Wall Horizontal Manual

20067 TRIBIANO, MilanPhone +39 02 906951 - Fax +39 02 90634238

METECNO INDUSTRIE S.p.A.

Phone +39 02 906951 - Fax +39 02 90634238www.metecno.com - [email protected]

WALL-PANELSPOLYURETHANE OR ROCK WOOLSELF-SUPPORTING INSULATINGMETAL PANEL

TECHNICAL HANDBO O K

ENG

HORIZONTAL ASSEMBLING

WALL-PANELS

1

TECHNICAL MANUAL

This document has been drawn up to help you in using the following panels.

time to carefully read the present manual to refresh your technicaland operative knowledge.

This manual is divided into several sections, which are identified bya number. Each section is subdivided into numbered chapters.

METECNO GROUP sales conditions apply to all aspects that are not covered bythe present technical manual.

For any information or suggestion, please send your mail to:

Before using the products, we suggest to take some of your

MONOWALL A-B / B-BSUPERWALL MLSUPERWALL HFHIPERTEC WALLHIPERTEC WAND SOUNDROCKSTEEL WALLH-WALL 8P / 8M / 10P / 10MFIREMET WALL

(horizontal assembling)

21. GENERALS1.1 COMPOSITION AND USE

All the wall panels from Metecno are composite panels, formed by two metal sheets linked by a layer of insulating material, which can be manufactured upon request: with polyurethane foam with mineralwool

1.2 STANDARD SIZEPanels are manufactured in 1000 mm wide modules, their length depends on the specific design requirements and the feasibility of the manufacturing factory. Please request for that.

WALL-PANELS (horizontal assembling)

Monowall A-B / B-BSuperwall MLH-Wall 8P H-Wall 10P

Hipertec WallRocksteel WallSuperwall HF H-Wall 8MH-Wall 10M

(only for panel type: Superwall ML / HF ; H-Wall 8P / 8M)

1000

Gasket(polyurethane version only)

Monowall A-B

250 250 250 250

S

62,562,5

with combined insulationFIREMET Wall

S

62,5

Monowall B-B

1000

When the panel is laid horizontally, no secondary purlin structures (wall stringers and secondary columns) are necessary,since panels are directly fixed to the main columns.The shape of the panel longitudinal joint is such as to house the fastening screw, when using douple span or multi span.

In addition to the economic benefits for the structure costs, this solution is aninnovative architectural alternative.

Due to its geometrical configuration, the panel may also be assembled in a vertical wall position in the presence of thesecondary purlin structures.

wich is then hidden inside, making panel more pleasant and elegant looking



H-Wall 8P / 8M

HIPERTEC WALL / HIPERTEC WALL SOUND / ROCKSTEEL WALL / FIREMET WALL

S

62,51000

62,562,562,5

s125

62,5

1000

20


H-Wall 10P / 10M

s

1000

100 62,5

18

1000

S


25

62,5

SUPERWALL ML / HF

3

41.3 REACTION AND RESISTANCE TO FIREContact METECNO for detailed information.

1.4 FASTENERSWhen panels are laid horizontally,


p a n e l ty p e th ic k n e s s th ic k n e s s s te e l c o n s t r u c t io n w o o d e n c o n s t r u c t io np a n e l a t th e p o in t > 1 ,5 m m > 5 0 m m

w e r e th e s c r e w s c r e w w ith s c r e w w ithis lo c a te d f in e th r e a d c o a rs e th r e a d

[m m ] [m m ] [m m ] [m m ]

M o n o w a ll A - B 2 5 2 0 4 5 8 53 0 2 5 5 0 9 03 5 3 0 4 5 9 54 0 3 5 6 0 1 0 05 0 4 5 7 0 1 1 06 0 5 5 8 0 1 2 08 0 7 5 1 0 0 1 4 0

1 0 0 9 5 1 2 0 1 6 01 2 0 1 1 5 1 4 0 1 8 01 4 0 1 3 5 1 6 0 2 0 01 5 0 1 4 5 1 7 0 2 1 0

M o n o w a ll B - B 2 5 2 5 5 0 9 0F ir e m e t W a ll 3 0 3 0 5 5 9 5H ip e r te c W a ll 3 5 3 5 5 0 1 0 0

4 0 4 0 6 5 1 0 55 0 5 0 7 5 1 1 56 0 6 0 8 5 1 2 58 0 8 0 1 0 5 1 4 5

1 0 0 1 0 0 1 2 5 1 6 51 2 0 1 2 0 1 4 5 1 8 51 4 0 1 4 0 1 6 5 2 0 51 5 0 1 5 0 1 7 5 2 1 5

S u p e r w a ll 6 0 6 0 8 0 1 2 08 0 8 0 1 0 0 1 4 0

1 0 0 1 0 0 1 2 0 1 6 01 2 0 1 2 0 1 4 0 1 8 0

H - W a ll 8 5 0 /7 0 5 0 7 0 1 1 08 0 /1 0 0 8 0 1 0 0 1 4 0

p a n e l ty p e th ic k n e s s th ic k n e s s s te e l c o n s t r u c t io n w o o d e n c o n s t r u c t io np a n e l a t th e p o in t > 1 ,5 m m > 5 0 m m

w e r e th e s c r e w s c r e w w ith s c r e w w ithis lo c a te d f in e th r e a d c o a rs e th r e a d

[m m ] [m m ] [m m ] [m m ]

S u p e r w a ll 6 0 4 6 6 0 1 0 58 0 6 6 8 0 1 2 5

1 0 0 8 6 1 0 0 1 4 51 2 0 1 0 6 1 2 0 1 6 5

H - W a ll 8 5 0 /7 0 4 0 6 0 1 0 08 0 /1 0 0 7 0 9 0 1 3 0

w a s h e r w ith d ia m e te r o f 1 6 o r 1 9 m m

* r e c o m m e n d e d m in im a l le n g th o f th e s c r e wT h e a d v e r t is e d le n g th o f th e s c r e w d e p e n d s o n th e s te e l th ic k n e s s o fth e s u p p o r t c o n s t r u c t io n a n d d if fe r e n s e b e tw e e n th e v a r io s s c re w s u p p lie r sI f y o u u s e s e lf d r i l l in g s c r e w s , p le a s e c o n ta c t u s b e fo r e .

le n g th o f th e s c r e w *h id d e n f ix in g

le n g th o f th e s c r e w *v is ib le F ix in g

they require the following type of fastening.

5WARNING !Carefully follow these

handling and storage instructions

Sling the package by using a rocker arm and min. 200 mm-wide nylonbelts. Insert min. 200 mm-wide wooden boards between the packageand the belts. The wooden boards will have to be approximately 2 cmlonger than the package width.

Do not store more than three packages one on top of another, and placespacers or boards between them.

Place the package on a flat and rigid surface, and position 50 mm-thickand 200 mm- wide polystyrene spacers or wooden boards at max. 1 mintervals. Panels will have to be stored slightly sloping in order to helppossible condensation flow and to prevent backwater.

Store packages under cover; if this is impossible, protect them withrainproof membranes. Make sure that the goods are appropriatelyaerated. Any protective film should be not exposed to direct sunbeamsand, in any case, should be removed within 45 days after the date whenthe panels are prepared.

S i ht slope - min

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3

2

1

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00 mi .

2n

S light s lope - min. 5%

m1 m1 1 m eRemov

ro c np te tio

ose to sun

K e unde v r

Do not exp

beams - e p

r co e

NOTE: The extendable polyethylene forming the external wrapof this package is not suitable for a long exposition outdoor,since sunbeams change its properties.

When panels have to be moved one by one due tobuilding yard needs, they should be always carriedas shown in the illustration.

2.3 HANDLING AND STORAGEPackage handling and storage is a very delicate phase, in which panels can get damaged. For this reason, a label with thefollowing instructions is applied to each package:


3. ASSEMBLY TOOLS

PORTABLE DRILLING MACHINEPortable drilling machine with max. 8-mm diameter spindle and relevant helical drills.

ELECTRIC SCREW-DRIVERReversible electric screw-driver with relevant bushes.

HACK SAWING MACHINE

RIVETING MACHINERiveting machine for 2.5-5 mm diameterrivets and relevant rivets.

VACUUM CLEANER RELEASE PINCERS

PLIERS HAND LEVER SHEARS (right and left)

SCRAPER OR SPATULE PLUMB LINE SPIRIT LEVEL

SLEDGE HAMMER


6

74. ASSEMBLY INSTRUCTIONS

4.1 PRELIMINARIES

a) Check that the storage has been carried out according to the directions in chapter 2.b) Check that the panel support structures are level.c) Position the packages of panels near the points of use.d) Prepare a fixed or cradle scaffold, according to the working height, 30/40 cm far from the external edge of the main

columns and comply with the rules on safety in the workplace.e) Control that all workers are equipped with individual safety equipment according to current regulations.f) Prepare all the power supply lines for tools according to current regulations.g) Prepare the panel lifting vehicles.h) In addition to the traditional scaffolding, when assembling wall panels horizontally, automatic scaffolds with platform

can be profitably used. These platforms may be either the type with masts starting from the ground or the self-propelled type with telescopic arms.

4.2 PREPARING PANELS

4.2.1 Before the assembly, the polyethylene protecting film must be taken away from the entire panel. Thoroughly check that notraces of residual glue of the protecting film are left on the surface. In case, remove them using a detergent in a water-based solution.

4.2.2 If the panel surface shows clear damages in the sheet, set the panel aside and use it when undersizes are required.

4.3 WALL WITH HORIZONTAL PANELS IN GENERAL

4.3.1 Metecno wall panels, depending on the distances between centers of the main columns (Figure 5), can be assembled on single, double and multiple spans. Due to space limitations, only the assembly on double spans is illustrated here. For single and multiple spans, adopt similar assembly methods.

Figure 5

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Drip


84.3.2 When panels are assembled horizontally, the purpose of the base flashing is draining the water flowing along the faade(Figure 6). In order to guarantee that the wall is perfectly horizontal, the base substructure (tube) must be positioned usingthe traditional floor control level. Once the base flashing and/or, if required, also the internal flashing is assembled (Figur e6), install the U-shaped zinc-plated steel profile (Figure 6a) on top of the above mentioned base substructure, which issuitable to house and block the panel without using the screw (Figure 6a).

Figure 6 Figure 6a

4.3.3 Based on the executive drawings, find out the starting point of the initial bottom panel and position it on the prepared U -shaped profile (Figure 7), holding it to the columns by means of release pincers (Figure 8).

Figure 7

Figure 8

Tube

Main column

Base flashingInternal flashing

Drip

Panel blocking profile

Drip

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Drip

Panel Base flasing

U-shappedprofile

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Drip

PanelRelease pincers


94.3.4 After checking that the panel is horizontal, fix the top joint to the main columns (Figure 9) according to the schemeindicated at point 1.7 (Figure 4). Remove the release pincers, control that the panel is level and then assemble thepanel.

Figure 94.3.5 Before assembling the second panel, check that the joints are thoroughly clean.

4.3.6 For an easy and proper assembly, the second panel must be approached to the fixed panelfrom above and slipped into the joint (Figures 10-11).

Figure 10 Figure 11

Drip


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4.3.7 Verify that the joint is perfectly executed by checking that thelengthwise edges of the two adjoining panels are perfectly in touch.If necessary, change the horizontal level of the panel by holding itwith the release pincers and fix it (Figure 12). Proceed as abovewith the remaining panels until the first wall section is completed.

Figure 12

4.3.8 When the wall is higher than 5 m, we suggest you to proceed simultaneously on all sections forming the building wall byassembling 4-5 panels for each section, so that you can always monitor the horizontal level of the panels of the varioussections (Figure 13).

Figure 13

For the distance between the edges of the panels of two adjoining sections, stick to the indications given at point 4.3.11.

Drip


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4.4 FASTENING AND SCREW CONNECTION FOR THE DIFFERENT PANEL TYPES

4.4.1 Type Superwall


Fixing with a screw in the joint

Fixing with a screw and a load distribution plate in the joint co

vrf

ashn

ge

-li

supporting structure (concret column)

supporting structure (steel column)

GasketHTU-bar

the joint-distance depends on type of the cover-flashing


insulation

It is necessary to prepair the fixing connections between column and panel with gaskets before, to obtain a rain- and windproof wall (vapour barrier) . Please be shure, that you installed the panels in the right direction. The panel on the top must overlap the joint of the panel below, for the correct water-bearing on the surface of the building.

insulation

12

4.4.2 Type H Wall 8




It is necessary to prepair the fixing connections between column and panel with gaskets before, to obtain a rain- and windproof wall (vapour barrier) . Please be shure, that you installed the panels in the right direction. The panel on the top must overlap the joint of the panel below, for the correct water-bearing on the surface of the building.

cove

rflas

hing

-

1 Fixing with a screw in the joint

1a Visible fixing in the valley (if necessary)

2 Fixing with a screw and a load distribution plate in the joint.

HTU-bar

insulation the joint-distance depends on type of the cover-flashing


Gasket

insulation

13

4.4.3 Type H Wall 10 / Monowall / Hipertec Wall / Rocksteel Wall / Firemet Wall




It is necessary to prepair the fixing connections between column and panel with gaskets before, to obtain a rain- and windproof wall (vapour barrier). Please be sure, that you installed the panels in the right direction. The panel on the top must overlap the joint of the panel below, for the correct water-bearing on the surface of the building.

HTU-bar

insulation the joint-distance depends on type of the cover-flashing


Gasket

vr

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g

1 Fixing on both sides near the joint

slot (top)

key (down)or

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insulation

14

4.5.2

4.5.3 The vertical joint between the panel end sections is placed in front of a main column. The gap between panels should be 40 m m (Figure 15).

Figure 15

4.5.4 Position a distance-holder (previously prepared in the building yard) consisting of a 3-4 m long and 40 mm wide (tube made in aluminum or another material, vertically in contact with the edges of the first sectionpanels that have been already assembled (Figure 16). If the panel lengths are slightly different from the nominal value(anyway within the standard tolerance), a template of a slightly different size may have to be used.

Figure 16

40

40

20


VERTICAL WALL JOINT

4.5.1 When the first wall section is assembled,move the scaffolding for assembling thepanels of the second section (Figure 14)

Figure 14

First panel section

Drip

Second panel section

4.5

Main column

d i s tance -holder

Joint gap

Main column

Second section panelFirst section panel

First section panel

Corrugated sandwich wall panels (H-Wall 8P / 8M / 10P / 10M)

Before assembling the second panel section, check again that the first panels is in level and than assemble the following panels.

Main column

Temp lateAlignment line

Assembled panel

Panel to be assembled

Main column

First section panel Second section panel

Temp late40

20

4.5.6 Control that the distance-holder is perpendicular and position the first panel of the second section against the wall, push theedge against the prepared template (Figure 17).

Figure 17

4.5.7 Control that the panel is horizontal and aligned with the already assembled adjoining panel. This operation may be easierif a mark and/or an alignment line is drawn on the distance-holder (Figure 18).

Figure 18

4.5.8 Fix the panel to the column with the release pincers and fasten it (Figure 19) according to the scheme described at point1.5 (Figure 4).


15

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)

16

Main column

First section panel Second section panel

Temp late 40

20

Screw

Screw

20 20

4.5.9 After assembling all the panels of the section covered by the template, take the template out of the joint area andreposition it into the following vertical wall joint.

Figure 19

4.5.10 Assemble the next panels following the same method until the various panel sections forming the faade are finished.

4.5.11 Always check the horizontal direction of panels in order to keep them perfectly aligned.

4.5.12 Once two panel sections are assembled, the joint profiles connecting the base gap between panels can be assembled, sothat the faade wall looks continuous. This operation may be carried out by another team of workers, while the panels ofthe next sections are laid.

4.5.13 The profiles for the vertical joint are in different solutions possible, some examples are shown in the pictures below.

Standard Joint (Figure 20) Special Joint (Figure 21)

Figure 20 Figure 21

S + 40


GasketGasket

4.5.17 Insert the supplied insulation element into the joint gap, as explained in point 4.3.11 (Figure 22).

Figure 22

4.5.18 Apply the joint profile, on whose sloping sides two self-adhesive gaskets must be stuck (Figure 23). Insert the profile intothe joint gap and fix it to the high peaks of the panels by (in case, pre-painted) rivets (No. 0.8/m) (Figure 24).

Figure 23

Figure 24

4.5.19 With this operation, the gasketsprepared on the profile are compressedand seal the corrugated side of thepanels quite effectively.

Figure 25

Rivet Rivet

17


Gasket

Figure 26


18

Low profiled sandwich wall panels (Monowall / Hipertec Wall / Rocksteel Wall / Firemet Wall)

The assembling steps principaly are the same like the instruction point 4.4 ff. The only difference in the construction detail for the vertical joint (low profiled sandwich wall panels like the types Monowall, Hipertec Wall, Rocksteel Wall and Firemet Wall) is the use of a different cover-flashing be able to cover the screw-heads at the panel near the joint. The cover flashing is to be fixed with self cutting screws or rivets on the panel, like shown in the picture below.

Main column

gasket 10/20 or 20/20

insulation

cover flashing20mm

4.5.21

Holding ring

Spring

Steel rope

Adhesive tape

Cutting line marked with a felt-tip pen Panel cut made with a hack sawing machine

Hole

5. LIFTING PANELS

USEFUL CONSIDERATIONS

In the assembly stage of the Metecno wall panels, especiallywhen they are handled along the wall, considering theirhorizontal size, special lifting devices can be used, like:

5.1 a suitably sized device with clamps, which in its turn is held bya lifting device (Figure 29)

Figure 29

6. CUTTING PANELS

6.1 If panels need to be cut to make openings or passages, proceed as follows (Figure 31): Protect the surface to be cut with adhesive tape. Draw the cut to be made on the tape using a felt-tip pen. Cut using a hack sawing machine. Clean the surface from the shavings formed during the cutting, because they can cause corrosion over time. Remove the adhesive tape.

Figure 31


5.2 one of the most innovative lifting tools is a retaining jig with pneumatik air sucker (Figure 30)

19Figure 30

20

7. CONSTRUCTION DETAILS

Some construction details relevant to the individual points of a wall formed by Metecno wall panels are enclosed to thepresent document.

NO. 12 DRAWINGS(annexed to the present manual)


34

8. PANEL MAINTENANCE8.1 For the good panel maintenance, two phases must be distinguished:

First phase: regards the time necessary to assemble the panels.

Second phase: regards the use of the building, to which the panels have been assembled.

In the first phase, in order to maintain panels undamaged, you should take care of what follows:

the handling during the unloading operations from vehicles must be carried out with suitable means and appropriateprotections, in order to prevent panels from being indented or scratched.

the handling during the removal of the protective film and the distribution near the works. In this stage, we alwayssuggest that the panel and sections are controlled to remove any excess of the insulating material for the benefit of theperfect execution of the panel coupling joint.

the lifting operations near walls, to be carried out with suitable means and safety systems for the staff.

the assembly stages, taking particular care to the fastening operations, immediately removing all the shavings causedby drilling from the panel surface. In order to insert screws and avoid indentations to the panel, use screwdrivers thatare equipped with a depth limiting device.

when, during the distribution of panels, stains or deformations (indentations) that cannot be easily fixed are found,avoid to assemble such panels and set them aside for use as undersize elements, where possible.

8.2 If the above-mentioned recommendations are truly complied with, they guarantee the product integrity and avoid theannoying building yard objections that very often translate into unpleasant financial costs. The second stage regards thepanel maintenance, which is the final users task, in order for the panels of his building to maintain their original look andhave the building look pleasant.

8.3 The consequences of a slow degradation of the pre-painted external sides are mostly originated from the contact withaggressive substances contained in corrosive air and gaseous emissions from surrounding activities. Therefore, periodicalinspections to the panels should be planned in order to find possible corrosion; if it is found, action should be takenimmediately, starting protective cycles to stop the process. In the long run, smog deposits on painted surfaces and maycreate a dirt film, and the walls will have to be cleaned with water jets.

8.4 The existing seals will have to be controlled, verifying that they are still airtight and waterproof, which otherwise maycause deterioration. All the fastenings will have to be controlled to verify that they are still in good conditions. Anyscratches of the paint that may have been caused accidentally will have to be protected by retouching: cleaning andpainting. In case of large size dents caused by impacts, the panel will have to be replaced.

8.5 DISPOSALIn case of yard working wastes and/or dismissal, the panel disposal shall only be entrusted with authorizedcompanies and carried out in compliance with the current laws in each country.

WALL-PANELS (vertical assembling)

9. SAFETY INFORMATIONEach user and/or worker must be aware of all the problems connected with the assembly of these panels, and shouldprepare a SAFETY PLAN in order to prevent dangerous situations.

THEREFORE, WE REMIND YOU TO STRICTLY COMPLY WITH THE REGULATIONS ON SAFETY IN WORKPLACES,BUILDING YARDS AND EQUIPMENT SAFETY.

WALL-PANELS (vertical assembling)

35

METECNO S.p.A.Via Per Cassino, 19

20067 TRIBIANO, Milan

Phone +39 02 906951 - Fax +39 02 90634238

www.metecno.com

METECNO INDUSTRIE S.p.A.Via Per Cassino, 19

20067 TRIBIANO, Milan

Phone +39 02 906951 - Fax +39 02 90634238

www.metecno.com - [email protected]

IMPORTANT

The information contained in this manual has

been prepared in connection with our

customers needs. It has been processed

based on our know-how at the time of

publishing and, therefore, it is subject to

changes without any prior notice.

For the same reason, this is not a full guide

to installation, use and maintenance of

METECNO products. In case of doubt or

difficulty, the user must seek for METECNOs

advice before proceeding.

METECNO does not accept any responsibility

for damages to individuals or properties,

caused by faults in assembly or installation,

by improper use and wrong maintenance of

Superwall ML

sandwich panels.

Metecno trademark

Metecno copyright

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