panels

• Field Formed 180 degree double lock Seam

• Improved to make it 100% leak proof

• Tested and proven technology world wide

• KLIP-LOK™ 770 profiled sheeting of 770 mm cover width 31 mm crests depth with 3

intermediate pan at 256mm distance

• Two longitudinal stiffeners between ribs makes it a strong profile

• Clip fixed system – no piercing on roof sheeting

• Visually striking bold rib makes a strong statement rising from the flat pans

• Concealed fix system controls thermal expansion and contraction most effectively

• On-site roll forming option to provide single length sheet from ridge to eave

• Economical design, easy installation and outstanding value

• Fixed on the specially designed clip - KL-77

• Manufactured from high strength steel ZINCALUME® steel and COLORBOND® steel

• KLIP-LOK™ 700 profiled sheeting of 700 mm cover width 43 mm crests depth with

3 intermediate pan at 233 mm distance with cross micro flutes

• Clip fix system - no piercing on roof sheeting

• Cross micro-flutes makes it a strong profile

• Visually striking bold rib makes a strong statement rising from the flat pans

• Concealed fix system controls thermal expansion and contraction most effectively

• Economical design, easy installation and outstanding value

• Fixed on the specially designed clip - KL-70


12

MR-24®

KLIP-LOK™ 770

KLIP-LOK™ 700

• BR-II™ is a 900 mm wide coverage profile with 38.1mm deep ribs with pitch of

304.8 mm centre to centre and two stiffeners at every pan

• Specially designed end laps, with anti-capillary side lap, which makes to leak proof

• Strongest and fully tested roofing profile

• Available in factory punched option- to assure proper fit and alignment of each panel

joint ensuring weathertightness

• Pre-formed sealant grooves and guides promote accurate sealant placement between

panels


BR-II™ 900

Profile Design Benefits

13


• TRIMDEK® 1015 is 1015 mm wide coverage profile with 28.5 mm deep ribs with

subtle square fluting in the five pan at nominal 203 mm centre-to-centre

• Unique Anti-capillary side lap which makes it leak proof

• Excellent spanning capacity

• Covers large surface area


• SPANDEK® 935 is 935 mm wide coverage profile with 24mm deep ribs at 93.5 mm

centre to centre

• Unique anti-capillary side-lap which makes it leak proof

• Bold and strong appearance

• Longer Spanning capability

• Strongest cladding can withstand high wind load, snow load or impact load


• CUSTOM ORB® is 990 mm wide coverage profile with 19 mm deep ribs with pitch of

76.2 mm centre to centre.

• Smooth sinusoidal profile

• Covers large surface area

• Long , wide strong and easy to install

• Wall panels can be installed in horizontal as well as in vertical direction

• Can be curved for stylish architectural design (by using G300 grade material)


TRIMDEK® 1015

SPANDEK® 935

CUSTOM ORB® 990

• SHADOWRIB profile sheeting is 900 mm wide coverage profile with 38.1 mm deep

ribs at 300 mm center-to-center with two flutes in between the ribs

• Engineered to withstand high wind load and pressure

• Wide pan visibility gives an aesthetically pleasing look to the exterior of the building

• Fewer fasteners than most ribbed panels

• Fasteners are recessed deep in the corrugation, Shadowall panel gives walls an

attractive uniform pattern


• PANELRIB® is 1110 mm cover width, 3.5 mm longitudinal flutes

• Lightest wall cladding for interior and exterior application

• Provides easy solution for false ceiling and wall partition

• Panels can be installed in horizontal as well as in vertical direction


SHADOWRIB™

PANELRIB® 1110


Roo

fing

and

Wal

l Cla

ddin

g

14

• FLEXICLAD™ profile sheeting is 1110 mm wide coverage profile with 11.6 mm deep

ribs at 222 mm center-to-center with three stiffeners in between the ribs.

• Cover very wide surface area

• Quick, easy and economical to install


STYLWALL® panel is plain 406 wide coverage panel

• Laminated with the rigid insulation board on the inside, which improves insulation

properties of the wall and maintains its flatness

• Rigid backer along with a special joint allows for simple and secure installation

• Each new panel is nested perfectly against the next, causing no unsightly variation in

the joint size

• Concealed fastening system makes it leak proof

• Manufactured it from COLORBOND® steel or ZINCALUME® steel (G300)

FLEXICLAD™ 1110

STYLWALL®


• Can be used with steel or concrete structural buildings

• High rigidity performance

• Inherent internal ceiling and increased interior height; Flexible range of accessories

meets your hanging requirement

• Used in composite design, LYSAGHT SMARTDEK™ 51 performs as positive

reinforcement as well as permanent formwork, providing savings in concrete and

reinforcing steel.

• The fast and simple installation of this high-strength product gives immediate access

to a working platform and requires no stripping after concrete curing

• Keeps the construction site neat and safe

• Provides overall construction cost savings

• Manufactured from high tensile(G550) GALVANISED steel with coating mass of 275

g/m2 total on both side

SMARTDEK™ 51


Structural Decking

Our Health, Safety, Environment andCommunity (HSEC) Policy

Tata BlueScope Steel Limited, our health, safety, environment

and community responsibilities are integral to the way we do

business.

Our commitmentsWe are committed to continual improvement in our HSEC per-

formance.

Health and SafetyWe aspire to zero harm to people. Our fundamental belief is that

all injuries can be prevented. This responsibility starts with each

one of us.

EnvironmentWe care for the environment. We are committed to the efficient

use of resources, reducing and preventing pollution, and product

stewardship.

CommunityWe strive to be valued corporate citizens in our communities. We

respect the values and cultural heritage of local people.

Our actionsTo meet our HSEC commitments, we will set targets, develop,

implement and maintain management standards and systems,

and comply with relevant industry standards and legal

requirements.

We will regularly monitor and report publicly on our progress. We

will engage with our stakeholders to build relationships based on

honesty, openness and mutual trust and share responsibility for

meeting the goals of our HSEC Policy.

4Safety Policies and

Protective Personal Equipments

15


Safety Helmets Safety Shoes Safety Goggles

List of PPE and Safety Tools Required

All PPE's and safety tools should be CE certified rather than IS certification.

Safety equipment is the responsibility of each Builder.

PPE

and

Erec

tion

Tool

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16

Hand Gloves (Electrical) Ear Mask Life Line (PP Rope)

Hand Gloves (Other) Dust Mask Crawling Board

Face Shield Full Body Harness Fire Extinguisher

First Aid Box Safety Net Sand Buckets

Apron Fall Arrestor Electrical Board

Erection Tools

17


List is based on an average size crew and may need to expand as required.

Allen Key Set 1

Belts 4 With test certificates

Bolt Bag 8

Box End Wrenches 2 Sets assortment 12 mm to32 mm dia Bolts

Brooms 2

Tool Name Qty. Remarks

PPE

and

Erec

tion

Tool

s& E

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ts

18


Cable Clamps Assorted Sizes

Caulking Guns 4 Cartridge Type

Chain Block 1 Tonne With test Certificates

Chain Block 3 Tonne With test Certificates

Chisel 2

Chalk-Line 4

19



Crow Bars 2 Heavy Duty

Drift Pins 4 Heavy Duty

D-Shackle 6

Dust Pans 2

Electric Arc Welder 1 With leads and extra welding head

Electric Drill Motors 2 12 mm (1/2 inch) with twist drill bits

PPE

and

Erec

tion

Tool

s& E

quip

men

ts

20


Electric Extension Cords Sufficient for maximumnumber of tools

Extension Ladder 2 6 meters

Framing and Tri Squares 1

Gas Cutting Torch 1 With hose, gauges and flash back arrestor

Hacksaw 4 With assorted blades

Hammers 2 Shop, sledge, rubber

21



Level 2 Each 1.2 meters, 2 meters

P P Rope 1/2 inch 100 m

P P Rope 3/8 inch 100 m

Nylon Line 3/8 inch 100 m

Open End Wrenches 2 Sets assorted sizes 12 mm to 32 mm dia bolts

Pipe Wrench 4 14 inches

PPE

and

Erec

tion

Tool

s& E

quip

men

ts

22


Plumb Bob & Chaulk String 2

Pop Rivet Tool 2 Manual

Pop Rivet Tool 2 Electric

Power Generator To supply job site electrical

Power Impact Wrench 2 With assortment of impact sockets for 12, 16, 20, 24 & 32 mm dia nuts & bolts

Screw Guns 2 With Magnetic Socket Heads and replacement drivers

23



Sheet Metal Nibber 1 Electric Sheet Cutting tool with replacements bits

Sheet Metal Cutter 2 Each left, right, straight

Skill Saw 1 Electric or gas powered with metal & carbide tip blades

Slings 4 With test certificates

Socket Wrenches 2 sets 12 mm (1/2inch) drive with assorted sockets and ratchet drive handle

Spreader Bar 1 3 m, 5 m each withtest certificates

PPE

and

Erec

tion

Tool

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ts

24


Spud Wrenches 5 Each assorted sizes 12 mmto 32 mm dia bolts

Staple Guns (Big) 4 With steples

Steel Cable 100 m With eight turnbuckles

Steel Measuring Tapes 4 Each 3 m and 5 m

Steel Measuring Tapes 2 Each 15 m and 30 m

Torque Wrench 2 2000 N-m

25



Transit and Level Rod 2

Turnbuckle with Klein Grip 1

Vice grip pliers 10

Water can with cup holder

Wedge 4

Work Platform 2 Steel

PPE

and

Erec

tion

Tool

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ts

Erection Tools and EquipmentsAll tools and equipment used for installation must have test

certificates and calibration certificates if required. The

concerned Product Consultant / Project Safety Officer /

Project Manager or competent person should check the

certificates before using the equipments on site.

Mobile Equipment

• Mobile equipment includes delivery trucks, truck cranes,

hoists etc.

• Only certified mobile equipment and qualified operators are

permitted to enter the site.

• All power lines must be barricaded or flagged when

there is a danger of contact by mobile equipment. Lines,

which could be reached accidentally, must be de-energised

or otherwise made safe before any work is started.

• No equipment is to be operated over the top of power lines.

• Never operate equipment closer than 4.5 m to a voltage line

of 220 volts or more.

• Only an appointed signalman may give signals to the

operators except for emergency stop signal.

• Stay clear of moving equipment whenever there is danger

from swinging booms, crane cabs, suspended loads, etc…

• Accessible areas within the swing radius of the rear of

the rotating superstructure of the crane shall be

barricaded.

• Avoid walking near or walking under a suspended

load of hoisting operations.

• All suspended load must have tag lines.

• Prior to start of any lifting work, the location for

position of the cranes and materials laid down at the

erection areas shall be identified. Job safety and risk

analysis shall be done (you can also refer to

Customer Site Installation Safety Procedure). All

cranes and its safety devices and rigging equipment

shall have appropriate certificates and suitable

capacities for the intended lifting operation. All crane

operators shall be experienced and have valid

licenses from relevant government authorities. The

crane load charts should be always available in the

operators cabin.

• The crane shall be positioned and out riggers set

prior to lifting. Boom length, boom angle, operation

radius and safe lifting capacity shall be assessed as

per crane manufacturer's load chart prior to the lift.

• Damage to completed paintwork shall be

avoided/minimised at all stages of the erection work

by using nylon slings or belts and protective pads in

26

contact with steel work or by lifting with anchor

shackles through bolt holes.

Tag lines and load lines

• Tag lines and load lines must be carefully inspected

each time they are taken down. Defective or

damaged rope or cable will be cut immediately to

prevent further use.

• Before any load is lifted with any rigging for the first

time, a qualified supervisor will inspect all portions of

the rigging and a static load test will be performed i.e.

lift the load clear of the ground, hold for final

inspection of slings, shackles etc. prior to lifting the

item into the air.

• Tag lines must be flagged where they cross any path

or roadway.

Slings

• All slings are to be inspected each day prior to their

use. This includes chain, wire rope and synthetic

slings and their attachments, i.e. master links,

alligators, clips, hooks, quick-alloys etc.

• Defective cables and slings shall be cut and

destroyed immediately.

• In lifting operations, protect slings from abuse.

Protect slings by padding sharp corners, and never

jerk the load. Jerking may triple the load on the sling.

• Hang up slings when not in use.

• Never overload a sling.

Scaffolds

• Scaffolds shall be planned and installed in a way so

as not to restrict crane access and boom clearances

or make erection activities difficult.

• Scaffolds must always be placed on a firm ground

position and foot bases always supported by

adequate wood planks with minimum size

200 x 200 mm.

• Scaffolds installed separately must be fixed to static

structure at a minimum space of 1.5 m and every

upper scaffold frame must be fixed to the below scaf

fold by steel rod or scaffold tubing in a safe method.

• All scaffolds shall be installed with handrails, midrails,

ladders, and a platform at every floor level. Handrails

and midrails should be steel pipe D 50 x 2 mm and be

fixed at 0.5 m and 1 m above each platform. At each

ladder anchor points, an appropriate wire 'tie-off' shall

be used to tighten.

• Access-to-roof scaffolds shall have at least 6 support

feet as recommended.

27


1750

015

000

1100

070

00

12.0 21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

2.0

16.512.0

8.56.5

5.5

4.6

4.0

3.3

3.0

2.5

2.3

2.1

1.0

2.01.6

1.7

2.0

2.7

3.7

5.8

9.513.0

25.0

25.017.0

12.011.0

8.57.2

5.5

12.0

7.06.0

8.8

18.025.0

30.0

30.0

30.027.0

19.0

22.017.5

16.013.0

10.0

7.0

5.0

3.53.5

4.0

1.0

7.06.5

9.8

2.35

1.85

1.34

1.3

8.57.9

4.53.5

2.8

2.5

2.0

1.8

1.6

1.55

1.5

1.25

Chain Sling Synthetic Web Sling Wire Web Sling

PPE

and

Erec

tion

Tool

s& E

quip

men

ts

ELCB Box

• The electrical system for installation works at site requires

having overload CB and ELCB.

• The ELCB box must be standardised

including the sealed box, ELCB (30mA

- 60mA), 3 pin sealed plugs for outlets.

• For extended power supply distances

an ELCB box is required every 30 m.

• At least, 1 of ELCB shall be put on the

roof when doing the roof installation.

Hand Tools

• All hand tools to be fixed with wrist lanyards for

prevention of dropping.

• Tools are to be carried in purpose made tool belts

with leather frogs for safe carriage.

• Use the right tools and

never use hand tools for

the purpose other than

that for which they were

intended. Never use

makeshift device.

• All wrench, spanner

required to have sockets.

For fixing and

pre-tension purpose, it's

recommended to use the

sash socket spanners.

• Damaged tools, frayed or defective electric cords and

unguarded machinery must never be used.

• Tools, equipment, or materials shall be checked to

ensure the gear, belts, or other moving parts of the

machinery will not endanger anybody and all guards are

secured in place.

• Shut down and isolate the power source of machinery

and use extreme caution when cleaning or making

adjustments.

• Be sure the machine is inoperable before removing

safety guards when making repairs or adjustment.

• Report all the frayed, broken equipment to team

leader.

Tips onGas Cutting, Welding and Grinding

Gas Cutting, Welding

• Only qualified, properly trained, and instructed

personnel are permitted to use oxygen, fuel gas, weld

equipment. The Project Safety Supervisor must

perform an initial check and record the document

prior to permitting use.

• Keep oil and grease away from oxygen equipment.

• All gas bottles must be stamped and approved.

Compressed gas cylinders shall be handled carefully.

Avoid jarring, bumping or dropping them. Always

secure in an upright position.

• Cylinder shall be moved by cart, never rolled. Use a

cradle or holder when lifting cylinders with crane,

never use a magnet.

• Protective caps shall be kept on cylinders when not in

use and when being transported.

• Oxygen cylinders in storage shall be separated from

fuel gas cylinders by a minimum of 6m or a fire wall

1.5 m high.

• Flash - back protection shall be provided by an

approved device that will prevent flame from passing

into the fuel-gas system.

• Torches will not be used as a hammer to remove slag

or scale.

• Before burning, welding or heating, the worker shall

be responsible for checking conditions on opposite

side or underside to see that all danger of fire or injury

is eliminated. A proper fire extinguisher shall be made

available.

28

• Never heat an object lying flat on a concrete floor. Be

sure there is an air space between the material and

floor as concrete will explode under extreme heat.

• Never leave a torch inside a vessel or closed

container. A leak could be the start of a disastrous explosion.

• When leaving the area, turn gas off at the

inlet to the hose first and then at the torch. Make

certain that there are no leaks.

• Inspect all torches, hoses, gauges and other burning

equipment regularly. ALL GAUGES MUST BE

MARKED FOR INTENDED SERVICE.

• Keep hoses clear of spark and hot slag area.

• All hose connections shall be screw/thread clamps.

No tie wire for connection shall be allowed.

Portable Grinders

• Only qualified, properly trained, and instructed personnel

are permitted to use a portable grinder. The Project Safety

Supervisor must perform an initial check and record the

document prior to permitting use.

• Grinders shall be equipped with guard at all times.

Guards shall not be removed or altered. Only use a

grinding disk for grinding and cutting disk for cutting.

• Must not attempt to change a wheel without first

getting authorised and adequate instructions. Always

be sure to check the speed on the label against

speed for conformity.

• Check to be sure that the wheel is properly mounted

before starting a grinder. Straight wheels will be

mounted between matching safety flanges at least

1/3 the wheel diameter. The nut will be tightened

securely but not excess, which could crack the wheel.

• When first starting a grinder it shall be held under a bench

inside the job or shielding and run for about a minute to

prevent being struck by a piece of broken steel with a defect

or excess speed causes it to fly apart.

• Cup wheels shall be used on the face only.

• Straight wheels shall be used on the circumference

only, never on the sides.

• Banging a grinding wheel against the work will not

clean the wheel and may cause the wheel to break.

• Never force a wheel by using excessive pressure.

• Handle grinders with care to prevent damage from

dropping. If you drop a grinder, have it checked

before using. Do not handle grinder by electrical cord

or air hose.

Always stop the wheel on the work piece before setting the

grinder down. When you set a grinder down do not rest it on the

wheel.

29


PPE

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Tool

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ts

Prior to commencement of erection work, it is essential to have

a clear understanding of the engineering documents. In the case

of erection, we specifically refer to Erection drawings and

Shippers list.

Erection drawings to be used at site should be 'ISSUED FOR

CONSTRUCTION' and be the latest revision. 'FOR APPROVAL'

drawings should never be used for the works. The revision

boxes at the bottom right corner of each sheet indicate the latest

status, i.e. “For Approval,” “Issued for construction”, “Revised as

Noted,” etc.

I. Anchor Bolt Setting Plan

This drawing shows the layout of all anchor bolts, normally on

one sheet, but for very large buildings, could be on two or more

sheets. Erection drawings are not to scale, so do not attempt to

scale any dimensions. The drawings are proportioned although

sometimes this can be misleading, and care is needed in

reading drawings. All dimensions are in millimetres.

The anchor bolt layout contains an anchor bolt schedule, which

is in the form of a table showing quantities and sizes of anchor

bolts.

The key plan shows center to center dimensions, bay spacing

dimensions, bolt setting details and critical dimensions for the

span. The details show if grout is required under columns along

with grout thickness and anchor bolt projection. Adherence to

anchor bolt setting tolerance is important and shall not exceed

the deviation laid down in the standards.

II. Roof Framing Plan

The roof framing plan shows the purlins, bracing and

miscellaneous details. Part numbers for purlins and bracing are

shown, also sag rods (where applicable), and strut tubes etc.

The drawings should be studied very carefully otherwise it is

quite possible to overlook critical details such as nested purlins,

strut purlins and strut clips.

III. Cross-Section

The cross-section is one of the most important drawings as it

contains a lot of vital information. Columns and rafter references,

purlins, girts, vertical and roof bracings, connection details, bolt

schedules, flange brace schedules and other details as

applicable, such as strut tubes, flashing etc.

In conjunction with the Erection drawing it is possible to find out

the number of members required. This being essential during the

pre-planning stage of erection, and cross-checking to be done

with the shipper list before receipt of material at site. The

cross-section drawing may be typical throughout in standard

buildings or in more complex jobs, there may be several

cross-sections, identified by grid numbers.

IV. Roof Sheeting Layout

All roof panels are shown with length and part number. Panel lap

details are shown, also skylight and downspout positions.

Standard details of fasteners, trims and insulation are included.

It is very important to check the starting dimension of the

sheeting, from the steel line.

V. Sidewall Sheeting and Framing

Depending on the job, sidewall framing and sheeting may be on

one drawing or more. The framing elevation shows the position

and part numbers of girts, eaves struts, bracing and sag rods.

The sheeting elevation shows the panel positions with length

and part numbers. Eave trims, gutters and downspouts are

shown with part numbers. Standard details are included which

indicate the number, size and position of fasteners and other

trimming details. End-walls are detailed similarly.

VI. Other Drawings

Other drawings may include crane beam layouts and details;

Mezzanine layouts and details; Accessories such as Sliding

Doors, Roll-up doors, personnel doors, windows, louvers and

ventilators.

5Understandingthe Engineering Documents

30

VII. Shipper List

The shipper list supplied with the erection drawings is the

customers Bill of Material. The BOM comprises a cover sheet

which includes job number, building number and phase,

customer name, Location, and Building size. The cover sheet

also shows the number of phases in the building, any revisions,

plus any special notes.

The Shipper List has 7 columns indicating

1. Serial number

2. Part number

3. Quantity

4. Revision number

5. Description of part

6. Colour

7. Length of item

The last page indicates the total BOM quantity of items. The

Shipper List is a comprehensive list of total parts/items in a

particular building and it is a reference to the items shown on the

Erection Drawings and should be used to double check items

against the packing list.

31


Und

erst

andi

ng E

ngin

eerin

g D

ocum

ents

If the foundation has been poured, check to see that it is square

and level. If the floor slab has not been poured, check all

elevations for column and post locations. Concrete should be

chipped or grouted where necessary to provide a level surface

at the required elevations

Guidelines for Setting of Anchor Bolts

• Anchor bolts shall be set in accordance with Tata BlueScope

Steel issued 'FOR CONSTRUCTION ANCHOR BOLT PLAN'.

• Finalise the FFL with the client or Consultant. Normally FFL is

bottom level of column base plate, in some cases it changes

as per customer requirement.

• Concreting has to be done finally 25 mm below the FFL level

(or as specified in civil drawing). This margin is for levelling

and grouting purpose.

• Establish the reference pillars at 3m away from intersections

of axis and grid lines at all four sides. Top level of reference

pillars should be kept 150 mm above the FFL. (Please refer

sketch)

• Mark the grid lines as indicated in AB setting plan on the

reference pillars and check whether foundation is square.

Squaring can be done by following methods.

A. Diagonal Method

The method is used when building width and length is less then

25 m or when diagonal of total building can be checked by

single measuring tape. In this, centre lines of four corner

pedestals can be marked by calculating diagonal length as per

drawing. Diagonal 'A' and 'B' should be equal to calculated

length as per drawing. Tie the piano wire or thread on the

reference pillars at all four side and mark the internal pedestal

centre line as per bay spacing given in the drawings.

B. Right Angle (3 - 4 - 5) Method

The method is used when building width is less than 30m and

length is less than 50m. In this case angle between two lines can

be set by chart given below. Mark a distance “x” along width and

distance “y” along length of building. Adjust two lines such that

diagonal distance between points equal 'z' .Refer table.

After setting the angle between two lines, measure distances

and establish reference pillars as per grid lines given in the

drawing and close the transverse to confirm the correctness.

Same above procedure is to be followed at other corners of bldg

and establish reference pillars and mark centre lines of

remaining pedestals as per sketch given below. After marking

centrelines of all pedestals check diagonal between individual

pedestals and anchor bolts.

C. Theodolite Method

Buildings larger than 30m wide and 50m long should be squared

with the help of theodolite. Be sure to check condition and

calibration of theodolite. Set the theodolite over corner

intersecting reference pillars. Sight along the building line mark

on the reference pillar; swing theodolite through 90 degree to

establish adjacent building line and mark on reference pillars.

Similarly shift theodolite and mark other lines on reference

pillars.

1. Ensure rigidity of shuttering and reinforcement and make

sure cover blocks are in place.

2. Place the anchor bolts in respective templates. Mark

centrelines on template

3. Check the level and projection of threaded portion of anchor

bolts; it can adjusted by adjusting nut below and above the

template.

6Foundation and Anchor Bolt

32

X Y Z

3 4 5

6 8 10

9 16 25

4. All anchor bolts should be located in concerned templates,

check distances and diagonal. Nail template to outer

formwork.

5. Verticality of anchor bolts can be maintained by tying it to

reinforcement; if required it can be also tack welded with

reinforcement.

6. Before pouring concrete re-check the elevations of anchor

bolts using the level instrument and ensure that the nuts are

tight.

7. During concreting ensure that concrete surface under

template is rough and level.

8. Remove the template after setting of concrete and clean the

protruded portion of anchor bolts and apply the grease to

threads and cover it with hessian cloth to protect it from

dust.

9. The gap below the base plates should be grouted by civil

contractor after completing the plumbing, alignment and bolt

tightening of building.

10. The anchor bolts shall be restrained in position in vertical,

horizontal direction and level during all setting in operation.

The allowed tolerances are as followed:

a. ± 3mm center-to-center of any 2 bolts within an anchor

bolt group.

b. ± 6mm center-to-center of adjacent anchor bolt groups.

c. Maximum accumulation of ±6mm per 30,000mm along

an established column line of multiple anchor bolt

groups, but not to exceed a total of 25mm.

d. ± 6mm center-to-center of any anchor bolt group to

establish column line through that group.

11. Anchor bolts shall be set perpendicular to the theoretical

bearing surface; threads shall be protected from falling of

free concrete and nuts shall run freely on the threads.

12. The projection of anchor bolts from the theoretical bearing

surface shall strictly follow the drawing or shall not be more

than 10mm longer nor 10mm shorter than 100 mm.

33


Foun

datio

n an

d A

ncho

r Bol

ts

All materials are carefully inspected and crated before leaving

Tata BlueScope Steel plant and accepted by the transportation

company as being complete and in first class conditions. It is the

carrier responsibility to deliver the shipment intact.

It is the consignee responsibility to inspect the shipment for loss,

damage and shortage when it is delivered. Instructions for mate-

rial inspection and handling any resultant claims for damages or

losses are thoroughly covered in a check sheet located in the

same packet containing the shipping manifest.

Handling and placement of material will vary according to size,

site conditions and equipment available. Whenever practical,

located and stored in and around the building site where it is to

be used.

For example:

- Rigid frame columns can be laid in position for raising;

- Roof beams / Rafters can be stacked for subassembly at

locations accessible for setting;

- Secondary structural and braces can be divided and

located according to requirement of each bay.

Access area is plan such that crane / equipment can be fully

utilised and down time kept to a minimum. Most builders find it

advantages to leave an access area at one end of the

building and running the full length of the building for

maneuvering erection equipment.

Material that will not be used during the erection of the framing

should be stored in area that offer protection from physical dam-

age and covered to provide protection from the weather.

The Procedure

1. Shipping department shall give the Product Consultant /

Builder sufficient advance notice for all site deliveries to

ensure there is a plan for unloading, so that Product

Consultant / Builder can mobilise suitable crane and

manpower for unloading of material.

2. A delivery note is always enclosed with the supplied

materials to clarify name of project, location, building

number, type of materials, quantity, date of delivery, etc.

3. Upon arrival of materials at the storage yard, the Builder's

material controller will match delivery notes and shall verify

the consignment. The material controller, then, reports to the

site supervisor the received material list and quality

condition.

4. There should be an Appointed Person by Builder who will be

having overall control of all lifting operations on site and the

Appointed Person must ensure that everyone in the crane

team has studied this manual and is aware of the correct

procedures to adopt in the cases not covered by this

manual.

5. Planning the Lift

Planning the lifting operation is essential to ensure that the

lift is carried out safely and efficiently. The following points

must always be considered:-

• Where the load is to be picked up from

• Where the load is to be placed

• What areas are to be passed over

• Proximity of the other contractors workers

• Any obstructions in the way

• How the load is to be slung

• How the slings are to be removed

• How the crane driver will be directed

• The weight of the load

• The weather

6. The Lift

a) Before Lifting

Only authorised slingers / signallers should sling the loads.

After slinging, but before lifting, the following must be

considered:

• Are the slings undamaged and properly attached to the

load?

7Material Management at Site

34

• Is the crane hoist rope vertical?

• Is the load free to be lifted, i.e. not fixed to anything else?

• Is the safety latch on the lifting hook closed?

• Are all personnel clear of the load?

• Is the landing site prepared to take the load?

• Are the legs of a multi-legged sling equally loaded?

• Is there a slinger / signaller in position to receive the load?

• Are the weather conditions acceptable?

• Are there any obstructions above the load preventing a

straight load?

b) Taking the weight

Be sure to hook the slings to components with the right no.

of points and position so that the load does not get

damaged. A spreader should be used for lifting long

components. Nylon belts or cloth slings with suitable SWL

shall be used for unloading the materials to minimise the

damage. Then, and only then, should the load be lifted. As

the load comes onto the crane, the jib may start to deflect

(especially telescopic jibs). The crane operator must correct

this so that the hoist rope remains vertical. The signaller

should also be aware that the load may swing.

Now slowly lift the load a short distance above the ground.

Then check that:-

• The load is balanced and stable

• The legs of the sling are at the correct angles

• Any packing pieces are in place and sound

• The load itself is not over-stressed, especially when lifting

packing cases like that of gutter and flashing boxes, sheet

bundles etc., which can fail under the loads applied due to

lifting.

35


Do not work during rainy condition orwalk on wet surface M

ater

ial M

anag

emen

t at S

ite

c) During the Lift

The load can now be lifted and moved to its landing area.

While in the air avoid:

• Passing over personnel working on the site

• The public

• Power lines

• Projecting scaffolding

Make sure that all personnel are clear of the load moving path.

d) Landing the Load

The load should be landed gently to ensure that it is not

damaged, and that the crane does not receive any shock

loading.

Before landing the load, check that;

• The landing area will take the weight of the load

• There is sufficient space for the load

• There are strips of timber or similar supports on which to

land the load such that the slings can be easily removed by

hand.

The signaller must ensure that he is in a place of safety

when receiving the load, ensuring that he cannot be crushed

between the load and a fixed object or pushed over an open

edge.

e) After the Lift

Take care with bundles of tubes and similar items as they

can collapse when landed, and pipes can roll, so make sure

suitable blocks are used to prevent this from happening.

Never drag chains from beneath the load and jump down

from the moving trailer.

7. Webbing slings, or any sling made from synthetic fibres,

should be examined before and after every lift as they are

vulnerable to being cut by sharp edges. If there is any sign

of a cut or fraying in the fabric, they should be taken out of

use and examined by a competent person.

8. All materials received onsite shall be visually inspected by

the site supervisor for any damage. Material Inspection

Report should

be sent to HO / Factory on the same day.

Remedial works to the damage shall be undertaken

immediately, if possible, to avoid any delay to erection.

36

Do not stand wherea moving load could trap or crash you

Never jump down from the moving trailer

1. Choose a firm and dry area for storage.

2. The material shall be stored above ground level with timber

packing.

3. The materials shall be stacked in locations according to the

building/areas, and should be at a lifting position adjacent to

the area to be erected. This is to facilitate the sorting and

delivery during the erection.

4. The materials shall be stored separately, above ground

level on timber packing. They shall not be stacked directly

on top of each other but must be separated by 50mm thick

timber, and shall not be stacked in contact with other steel

components and must be separated by a minimum 250 mm

gap.

5. Particular care shall be taken to stiffen free ends at a

distance of 200mm from the ends to prevent permanent

distortion. Incorrect handling may break crates and

materials particularly sheeting may become beyond use..

37


Material Storage

Timber packing provided for bottom member and in between members

Never keep members on ground. Always provide Timber packing.

Wrong Practice. Trip hazard possible and also material may get damaged.

Mat

eria

l Man

agem

ent a

t Site

Generally, most structures follow a basic sequence of erection

that enable you to utilise personnel and equipment as effective-

ly and efficiently as possible. For example, after several bays

have been erected and plumbed and squared, work crew can

start on other phases of the erection simultaneously as the fram-

ing progresses; overhead and sliding door may be installed; side

wall and end wall panels can be applied after several bays are

completed; overhang canopies and fascia can be installed after

the wall panel are up; roofing crews cab follow.

Pre-lift checklist and Meeting

The required material, accessories, crane, tools, tackles and

safety equipments shall be checked for availability at site and

ready to be used prior to starting of lift.

A pre-lift meeting shall be held before lifting any structure to

ensure everybody at site understands the lifting method or step

for the erection of the entire building. The Project Manager /

Product consultant of BSBS shall check details of the specifics

given in the check list attached in the annexure.

Framing Sequence -The general sequence of framing is as follows:

1. The brace bay closest to the endwall, standard location for

brace rods is usually the first interior bay. Be sure to refer to

your erection drawings for specific bracing requirements.

2. Plumb and square the braced bay

3. Install roof and wall braces

4. The end wall adjacent to the braced bay including secondary

structurals.

5. The intermediate bay adjacent to the braced bay

6. Continuous erection sequence, making sure each

intermediate bay is aligned before erecting succeeding bays,

until the structure is completed.

Note: temporary bracing shall be introduced wherever necessary

to take care of all loads to which the structure may be subjected,

including equipment and the operation of same. Such bracing

shall be left in place as long as may be required for safety.

Where ever piles of material erection equipment or other loads

are carried during erection, proper provision shall be made to

take care of stresses resulting from such loads.

The structural frames and other parts of the building can be

erected in various ways which will depend on the following key

factors:

• The type of structures such as: small clear span, large

clear span, low rise building, high building, o p e n - w e b

structure, etc.

• The availability of equipment such as cranes, winch,

manually lift, etc.

• In case of long rafters / members spreader bars multiple

cranes should be used

• The site conditions.

• The experience level of the erectors

Step 1 - Anchor bolt checking

Check the anchor bolt casted for compliance with details

provided in Anchor bolt setting plan. Check whether

concerned template goes freely into bolts. If not, make the

bolts vertical with the help of pipe without damaging the

treads of anchor bolts. This pre check is required to avoid

time lost during the actual correction.

Check the foundation levels. In buildings that require grout,

shim packs are placed in the centre of bolt pattern. Buildings

without crane system generally do not require grout, but

variances in concrete levels may necessitate the use of

shims. Level the base of RCC pedestal by keeping required

shims, check the level with Dumpy level. Top level of all

8Frame Erection Procedure

38

shims should be at same level. Shim plates should be

provided by Builders. In any case, nuts should not be used

as shim plates.

The sequence / method of erection shall be studied and

planned so that execution can be carried out in a safe,

economical and efficient manner. There are certain erection

practices that are in general use and have proven sound

over the years. Below are typical instructions applied for a

LRF and MRF structure.

Step 2 - Install Columns at Braced BayAlways erection should start from braced bay. Here bays

2-3 and 4-5 are braced bays.

• Check position and part mark of column

• Install column A2

• Tighten anchor nuts

• Set up scaffold or ladder at columns

Tie temporary bracings on two sides of column. Temporary bracing should be either PP rope of 20 mm dia or wire rope of 12 mm dia minimum.

• Check the plumb of column on either side

• Slightly release the load on slings and

Check the stability of column

• Remove the slings

Step 3 - Install column 'A3' as per [step 2]

Step 4 - Fixing of Girts

• Fix all the side girts and tie them between each column

• Rope with safety-lock hook to lift girts

• Tighten the bolts with normal torque

• Install temporary bracings on 2 sides of each column

• V shape cleats used to fix the other cable end on to 2

anchor bolt heads

Step 5 - Install other side wall columns

• Install other sidewall columns E1 and E2 and girts by

repeating Step [2], Step [3] and Step [4].

Step 6 - Install the 1st Rafter.

• Shift all material for the first braced bay erection.

• Identify the rafter part mark.

• Assemble RF-2 on the ground with correct size of bolts

near as possible to the lifting position.

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• 50 mm thick wooden block to be used to support

members for assembling.

• Torque wrench to tighten hi-strength bolts with minimum

recommended torque (lookup in the torque table for

Hi-strength bolts.)

• Attach temporary bracing at every 6m and fly bracing to

rafters. Attach support pipes D 50 x 2 mm x 2 M and

safety static lines to rafters. Two pipes fixed to in-flange

and out-flange of rafters, one at 1m distance from eave

and the other right at the top ridge of rafter end, the pipe

on top is used for both roof slopes. Static lines are fixed

from pipe to pipe by brackets at 800 mm high from outside

flange.

• Abrasive paper and cloths are to be used to clean. Touch

up paint by roller.

• Attach the slings to the member at 2 points about 1/4 from

ends ( 3.5 m ) and next-to the purlin cleats toward the

ends.

However, the overhang must be calculated properly to

prevent the distortion of the member caused by the weight

itself. The belt pickup angle also needs to be calculated to

avoid the distortion of material caused by force along the

member. For safety, it is recommended to use more than two

points on member for belts.

• Install assembled rafter with the help of crane to columns.

• Workers on scaffolds at columns to tighten bolts to a snug

tight condition at rafter-column connection plates.

40

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• Temporary bracing at every 6m to hold the first rafter on

2 sides to anchor bolts groups by V shape cleats or any

other immovable object

• Release the crane slightly to check the stability of rafter

before fully releasing the crane.

Step 7 - Install the 2nd Rafter

Repeat the same [step 5] for the second rafter

• But do not release the crane.

• Install purlins and Fly bracings from ridge to eave to hold

rafter in place.

• Fix temporary bracings at 6m each on both the sides of

rafter.

• Rope with safety-lock hook to pull up purlins manually.

• Sash socket spanner for M12 with normal torque.

• Erect roof and wall bracings.

• Release the crane.

Step 8 - Finish 100% the first braced bay

1. Fully install struts, purlins, fly bracing - 100%

• Crane to pick up struts to roof.

• Rope with safety-lock hook to pull up purlins

manually.


• Install the static line D8mm to anchor pipes at ridge

and eave of rafter at every 02 bays.

• Install another movable static line (D8mm) from static

lines at eave and ridge moving at the middle of each

bay for installing the purlin bracing safely.

2. Install permanent cross bracing for roofs and sides fully at

this bay

• Leave the bracing in loose condition.

The Alignment (Plumbing and Squaring) is one of most important

activity in the erection Sequence. It is very important to align first

braced bay before proceeding with further erection to avoid

problems when continuing the Erection Sequence.

42

Step 9 - Alignment and Tightening of Braced Bay

• Check the level of Columns

• Check plumb of column on both sides. Plumb of Columns

in the direction of length of building can be made by

tightening and loosening the braced rods. Ensure that

one braced rod is tightened, other rod must be loosened.

The plumb of column along the frame can be made by

temporary bracings.

• Check the rafter alignment by dropping of plumb from

rafter at ridge and at every 6m.

• Rafter can be aligned by loosening and Tightening cross

Bracings.

• Use temporary bracings to get Rafter in alignment if

required.

• Check to be Sure that Ridge point of rigid rafter is over

the centre line of building.

• Make sure that fly bracings are fixed in the correct

location.

• Fully tighten the permanent bracing and all the hi-

strength bolts with correct torque setting.

Key Note:

a) Bolts Tensioning Torque Check

(For Hi-strength Bolts)

1. All hi-strength bolts shall be 100% checked by the team

leader.

2. The site supervisor will do the 10% check and report to

the site manager.

3. Packing/shims, made from material of the same grade,

shall be provided wherever necessary to ensure that the

load-transmitting plies are in effective contact when the

connection is tightened. All shims shall be painted to the

same colour as the main material.

4. Tightening and final tensioning of the bolts in a

connection shall proceed from the stiffest part on the

connection towards the free edges.

5. Re-tensioning of the bolts, which have been previously

tensioned shall be avoided, except that if re-tensioning

is carried out, it shall only be permitted once and where

the bolt remains in the same hole in which it was

originally tensioned and with the same grip.

Re-tensioning of GALVANISED bolts shall not be

permitted. Under no circumstances shall the bolts, which

have been fully tensioned, be reused in another hole.

Touching up or re-tensioning of previously tensioned

bolts which may have been loosened by the tensioning

of adjacent bolts shall not be considered as

re-tensioning.

6. Final tension of bolts shall only be performed after

alignment and level checks have been performed and

found to be satisfactory.

b) Bolt Tightening Sequence

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1. The following figures show the allowable sequence for

bolt tightening at any joint.

2. The tightening work shall be implemented in two rounds,

the second being done to ensure all bolts are equally

stressed.

3. Allowable torque for bolt tightening and inspection

4. In the completed connection, all bolts shall have at least

the minimum torque applied on specified below when all

bolts in the bolt group are tightened.

5. There is another method of inspecting the bolt tightening

called part-turn method. All nuts in a connection shall be

first tightened (the effort of one person using a 300 mm

long spud wrench). Mark the relative position of each nut

and bolt before tighten a further 1/3 turn.

c) Alignment Check

1. It is the responsibility of the team leader to do the

alignment inspection for 100% of the structure members

while the site supervisor needs to do the re-inspection

and officially report for one main frame and two end

frames.

2. Each part of the structure shall be aligned as soon as

practicable after it's erection. Permanent connections

shall not be made between members until a sufficient

part of the structures have been aligned, leveled, plumb

and temporarily connected in such a manner that the

members will not be displaced during erection and

alignment of the remainder of the structure.

STEP 10 - Install the first end frame

1. Install all side and internal columns at line 1 and girts.

2. Adjust alignment, position and level

• Scaffolds setup at each column

• Tighten anchor bolt nuts

• Plumb-line and tape measure

3. Tighten all anchor bolts

4. Install the first rafter member to columns

• Attach fly bracing to rafters.

• Attach pipes D50 x 2 mm x 2 M and safety static

lines to rafters. Two pipes fixed to in-flange and

out-flange of rafters, one at 1m distance from eave

and the other right at top ridge of rafter end, this pipe

on top is used for both roof slopes. Static lines are

fixed from pipe to pipe by brackets at 800mm height

level from out flange.

44

Bolt Diameter Minimum Recommended Torque

Dia (mm) Clause 8.8 (Nm) Clause 10.9 (Nm)

12 87 128

16 214 315

20 431 615

24 745 1060

32 2013 2865

36 2586 3680

42 4135 5880

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• Use abrasive paper and cloths to clean and touch

up.

• Lift the first rafter member into position at the top of

column, hold rafters in place with crane.

• Workers on scaffolds at columns to tighten bolts at

rafter-column connection plates.

• Install 50% purlins lines from ridge to eave to hold

rafter in place.


manually.


• Release the crane slightly to check the stability of

the rafter before fully releasing the crane.

STEP 11 - Install all remaining columns, raftersand roof purlins

1. Install all side and internal columns and Girts at line 4, 5

and 6.


• Scaffolds setup at each column.

• Put shims under the base plates as required and

tighten the anchor bolt nuts.

• Plumb-line and take measurement.

3. Repeat the same [step 6] and [step 7] for all rafters and

roof purlins

STEP 12 - Install the second end frame

1. Install all side and internal columns along with Girts at

line 6.


• Scaffolds setup at each column.

• Tighten anchor bolt nuts.

• Plumb-line and take measurement.

3. Tighten all anchor bolts

4. Install the first rafter member to columns

• Attach fly bracing to rafters.

• Attach pipes D 50 x 2 mm x 2 M and safety static

lines to rafters. Two pipes fixed to in-flange and

out-flange of rafters, one at 1m distance from eave

and the other right at top ridge of rafter end, this pipe

on top is used for both roof slopes. Static lines are

fixed from pipe to pipe by brackets at 800 mm height

level from out flange.

• Use abrasive paper and cloths to clean and touch

up.

• Lift the first rafter member into position at the top of

column, hold rafters in place with crane.

• Workers on scaffolds at columns to tighten bolts at

rafter-column connection plates.

• Install 50% purlins lines from ridge to eave to hold

rafter in place.


manually.


• Release the crane slightly to check the stability of

the rafter before fully releasing the crane.

STEP 13 - Finish 100% Frame & Roof Purlins

1. Install struts, purlins, fly bracing 100% for 2 end bays

46

• Crane to pick up struts to roof.


manually.


2. Install permanent cross bracings for columns fully at

these bays

• Leave the bracing in loose condition.

Step 14 - Alignment and Tightening

Follow Step [9] for alignment and Tightening

Release some temporary bracings of the building if

required.

Final Inspection 1. The draft final inspection shall be done between the

Product consultant and Builder to ensure the quality

compliance and planning for repair, clean and touchup.

The record must be signed-off and documented as a part

of contract.

2. The official final inspection shall be completed with a

witness of client's representative. The record must be

signed-off and documented as a part of the contract.

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MRF Buildings

For MRF buildings repeat Step - 1, Step - 2,Step - 3, Step - 4 and Step - 5 given inthe LRF structure.

Step - 6 Install central columns C2, C3 andcentral rafter

1. Install columns C2 and C3 and tie column with temporary

bracing.

2. If possible, assemble central rafter piece and column on

ground and then erect.

3. Erect central rafter piece 2B on column C2. Tighten the

anchor bolt.

4. Tie the rafter with at least 6 temporary bracings on both

the sides.

5. Release the crane slowly to check the stability of rafter.

6. Release the crane fully.

Step - 7 Install rafter 3B

1. Repeat step [6] for installing the central rafter on column

C3.

2. Do not release the crane.

3. Install all purlins and fly brace.

4. Install temporary bracing. And then release the crane.

Step - 8 Erect the rafter 2C

Attach temporary bracing at every 6m on both the sides and then

release the crane.

Step 9 - Erect the rafter 3C1. Install all the purlins and fly braces.

2. Install rod bracing

3. Release the crane.

Step - 10 Erect the rafter 2A and attachtemporary bracings

Step - 11 Erect the rafter 3A and install purlins

Step - 12 Finish 100 % of the braced bay

Step - 13 Check alignment of braced bay

Step - 14 Erect First end Frame

Step - 15 Erect Remaining columns, Rafters, Purlins and other members

48

Step - 16 Erect other End Frame

Step - 17 Erect 100% other Bays

Step - 18 Check final Alignment and tightening

Step - 19 Check final Inspection

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Secondary Structural Connections

Secondary structural consist of the purlins, Eave strut, and girts.

These structural are installed in the bays as the rigid frames are

erected. Widespan buildings may use either simple span or con-

tinuous structurals or both.

PurlinSimple span purlin connection - when simple span purlin are

used, purlin clips are used at purlin - to - roof beam connections.

Clips may be preassembled to the purlins before installation

Continuous span Purlin connection: when continuous purlins

and used, install the bolts finer - tight as it will be necessary to

remove the bolts later in order to lap adjacent structurals. After

the splice is made, the bolts are drawn up tight.

Eave strut

Standard eave struts ar installed using a basic simple span con-

nection and bolt directly to the roof beams.

Girts

Simple span girts terminate at the centreline of the columns and

attach directly to the columns. Continuous girts are assembled to

the columns in the same manner as continuous purlins to the

roof beam. Adjacent ends of girts must be lapped and bolted to

the columns at the same line.

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End Wall Erection

Beam and post endwalls can be erected in sections preassem-

bled on the ground including posts, roof beams sections, and

girts. Because of common connections between sections,

reassembly is usually limited to alternating sections.

Layout the structurals in the relative position in which they will be

assembled.

End wall posts may be either single sections or double sections

(two post bolted back to back). If double post construction is

required, bolt these sections together first.

Attach girts clips to endwall posts.

Field notch end-wall girt at corner post location and connect

between corner post and end wall post girt clip. Intermediate

Girts do not require cutting.

Attach roof beam sections between posts. A clip is used to attach

the roof beam to the corner post and a splice plate at inside post

connections. If double end-wall posts are used, the splice plate

is not required.

Raise the corner endwall section into position and hold in place

with crane until secured to the foundation and sufficient second-

ary structurals are installed to stabilise the sections.

Install sidewall girts, eave struts and purlin.

Finish the endwall by raising alternate sections and filling in

secondary structurals and roof beam sections.

54

CORNER POST TO ENDWALL ROOF BEAM

Intermediate frame endwall

The intermediate frame endwall uses a standard rigid frame

located 2' in from the end of the building. The purlin extend past

the frame to the end wall structural line. Endwall post locations

are the same as beam and post endwalls except that corner

posts are not used at intermediate frame endwalls.

Erect the intermediate rigid frame at the endwall location and fill

in secondary structurals.

Preassembled base clips, girt clips and clips for attaching end

wall posts to the intermediate frame roof beam. One clip is

required for single endwall posts and two for double endwall

posts.

Erect end wall posts and install girts to complete the endwall

framing.

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Purlin clips to purlins

Purlin clips are used to attach the purlins to the endwall roof

beam. The clips can be pre-assembled to the roof beam before

raising the end wall sections.

If the building has a flat roof beam section the purlin clips loca-

tions on the endwall roof beam is varied to maintain the proper

roof slope. Clip locations are determined from the erection

drawings.

Complete bracing

Proper use of bracing is extremely important in the structure to

provide strength and rigidity and for frame alignment. Typical

bracing connections are shown below and it will be necessary to

refer to the erection drawing for specific location and application

of these components.

Brace rod are required in the sidewall and roof at braced bay

locations. Endwall bracing in used only at beam and post end-

wall locations. They are not required with intermediate frame

endwall.

Alternative attachment at column

Flange brace installation

Flange brace are used to provide lateral support to the roof

beam or column and their installation at specified locations is

important in obtaining a sound structure. Flange brace bolt to the

web of the purlin or girts and to the roof beam or column flange.

An exception may occur on some frames near the knee where

the flange are inaccessible. In these instances, threaded studs

are factory welded to the frame braces are usually attached to

the roof beam of the ground, leaving the connections to the

purlin to be made in the air.

Flange brace locations and part numbers are determined from

the erection drawings which also indicate visually the proper

hole in the flange brace to use.

56

ALTERNATE ATTACHMENT TO COLUMN

Flange brace assembly

Base angle installation

Base angle is installed around the perimeter of the foundation for

supporting the bottom of the wall panels. The base angle instal-

lation used with a particular wide span building will depend on

the type of wall system specified as indicated in the illustration.

Any of several methods amy be used to attach the angle to the

foundation; preset anchor bolts must be set when the foundation

is poured ; drilled in anchors may be used; or drive pins may be

used. Regardless of the method of attachment, anchor spacing

and minimum shear strength conditions must be met as speci-

fied in the erection drawings. This is particularly important when

panel diaphragm action is dependant upon for wind bracing.

Gable angle installation

The gable angle fastens to the top edge of the purlins and eave

struts at the end wall and is used for supporting the endwall pan-

els. Gable angle is furnished in 20' lengths and the installation

sequence is from eave to ridge.

Gable angle may require filed cutting at the ridge in which case

the cutting dimensions will be indicated on the gable angle erec-

tion drawing.

Gable angle never used on structurals which extend [past the

building structural line. If the endwall has an overhang or fascia,

the gable angle is notched to fit around the purlin and eave strut

and is installed at the structural line location

Sag angle installation

Sag angle serve two purposes; they provide lateral support to

the purlin flange and may also be used to keep roof secondary

structural in alignment for easier roof installation. Except where

57


Fram

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necessary because of design requirements or to satisfy local

building code, sag angles are optional and furnished with the

building as ordered.

As a general rule sag angle is installed at the top location on the

Purlin when ordered for erection alignment of roof structurals

and in the bottom location when required for bracing. Start the

sag angle installation at the ridge and work towards the eave.

The ridge sag angle bolts between the ridge purlins and must be

installed so the short leg of the angle is always at the bottom.

Intermediate sag angle are installed by inserting the tab on the

end of the angle into the slot in the web of the purlin and bend-

ing the tab to lock the angle into position. Tab may be bent down

with a hammer. If the sag angles are installed in the top of the

purlin, the leg of the angle and the tab should face downward. If

the sag angle are located in the bottom of the purlin, the leg of

the angle and bent tab should face upward.

The adjacent sag angle is used between the eave strut and first

purlin. This angle bolt to the web of the eave strut and threaded

rod on the opposite end passes through the purlin web. Two

nuts, one located on each side of the purlin web, are adjusted to

pull the eave member into alignment with the purlin.

On building with a width extension or canopy, a sag rod is used

instead of a sag angle between the eave strut and the adjacent

canopy or width extension purlin. The two nuts at each end of the

sag rod are adjusted to align the purlin with the eave strut.

Sag rod is not required in 4' sidewall overhangs, however an

adjustable sag angle can be used between the building and

overhang eave struts for alignment purpose.

Sag strap installation

Sag strap are used only for bracing the wall structural and not

intended to be used for alignment purposes. Sag strap are usu-

ally installed after the wall panel are in place ot permit easier

alignment of panels and girts.

58

Installation of Wall Panels

The roof of any type of structure is the area most subjected to

problem… the wall most subject to critical inspection. These

areas should receive careful attention during installation.

All our panels are designed to withstand the severest of weath-

er conditions and incorporate design features.

General Procedures

Prior to commencement of fixing, the installer should ensure that

the purlins, girts or battens are truly in place and that the slope

requirements are met. Any adjustments found necessary should

be made prior to proceeding with fixing, as they will be difficult or

impossible to rectify later.

Initial Preparation

1. Scaffolding Preparation

• Erect scaffolds with handrails, midrails and platforms. They

shall be supported from falling by pipe D50 x 2mm x 6M to

ground. The scaffolds shall be tightened on the top to the

roof anchor pipes.

• Scaffolding system will be setup at 300mm away from the

out flange of the Girts. All material shall be moved up

through this 300mm gap.

• The scaffold system shall be used to install all the items on

the wall cladding completely such as girts, wall sheets,

gutters, down-pipes, louvers, doors, windows, etc. which

are above 2 m from the ground. They can only be moved

after finishing the installation for above items at the area.

• Another scaffolding system should be setup ready for the

next walling area so that the installation will not be

interrupted due to the movement of the scaffolding system.

• Workers shall directly attach the safety harness to the

scaffolds or handrails.

2. Electrical system preparation

• Electrical wires and ELCB boxes must be taken to the roof

in a safe condition. They must be supported above ground level.

• The electrical wires should be attached to the anchor pipe

positions to avoid direct contact to roof sheets and purlins.

• ELCB box must be taken to the roof for protection against

electrical short-circuit. Two other electrical cables with 3

plug connections shall be connected to ELCB box and

taken to the installing positions ready for using.

Base condition

Three different types of wall base conditions are used with wall

panels. Before starting paneling, be sure to determine which

condition is furnished with your building.

Metal closure: This metal clo-

sure is intended as a vermin

closure only and is not effec-

tive where a light - tight condi-

tion is required or where con-

trol of air movement is

required.

This closure can also serve as

an effective insulation retainer.

Foam closure: a foam closure

can be used in lieu of or in addi-

tion to the metal base flashing to

effect better light or air closure.

The closure is not opaque so

complete light closure should not

be expected.

9Roof and Wall claddingpanel installation

59

Part 3 - Sheet Installation

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Notched foundation: a

notched foundation edge may

be used in lieu of or in addition

to either closure method to pro-

vide a base of wall closure.

Before installing insulation /

wall panels, level the girts with

the wooden blocks. Keep the blocks until the panels to structure

fasteners are installed. The general practice is to install the wall

panel in sequence with the insulation. Align the first panel with

building structural as shown below. Apply the panel over the

insulation and drill required holes in the structural members for

the self-tapping screws. Install the wall panel fasteners and

remove clamps. Trim excess insulation and raise the next pre-

cut run of insulation.

It is extremely important that the first wall panel be installed

plumb. Use a spirit level or transit on each panel.

Adjoining panels are installed with overlapping rib toward the last

erected panel. Position panel to structural making sure that it is

kept plumb. Drill structural members if required and install fas-

teners at lapped rib. Use a chalk line to mark the girt location and

maintain a straight line of screws, thus avoiding mis-drilling and

possible leakage. The preferred procedure is to complete all wall

sheeting before starting the roof sheeting, for smoother fixing of

eaves flashing, closures and eaves gutter.

Installation of Roof Panels

Pull Up the Roof Sheets to Roof

1. Fix the anchor pipe to ground

• Anchor pipe D 50 x 2 mm, 500 mm long fixed at a 300 mm

depth into the ground at parallel 6m distance from each

other, and at 45 degree angle opposite to the building

• Turn buckle attached to the top end of the anchor pipe

2. Install the anchor pipe and static line on the rafter

• Pipes D 50 x 2 mm x 5 M fixed to the out-flanges and

in-flanges of the end rafter at a spacing of 6m from each

other and aligned with the anchor pipes on the ground

• Static line to be fixed from pipe to pipe by brackets at

800 mm height level above the out-flange of rafters

3. Install the supporting cables / ropes from roof to ground

• Put a pipe D 50 x 2 x 600 mm into each supporting cable.

Attach ropes to each pipe for lifting to roof

• One cable end is to be fixed to anchor pipe on the rafter,

while the other end is to be fixed to the turn buckle that was

attached to anchor pipe on the ground

• Turn buckle used to maintain cable tension

4. Lift the roof sheets to roof

• Put each piece of sheet into the sliding pipe, sheet will be

held by steel rods

60

• Each worker at the anchor pipe position on the rafter will pull

the sliding pipe by rope carrying the sheet

• After sheets reach the rafter, they shall be manually moved

onto roof purlins

After enough sheets are picked up for the first bay, another team

will start the roof installation.

Roof Sheeting Sequence

It is advised that both sides of the ridge of a building be sheeted

simultaneously. This will keep the insulation covered for the max-

imum amount of time and the panel ribs can be kept in proper

alignment for the ridge panel. Check for the proper coverage as

the sheeting progresses. One can follow the panel-sheeting as

shown below.

When lifting sheets onto the roof frame ready for laying and fas-

tening, care should be taken to make sure all sheets are the cor-

rect way up with the overlapping side towards the edge of the

roof from which installation will commence. Otherwise, sheets

will have to be turned over and/or turned end for end. Sheet bun-

dles should be placed over or near purlin supports, not at mid

span of the purlins.

Fastener Installation

Correct fastener installation is one of the most critical steps

when installing roof panels. Be sure the fasteners are installed at

locations indicated on the building drawings. Panel to structurals

connections are usually located by eye. It is easy to misjudge the

location of the purlin, resulting in a fasteners off the purlin or

below the sealant at the end lap. The installer should stand 90

degree to the panel, facing the purlin. Drive the fastener in until

it is tight and the washer is firmly seated. Do not overdrive fas-

teners. A slight extrusion of neoprene around the washer is a

good visual tightness check. Always use the proper tool to install

fasteners. A fastener driver (screw gun) should be used for self-

drilling screws. Discard worn sockets, these can cause the fas-

tener to wobble during installation.

Applying Mastic Sealant

Proper mastic application is critical to the weather tightness of a

building. Mastic should not be stretched when installed. Apply

only to clean, dry surfaces. Keep only enough mastic on the roof

that can be installed in a day. During warm weather, store mas-

tic in a cool dry place. During cold weather (below 60 degrees)

mastic must be kept warm (60 degrees - 90 degrees) until appli-

cation. After mastic has been applied, keep protective paper in

place until panel is ready to be installed.

Preparing the Eave

Prepare the eave for the first panel by applying tape mastic

along the eave (outside of the insulation, if any) and leaving

release paper in place. Mastic must be applied in a straight line

and with out voids.

Do not stretch the mastic. Use a knife to cut if necessary. Cut an

inside closure strip as shown above and place starter piece on

top of the mastic. Align the major rib of the closure with the edge

of the endwall roof line. Splice a full closure to the starting clo-

sure and apply along the top of the eave mastic.

61


Underdriven Correctly driven

Overdriven

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Along the top of the closures that have been placed along the

eave, apply a second run of tape mastic. Prior to removing paper

backing, check and mark for proper alignment of the first roof

panel. Remove paper and fix the mastic.

Installation of the First Roof Panel

Once the eave is prepared, the first roof panel may be installed.

Check the erection drawings to determine the roof overhang at

the eave. Set the roof panel in place over the inside closure

insuring the major ribs of the panel nest properly with the inside

closure. Align the panel edge with the edge of the endwall roof

line.

With the panel properly placed, adjust the line of panel for

squareness to avoid “Saw toothing” at the eave line. Use a nylon

line projected from the eave strut by a certain distance to give

correct distance and line. Make sure that the panel ribs are kept

in straight line from Eaves to Ridge. Use a chalk line to mark the

purlin location and maintain straight line of screws, thus avoiding

mis-drilling and possible leakage. Secure the panel to the struc-

ture with appropriate fasteners. If the building requires more than

the one panel per run, do not install fasteners at the purlin locat-

ed at the upslope end of the panel. These fasteners will be

installed after the overlapping is installed.

Sealing the Sidelaps

Apply the sidelap tape mastic to the weather side edge of the

lower major rib as shown in the figure. The mastic should only be

applied to clean, dry surfaces. With the release paper in place,

press firmly along the length of the mastic to insure proper adhe-

sion. In removing the protective paper from the mastic, care

should be taken not to pull the mastic away from the panel.

Install the adjoining panel positioning the overlapping rib with

care. Drill, at the center of the clearance holes in the overlapping

panel, required size pilot holes for the lap fasteners. Stitch the

lap with the self-fastening fasteners supplied with the screw line.

Never allow the mastic to be placed to the inside of the screw

line.

Installation of Remaining Roof Panels

With the first panel run installed and secured and sidelap mastic

applied, the second panel run may be started. Prepare the eave

with an inside closure and mastic. Position the panel so that the

overlapping ribs will nest properly. Be sure to check for proper

62

overhang and panel coverage. Stitch the major ribs of the two

panels together and attach panels to the purlins.

Sealing the Eave

Mastic location at the eave is critical. To insure a weather tight

seal, the sidelap mastic must extend down from the top of the rib

to the mastic on the eave closure. The mastic extension must

splice into the eave mastic.

Sealing the endlaps

At the panel endlaps, place a run of mastic across the full panel

width 25 mm below the fastener line. The panel endlaps have a

150 mm minimum overlap located over a purlin as shown or as

per respective erection drawings. Locate the fasteners on the

center of the flange of purlins.

Skylight Installation

One of the simplest methods of getting natural light through a

steel roof is the inclusion of translucent sheets which match the

steel profiles.

It is preferable to use profiled translucent cladding in single

widths so that they can overlap, and be supported by, the steel

cladding on both sides. It is also preferable to position the

lengths of translucent cladding at the top of a roof run so the high

end can lap under the capping or flashing and the low end can

overlap a steel sheet. This is because the translucent cladding

will readily overlap a steel sheet but the reverse is difficult.

Skylight panels are also installed using the same procedures as

a steel panel (Subjected to skylight manufacturers

recommendations). Care should be taken when installing

fasteners in the skylights to avoid cracking the material.

Ridge Installation

Ridge panels are to be installed as each side of the roof is sheet-

ed. This will aid in keeping both sides of the roof aligned. After

having installed a run of panels on each side of the roof, apply

mastic to the panels. Set ridge panel in place and install lap and

purlin fasteners. Apply mastic along the top of the leading rib to

prepare for the next sidelap.

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Tape Sealant Application atRidge Flashing

Apply panel sidelap tape sealant as shown for building with ridge

flashing and outside closures. The mastic is placed along the

inside edge of the major rib from the ridge purlin web line to the

upper end of the panel.

Cleaning of Roof Panels

As work proceeds, it is important to keep the roof area clean. A

soft brush or broom should always be readily available to sweep

off drill swarf, metal fillings or grinding dust, which will cause light

surface corrosion if not removed. With a little practice in applica-

tion, squeeze out removal will generally be unnecessary.

However, for practical or aesthetic reasons, uncured sealant can

be removed with a clean, dry rag and any excess then removed

with material turpentine or white spirits.

Excess cured sealant is to be removed with a plastic stapula to

avoid damage to the surface finish. Avoid any unnecessary

smearing of sealant on surfaces intended for painting as silicone

can affect over-paint adhesion. If contamination has occurred,

this may be treated by lightly abrading the area with a non-metal-

lic scouring medium.

64

Pierce-fixing is the method of fixing sheets using fasteners

which pass through the sheet. This is different from the

alternative method called concealed-fixing. The method of fixing

you use is determined by the cladding profile you are using.

You can place screws through the crests or in the valleys,

however, to maximised watertightness, always place roof screws

through the crests. For walling, you may fix through either the

crest or valley.

Always drive the screws perpendicular to the cladding, and in the

centre of the corrugation or rib.

The following procedures are described for roofs, but the same

general principles apply to walls.

General installation procedure

Check flatness, slope and overhang

Before starting work ensure that:

• The supports for your cladding are truly in the same plane

• The minimum roof slopes

• The overhangs of sheets from the top and bottom supports

do not exceed the limit, whilst also overhanging at least

50 mm into gutters

Make any necessary adjustments before you start laying sheets,

because they will be difficult or impossible to rectify later.

Orient sheets before liftingFor 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.

It is much easier and safer to turn sheets on the ground than up

on the roof. Before lifting sheets on to the roof, check that they

are the correct way up and the overlapping side is towards the

edge of the roof from which installation will start.

Place bundles of sheets over or near firm supports, not at mid

span of roof members.

Position first sheet

With particular care, position the first sheet before fixing

to ensure that it is correctly located in relation to other parts

of the building. Check that the sheet:

• Is aligned with the end-wall (or its barge or fascia),

bearing in mind the type of flashing or capping treatment to

be used; and

• Aligns correctly at its ends in relation to the gutter

and ridge (or parapet or transverse wall). Roof sheets should

overhang at least 50 mm into gutters

Fix the sheet as described later in this chapter

Position other sheetsAfter fixing the first sheet in position, align the following

sheets using:

• The long edge of the previous sheet; and

• A measurement from the end of the sheet to the fascia or

purlin at the gutter. It is important that you keep the

gutter-end of all sheets in a straight line

Fix the sheet by either:

• fixing each sheet completely, before laying the next; or

• fix the sheet sufficiently to ensure it can’t move, complete

laying all sheets, then return to place all the intermediate

fasteners later

10Installing pierce-fixed cladding

65


Crest fixing (roofs & walls)

Valley fixing (walls only)

Crest and valley fixing

Prevailing weather Direction of laying

Sheet 1Sheet 2Sheet 3

Lay sheets towards prevailing weather

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Check alignment occasionally

Occasionally check that the sheets are still parallel with the first

sheet, by taking two measurements across the width of the fixed

cladding.

At about half way through the job, perform a similar check but

take the measurements from the finishing line to aim for the final

sheet to be parallel with the end of the roof. If the measurements

are not close enough, lay subsequent sheets very slightly out of

parallel to gradually correct the error by:

• properly align and fix a lap, then

• fix the other edge of the sheet, placing the fasteners slightly

closer or further from where they would normally be if there

was no error.

Side-lapping & positioningpierce-fixed sheets

To prevent moisture being drawn into laps by capillary action,

the edges of sheets are slightly modified. CUSTOM ORB® and

custom blue orb have the edges of the sheet over-curved,

other products like SPANDEK®, TRIMDEK® all have flutes

formed into the underlapping rib. It is important that sheets be

lapped correctly.

After fixing the first sheet, place the next (and subsequent)

sheet with its side lap snugly over the previous sheet. Secure the

sheet firmly in place until each end of the sheet has been fixed.

You can do this easily by:

• align the bottom edge accurately by a measurement from the

end of the sheet to the fascia or purlin at the gutter;

• clamp the lap with a pair of vice grips;

• at the top of the sheet: nestle the side lap snugly,

check alignment, and fix the sheet with a fastener.

Pierce-fixing on valleys(for walling only)

Wall fasteners may be placed on the crests, but they are

usually placed in the valley of wall cladding because:

• they are less conspicuous and don’t break the aesthetic

lines of the steel cladding;

• there is no risk of the profile being deformed,

because the fastener is placed through the cladding

where it rests flat against its support; and

• water penetration is not a problem.

However, when valley-fixed, the cladding needs a side-lap

fastener in all laps, at each support. You will find it more

economical in labour, time and cost of fasteners to use a crest

66


Later checks =

Fixed sheets

Early checks = Later checks =

Early checks =

Star

t

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Crest fixing

CUSTOM ORB to steel support

TRIMDEK HI-TEN to timber supportTypical also of INTEGRITY (see detail)

SPANDEK HI-TEN to steel support

Sealingplate

Adhesive layer onunderside of sealingplate, bonds washerto roof sheeting

Non-conductiveEPDM washer

Roofingsheet

Detail of INTEGRITYconnection


TRIMDEK HI-TEN to timber supportTypical also of INTEGRITY (see detail)

SPANDEK HI-TEN to steel support

Sealingplate

Adhesive layer onunderside of sealingplate, bonds washerto roof sheeting

Non-conductiveEPDM washer

Roofingsheet

Detail of INTEGRITYconnection


TRIMDEK HI-TEN to steel support

Don't fix this valey

Typical valley fixing (for walls only)

fastener at each side lap in place of the lap fastener and adja-

cent valley fastener.

Pierce-fixing on side-lapsWhere roofing and walling are installed according to the support

spacing, side-lap fasteners are generally not required.

You may need to use side-lap fasteners where the cladding is

laid a little out of alignment and the weather resistance of a joint

is questionable. Decide on the number of side-lap fasteners by

what looks effective in each individual case.

Where valley fasteners are used, you need side-lap fasteners

along each lap at each support. Alternatively a crest fastener

may be used at each side-lap, in place of the side-lap fastener

and adjacent valley fastener.

Side-lap fasteners are located in the centre of the crest of the

overlapping corrugation.

67


Alternative valley fixing with crest fixing at side laps (for walls only)


TRIMDEK HI-TEN to timber support

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Concealed-fixing is the method of fixing sheets using fasteners

which do not pass through the sheet. Instead, the cladding is

held in place with clips. This is different from the alternative

method called pierce-fixing. The method of fixing you use is

determined by the cladding profile you are using.

Concealed-fixing is used for:

• KLIP-LOK™ 700

• KLIP-LOK™ 770

Very steep pitches

To prevent concealed-fixed cladding from sliding downward in

the fixing clips, on very steep pitches, you should pierce-fix

through each sheet under the flashing or capping, along the top

of the sheets.

Installing KLIP-LOK™ roofsUse the same general procedure described in general

installation procedure. However, at the start of installing

KLIP-LOK™ 700 and KLIP-LOK™ 770, a row of clips is fixed to

the supports before the first sheet is located over them and

locked in position.

Clips

For KLIP-LOK™ 700 use KL70 clips

For KLIP-LOK™ 770 use KL77 clips

PreparationAs described in General installation procedure:

• check flatness, slope and overhang;

• orient the sheets before lifting. Note the overlapping rib

is towards the end of the building where you start;

• Check that the overhang of the sheets from the clips,

at both eaves and ridge, is not less than the minimum

Position the first sheetWith particular care, position the first sheet before fixing,

to ensure that it will correctly locate in relation to other parts

of the building. Check that the sheet:

• is aligned with the end-wall (or its barge or fascia),

bearing in mind the type of flashing or capping treatment

to be used; and

• aligns correctly at its ends in relation to the gutter and

ridge (or parapet or transverse wall). Roof sheets should

overhang at least 50 mm into gutters.

Fix the first clips

KLIP-LOK™

Starting method 1. Cut the 1st clip 25 mm from the centre of the

second tower (as shown). The first tower on the cut clip locates

in the 1st rib of the first sheet. This method is preferred because

you don’t have to reach so far to fix the remote end of the clip.

Starting method 2. The first tower on the first clip locates in the

first rib of the first sheet. The clip fixes the edge of the first sheet,

but you must fix two clips at the start, and thus reach out further

for the first and all subsequent sheets.

The following description is for Method 1.

all KLIP-LOK™ profiles

Fix the first clip on the purlin nearest the gutter, with the clip

pointing correctly in the direction of laying. Be sure the clip is 90

degrees to the edge of the sheet.

Using a string line (or the first sheet as a straight edge) to align

the clips as you fix a clip to each purlin working towards the high

end of the roof.

11Installing concealed-fixed cladding

68

KLIP-LOK™ clipsFixing hole Dimples for

additional screws

KL65 fixing clip for KLIP-LOK 406

KL65

Direction of laying

700 HS fixing clip for KLIP-LOK 700

Direction of laying

Fixing screw through each tower

Place the first sheet

1. Locate the first sheet over the fixed clips

2. Using a measurement from the gutter-end of the sheet to the

fascia or purlin, position the sheet so that it overhangs the

desired amount into the gutter (usually about 50 mm). It is

important that you keep the gutter-end of all sheets in a

straight line.

all KLIP-LOK™ profiles: Fully engage the sheet with the

clips, using vertical foot pressure on all the ribs over each

clip.

Fix the next (and subsequent) clips and sheets

1. Fix the next row of clips, one to each support. Be sure the

clip is 90 degrees to the edge of the sheet, and the

embossed arrow on the clip points in the correct direction

KLIP-LOK™: Engage the slots and tabs on the clips.

KLIP-LOK™: Engage the clips over the rib of the installed

sheet. If a spur on the edge of the sheet fouls a clip, flatten

the spur with a rubber mallet to allow the clip to sit down over

the rib

2. As before, place the next sheet over its clips also engaging

the edge of the preceding sheet

3. Accurately position the sheet so that it overhangs the

desired amount into the gutter. It is important that you keep

69


Fix the first row of clips

KL65

KL65

KLIP-LOK 406 & 700 (KL65 clips shown)

KLIP-LOK 700

KLIP-LOK 700HS: Starting method 2

Standard flashing

KLIP-LOK 700HS: Starting method 1

Standard flashing

First clip Second clip

25 mm

Discard

Second clip

cut

here

Placing the first sheet

KLIP-LOK 700

KLIP-LOK 406 & 700 (KLIP-LOK 406 shown)

KL65

Overlapping rib

Underlapping rib

Overlapping rib

Underlapping rib

Engaging edges of sheetsSpurs on edge of bottom sheet must be fully engaged in shoulder of top sheet.

Don't step in this pan until ribs are engaged

KLIP-LOK 406

KLIP-LOK 700

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d C

ladd

ing

the gutter-end of all sheets in a straight line

4. Fully engage the two sheets along the overlapping rib.

You can do this by walking along the full length of the sheet

with one foot in the centre pan of the previous sheet and the

other foot applying vertical pressure to the top of the

interlocking ribs at regular intervals. It is important that you

don’t walk in the unsupported pan beside the overlap. A

rubber mallet may help engagement of laps on long spans

5. Similarly, engage all the clips by applying vertical foot

pressure to the top of the other ribs over each clip.

It is essential that the sheets interlock completely. It is important

that your weight is fully on the sheet you are installing.

KLIP-LOK™ 700: The spurs on the free edge of the underlap-

ping rib must be fully engaged in the shoulder of the overlapping

rib. You will hear a distinct click as the spurs snap in.


Occasionally check that the sheets are still parallel with the first

sheet, by taking two measurements across the width of the fixed

cladding.

At about half way through the job, perform a similar check but

take the measurements from the finishing line to aim for the final

sheet to be parallel with the end of the roof. If the measurements

are not close enough, lay subsequent sheets very slightly out of

parallel to gradually correct the error. To allow this to happen,

flatten the tabs on the base of subsequent clips - the slot in the

clip will allow the clips to be fixed out of standard pitch.

Place the last sheetKLIP-LOK™ 700: If the final space is less than the full width

of a sheet, you can cut a sheet along its length and shorten

the clips as appropriate.

Installing KLIP-LOK™ wallsThe installation procedure for walls is similar to that described

for roofs. To engage clips, use a rubber mallet (instead of foot

pressure).

To prevent KLIP-LOK™ from sliding downward in the fixing clips,

you should pierce-fix through each sheet under the flashing or

capping, along the top of the sheets.

70


Later checks =

Fixed sheets

Early checks = Later checks =

Early checks =

Star

t

Fini

sh

Purlin

This chapter describes how you can treat the ends of sheets to

maximised waterproofing, or to stop vermin entering.

Turn-upsAt the high end of roofing, wind can drive water uphill, under the

flashing or capping, into a building. To minimise this problem,

you turn up the valleys (or pans) at the high end of roofing. The

process is called turning-up (or stop-ending).

All roofing on slopes below 1 in 2 (25°) should be turned-up.

You can turn-up sheets before or after they are fixed on the roof.

If you do the latter, you must have sufficient clearance for the

turn-up tool at the top end of the sheets (about 50 mm).

Turning-up CUSTOM ORB®

With pliers, multi-grips or a shifting spanner closed down

to approximately 2 mm, grip the valley corrugations 20 mm

in from the end of the sheet and turn up as far as possible. Be

careful not to tear the sheet.

Turning-up TRIMDEK® and SPANDEK®

Slide the turn-up tool onto the end of the sheet as far as it will go.

Holding the tool against the end of the sheet, pull the handle to

turn up the tray about 80°.

Turning-up KLIP-LOK™You get the best results by first cutting off the corner of the

down-pointing leg of each female rib. Do this before you place

the sheets on the roof.

• With the hinged turn-up tool open: position the tool on the

sheet with the locating pins hard against the end of the

sheet.

• Hold the handles together to clamp the tool onto the tray, and

pull them to turn-up the tray 90°.

Flush turning-up KLIP-LOK™In normal turning-up of KLIP-LOK™, the tops of the ribs protrude

past the turned up tray. Consequently the turn-ups cannot be

positioned hard against a fascia or wall, or the ends of the sheets

on either side of the ridge cannot be butted together. This is

12End of Sheets

71


Turning-up CUSTOM ORB®

CUSTOM ORB

Turning-up (TRIMDEK® shown)

KLIP-LOK™ tool ready for turn-up

Completed turn-ups

KLIP-LOK™ tool ready for turn-up

40 mm

'Ear' flattened

'Ear' awaitingflattening

End

of S

heet

s

usually of no consequence because the turn-up is completely

covered by a flashing or capping. However, if you want the ribs

not to protrude past the turn-up, you can make a flush turn-up.

You need an extra 40 mm in sheet length for flush turn-ups.

1. Cut the top of each rib before turning-up the pans. Turn-up

the pans as described before.

2. Position the backing tool in the tray and hold it hard against

the turn-up with a foot.

3. With a rubber mallet, fold the protruding ‘ears’ flush against

the backing tool.

Turning-downAt the low end of roofing, wind or capillary action can cause

water to run back up the underside of the cladding. To minimise

this problem, you turn down the valleys (or pans) at the low end

of roofing. The process is called turning-down (or lipping).

All roofing on slopes below 1 in 5 (10°) must be turned-down.

Turning-down is usually done after the cladding is fixed on the

roof, provided there is no obstruction to the operation of the

turn-down tool.

• Push the turn-down tool over the end of the tray, as far as it will

go.

• Hold the tool hard against the end of the tray and push the

handle to form a turn-down about 20°.

SPANDEK® overlapsWhen SPANDEK® is laid on slopes of 5 degrees or less, cut back

the corner of the under-sheet, at the downhill end of the sheet,

to block capillary action.

Blocking off rib cavitiesDust, insects, birds, rodents and wind-driven rain can enter

a building through the cavities under ribs. To minimise these

problems the cavities can be blocked off. Rib end-stops are

available for KLIP-LOK™; strips of plastic foam can be used for

other profiles.

Infill strips

Closed-cell, foam-plastic infill strips are available to match the

top or bottom profile of our roof cladding.

At the lower end of cladding, the strip is sandwiched under the

roof cladding. Similarly, at the upper end, the strip is sandwiched

between topside of the roofing and the underside of the flashing

or capping.

Don’t use infill strips that can absorb water because retained

moisture can lead to deterioration of the sheet coating. Avoid

using infill strips made from, or treated with, flammable materi-

als, particularly in areas prone to bushfire.

72

Edge of sheet

turned-down

Turning-down the gutter end (TRIMDEK® shown)

Approx. 5 mm

Cut back corner

Approx. 5 mm

Cut SPANDEK® on low slopes.

Profiled closed-cell infill at eaves

Where roof pitches are below 1 in 5 (10°), you should incorpo-

rate infill strips to maximised waterproofness.

End-lappingBecause our roofing and walling is manufactured by continuous

processes, sheet lengths can be supplied up to the limits of

transport regulations which are frequently long enough to cover

roofs without end-lapping the sheets.

If you contemplate using sheets that are shorter than the full

span, and overlap them, you need to consider:

• the roof slope, because it affects the amount of overlap

• the method of fixing of the cladding to its supports,

because it affects the maximum length of sheet

Fixing methods for end laps

There are three methods of fixing cladding at end laps.

• Pierce-fixed through crests

Position the lap centrally over the support; and the fastening

secures both the lap and the cladding. Space the fasteners as

for an end span (layout in Figure a, terminology and recom-

mended spacing). The thermal expansion is away from the fas-

tener and towards the outer ends of the sheet run.

• Pierce-fixed through valleys

Position the lap centrally on the support, and the fastening

secures both the lap and the cladding. (in Figure b). The thermal

expansion is away from the fastener and towards the outer ends

of the sheet run.

• Concealed-fixed sheets

You can either pierce-fix through the crests or the valleys (in

Figure a and b), or use clips near the lap (in Figure c).

KLIP-LOK™ sheets deform at the clips so that sheets won’t nest

together. If you use clips, the lap is placed just clear of and on

the high side of the clip (in Figure c). The lap is secured with

pierce-fixing through the valleys. The clips allow the sheets to

slip when they expand with heat.

To make the end-lapping of KLIP-LOK™ easier: remove, for the

length of the lap, the down-turn of the underlapping ribs of the

top and bottom sheets in each sheet run. The cut-back ribs are

covered by the sheets of the next sheet run.

longline 305, can be fixed using any of the three methods.

The underlapping ribs have to be slightly squashed at the lap to

allow them to nest. An end-lap tool is available.

73


(a)Pierce-fixed

through crest

Fastened clipon purlin

2 fasteners per trayself-drilling screws

with EPDMsealing washer

(b)Pierce-fixed

through valley

2 fasteners per trayself-drilling screws

with EPDM sealing washer

(c)Concealed-fixed

withpierce-fixing

through valley

See text forspacing of fasteners

See Table 10.4.1

See Table 10.4.1

See Table 10.4.1

Fixing at end laps

Table- End laps

pal-dnE)mm(muminim

pal-dnE)mm(mumixam

epolsfooR)°51(4ni1nahtsseL 002 003

)noitcessihtniretal('seerged51nahtsselsehctipnispal-dnE'eeS

)°51(4ni1nahtretaerG 051 052

sllaW 001 002

End

of S

heet

s

Flashings and cappings are strips of metal formed to weather-

proof the edges of roofing and walling. For the purposes of this

chapter, only the term flashing is used.

Similar methods of flashing are used for different cladding-pro-

files. You can adapt the principles to suit your application.

In all cases it is important to have ample cover provided by the

flashing and proper turn-up of the cladding underneath.

Be careful when moving between supports. Do not walk in the

pan immediately adjacent to flashings or translucent sheeting.

Walk at least one pan away.

bluescope lysaght has a range of standard flashings. We can

also supply custom flashings to your requirements - ask your

local service centre for details.

MaterialsIt is very important that flashings be made from materials that are

compatible with the cladding.

Lead flashing is not recommended, however it will usually be

retained when re-roofing, because it is usually cemented into the

structure. In these cases:

• the top surface of the lead flashing must be painted with

a good quality exterior paint system (to limit contamina-

tion with lead compounds in water running off the flash-

ing); and

• there must be a barrier between the lead flashing and

the cladding: either a plastic strip (such as polythene

dampcourse), or paint.

Flashings should conform to AS/NZS 2179.1:1994, and be com-

patible with the cladding.

Materials for non-standard flashings and other accessories are

available in ZINCALUME® steel or COLORBOND® steel finishes.

Longitudinal flashingsLongitudinal flashings run parallel to the pans or valleys, and are

made to suit the sheet profile. They should have an edge turned-

down to dip into the pan or valley.

Transverse flashings Transverse flashings run across the pans or valleys. They

usually have a stiffening bend, along the lower edge, which is

turned-down to dip into the pan or valley. To maximised weather

proofing, the bent edge is fashioned to fit the profile.

13Flashings

74

Fix at 600 mm centres (See Chapter 3 for fasteners)

Fasten at 600 mm centres (See Chapter 3 for fasteners)

Soft aluminium or zinc over-flashing, stepped and tapered to follow

fall of roof

Typical longitudinal flashings

Fascia capping

Parapet flashing

Ridge capping

Approx. 600 mmfor all profiles

Typical transverse flashings

The turn-down for transverse flashings for CUSTOM ORB® and

custom blue orb can be either notched, scribed to match the

corrugations, or lightly dressed into the valleys. Scribing or

notching is preferred for low-slope roofs.

The turn-down for transverse flashings for ribbed cladding is

always notched to fit over the ribs, except in the case of

CUSTOM ORB® and custom blue orb where the flashing is

dressed into the valleys.

Notching toolsHand-operated notching tools cut one notch at a time. Each tool

matches only one cladding profile. There are two types of tool;

their use depends on whether or not the edge of the flashing has

first been bent down.

Using notching tools

After the cladding is fixed and the turn-ups finished, proceed

as follows.

• Place a flashing with the notch-edge resting on the ribs.

• Locate your notching tool over a rib with the notching head

against the flashing.

vertical tool: The body locates along the rib.

horizontal tool: the lugs on the underside locates on top

of the rib.

• Raise the handle to open the tool and:

vertical tool: lift the flashing into the mouth of the tool;

horizontal tool: slide the mouth of the tool over the edge

of the flashing as far as it will go.

• Push down on the handle to perform the notching.

• Repeat for all ribs, checking in each case that the flashing is

correctly positioned.

• If you are using a horizontal tool, bend down the tongues

between the notches over a suitable straight edge (such as

a piece of timber).

Notching with tinsnipsIf notching tools are not available, flashings can be notched to

the rib profile with tinsnips. The procedure is sometimes known

as scribing. After the cladding is fixed and the turn-ups finished,

proceed as follows.

• Place the flashing with the turned-down edge resting

on the ribs.

• Mark out the notching using a template positioned over

each rib.

• Cut the notches with tinsnips.

This procedure is also used for hip cappings.

Joining flashings

The overlaps of transverse flashings should be sealed with a

recommended sealant and fastened. Before finally positioning

and fixing the lap, turn over the top piece and apply a 3 mm

bead of sealant across the flashing, about 12 mm from the end.

75


Table - Notching tools

lootfoepyT nwoddenrutegdEgnihctonerofeb rofelbaliavA

slootgnihctonlatnoziroH oN PILK - KOL , KEDNAPS , KEDMIRT

slootgnihctonlacitreVdellacosla( deeps

srehcton )seY

PILK - KOL , KEDNAPS,KOL-PILK ,KEDMIRT , BROMOTSUC ,

Horizontal notching tool (KLIP-LOK 406 shown)

Vertical notching tool (KLIP-LOK 406 shown)

Using notching tool

Flas

hing

s

There are many types of insulation installed in the steel build-

ings. However, fibreglass, rockwool blanket insulation is com-

mon type used, and these instructions pertaining to this type

only. One side of the blanket insulation should have proper bar-

rier that must face the inside of the building regardless of

whether the insulation is for heating or cooling.

Choose correct length, density and thickness of insulation as per

the erection drawing. If require pre cut roof insulation to reach

from eave to eave or eave to purlin allowing approximately 2

feet of additional length to facilitate handling. Hold insulation at

one sidewall and roll out insulation across the purlins, vapour

barrier to the inside of the building. Stretch the insulation to pro-

vide a tight, smooth and wrinkle free side surface. Weight clamp

can be used at each end to hold tight. Double adhesive tape can

be used on eave strut and purlins below the insulation to prevent

insulation from flying off due to wind. Trim excess insulation at

the edge of eave and cut fibreglass approximately 100 mm from

end leaving only facing. Fold facing over end of blanket insula-

tion to seal the ends.

After installing the first roll of insulation, fix the closure on to the

eave strut with the help of double adhesive tape. Install the first

roof panel, before installing the fasteners check the alignment of

roof panel and projection of roof panels beyond eave strut and at

gable end. After installing the first run of roof cladding, lay the

second run of insulation in same manner given above and sta-

ple the side lap by folding as shown in the figure The general

sequence is to install the roof cladding in conjunction with the

insulation.

It is recommended that both sides of the ridge of a building be

insulated and sheeted simultaneously.This will keep the insula-

tion covered for the maximum amount of time and panel ribs can

be kept in proper alignment for ridge cap.

At the sky light portion insulation is cut keeping 150 mm projec-

tion on all side as shown in figure. Cut fibre glass leaving only

facing. Facing to be properly folded and on all sides. If insulation

termination angle is provided the insulation is properly folded

and screwed to the angle.

The insulation blankets 6 inch and thicker require longer screws

(1_ or 1_ in) than commonly used for roofing attachment, to

avoid squeezing the insulation so tight that the panel gets dim-

pled.

14Insulation

76

Insulation cutting at the FRP Sheet

Wall Insulation

The first run of insulation is temporally attach to the eave strut or

support angle with the help of vice grips or other clamping

arrangements as shown in figure. Install double face tape at the

eave strut to hold the insulation. Obtain smooth wrinkle free

inside surface by pulling the insulation tight from top to bottom.

Use double face tape to hold the insulation to the base angle or

bottom girt. Cut the fibreglass from vapour barrier on excess

length and fold up to seal the ends.

The general practice is to install the wall panel in sequence with

the insulation. It is extremely important to check plumb and level

of wall panel before installing. Similarly second run of insulation

is installed side laps are to be properly folded and stapled. There

must not be any holes in the facing.

Sealing Insulation laps

Double tab insulation is sealed together at the sidelaps by fold-

ing and stapling as shown below. The stapling is done from the

outside as the insulation is applied. Pull the adjoining tabs out-

ward at the joint and align the edges. Staple, fold and staple as

shown.

1.

2.

3.

4.

5.

Storage of Insulation Roll

When the rolls of insulation are received they should be careful-

ly stored, protected from the weather. Handle the rolls with care

to avoid damaging or punctur-

ing the insulation facing. Do

not store the rolls which are

multiples of the wall height and

are to be filed cut to required

length.

77


Perfect sealing of side lap of insulationIn

sula

tion

SafetyIt is commonsense to work safely, protecting yourself and work-

mates from accidents on the site. Safety includes the practices

you use; as well as personal protection of eyes and skin from

sunburn, and hearing from noise.

Occupational health and safety laws enforce safe working con-

ditions in most locations. Laws in every state require you to have

fall protection which includes safety mesh, personal harnesses

and perimeter guardrails. We recommend that you aquatint your-

self with all local codes of safe practice and you adhere strictly

to all laws that apply to your site.

Care and storage before installationRain or condensation is easily drawn between the surfaces of

stacked sheets by capillary action, or they can be driven in by

wind. This trapped moisture cannot evaporate easily, so it can

cause deterioration of the coating which may lead to reduced

life-expectancy or poor appearance.

If materials are not required for immediate use, stack them neat-

ly and clear of the ground. If left in the open, protect them with

waterproof covers.

If stacked or bundled product becomes wet, separate it without

delay, wipe it with a clean cloth and stack it to dry thoroughly.

The sheeting material shoud be placed with a minimum 50 slope

to avoid a water pond.

Handling cladding on siteOn large building projects you can reduce handling time by lift-

ing bundles with a crane direct from the delivery truck onto the

roof frame. Use a spreader bar for long sheets. For small to

medium size projects, without mechanical handling facilities, you

can unload sheets by hand and pass them up to the roof one

at a time.

For personal safety, and to protect the surface finish, wear clean

dry gloves. Don’t slide sheets over rough surfaces or over each

other. Always carry tools, don’t drag them.

Walking on roofsIt is important that you walk on roofing carefully, to avoid

damage to either the roofing or yourself.

Generally, keep your weight evenly distributed over

the soles of both feet to avoid concentrating your weight on

either heels or toes. Always wear smooth soft-soled shoes; avoid

ribbed soles that pick up and hold small stones, swarf and other

objects.

When you walk parallel to the ribs:

• for ribbed roofing walk on at least two ribs or

corrugations (CUSTOM ORB®, and SPANDEK®);

• for pan-type roofing walk in the pans (KLIP-LOK™,

TRIMDEK®).

When you walk across the ribs, walk over or close to the roofing

supports.

15General care, safety andhandling

78

Where possible do not leaveuncovered stacks of sheets lying

in the open.

If stacks cannot be kept under cover,barricade the stack and cover it with

a waterproof tarpaulin, but leavespace between the cover and the

sheets to allow air to circulate.

Store off the ground and on a slopeso that if rain should

penetrate the covering,water will drain away.

Inspect the storage site regularlyto ensure that moisture has not

penetrated the stock.

Be careful when moving between supports. Do not walk in the

pan immediately adjacent to flashings or translucent sheeting.

Walk at least one pan away.

Always take particular care when walking on wet or newly laid

sheets - particularly on steeply pitched roofs.

If there will be heavy foot traffic on a roof, provide a temporary

walkway or working platform to minimise damage.

Never step on the Skylight panel or translucent panel.

Marking out, cutting and drilling

Marking outA pencil of any colour may be used except black or so-called

lead pencils. Don’t use black pencils to mark roofing or walling

because the graphite content can create an electric cell when

wet and thus cause deterioration of the finish. You can also use

a string line with chalk dust, or a fine, felt-tipped marker.

Cutting

Where possible, you should minimise site-work by using sheets

cut to length in the factory.

For cutting thin metal on

site, we recommend that

you use a power saw with

a metal-cutting blade

because it produces

fewer damaging hot

metal particles and leaves less resultant burr than does a car-

borundum disc.

Cut materials over the ground and not over other materials

where hot particles can fall and cause damage to finishes -

especially COLORBOND® steel prepainted finishes. It is best to

have the exterior colour finish of a COLORBOND® prepainted

sheet facing down, however you must then protect the paint fin-

ish from scratching by your work supports.

If you have to cut materials near sheets already installed, mask

them or direct the stream of hot particles away.

Reciprocating nibblers are also widely used in the roofing trade,

and they produce an excellent cut. The resulting small, sharp

scraps can rust and damage finishes; and they can cause per-

sonal injury. Take special care to collect these scraps.

Making holes

Holes are often made by drilling or cutting by hole saw or jig saw.

Mask the area around the hole to protect paint from damage by

swarf.

Clean upSwarf (metal scraps or or abrasive particles resulting from cut-

ting and drilling) left on the surfaces of materials will cause rust

stains which can lead to reduced life of the material.

• Sweep or hose all metallic swarf and other debris from roof

areas and gutters at the end of each day and at the comple-

tion of the installation.

• If swarf has become stuck on a finish, it can be removed.

Take great care not to remove the paint or the metal coat-

ings.

• For critical applications inspect the job two weeks after com-

pletion, when rain or condensation will have caused any

remaining swarf to rust, and thus highlight affected areas.

Warn other contractorsMany stains arising from swarf do so, not from the work of roof-

ing-installers, but from other contractors working on the job.

Similarly, problems can arise from contact with incompatible

materials, like copper piping or chemically treated timber. Acid

cleaning of bricks can also be a problem. Architects and builders

need to be aware of this, and warn contractors accordingly.

79


Swarf Cleaning

Gen

eral

Car

e, S

afet

y an

d H

andl

ing

SealantsRecommended sealantsNeutral-cure silicone sealants have been successfully used with

the range of steel finishes on our roofing and walling; and on

flashings, cappings, and gutters made from the same materials

as the cladding.

Neutral-cure silicone sealants:

• have good adhesion to the clean surface of all our roofing

and walling;

• are water resistant and non-corrosive;

• are resistant to extreme of heat and cold while retaining

good flexibility;

• provide high resistance to ultra-violet rays (sunlight); and

• have a long service life.

It is important that only neutral-cure silicone be used with sheet

steel. Other silicone sealants, often have a vinegar or ammonia

smell, and give off aggressive by-products during curing which

are detrimental to sheet steel.

If in doubt, look for a message on the sealant package like:

Suitable for use with galvanised and ZINCALUME® steel products.

Cleaning surfaces

For effective bonding, all surfaces must be clean, dry and free

from contaminants such as old sealant or oil.

Mineral turpentine is suitable for cleaning the surfaces but care

must be taken to completely remove all residual solvent with a

clean dry cloth. White spirits is an alternative.

Sealant must be applied on the same day as the surface is

cleaned.

Joint strength

Seams sealed with sealant should be mechanically fixed for

strength. Fasteners in joints should generally be no further apart

than 50 mm.

The sealant does not require significant adhesive strength in

itself, but it must bond positively to all the surfaces it is to seal.

To ensure complete sealant cure, the width of sealant in a lap

should not exceed 25 mm when compressed.

Applying sealant

Always apply the bead of sealant in a continuous line along the

centreline of the fastener holes. This ensures that, when com-

pressed, the sealant positively seals the fastener.

Be careful not to entrap air when applying sealant. Especially,

don’t place a ring of sealant around fastener holes because

entrapped air compresses during tightening of fasteners, and

may blow a channel through the sealant, which could prevent the

fastener from being sealed.

Fasteners

Use solid or sealed fasteners, otherwise you have to apply

sealant to the hollow centre of open blind rivets.

To preserve the life of your cladding, is very important that

fastener materials are compatible with the cladding.

ProcedureThe preferred procedure for lap fabrication is:

1. Assemble, clamp and drill;

2. Separate components and remove drilling debris;

3. Clean joint surfaces as recommended above;

4. Apply bead(s) of sealant;

5. Relocate components and fix;

6. Externally seal each fastener if hollow blind rivets are used.

To prevent premature curing (which causes poor bonding), finish

the joint as soon as practical after applying the beads of sealant.

The manufacturer’s specified sealant open times should be fol-

lowed.

Sealant clean up

80

Typical joints with sealant

Sealant 25 mm max.

Sealant 25 mm max.

Sealant 25 mm max.

With practice you will be able to judge the size of beads thus

avoiding squeeze-out and the subsequent need to clean up.

Uncured sealant can be removed with a clean, dry rag and any

excess then removed with a cloth lightly dampened with mineral

turpentine or white spirits. Excess cured sealant is best removed

with a plastic spatula to avoid damage to the surface finish of

the metal.

Avoid any unnecessary smearing of sealant on

surfaces intended for painting as silicone can affect adhesion of

paint. Smeared sealant may be treated by lightly abrading the

area with a non-metallic scouring medium.

Maintenance

Factors that most affect the long life of a roof (or wall) are

original design, the environment of the installation, and the

maintenance of the installation. Maintenance is probably the

biggest factor.

Maintenance includes:

• Regular inspection for problems before they become major

corrosion sites;

• Regular washing down, especially near coastal or industrial

influences;

• Removal of leaves and other debris from gutters;

• Keep walls free of soil, concrete and debris near

the ground;

• Don’t overspray pesticide.

Maintenance of COLORBOND® steel

The paint system on COLORBOND® steel sheet is very durable.

Simple maintenance of the finish enhances its life and maintains

attractiveness for longer periods.

Where the paint finish is naturally washed by rainwater (roofs, for

example) there is usually no additional maintenance needed.

However areas to be washed include soffits, wall cladding under

eaves, garage doors, and the underside of eave gutters.

Washing should be done at least every six months and more

frequently in coastal areas where sea spray is prevalent, and in

areas where high levels of industrial fallout occur. Avoid

accumulation of salty deposits or industrial dirt.

Establish a regular routine for washing COLORBOND®

steel products. Often garage doors can be washed with clean

water at the same time as your car is being washed. Guttering

and eaves can be hosed down when windows are being

cleaned. Walls can be hosed down while watering the garden.

Where regular maintenance doesn’t remove all the dirt, wash the

surface with a mild solution of pure soap or non-abrasive non-

ionic kitchen detergent in warm water. Use a sponge, soft cloth

or soft bristle nylon brush; be gentle to prevent shiny spots.

Thoroughly rinse off the detergent with clean water.

Never use abrasive or solvent cleaners (like turps, petrol,

kerosene and paint thinners) on COLORBOND® steel surfaces.

For advice on grease, oil or deposits not removed by soap or

detergent contact our Information Service

A preventive maintenance program is a key factor in maximising

the life expectancy and dependability of the roof system. It is

important to carryout periodic maintenance of your building to

ensure trouble free service and extend the life span of the

building. As a part of on-going maintenance program, periodic

inspections, beginning at the completion of building are of

utmost importance.

81


Gen

eral

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Material Shortage Claim

Short materials: Immediately upon delivery of material, quanti-

ties should be verified against those mentioned in the packing

list. Also the material controller has to check for any damage of

material.

There are different reasons for material shortage at site and

claims can be raised on the appropriate grounds. Mentioned

below are common reasons for claims.

A. Items Not Received

1. Any material mentioned in the packing list but not received

at site due to lost during the transportation.

2. Any material mentioned in packing list but not loaded in

the vehicle.

3. Material required on site has been loaded to some other

site and some other material of other job not appearing in the

shipper list is loaded in the vehicle.

B. Damaged Materials

1. Material damaged in transportation and unloading, which

cannot be rectified at site.

C. Detailing Error

1. Material mentioned in the drawing but not listed in the

shipper list.

2. There could be surplus or shortage in any item due to an

error in preparing the shipper.

3. Missing holes / wrong location of holes on any member to

connect other member.

4. Incorrect length billed in the shipper list.

D. Improper Fabrication

1. Material wrongly fabricated and not suitable for installa-

tion.

E. Design Error

1. Any material fabricated, shipped and found unable to pro-

vide the function originally specified in the work order.

Claim: In case of material shortage due to category A & B men-

tioned above Builder/ Customer/Product consultant shall make a

written claim within 7 days for unpacked items such as Rafter,

Columns, purlins and other items which can be counted easily

and within 30 days for packed items such as bolts, screws, rods

etc. from the date of arrival to the job site by giving correct

description and quantities short received.

In case of category C, D & E time period will be any time during

erection.

All claims will be reviewed by BlueScope Steel's Product con-

sultant before forwarding to plant. Cost of items to be replaced,

lost or damaged during transportation including freight will be

paid eventually by the insurance company or by customer (If

shipment was not insured) and therefore request for such mate-

rials cannot be defined as claims and will be treated as an order

or straight sale.

Cost of items lost or damaged due to irresponsibility of builder or

customer has to be borne by the concerned builder or customer.

16Claims

82

Field Work and Claims

All erection work will as per procedures mentioned in the

American Institute of Steel construction code of standard prac-

tices for steel buildings.

The correction of minor misfits by the use of drift pins to draw the

component into line, shimming moderate amount of reaming,

chipping and cutting and the replacement of minor shortages of

material are a normal part of erection and are not subject to

claim.

Claims for Corrective Repair Work

In cases where installer believes there are errors in shop fabri-

cation that prevent the proper assembling and fitting of parts by

use of drift pins, reaming, chipping or cutting the installer shall

immediately report to the local BSBS office or Product consult-

ant for initial claim

Initial claim: In the event of error, the Builder / Customer

shall promptly make a written “Initial Claim” to the Tata

BlueScope Steel for correction of design, drafting or fabrica-

tion error. The initial claims include:

1. Description of nature and extent of the errors including

quantities, part marks etc.

2. Description of nature and extent of proposed corrective

work including estimated man hours

3. Material to be purchased from the other than the Tata

BlueScope Steel office including estimated quantities and

cost.

4. Maximum total cost of proposed corrective work and

material to be purchased from other than purchased.

Authorisation for corrective work: If error is the fault of the

Tata BlueScope Steel office an Authorisation for Corrective Work

shall be issued in writing by the Tata BlueScope Steel office to

authorise to corrective work at cost not to exceed the maximum

total cost set forth. Alternative corrective work other than that

proposed in initial claim may be directed by Tata BlueScope

Steel office.

Final claim: The final claim in writing shall be forwarded by the

builder /customer to the Tata BlueScope Steel office within ten

days of completion of corrective work authorised by Tata

BlueScope Steel office. The final claim shall include:

1. Actual numbers of man-hours by date of direct labour use

on corrective work and actual hourly rates of pay.

2. Authorisation from Tata BlueScope Steel office for correc-

tive work.

3. Taxes and insurance on total actual direct labour.

4. Other direct cost on actual direct labour.

5. Cost of material purchased from other than Tata

BlueScope Steel office including copies of main invoices.

6. Total actual direct cost of corrective work (sum of 1, 2, 3,

and 4) the final claim shall be signed by the builder.

7. Cost of equipment (rental or depreciation), small tools,

supervision overhead and profit are not subject to claim.

The Tata BlueScope Steel office is not liable for any claim result-

ing from use of drawings or literature not specifically released for

construction for the project.

Tata BlueScope Steel is not liable for any claim resulting from

use by the erector/customer of any improper material or

material containing defects which can be detected by visual

inspection. Cost of disassembling such improper or defective

material and cost of erecting replacement material are not

subject to claim.

83

Part 4 - Building Maintenance and Recommendations

Cla

ims

Fabrication and Erection Tolerances

Cold-Formed Structural Members

The fabrication tolerances indicated in figure for cold-formed

structural members are defined in the following table.

17Tolerances

84

Cold-Formed Structural Members

85


Built-up Structural Member

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86

Built-up Structural Member

87


Span A = 9.52 mm 6 mm / 6m

Straightness B = 9.52 mm 6 mm / 6m

Elevation C = 9.52 mm 6 mm / 6m

Beam toBeam TopRunning

D = 9.52 mm 6 mm / 6m

Beam toBeam

UnderhungE = 9.52 mm 6 mm / 6m

AdjacentBeams

F = 9.52 mm 6 mm / 6m

Item Tolerance Max. Rate of Change

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Workmanship Accuracyof Erected Steelork

Foundation Inspection

The steelwork contractor shall inspect the prepared foundations

and holding down bolts for position and level not less than seven

days before erection of steelwork starts. He shall then inform the

employer if he finds any discrepancies which are outside the

deviations specified in this specification guide, requesting that

remedial work be carried out before erection commences.

Foundation LevelDeviation from Exact Level

Vertical WallDeviation from exact position at steelwork support point

Pre- set wall boltDeviation from specified position

Permitted Deviations ofErected Components

Positions of column at base

Deviation of section centreline from the specified position

Single Storey Column Plumb

Deviation of top relative to base, excluding portal frame

columns, on main axes

Multi - Storey Columns Plumb

Deviation in each storey and maximum deviation relative to

b`ase

88

Gap between bearing surfaces

Deviation from the specified level

Alignment of Adjacent Perimeter Columns

Deviation relative to next column on a line parallel to the grid

line when measured at base or splice level.

Beam Level

Deviation from specified level at supporting column

Level at Each End of Same Beam

Relative deviation in level at ends

Level of adjacent beams within a distance of5 metersDeviation from relative horizontal levels (measured on

centreline of top flange)

Beam AlignmentHorizontal deviation relative to an adjacent beam above or below

Crane Gantry Column PlumbDeviation of cap relative to base

Crane Gantries Gauge of Rail TracksDeviation from true gauge

89


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Built-up Structural Members

DimensionsTolerances

+ -

Geometry a 30 - 6.35 Max 30 - 6.35 Max

b 6.35 6.35

d 4.76 4.76

e 3.18 3.18

c D / 1800 mm

f D / 1800 mm

Hole Location E1 3.18 3.18

E2 3.18 3.18

E3 3.18 3.18

S1 1.59 1.59

S2 1.59 1.59

F 3.18 3.18

Length (L) 3.18 3.18

Sweep (S) Runway Beams 1/8 " x L (ft) / 10

All other members 1/4" x L (ft) /10

Camber C 1/4" x L (ft) /10

Splice Plates N1 3.18 3.18

N2 4.76 4.76

G1 1.59 1.59

G2 1.59 1.59

H Upto 600 mm 3.18 3.18

600 to 1200 mm 4.76 4.76

> 1200 mm 6.35 6.35

J

91


Formed Structural Members

DimensionsTolerances

+ -

Geometry D 4.76 4.76

B 4.76 4.76

d 9.53 9.53

Hole Location E1 3.18 3.18

E2 3.18 3.18

E3 3.18 3.18

S1 1.59 1.59

S2 1.59 1.59

F 3.18 3.18

P 3.18 3.18

Length (L) 3.18 3.18

Camber C 1/4" x L (ft) /10

Minimum Thickness

Allowable torque for bolt tightening and inspection

In the completed connection, all bolts shall have at least the minimum torque applied as specified below when all bolts

in the bolt group are tightened.

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Bolt Diameter Minimum Recommended Torque

Dia (mm) Clause 8.8 (Nm) Clause 10.9 (Nm)

12 87 128

16 214 315

20 431 615

24 745 1060

32 2013 2865

36 2586 3680

42 4135 5880

A preventive maintenance program is a key factor in maximizing

the life expectancy and dependability of the roof system. It is

important to carryout periodic maintenance of your building to

ensure trouble free service and extend the life span of the

building. As a part of on-going maintenance program, periodic

inspections, beginning at the completion of building are of

utmost importance.

Safety

Whenever you perform maintenance on the roof system, safety

must be a prime concern. Building maintenance personnel

should have fall protection and other personnel protection

equipments. Failure to follow can result in serious personal injury

or even death of the maintenance personnel.

A completed roof system is a safe working surface except near

the edge of the roof and when any moisture (such as dew, frost,

snow etc.) makes the surface of the roof very slippery. Roof

installations with steep slopes can also be hazardous without

proper safety equipment. Appropriate safety measures and extra

caution should be exercised whenever these conditions are

present.

Make sure maintenance personnel are adequately instructed in

safety and that they are provided with appropriate safety equip-

ment. Working off the ground, even a few feet, can be danger-

ous and fall from any height can be fatal.

Whenever performing building maintenance, the following pre-

cautions must be taken:

• Always use fall protection, especially near building edges or

eaves.

• Do not walk on FRP sheets or translucent panels.

• Do not walk on wet roof panels.

• Do not walk, step or sit on skylights or ridge cap.

• Do not walk in gutters.

• Guard all skylights and other roof openings or holes.

Following are general maintenance recommendations for pre-

engineered steel buildings. We suggest that you develop a pre-

ventive maintenance schedule for your buildings based on the

guidelines given below and considering any special conditions

that are specific to your project.

A. Maintenance of Building ExteriorPeriodic maintenance of the exterior will depend on the location

of your building.

Building Location Maintenance Period

1. Upto 5 miles from the sea - 3 months

2. High pollution industrial area - 3 months

3. Medium pollution industrial area - 6 months

4. Areas of high humidity - 6 months

5. Low pollution industrial area - 9 months

6. Dry desert areas - 12 months

Preventive maintenance should commence immediately after a

project is erected, modified or repaired.

1. Check for any debris that may have been left on top of panel

or trim. Example of this are ferrous items such as screws, pop

rivets nails, sheet metal off-cuts, tin cans, etc. large or heavy

items should be removed by hand to avoid damaging the paint

or zinc layer on the panel. The remaining smaller items may be

swept-off with a soft nylon brush. Please note this check should

be made after any tradesman has worked on the building e.g.

electricians, plumbers, air conditioning technicians and steel

erectors.

2. Check for sand or dirt build up. These retain salt and mois-

ture and will rapidly break down the paint and zinc layers result-

ing in corrosion of the base metal.

3. The most vulnerable areas of building are:

a. Gutters

b. Roof sheets

c. Shelters areas under eaves or canopies

d. Top portion of walls sheltered by roof overhangs or

18Building Maintenance and Recommendations

92

gutters sand and dirt should be washed off with clean water

and a soft nylon brush. Clean from top to bottom and give

a final rinse with water when completed. Ensure no water

is trapped anywhere.

4. If building is in an area of high industrial pollution or close to

marine environment then water alone may not be enough. Salt

and other deposits build up at formed corners of panels and

quickly breakdown the paint and zinc layers and finally corrode

the base metal. As such deposits build up, the hardness of the

layers increases making removal more difficult. In these cases

the period between maintenance operations should be short-

ened and a mild detergent should be added to the initial wash-

ing water.

Gutter MaintenanceTwigs, dust, leaves and fungal matter (debris) should be

removed using the following recommended procedure, taking

care to ensure no damage occurs to the gutter during debris

removal. We recommend that the following procedure be adopt-

ed to remove the dust, debris and fungal matter.

• Sweep debris into a pile using a stiff, soft bristled brush

(shovels or hand tools should not be used).

• Place debris into a receptacle and lower to the ground.

• The whole roof and gutter should then be washed down with

a hose, including high ends of gutters possibly protected by

overhangs, rain heads, water spouts and overflow locations.

• If significant fungal growth is found it should be identified and removed.

• Any metallic staining should be investigated to determine

whether the cause is from a metallic deposit on the surface,

or from the breakdown of the coating. Metallic deposits on

the surface should be completely removed immediately.

Breakdowns in the coating would generally result from poor

maintenance techniques and scratching.

Downtake Pipe Maintenance

The downtake pipes and stormwater disposal pipes are to be

inspected for cleanliness and free flow of water. Growth of fun-

gus and other matter and collected debris at the inlet and outlet

locations is to be noted. Complete testing of the system for

blockage at each downpipe is recommended. Record and docu-

ment the observations of the inspections.

• Downpipes made from BlueScope Steel products should be

cleaned using a pressure water hose directed down each of

the downpipes.

• The hose should then be fed into the pipe from the inlet down

to the outlet, to ensure there are no obstructions.

• Constrictions in the downpipe system may make it necessary

to access the pipe from inspection points downstream of the

downpipe inlet location.

• Any noted blockages should be removed immediately, to

avoid water back-up in the gutters.

Penetrations, Flashings, Cappings

All penetrations and cappings are to be inspected for the build-

up of debris or organic material located between the flashings or

cappings and the cladding materials, visually noted to be pro-

truding from, or staining the joint. Care is to be taken in noting

any staining at the high side of penetrations. All observations are

to be recorded and documented in accordance.

• Build-up of debris or organic matter (debris) should be

completely removed using a stiff bristled soft brush. No hard

tools should be used.

93


A typical gutter clogged with leaf litterprior to cleaning

Wear correct protection whenclearing leaves and twigs

When litter is removed, the layer ofhardened dirt is revealed below

Spray the gutter & downpipes withwater to soften and break up dirt

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• The area should then be washed down with a pressure hose.

Care should be taken to ensure that debris is not lodged

between sheets or the sheeting and flashing and that water

from the pressure hose is not driven into the building.

• Stubborn stains and dirt not removed in the hosing can be

removed by application of soaps and detergents which are

detailed in this document.

Roof Sheeting Maintenance

All cladding are to be inspected for the deposition of any debris,

dust, pollutants or organic growth. In particular, care is to be

taken in the inspection of cladding for these points:

• Staining of cladding at possible ponding locations

• Build up of dust and debris

• Metallic staining of the gutter, surface rust

• Record and document the observations of the inspections.

Maintenance

Twigs, dust, leaves and fungal matter (debris) should be

removed using the following recommended procedure, taking

care to ensure no damage occurs to the cladding during debris

removal. We recommend that the following procedure be adopt-

ed to remove the dust, debris and fungal matter.

• Sweep debris into a pile using a stiff, soft bristled brush

(shovels or hard tools should not be used).

• Place debris into a receptacle and lower to the ground.

• The whole roof and gutter should then be washed down with

a hose, including high ends of gutters possibly protected by

overhangs, rain heads, water spouts and overflow locations.

• If significant fungal growth is found it should be identified and

removed.

• Investigate metallic staining of the roof or gutter to determine

if it is caused by a metallic deposit, or by breakdown of the

coating on the cladding. If it is a metallic deposit, completely

remove it immediately.

Breakdowns in coating would generally result from poor mainte-

nance techniques and scratching.

The following is suggested solution

a. 1/3 cup detergent (e.g. tide)

b. 1/3 tri-sodium phosphate(eg soilex)

c. 1 quart sodium hypochlorite-5% solution (e.g.chlorox)

d. 3 quarts water.

Wash down the panel with the above solution and soft nylon

brush. A final rinse with clean water should follow.

Caulking compounds, oil grease, tar wax or similar substances

can be removed with mineral spirit. Follow this by cleaning with

detergent solution and clean water rinse.

AVOID SOLVENT AND ABRASSIVE TYPE CLEANERS AS

THEY CAN DO MORE HARM THAN GOOD BY WEARING

AWAY BOTH THE PAINT AND ZINC LAYERS

5. Check the base of wall panels to ensure the ground level is at

least 11/2” below the bottom of panels. If wind blown soil has

built up at the base of the wall, it should be removed. If

plants/shrubs etc. are around the building, make sure they are

not touching the wall panels, particularly thorn-type bushes.

6. Check all equipment which is located through or adjacent to

any panel (Roof or Wall). Ensure there is no moisture build up on

or near the panel; if there is, then corrosion is inevitable. If this

condition exits, then modifications are required to avoid it.

The following situations are examples of conditions to be avoided.

a. Water run-off from water services or air conditioners.

b. Copper pipes fastened directly to the steel panel.

c. Open water storage tanks or ponds adjacent to the

panels.

7. Standard gutter and valley gutters:

a. Regular checks should be made and all rubbish and

sand should be removed.

b. Flush the gutters with water.

c. Check the downspouts are clear.

d. Check the downspouts have adequate drainage away

from the building.

8. If minor damage occurs to the sheeting or trims and paint

94

touch is required, then the following procedure should be fol-

lowed:

a. Abrade the effected area.

b. Clean down with a solvent (e.g. sigma 9053)

c. If base metal is exposed, apply one coat of zinc chromate

primer. If base metal is not exposed, then primer is not

required.

d. Apply one coat touch up paint available from BlueScope

steel.

B.Maintenance of Accessories

Personal Doors

a. Occasionally lubricate the hinges and locksets.

b. Remove any dirt or grit from the threshold.

c. Make sure the door is not allowed to swing back against

the wall; this can spring the hinges, and damage the

panels.

Sliding Doors

Regular cleaning of bottom door guide by removal of stones and

sand will ensure smooth running.

Roll Up Doors

a. Occasionally clean and lubricate and chain and reduction

drive gears

b. Lightly grease the vertical guides

Power Vents

Periodically clean the blades to avoid build-up of dust and dirt.

Check electrical connections and check tightness of all

fasteners.

Building with Cranes

a. Every three months, check the diagonal rod bracings are

tight.

b. After one month of operation, check the high strength

bolts on crane beams are tight. Also, this check is to be

carried out every 3 months subsequently.

c. Crane rails checking to be done every 3 months for the

weldments.

d. End stoppers to be checked once every 3 months.

C.Safety PrecautionsRoofs

Extreme caution should be exercised when working on roofs:

a. Only use ladders which are long enough to reach one

meter above the step off.

b. Always secure the ladder to the building and make sure it

is on a firm base.

c. Do not step on a skylight panels.

d. When walking on the roof, step on low corrugations,

walking on high corrugation can damage the sheets. Walk

on screw line wherever possible.

Overhead Cranes

a. When maintaining overhead or associated parts, lockout

the electricals on the crane before commencing work.

b. After the days work, the overload crane should be placed

always between the two rafters / truss i.e. never below a

rafter or a truss.

c. Whenever the building is close to any road curve / access

curve, “Ballard Foundation” should be provided to avoid

vehicle striking the building

95


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19Annexure

96

SatisfactoryNo. Items Type Qty. Position

Yes No

1 Anchor point of temporary bracings

2 Temporary bracings

3 Permanent bracings

4 Struts

5 Girts

6 Purlins

7 Fly Bracings

8 Alignment

9 Rafter & Column

10

11

12

13

14

15

16

17

18

19

20

Braced Frame Check

Project:

Building:

Remarks / Proposals:-The authorised person (Project Manager) must follow this braced framed checklist to approve and sign off before allowing the team to continue to install otherframes.

Builder Tata BlueScope Steel Client:

Name: Name: Name:

Sign: Sign: Sign:

Date: Date: Date:

Inspection Satisfactory Yes No

97

Annexure

Minimum No. of Bolts SatisfactoryNo. Member No.1 Member No.2 Line Bolt Dia. Torque Required Inspected Yes No

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Bolt Tensioning Torque Check

Project:

Building:

Remarks / Proposals:


Name: Name: Name:

Sign: Sign: Sign:

Date: Date: Date:


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SatisfactoryNo. Checked Points Line Deviation X Deviation Y Deviation H

Yes No

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Frame Alignment Check

Project:

Building:



Name: Name: Name:

Sign: Sign: Sign:

Date: Date: Date:


99

Annexure

No. Description SWL Date of Testing Validity Test Certificate Calibration Certificate Identity Marks

1 Mobile Crane

2 Hydra

3 Slings

4 D-Shackles

5 Double Hook Lanyard

6 Chain Blocks

7 Harness System

8 Torque Wrench

9 Fall Arrestor

10 Spreader bar

11 Temporary Bracings

12 Any Other

13

14

15

16

17

18

19

20

Tools and Equipment Check

Project:

Building:



Name: Name: Name:

Sign: Sign: Sign:

Date: Date: Date:


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101

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103

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105

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107

Annexure

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Tata BlueScope Steel BUTLER INDIA Erection Manual

Documents

metal building erection

erection of buildings

erection ofprimary

thesequence of erection

erection information

metal building terminology

metal building erection4

frame erection procedure