Zamil Steel Erection Manual
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Descripción: Zamil Steel erection Manua...
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Contents
1. Understanding the Engineering Documents ............................. 1.1 1.2 1.3 1.4 1.5 1.6 1.7
2. Preparation for Erection ....................................................................... 2.1 2.2 2.3 2.4
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Introduction Pre-Erection Checks Receiving Materials at Site Unloading Containers (for Overseas Shipments)
3. Erection of the Framing ........................................................................ 3.1 3.2 3.3 3.4
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Anchor Bolt Setting Plan Cross Section Roof Framing Plan Roof Sheeting Layout Sidewall & Endwall Sheeting & Framing Other Drawings Bill of Materials (BOM)
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Preparation of the First Bay Main Frames Mezzanine Floors Crane Beams
4. Sheeting & Trimming .............................................................................. 19 4.1 4.2 4.3 4.4 4.5
Sheeting Preparation Sheeting the Walls Sheeting the Roof Miscellaneous Trimming Fascia
5. Care & Handling of Sheeting .............................................................
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5.1 Handling & Installation of Sheeting 5.1.1 Unloading 5.1.2 Storage 5.1.3 Handling 5.1.4 Cutting & Fixing 5.1.5 Completion & Inspection 5.1.6 Paint Repair 5.2 Water Test Procedures for Roofing 5.3 General Tips
6. Maintenance Procedure ....................................................................... 6.1 6.2 6.3 6.4 6.5
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Maintenance for Longer Life Safety Notes Exterior Maintenance Procedure Maintenance of Accessories Record of Maintenance
7. Safety Precautions ...................................................................................
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8. Quality Control ..........................................................................................
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9. Basic Erection Equipment ....................................................................
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Mobile Crane Forklift Telescopic Handler Scissor Lift Lifting Beam Slings
Guy Wires Clamps, Shackles & Clips Ratchet Puller Light Duty Scaffolding Ladders
9.2 Electrical Equipment & Tools ......................................................... 37 Generator Screw Gun Nibbler Grinder Hammer Drill Hole Cutter Impact Wrench Electric Shear Heavy Duty Drill with Reamer Reciprocating Saw Drill 10 mm Powder Actuated Tool Pop Rivet Puller
Aviation Snips (Left & Right Cut) Vise Grips Torque Wrench (With Sockets) Ratchet Spanne (With 19 mm Sockets) Staple Applicator Utility Knife Hacksaw Mastic Gun Spud Wrench Drift Pin Miscellaneous Tools Tool Belt & Bolt Bag Chalk Line
9.3 Measuring & Surveying Equipment ........................................... 42 Plumb Bo Theodolite Automatic Level Spirit Level Measuring Tape & Square
9.4 Safety Equipment ..............................................................................
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Welding Hood Goggles Gloves Safety Harness & Fall Arrest Safety Boots Hard Hat First Aid Box Cones & Ribbons Portable Fire Extinguisher Ear Protection
9.5 Other Equipment ...............................................................................
44
Welding Machine Oxy - Acetylene Cutting Outfit
10. Attachments .................................................................................................45 Glossary ........................................................................................................... 55 Commonly Used Abbreviations ............................................................. 58
Zamil Steel Pre-Engineered Buildings I Erection Manual
9.1 Main Erection Equipment ............................................................... 35
Introduction The primary goal of Zamil Steel is the satisfaction of our customers. We design, detail and fabricate our buildings using sound principles of engineering, and fabricate every component with the utmost attention to quality and detail. When work at the factory is finished, only one final operation remains, erection. The importance of following a specific method of erection cannot be underestimated, and the purpose of this manual is to facilitate and ensure Quality Erection, thereby creating the finest possible steel structure. For purpose discussed here, erection refers to the assembling of the various component parts that make up the pre-engineered steel building. The erection process entails much more than merely installing the fabricated steel for the building. It actually begins with the foundation and building anchorage and continues to cleaning the job site upon completion. The methods and procedures suggested by this Erection Guide represent basic, safe erection practices. They can, and should, be modified when necessary to adapt to special conditions or circumstances. Before beginning erection work, familiarize yourself with the building details and the sequence of erection. This will enable you to plan your work efficiently and avoid unnecessary delays during construction. Zamil Steel’s policy of continuous product improvement may necessitate changes in materials, design specifications, and procedures without prior notice. Important notice: Zamil Steel recommends that the erection work, be caried out by a Zamil Steel certified builder. However, Zamil Steel accepts no responsibility for erection quality, leakage, defects or collapse due to negligence or failure to follow proper erection procedures.
Understanding the Engineering Documents
Zamil Steel Pre-Engineered Buildings I Erection Manual
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1.1 Anchor Bolt Setting Plan 1.2 Cross-Section 1.3 Roof Framing Plan 1.4 Roof Sheeting Layout 1.5 Sidewall & End wall Sheeting & Framing 1.6 Other Drawings 1.7 Bill of Materials (BOM)
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1. Understanding the Engineering Documents Prior to beginning the erection work, it is essential to have a clear understanding of the Engineering Documents, especially the Erection Drawings and Bill of Materials. Erection Drawings to be used at site should be labeled “Issued for Construction” and represent the latest project revision. Approval Drawings should never be used at the erection site. 1.1 Anchor Bolt Setting Plan This drawing shows the layout of all anchor bolts, it is normally presented on one sheet, but for relatively large buildings, this layout may be represented on two or more sheets. Erection drawings are not made to scale, so do not attempt to scale any dimensions. All dimensions appear in millimeters unless otherwise noted on the drawings.
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The Anchor Bolt layout also includes an anchor bolt schedule, in table form, showing the, quantities and sizes of the anchor bolts required. The key plan specifies out-to-out the dimensions, bay spacing dimensions, bolt setting details and critical dimensions for the span. Critical distances on the drawing should be respected at all times. The details specify whether grout is required under the columns. The grout thickness will be shown on the drawings, as well as the bolt projection. Adherence to anchor bolt setting tolerance is important; deviation shall not exceed 6mm.
Zamil Steel Pre-Engineered Buildings I Erection Manual
1.2 Cross-Section The cross-section drawing indicates columns and rafter references, connection details, bolt schedules, flange brace schedules and other information as applicable, such as strut tubes and flange brace details. When reviewed in conjunction with the Bill of Materials it is possible to determine the weight of individual members, or a combination of assembled members. This data is essential during the planning of erection, and needed in order to determine the capacity of the erection crane to be used. The cross section drawing may be typical throughout in standard buildings but for more complex jobs, there may be several cross sections, identified by grid numbers.
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CROSS SECTION
CROSS SECTION
1. Understanding the Engineering Documents 1.3 Roof Framing Plan The roof framing plan illustrates the purlins, bracing and related miscellaneous details. Part numbers are indicated on this drawing for purlins, bracing, sag rods (where applicable), strut tubes etc. The drawings should be studied very carefully, otherwise it is possible to overlook critical details such as nested purlins, strut purlins, strut clips, and purlins/girts at expanstion joints.
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ROOF FRAMING PLAN
ROOF FRAMING PLAN
Zamil Steel Pre-Engineered Buildings I Erection Manual
1.4 Roof Sheeting Layout The roof sheeting plan displays all the panels including their length and part numbers. It also shows the sky light distribution and downspout positions. Standard details of panel lap, fasteners, trims and insulation are also included. It is very important to note the starting dimension of the sheeting from the steel line.
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ROOF SHEETING LAYOUT
ROOF SHEETING PLAN
1. Understanding the Engineering Documents 1.5 Sidewall & Endwall Sheeting & Framing Depending upon the drawing and erection requirements, sidewall framing and sheeting may be represented on one drawing or more. The framing elevation shows the position and part numbers of girts, eave struts, bracing and sag rods. The sheeting elevations show the panel positions with length and part numbers. Wall lights eave trims, gutters and downspouts are also shown along with part numbers. Related standard details are included which indicate the number, size and position of fasteners. Additional trimming details are also included in the drawing. For side walls, it is important to check the starting dimension of the sheeting from the steel line. End-walls are detailed in a similar manner.
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SIDWALL SHEETING
SIDWALL FRAMING AND SHEETING ELEVATION
Other drawings may include crane beam layouts and details; Mezzanine layouts and details; and accessories such as Sliding Doors, Roll-up doors, Staircase Cage Ladders, Personnel doors, Windows, Louvers and Ventilators. 1.7 Bill of Materials (BOM) The BOM supplied with the Erection Drawings is the Customer BOM. The BOM begins with a cover sheet indicating the 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, and special notes. The second page indicates the various sub-areas of the phases. On the next page, the detailed BOM list of the items included in each phase begins.
The sub total of weight and the total number of items is shown at the end of each sub-area. The last page indicates the total BOM quantity and weight. The BOM is a reference to the items shown on the Erection Drawings and can be used to verify that all items have been received at the site. It is also used to identify frame weights for crane capacities.
Zamil Steel Pre-Engineered Buildings I Erection Manual
1.6 Other Drawings
The BOM has 9 columns indicating 1 - Line number 2 - Part number 3 - Quantity 4 - Revision number 5 - Description of part 6 - Colour 7 - Length of item 8 - Weight of item 9 - Total weight of line item
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Preparation for Erection 2.1 Introduction 2.2 Pre-Erection Checks 2.3 Receiving Materials at Site 2.4 Unloading Containers (for Overseas Shipments)
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Zamil Steel Pre-Engineered Buildings I Erection Manual
2.1 Introduction Erection of Pre-Engineered steel buildings is a straightforward operation, provided some basic principles are followed and common sense used. The light weight of built-up and cold formed members used in pre-engineered steel buildings require less crane capacity but will need more temporary bracing during the erection stages. Due to the synergic design, temporary bracing should be left in place until the braced bay components are completely erected, aligned and tightened. A clear understanding of the sequence of erection is necessary together with careful planning. The erection drawings and bills of material provided by Zamil Steel should be studied before commencement. Familiarize yourself with the various components and their weights, evaluate the site conditions, and decide where to start, bearing in mind the stability of the building during erection thence a braced bay must be erected first.
Anchor bolts in concrete foundations
The major components comprise of, rigid frame columns and rafters, eave struts, purlins, girts, flange braces, end-wall columns and bracing systems which may be cables, rods, angles or portals.
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2.2 Pre-Erection Checks Make sure that the building foot print, in addition to 10m wide strip around it, is clear of obstructions, level and compacted. Check the anchor bolt settings for compliance with the details provided on the Anchor Bolt Setting Plan. The allowable tolerances are given in the General Notes on the drawing. Check the foundation levels. In buildings that require grout, shim packs are placed in the centre of the bolt pattern. Buildings without crane systems generally do not require grout, but variances inconcrete levels may necessitate the use of shims if the concrete is outside the stated tolerances. Due to design requirements on certain buildings, double nuts may be used. A comprehensive survey report should be made and documented. A site take-over report from the client will assure site accessibility and level for cranes and trucks to maneuver freely.
The following dimentions must be controlled: A B C C D E
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Steel Line to outer bolt row Diagonal distance between bolt groups Distance from axis center line to bolt row Distance between bolts Distance between frame axis Destance between Steel Lines Levels of foundations Anchor Bolt protrusion
2.3 Receiving Materials at Site Receiving and unloading of materials should take place as near as possible to the place of erection. The lay-down area should be clean and leveled. A suitable forklift or telescopic handler is ideal for unloading, but a mobile crane is equally suitable. In either case, care needs to be exercised in handling the various components and bundles, to minimize damage to paint. Protect cold-formed members such as purlins, girts, and channels from weather, by storing the bundles with an inclination to permit water drainage in case of rain or condensation. It is advisable to lightly cover with a tarpaulin. Bundles of sheets should be stored in the same way, keeping the bundles clear of the ground. Check materials against the Packing List and immediately report shortage or excess material to Zamil Steel representative.
Unloading from trailer
2.4 Unloading Containers (for Overseas Shipments)
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Good Preparation will make container unloading a straight forward operation. If possible select a firm, level, asphalt, concrete or compacted area. Unloading will be considerably easier if a small step is made so that the inside base of the container is level with the external ground.
Unloading to lay-down area
Unload the container from the trailer using a mobile crane and four leg slings or chains of the correct capacity. Set the container on the ground, and level it, open the doors before final positioning. Sliding tracks are provided in the container for withdrawing the skid. Pull out the tracks, lay them on the leveled ground, and align them with the inside tracks. Secure the tracks by nails or steel pins, the tracks must be continuous from the container to end of the runway, (Length of Container). Attach chains to the front of the skid in the container, and then attach to the pulling vehicle. Take up the strain on the chains, and steadily pull the skid from the container. When the materials are clear of the container, remove the skids from the container floor.
Stacking on wooden planks
Unloading containers
Erection of the Framing
Zamil Steel Pre-Engineered Buildings I Erection Manual
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3.1 Preparation of the First Bay 3.2 Main Frames 3.3 Mezzanine Floors 3.4 Crane Beams
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3. Erection of the Framing 3.1 Preparation of the First Bay
3.2 Main Frames
Prepare all materials for the first bay erection with permanent bracing, (braced bay). Identify the rafter sections required by part number, assemble the rafter sections as near as possible to their intened positions. The splice connections are made with high strength bolts; the sizes are shown on the drawing cross section, identified as S1, S2, and S3 etc. Tighten the splice bolts and check for correct torque value using a calibrated torque wrench, or by turn of nut method. Attach eave strut clips using high strength bolts. Fix flange braces to the rafter using machine bolts, the flange brace positions and part numbers are shown on the drawing cross section. Flange braces are fitted on one side of the rafter only. For uniformity it is preferable to maintain the same side throughout the building.
Erect the first four columns at the braced bay. Verify the part number and orientation, and position over the anchor bolts. Adjust the columns for plumb by tightening or loosening the anchor bolt nuts (Step 1).
Attach temporary guy wires to the rafter, manila or nylon ropes are not recommended for temporary guying, they can stretch and break. They are also unsuitable for aligning purpoes.
Fix the wall girts to the columns for additional stability. Girts are attached to the columns by mild steel (MS) bolts. Position the crane for lifting the assembled rafter sections. Make sure that the ridge connection is torque-tightened (Step 2). Check that slings, chain and shackles are in good condition and of adequate capacity for the weight to be lifted. The chains or slings should be long enough to provide sufficient spread, at an angle of not less than 45 degrees. The spread of the slings is normally calculated by dividing the member length by four, which will give the distance of the lifting point from each end. This formula may require some minor adjustment depending on the weight
Prepare the mobile crane and Forklift for erection.
15 Step 1
Step 2
Step 3
3.1 3 1 First frame of braced bay
3.2 3 2 Second frame of braced bay
3.3 Roof purlins
Flange clamps are a safe lifting device which also minimizes damage to paint. When using clamps, install temporary bolts in the purlins holes, or use “G” clamps to prevent the clamps from sliding. If clamps are not available, conventional slings may be used, in which case timber or other protection should be used on the flanges to prevent slipping and damage. Commence lifting the rafter (Step 3). Previously attached hand ropes will help to guide the rafter to its position. Carefully lower the rafter to the column cap plates, and position it using spud wrenches. Spud wrenches are an invaluable tool for aligning members and holding in position whilst bolting up.
placed from the top, with the nut and washer on the underside. Hand-tighten the bolts. Ratchet pullers are attached to the guy wires, which are then connected to suitable stable objects, such as anchor bolts. The rafter is now aligned by means of the guy wires and ratchet pullers. Once all guy wires are in place it is safe to release the crane (Step 4).
Zamil Steel Pre-Engineered Buildings I Erection Manual
distribution and configuration of the rafter. Refer to image 3.1.
Erect the second rafter and hold in place with the crane, at the same time position the purlins and bolt-up using mild steel bolts (Step 5). Connect the previously attached flange braces to the purlins with mild steel bolts (Step 6). The eave strut should also be installed at this stage, but unlike the purlins the eave strut requires high strength bolts. Refer to image 3.2.
Install the high strength bolts, nuts and washers in the knee connection. The bolt is normally
16 Step 6
Step 5
Step 4
3.4 Roof bracing
3.5 Erect next bay
3.6 Erect remaining bays
3. Erection of the Framing
Complete the purlin installation and then install the diagonal bracing. Before tightening the diagonal bracing, ensure that the lip of the hillside washer is correctly seated in the web slot. Adjust the tension of the bracing; at the same time adjust the rafter alignment. The bracing shall be just tight enough to eliminate visual sagging. In case of portal bracing, it must also be erected before proueding in the other bay. For high endwalls use temporary bracing during erection. Refer to image 3.3 on the previous page. The completed braced bay should now be aligned. A theodolite should be used for plumbing, if available, or for buildings of low eave height, a spirit level or plumb-bob may suffice (Step 7). A tolerance of 1:300 is allowable in low rise buildings. Refer to image 3.4. After completing the first bay alignment the high strength bolts at the knee connection shall be fully tightened. Time spent on correct alignment of the first bay will reap benefits as work proceeds with the remaining bays.
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The remaining bays are erected following the same procedure (Step 8). All components shall be installed as work progresses, including crane beams. Refer to image 3.5.
When the main frames are all completed, the end-wall framing is erected. Pre-assembly of columns and girts on the ground saves time and is more efficient. End-wall posts are connected to the purlins by post spanners using high strength bolts. The complete frame should be checked for plumb and alignment. Adjustments can be made by tightening or loosening bracing, or by ratchet puller, to pull a misaligned frame into plumb. After completion of all checking, bolt tightening can commence. Air or electric impact wrenches may be used and checked with a torque wrench, or they can be tightened manually using the “Turn of Nut Method” (preferred). The Turn of Nut Method is achieved by bringing all the bolts in the pattern to a snug tight position, using a normal spud wrench. Match mark the nuts against the connection plate, and then apply a further one third turn to all the nuts. Prior to sheeting, framed opening members for sliding doors shall be installed; this includes door jambs, brackets and header. PLUMBING THE BRACED BAY
Multi-span frames provide a degree of flexibility in erection in that partial spans may be erected if site conditions dictate. Refer to image 3.6.
Step 7
Step 8
Zamil Steel Pre-Engineered Buildings I Erection Manual
3.3 Mezzanine Floors When mezzanine floors are provided, they are erected with the main frames, generally prior to sheeting.
Alignment is achieved by setting each end of the beam to the correct dimension as shown on the drawing, and stretching a line from end to end, alternately, a theodolite can be used if available.
The mezzanine beams are first installed by connecting to the columns with clips and high strength bolts as indicated on the drawing details. The joists are then placed between the beams and connected as shown on erection drawings. An edge angle is then screwed at the perimeter of the mezzanine area, prior to laying and screwing the decking panels. The decking panels are attached by self drilling fasteners without washers. Openings for stairs and penetrations are framed before fixing the concrete reinforcement. It is important to advise the concreting crew about placement of concrete, particularly if a pump is to be used. The concrete should be evenly spread; concentrated piles of wet concrete could cause deformation in joists or decking, which could lead to collapse. It is, sometimes advisable to use temporary shoring at mid spans inorder to assure straightness of finished concrete.
The crane beam brackets have slotted holes to assist in ease of alignment, if the building has been carefully plumbed, adjustment will be minimal. During alignment install the “T” brackets and shim plates, and install the angle braces from column to beam. Once final alignment is confirmed, fully tighten all high strength bolts. 3.5 Important No loads should be supported from the purlins unless the building has been designed for those additional loads. In such cases, the loads can be supported from the purlins after the roof sheets have been installed and fully screwed. The following sketches show correct and incorrect methods of support from rafters and purlins.
Rafters
3.4 Crane Beams Special care should be taken in buildings with crane runways, the column supporting runway beams should be erected on shims provided, or double nuts in addition to grouting under the base plates. Alignment of crane beams i s very important, the centerlines of the crane beam webs should matche with the centerlines of the crane wheels, and the maximum allowabletolerance is 10mm.
Purlins
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Sheeting & Trimming 4.1 Sheeting Preparation 4.2 Sheeting the Walls 4.3 Sheeting the Roof 4.4 Miscellaneous Trimming
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4.5 Fascia
Zamil Steel Pre-Engineered Buildings I Erection Manual
4.1 Sheeting Preparation Touch-up any damaged paint on the main frame prior to sheeting. The base angle is fixed to the concrete slab by means of masonry nails. Power actuated tools are preferred for fixing. The fixings for the base angle are provided by the erection contractor, to ensure compatibility of nails and fixing tools. The base angle should be set at the wall grit line (steel line) which is 200mm from the column flange in the case of by-pass girts. There is a tendency for wall girts to sag under their own dead load, especially in bays over 7.5 meters. Girts are temporarily supported in a horizontal line with vertical timber props from floor to girt, girt to girt, and girt to eave strut. The props remain in place until the wall panels are screwed. They can then be removed and relocated to the next bay. The girts will remain straight and horizontal once the panels are installed. In bays over 8.5 meters sag rods are provided and once adjusted there is no requirement for temporary timber props. Before commencing with sheeting check the details on the drawings. A starting position will be given in relation to the steel line. Mark the starting position, and then mark out the gauge cover width of the sheets along the concrete notch. This will provide a check against “creep” or “bunching” of the panels. An important point in order for the corner trims to fit as detailed. Insulation is more convenient to handle if unrolled on the ground and pre-cut to the required lengths. A full length piece is used from eave to floor, with an allowance at top and bottom for folding over.
Tools
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Preparation on roof
4. Sheeting & Trimming
A chalk line is essential for marking the girt position and thus maintaining a straight screw line. All screws are self drilling and require an electric screw-gun with a speed of 2000 to 2500 RPM. Depth sensitive or torque regulated screw-guns should be used to control the screw tightness. The EPDM washer should be compressed 1 mm wider than the steel washer when correctly tightened. 4.2 Sheeting the Walls The first “drop” of insulation is fixed using double face tape on the eave strut and the base angle; this is used to hold the insulation in place. The insulation must be kept vertical, and pulled taught. Remove the fibres from the allowance at top and bottom and fold the white facing before placing the wall panel. Place the panel in the pre-marked position, plumb it and screw.
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Chalk Line
The second “drop” of insulation is fixed to the double faced tape and then the side tabs are stapled to the first “drop” at 300mm centres, folded and stapled again in-between the previous staples, thus providing a closed joint and vapour barrier. Then, the second panel is installed in the same manner and so on. Wall Insulation End-wall panels are pre-cut in the factory. The panels are stepped, the steps being covered by the gable trim. (Field cutting may be necessary on steep slopes). The preferred procedure is to complete all wall sheeting before starting the roof, as the eave trim covers the top of the wall panel and fits under the roof panel. Outside foam closures are placed between the wall panel and the eave trim to provide a dust free junction. If there is no wall insulation, foam closures are used between the panel and eave strut / base angle.
Multi-level Man-basket
Zamil Steel Pre-Engineered Buildings I Erection Manual
4.3 Sheeting the Roof Prepare the roof panels by segregating them by their length shown on the roof sheeting plan. The sequence of roofing is from eave to ridge on both slopes finishing with the ridge panel. To commence, it is advisable to temporarily fix one run of panels accross the building to walk on. The insulation can then be unrolled beside the “walkway”. Double faced tape is applied to the eave struts, or an intermediate purlin if the roll does not cover the full width of the building. The insulation is lifted into place and is retained in place by the double faced tape. Before placing the roof panel, the insulation end should be folded over to be concealed at the eave. It is necessary to scrape away the fibres on the folded portion. The inside foam closure is placed on the fold at the eave strut, and the panel is then positioned. Adjust the line of the panel for squareness to avoid “saw-toothing” at the eave line. Use a nylon line projected from the eave strut by 65mm to give the correct distance and line.
Direction of sheeting installation
Sheeting the roof
Screw the panel and move progressively panel by panel up to the ridge. After completing several runs of panel, the temporary “walkway” can be lifted, insulated, and sheeted.
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Panel end-laps require bead mastic. The bead mastic should be carefully unrolled from the release paper, and placed over the panel corrugations. Do not stretch the bead, otherwise it may break when the panel is placed over it Ensure that the panel end-laps are as per drawing details. Make sure that the panel ribs are kept in a straight line from eave to ridge. Use a chalk line tomark the purlin location and maintain a straight line of screws, thus avoiding mis-drilling and possible leakage. End-laps have additional screws as detailed on the drawing. Proceed with the next run of insulation, stepling the side tabs together, before placing the next run of panels. When both slopes of the roof panel have been fixed, the ridge panel or ridge cap is laid, connecting both slopes. If a ridge cap is used then outside foam closures are used to fill the panel profile, if a ridge panel is used as with Type’S’ panel, it nests without foam closures.
Double face tapes
Bead mastic
4. Sheeting & Trimming 4.4 Miscellaneous Trimming As work proceeds, it is important to keep the roof area clean, a soft brush should always be readily available to sweep off drill swarf, metal filings or grinding dust, which will cause light surface corrosion if not removed. Stitch screws are fixed at panel side-laps at 500mm centres, or as detailed.
Note: Roof panels are generally fixed in the valley of the panels, unless noted otherwise.
Upon completion of the roofing, gable trims are installed. Outside foam closures are used against the end-wall panel. The stitch screws securing the gable trim also keep the foam closures in place. Eave gutters are spliced using two runs of flowable mastic and pop-rivets at 25 mm centres. The gutter is then hung by means of gutter straps which are screwed through the roof panel with suitable screws. Down spout connections are cut with aviation snips in locations shown on the roof plan. The down spouts are assembled in straight sections and a shoe, the complete unit is then attached to the gutter by pop rivets and to the wall panel by straps and rivets. Personnel doors are supplied in knock-down form and are generally field-located. The frame is assembled and installed. The wall panels are carefully cut using an electric nibbler, final cutting and fitting of head trim should be done with aviation snips. The galvanized threshold support is fitted and screwed to the concrete before the frame is connected to the girt by clips, and anchored to the floor with expansion bolts. Check that the frame is plumb and square before final fixing. Head trim, jamb trims and the door leaf are now fitted.
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Fixing Eave Trim
Fixing Trims
Where interior liner panel is detailed, a base angle is fixed to the floor as for the external panels. It shall be positioned 200 mm away from the exterior base angle. The liner panels are pre cut to length, but may require cutting vertically at columns, depending on the bay width. Closure trims are fitted at columns, and a head trim along the top of the panel. Trims are fixed with 4.8 x 20 stitch screws, the panels with 5.5 x 25 self drilling screws. Sliding doors leafs are assembled on the floor. The framing members are connected by mild steel bolts and clips. The sheeting is fixed before hanging the door. The trolley trucks are located in the top member of the door leafs. The adjusting nuts on the trolley trucks should be set equally, final adjustments can be made after hanging the doors. Once the doors are hung and positioned over the bottom door guide, the stoppers, the landles and the door hood are installed. Note that there are two types of hood trim. One fits behind the sheeting in the door opening, and the other fits in front of the sheeting on each side of the opening. Complete details are on the drawing. Bottom running doors are also available.
Fascia posts are bolted to brackets. Fascia girts are then attached to the posts. The girts consist of “C” and “Z” sections, which must be correctly aligned and levelled before commencing sheeting the fascia. Use temporary props if necessary. Prepare the sheeting by installing the sill trim on the bottom girt. Check the starting dimension from the corner of the framing. Set up the first panel. Clamp it with vice grips when adjusted to its correct position. Mark the girt line with a chalk line and then screw the panel to the girt.
Zamil Steel Pre-Engineered Buildings I Erection Manual
4.5 Fascia
Continue installing panels on each elevation until sheeting is completed. The back-up panels are installed next; they are attached to the top girt, and overlap the valley gutter at the base. The external corner trims are installed using 4.8 x 20 stitch screws. The Cap flashing can now be installed using 4.8 x 20 stitch screws. Make sure that the flashing slopes into the building as shown on the drawing. The overlapping joints of the flashing should be sealed with flowable mastic. The soffit panel edge trim is fitted to the wall panel, make sure that it is level with the sill trim, and is levelled around the building. Starting the soffit in the correct place is important, if the soffit panel and wall/fascia sheets are the same type, the ribs should be aligned. Align the ribs, and fix the panels as shown in the detail. Corner panels should be mitred equally.
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Care & Handling of Sheeting 5.1 Handling & Installation of Sheeting 5.1.1 Unloading
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5.1.2 Storage 5.1.3 Handling 5.1.4 Cutting & Fixing 5.1.5 Completion & Inspection 5.1.6 Paint Repair 5.2 Water Test Procedures for Roofing 5.3 General Tips
Zamil Steel Pre-Engineered Buildings I Erection Manual
5.1 Handling & Installation of Sheeting It is important to use correct sized drill bits and screws for secure fastening of panels. During fixing, the panel should be correctly aligned and temporarily clamped to ensure the holes are drilled correctly. Drilling of holes produces very hot metal chips (swarf), which should be brushed off the panel. This should be done immediately, if possible, and the work area should be swept with a soft broom at the end of each day work. Care should be taken in walking on roof panels. Workers on the roof should use soft footwear. Metal studs or heel tips will cause damage to the painted panels.
Stand away from high corrugations
It is important to walk in the correct place on roof panels. Always step in the valley of the panel, which is in contact with the purlin. Standing on the high corrugations may result in deformation of the panel. For achieving a quality job, use a screwgun with a depth locator or torque adjuster, this will ensure correct fixing of fasteners.
Brushing metal chips
26
When drilling use a rubber or leather thimble on the drill bit to prevent the chuck of the drill damaging the panel paint when the drill goes through the material. 5.1.1 Unloading Sheets are packed in bundles, and may be unloaded by a suitable forklift truck or crane. Care must be taken not to “break the back” of the sheets when unloading. If chains or cable slings are used for unloading, good protection must be provided for the corners of the bundle. Step in the valleys of the panel Note: Long panels may be difficult to handle by lifting the bundle from beneath.
5. Care and Handling of Sheeting 5.1.2 Storage Packs of sheets should be stored in a safe area of the site. They should be stored clear of the ground and elevated at one end to allow for water drainage should they become wet. Preferably, the bundles should be loosely covered with a tarpaulin; this will afford additional protection but allow air circulation. 5.1.3 Handling Care should be taken when handling sheets. Erectors should use clean gloves to avoid dirty marks, oil or grease stains on sheets. When handling individual panels from the stack, each panel should be lifted clear, not dragged along, which cause scratches.
Storage
5.1.4 Cutting & Fixing Only proper tools should be used for cutting profiled sheets. An electric nibbler should be used for cutting across the ribs, an electric shear for cutting longitudinally, and aviation snips for small detail work. Never use a grinding desk for cutting sheets
27
Storage and handling
Handling individual panels
On completion, the sheeted area should be inspected. Any ferrous objects such as pop-rivet stalks, bolts, nails, screws etc. left on the roofing should be removed. Any accidental scratches or minor damage should be touched-up with the appropriate paint. The area should be left clean. 5.1.6 Paint Repair For minor scratches, a small brush can be used to apply touch-up paint of matching color to the damaged area. If damage has affected the galvanized coating, then the damaged area should be coated with special primer followed by a special polyurethane finish coat. 5.2 Water Test Procedures for Roofing There is really no better way of water testing a roof than actual rainfall, as to simulate even fall or wind blown rain is impossible. If medium to heavy rain has fallen after completion of roofing, and no leakage is visible then the roof should be considered tested and satisfactory. If the roofing has been completed during a dry season, and testing is required, then the following test can be carried out: A 25 to 30mm diameter hose will be required with sufficient mains pressure, or a tank and electric pump. Two tests can be done. 1. The hose should be positioned on the ridge, or highest point of the roof. The water should then cascade down each slope, down each valley between panel ribs. The hose should not be deliberately directed at the panel end-laps and side-laps. 2. The second and longer test can be carried out if desired by attaching a rotary garden sprinkler to the hose and allow the whole roof to be systematically “watered”. This is the nearest method of stimulating rainfall as the sprinkler system causes the water to bounce, thus finding any weakness in lap conditions.
5.3 General Tips 1. Erection shall start from a braced bay and the bracing shall be fixed before proceeding to the other bays. 2. Purlins and girts shall be immediately fixed to each erected bay to maintain the building stability during erection 3. Always check the starting position of roof panels.
Zamil Steel Pre-Engineered Buildings I Erection Manual
5.1.5 Completion & Inspection
4. Panels should be plumbed and held in place by Vice Grips before screwing. 5. The panel gauge should be marked on the sheeting notch. 6. A line should be used to maintain a straight sheeting line at the eave. 7. A chalk line should be used to ensure the screws are installed in a straight line, and avoid mis-drilling. 8. Roof sheets should be undamaged. 9. Bead mastic must be carefully placed over the corrugations at end laps. 10. Insulation should be neatly folded at the base angle and eave. It can never be neatly cut off afterwards. 11. Pre-drilling is required when using stainless steelfastner.
28
6
Maintenance Procedure 6.1 Maintenance for Longer Life 6.2 Safety Notes 6.3 Exterior Maintenance Procedure 6.4 Maintenance of Accessories
29
6.5 Record of Maintenance
6.3 Exterior Maintenance Procedure
Now that your Zamil Steel Building is complete, we recommend that you follow our simple maintenance recommendations. By doing so you will substantially enhance the life of your investment.
t 1SFWFOUJWF NBJOUFOBODF TIBMM DPNNFODF immediately after a project is erected or modified.
The frequency of maintenance is dependent upon the environmental zone in which the building is located. The table below contains the recommended maintenance frequencies for different building locations.
Building Location
Maintenance Frequency
Within 5 km of the sea
Every 3 months
High pollution industrial area
Every 3 months
Medium pollution industrial area
Every 4 months
Areas of high humidity
Every 4 months
Low pollution industrial area
Every 6 months
Dry desert regions
Every 6 months
6.2 Safety Notes t &YFSDJTF FYUSFNF DBVUJPO XIFO XPSLJOH PO roofs. t 6TF QSPGFTTJPOBM NBJOUFOBODF TUBGG GPS maintenance works. t &OTVSF UIBU BDDFTT MBEEFST SFBDI BU MFBTU POF meter above the step off poing. t 4FDVSFMBEEFSTUPUIFCVJMEJOHBOEFOTVSFUIBU they are on a firm base. t %POPUTUFQPOTLZMJHIUT t 8IFOXBMLJOHPOUIFSPPG TUFQJOUIFWBMMFZT of the panel, not on the ribs. t 8IFOFWFSQPTTJCMF XBMLPOUIFQVSMJOMJOF JF screws line. t 1SPUFDUBSFBTPGSPPG TVCKFDUUPGSFRVFOUBDDFTT by temporary or permanent walkways. t 8IFO NBJOUBJOJOH PWFSIFBE DSBOF SVOXBZT immobilize the crane before commencement of work.
t %FCSJT BOE TNBMM JUFNT TVDI BT TDSFXT QPQ rivets, drill bits or any ferrous object shall be removed by sweeping with a soft nylon brush. Large items such as sheet metal cut-offs shall be removed by hand to avoid damaging the surface of the roof panels. Such debris shall be removed after any trade (e.g., electricians, plumbers, air conditioning technicians, steel erectors, etc.) has worked on the roof.
Zamil Steel Pre-Engineered Buildings I Erection Manual
6.1 Maintenance for Longer Life
t4BOEBOEEVTUSFUBJOTBMUBOENPJTUVSF XIJDI will eventually breakdown the paint and zinc layers, resulting in corrosion of the base metal. Sand and dust shall be removed by washing with clean potable water and a soft nylon brush, working from the highest point to the lowest, followed by a final rinse using a hose and clean potable water. t 5IF NPTU WVMOFSBCMF BSFBT PG UIF CVJMEJOH BSF gutters, roof sheets, sheltered areas under eaves or canopies and upper portions of walls or roof extensions. t 'PSCVJMEJOHTMPDBUFEJOIJHIQPMMVUJPOJOEVTUSJBM areas, or close to marine environments, water alone may not be sufficient to remove saline deposits that have become encrusted on the panels. In such cases, a mild detergent shall be added to the initial washing water. Panels shall be washed with the mild detergent solution and a soft nylon brush. A final rinse with clean potable water should follow. Oil, grease, tar, wax or similar substances can be removed with mineral spirits followed by a detergent solution and a clean potable water rinse. t %P OPU VTF DBVTUJD PS BCSBTJWF DMFBOFST UIFZ may damage the paint and zinc layers. t (SPVOE MFWFM TIBMM CF NBJOUBJOFE BU MFBTU 150mm below the base of the wall panel. accoumulations of wind blown sand shall be removed. Plants and shrubs surrounding the building shall not touch the wall panel; They may scratch the painted panels.
30
t &BWF HVUUFST BOE WBMMFZ HVUUFST TIBMM CF thoroughly cleaned with a mild detergent solution and a soft nylon brush, followed by a rinse of clean potable water. Downspouts shall be clear of blockage and the downspout discharge shall have adequate drainage area. t .JOPS EBNBHF UP TIFFUJOH PS USJNT TIBMM CF repaired as follows: - Lightly abrade the affected area - If base metal is exposed, apply one coat of zinc chromate primer - Apply one coat of matching touch-up paint t &RVJQNFOU XIJDIJTMPDBUFEUISPVHIPSBEKBDFOU to roof or wall panels may cause moisture build up on or near the panel. The following conditions shall be avoided: - Water run-off from air conditioning units - Open water storage tanks adjacent to panels - Steam outlets - Acid storage - Copper pipes fastened to steel panels 6.4 Maintenance of Accessories
31
t #VJMEJOHTXJUI$SBOFT - Every 6 months check that all bracing is tight - Check that all high strenght bolts in the crane beams and the main frame connections are tight t 1FSTPOOFM%PPST - Lubricate hinges and lockset - Remove dirt and girt from the threshould - Ensure that the door cannor swing back and strike the wall panels, as this will sprain the hinges and damage the panel t 4MJEJOH%PPS - Regularly clean the bottom guide to recove sand and stones t 3PMMVQ%PPST - Clean and lubricate the chain and reduction drive gears t 1PXFS7FOUT - Clean fan blades to remove build-up of dust and dirt 6.5 Record of Maintenance A Periodic Maintenance Log Book shall be kept. All maintenance dates shall be recorded and signed by the maintenance staff.
Zamil Steel Pre-Engineered Buildings I Erection Manual
7
Safety Precautions
For safety reasons there are precautions that need to be taken during erection. 7.1
Make daily check on all lifting equipment.
7.11
Ensure that high strength bolts are used where indicated.
7.2
Make daily checks on all lifting slings, check forfraying and kinking.
7.12
Ensure that high strength bolts are correctly tightened.
7.13
Maintain a clean and tidy site, thus avoiding material loss or accidents.
7.14
Tie down sheeting once the bundle is opened.
7.15
Sweep roof sheeting at the end of each day work, drill swarf will corrode the panels if not removed.
7.16
When walking on the roof, step in the valley of the panels, not the ribs.
7.17
If when waking on the roof step on the purlinlines
7.18
Use the correct tools for the job, wrong tools will damage materials and produce poor quality.
7.3
Check that all access equipment is in good condition, including scaffolding and ladders.
7.4
Check weather conditions, strong winds are dangerous during erection and sheeting.
7.5
Check for overhead electric lines before moving in with a crane.
7.6
Check that all erectors have the correct personal safety equipment, hard hats, boots, safety harness etc.
7.7
Check electric cables for hand tools, discard frayed or split cables.
7.8
Ensure that there are sufficient guy wires on site for temporary bracing.
7.9
Ensure that erection always starts at a braced bay.
7.19
Do not step on the skylights while working on the roof
7.10
Ensure that permanent bracing and flange stays are installed as work proceeds.
7.20
Finally, acquire Insurance;
contractors
all
Risk
32
8
Quality Control
Erection Quality Plan The safety and Quality of Erection should be ensured by engaging experienced and qualified Engineers, Supervisors and Technicians on the job.
33
The Quality Control should be effective at various stages of erection starting from receipt inspection till the final handing over. To ensure this, Standard Inspection and Testing Program (ITP) / Quality plan (or) a project specific Inspection and Testing Program - ITP / Quality Plan shall be followed. The Quality Plan as a minimum should contain the following: a. ITP - Inspection and Testing Program (Attachment I, 2 pages) b. Erection Inspection Check list - EICL (Attachment II, 3 pages)
Erection shall not start without: t 5IFTVCNJTTJPOPGUIF2VBMJUZ1MBO t *EFOUJGZJOHBEFEJDBUFE2VBMJUZBOE Safety Person t $POEVDUJOHB1SF*OTQFDUJPO.FFUJOH1*.
c. Method Statement
See the Sample Quality Plan as attached.
d. Procedures and Inspection Forms referred in the ITP e. Bolt Tightening Procedure (Attachment III, 3 pages) f. Paint Touch up Procedure g. Site Organization chart including a dedicated qualified person for QC and Safety
Basic Erection Equipment
Zamil Pre-Engineered Steel Buildings I Erection Manual
9
9.1 Main Erection Equipment 9.2 Electrical Equipment & Tools 9.3 Measuring & Surveying Equipment 9.4 Safety Equipment 9.5 Other Equipment
34
9. Basic Erection Equipment 9.1 Main Erection Equipment
Mobile Crane Mobile Cranes are ideal for erecting pre-engineered steel buildings. The required capacity of the crane varies. The capacity must be calculated considering the heaviest member (or assemblies of members), the building configuration and the site conditions.
Forklift Forklift are ideal for unloading tralers, for meterial handling on site, and in certain cases, for the erection of the main frames. Buildings up to 6m eave height can be erected by rough terrain forklifts with a 3-stage mast and a capacity of at least 3 MT. By attaching a man platform, forklifts can be used for fixing wall sheeting, eave gutters, trims, etc.
Telescopic Handler
35
Telescopic handlers are even more versatile than forklifts. They can be used for many different operations of a construction site. Having a wide range of accessories, they can be used for building erection and other general construction work. With a man platform attachment, telescopic handlers are suitable for fixing wall sheeting and other external building accessories.
Scissor Lift Scissor lifts are suitable for use on level, paved areas for fixing roof liner panels. They are also very useful for other purposes such as electromechanical works.
Lifting Beam A purpose-made lifting beam (spreader bar) of 6 or 12 m long is required for lifting long span rafters and frame assemblies.
Purpose-made slings, used alone or in combination with lifting beams, are used for lifting building components or assemblies. One, two or four leg slings are available, with hooks or eyes, and for different load capacities. They are available as a chain, wire or polyester. The sizes and types of slings required shall be determined by the weights of the components and assemblies to be lifted.
Zamil Steel Pre-Engineered Buildings I Erection Manual
Slings
Guy Wires Guy wires are steel wire ropes of 8 to 10 mm in diameter and different lengths (length depends on building height). They are used to provide temporary bracing for the building normally used in combination with ratchet pullers. As a rule of thumb, the minimum length guy wire should be at least 1.5 times the building height. The guy wire should be attached to the rarter before it is lifted into place and then tied-off to a fixed object to provide temporary bracing during erection. The degree of bracing depends on the size of the building and local weather conditions. Guy wires are also used to achieve correct alignment of the building. Important Note: Nylon ropes shall not be used for temporary bracing.
Clamps Clamps are used for attaching guy wires to rafters or holding components (such as sheeting) in place prior to fixing.
Shackles Shackles are used for connecting slings and / or guy wires. Note: Shackles shall have the safe working load (S.W.L) clearly stamped on them.
Clips Clips are used for making eyes in guy wires or for adjusting their lengths.
36
9. Basic Erection Equipment
Ratchet Puller Ratchet & Tirfor pullers are used for tensioning the guy wires that are used in temporary bracing and aligment of the building. Various capacities of ratchet pullers are avialable.Normally one ton capacity pullers are adequate for bracing and aligning most pre-engineered buildings. Heavy duty pullers, Tirfors, are available when extra capacity is required.
Light Duty Scaffolding Access towers are mobile work platforms, useful for sheeting walls and installing wall accessories and trims.
Ladders
37
Extension ladders are used to access roofs. mezzanines, catwalks, etc. Step ladders are free standing ladders used for minor fixing and trimmings.
9.2. Electrical Equipment & Tools
Generator When a main electrical supply is not available, generators are required for the power tools 5 KVA generators are suitable for most electric hand tools.
Screw Gun Electric screw guns are necessary for installing self drilling fastners in roofs. In order to avoid over-tightening of the screws, screw guns should have either torque or depth controls. The recommened speed is 0 to 2000 RPM (revolutions per minute).
Electric nibblers are required to cut openings in profiled sheets. Cutting with nibblers guaranees controlled maneuverability and excellent cutting quality, preventing meterial distrotion and eliminating the risk of corrosion at the cut edges.
Zamil Steel Pre-Engineered Buildings I Erection Manual
Nibbler
Grinder In pre-engineered building erection, grinders are used for cutting mild steel angles such as base and gable angles. Note: Sheeting shall not be cut with angle grinders. Angle grinders produce rough and unsightly cuts, which will very quickly corrode.
Hammer Drill Hammer drills are mainly used for the installation of expansion bolts.
Hole Cutter In pre-engineered buildings, all holes are prepunched. Should circumstance dictate changes, then the hole cutter is the ideal tool for making the required site modifications.
Impact Wrench The impact wrench is used for tightening high strength nuts and bolts of the main frames. Both pneumatic and electric models are available. Pneumatic models are heavy duty wrenches and are suibable for the large diameter bolts. An air compressor is required when using a pneumatic model.
38
9. Basic Erection Equipment
Electric Shear Electrical shears produce a clean cut in flat sheet. They are not suitable for cutting over corrugations of panels.
Heavy Duty Drill with Reamer A heavy duty slow speed drill with a tapered reamer is used for enlarging holes in steel members, if needed. The recommended speed of the drill is 0 to 500 RPM (revolutions per minute).
Reciprocating Saw
39
A reciprocating saw is ideal for cutting insulated roof and wall sandwich panels (Zamil Steel Tempcon panels).
Drill 10 mm A 10 mm drill, with a speed of 0 to 2400 RPM (reolutions per minute), is required for pre-drilling holes for pop rivets and any other bolts that require field drilled holes.
Powder Actuated Tool Powder actuated tools are used for fixing base angles to floor slabs or tie beams. They can also be used to fix steel decking panels to mazzanine joists.
Pop Rivet Puller Pop rivet pullers are used for fixing pop rivets in trims and gutter joints.
(Left & Right Cut) Aviation snips are used for cutting trims and small openings in sheet panels. This method of cutting produces a very clean cut, which will not rust. They provide a fine control for intricate cuts.
Zamil Steel Pre-Engineered Buildings I Erection Manual
Aviation Snips
Vice Grips Vice grips have many uses as a “third hand” and are essential to clamp sheets and trims while fixing the screws or rivets.
Torque Wrench (With Sockets) Zamil Steel recommends that high strength bolts are tightened by the “turn-of-nut method” (see Chapter 3 of Zamil Steel Erection Guide). If the torque requires checking, a torque wrench (with different sockets sizes) should be used on which the torque value is preset perior to checking.
Ratchet Spanner (With 19 mm Socket) For quick tightening of purlin and girt bolts and other machine bolts.
Staple Applicator They are used for stapling tabs on fiberglass insulation.
Utility Knife Utility Knives are used for cutting fiberglass insulation
Hacksaw Hacksaws are used for cutting light gauge metal.
40
9. Basic Erection Equipment
Mastic Gun Mastic guns are required for the application of the flowable mastic, which is commonly used for sealing gutter joints and overlapping flashing.
Spud Wrench Spud wrenches are used during erection to align holes in two steel members and to tighten the bolts. Various sizes of spud wrenches are required that would suit the bolt sizes.
Drift Pin Drift pins are used to align holes in two steel members. They can be hammered if additional force is needed.
41 Miscellaneous Tools Hammers Wood saws Screwdrivers Comination spanner sets Sweeping brooms
Tool Belt & Bolt Bag A tool belt & bolt bag provides a safe and convenient way of carrying tools and bolts.
Chalk Line Chalk lines are used for marking staight lines on the panel along the position of purlins and girts. The marked line identifies the position of the screws.
Plumb Bob Plumb bobs are used for plumbing vertical members up to a height of 6 m.
Zamil Steel Pre-Engineered Buildings I Erection Manual
9.3. Measuring & Surveying Equipment
Theodolite Theodolites are used in setting out the building foundations and anchor bolts. They are also used for checking the vertical alignment of columns and the alignment of crane beams.
Automatic Level Automatic levels are used to check the elevation of anchor bolts, the finished floor level and the base plates of columns.
Spirit Level Spirit levels are used for leveling individual components and for plumbing.
Measuring Tape & Square Measuring tapes are used for miscellaneous checking, setting out and general easuring. A right angle square is used for setting out 90* angles.
42
9. Basic Erection Equipment
9.4. Safety equipment
Welding Hood Welding hoods shall be used during welding.
Goggles Goggles shall be used whilst cutting or grinding.
Gloves Gloves shall be worn when handling steel components. Clean gloves should be worn while handling sheets.
43 Safety Harness & Fall Arrest Safety harnesses shall be worn when working over 2 meters above the ground levels.
Safety Boots Protective footwear shall be worn at all times while on working site to avoid toe, sole or ankle injuries.
Hard Hat Personal head protection shall be used be on site at all times.
First aid boxes should be on site at all times under a qualified first aid person. All contents shall be maintained and expiry dates checked periodically.
Zamil Steel Pre-Engineered Buildings I Erection Manual
First Aid Box
Cones and Ribbons Cone and warning ribbons are used to indicate danger areas on sites.
Portable Fire Extinguisher Fire extinguishers shall be installed on vehicles and in areas where welding or burning works are executed.
44 Ear Protection Ear protection shall be used where noise is higher than 85 dB.
9.5. Other Equipment
Welding Machine Electric welding machines are used for light duty welding such as tack welding of light guage steel members.
Oxy-acetylene Cutting Outfit Oxy-acetylene is used for cutting steel members.
10
Attachments 10.1 Inspection and Testing Program (ITP-Standard Jobs) 10.2 Erection Inspection List (EICL) 10.3 Tightening and Inspection of High Strength Bolts
45
10.4 Anchor Bolt Installation Guide
Zamil Steel Pre-Engineered Buildings I Erection Manual
Attachment I
46
10. Attachments Attachment I
47
Zamil Steel Pre-Engineered Buildings I Erection Manual
Attachment II
48
10. Attachments Attachment II
49
Zamil Steel Pre-Engineered Buildings I Erection Manual
Attachment II
50
10. Attachments Attachment III
51
Zamil Steel Pre-Engineered Buildings I Erection Manual
Attachment III (Continuation)
52
10. Attachments Attachment III (Continuation)
53
Anchor Bolt Installation Guide Prior to pouring of concrete, anchor bolts may in the manner shows below.
Zamil Steel Pre-Engineered Buildings I Erection Manual
Attachment IV
54
Anchor Bolts whenever not supplied by Zamil should be of the sizes shown on Zamil’s Anchor Bolt Erection drawing and of a quality to resist column reactions given. Material should conform to ASTM A 36M (or Equivalent) (36 KSI=2500 kg/am2 Min, yeld) of equivalent, unless otherwise specified. Embedment lengths are base on a minimum concrete compressive strength of 3 KSI = 200 kg/cm2 at 28 days. Anchor bolts shall be accurately set as shown on Anchor Bolt plan with a tolerance of 2mm within a set. Note: 1. All reinforcing steel for foundation walls and footings, tie rods, plywood template, mesh or any materials used specifically for concrete application shall be designed by professional foundation engineer and supplied by others. 2. Foundation contractor shall fill all voids in concrete slab perimeter wall prior to erection of building. Placed fill shall be properly compacted in layers and controlled moisture.
Glossary
55
Accessories
:
Additions to the basic building, such as doors, windows, louvers, ventilators etc.
Anchor Bolts
:
Hooked bolts cast in concrete foundations for anchorage of structural members.
Base Angle
:
Countinuous angle fixed to floor slab or grade beam for attachment of all panels.
Base Plate
:
The plate of a column or beam which rests on the supporting surface.
Beam
:
Horizontal Structural Member.
Brace Rods
:
Rods placed diagonally in roof and walls for transferring wind loads to foundations and stabilizing the building.
Bridge Crane
:
Overhead travelling crane supported on beams and rails.
Built-up Member
:
(B.U.) Structural member formed by welding together web and flange plates.
Caulking
:
Sealant used in making watertight joints.
Clear Span
:
Building without internal columns.
Closure
:
(Foam Closure) Profiled foam material used inside or outside profiled roof or wall panels to form weathertight seal.
Cold Formed
:
Various steel shapes manufactured by roll-forming or pressing.
Column
:
Vertical structural member.
Crane Beam
:
Support for overhead travelling bridge crane.
Crain Rails
:
Rails welded or bolted to crane beams to form the track for bridge crane wheels.
Curb
:
Raised flashing around roof openings to form waterproof opening.
Damper
:
Baffle plate in a ventilator.
Dead Load
:
Weight of the structure.
D.S.D
:
Double slide door.
Eave
:
Top of the sidewall.
Eave Height
:
Height from top of eave strut to finished floor level.
Eave Strut
:
Structural member at the eave which supports roof and wall panels.
Expansion Joint
:
A break in the construction to allow for thermal expansion.
Flange Brace
:
An angle from the flange of columns or rafters to girts and purlins to provide lateral support and stability.
Girt
:
Secondary horizontal member to which wall panels are attached, usually cold formed “Z”.
Grout
:
Non-shrinking sand cement mixture used under base plates to obtain uniform bearing surface.
:
Intersection of column and rafter.
Header
:
Horizontal member over and opening in a wall.
H.S.B.
:
High strength bolts.
Hot Rolled
:
Steel shapes formed while the steel is semi-molten.
Jack Beam
:
A beam used to support a rafter instead of a column.
Jamb
:
Vertical member at the side of a wall opening.
Joist
:
Horizontal members for supporting floor or roof decking.
Knee
:
See Haunch.
Liner Panel
:
Interior wall sheeting.
Live Load
:
Any variable temporary load on the structure.
Main Frame
:
Primary members which support secondary members.
Mastic
:
See Caulking - Sealant.
M.B
:
Machine Bolt.
Mazzanine
:
Intermediate floor between ground floor and first floor or roof.
Mono-Slope
:
Single slope roof.
Multi-Span
:
Building with intermediate columns.
Parapet
:
Vertical wall extension above the eave line.
Partition
:
Internal wall.
Pitch
:
Slope of the roof.
Pop Rivet
:
Used for joining flashing and light guage metal trims.
Portal Frame
:
Column and beam bracing used in lieu of standard rod bracing to prvide clear access.
Post & Beam (P&B)
:
Light end wall framing.
Primer Paint
:
Factory applied paint to structural members providing protection during shipping and erection.
Purlin
:
Secondary horizontal member to which roof panels are attached usually cold formed “Z”.
Rafter
:
Primary member supported on columns.
Ridge
:
Peak of a gabled building.
Zamil Steel Pre-Engineered Buildings I Erection Manual
Haunch
56
Glossary
57
Rigid Frame (R.F.)
:
Main frame of the building comprising columns and rafters
Sag Rod
:
Tie rods used to support flanges of girts or purlins.
Sealant
:
See Mastic - Caulking.
Secondary Framing
:
Secondary members of framing such as girts, purlins, eave struts etc.
S.D.S.
:
Self drilling screw - used for attaching panels and trims to girts and purlins. Pre-drilling is not necessary.
S.T.S.
:
Self tapping screw. Same function as S.D.S. but needs pre-drilled holes.
Shims
:
Small steel plates used for levelling base plates or packing between structural members.
Sill
:
The bottom horizontal member of a door or windows opening.
Skylight
:
Translucent fibreglass panel used in the roof to transmit natural light.
S.S.D.
:
Single Slide Door.
Soffit
:
Underside of canopy, fascia or roof extension.
Span
:
Distance from out to out of wall girts.
Splice Plate
:
Plate used to connect two members.
Stiffener
:
Plate welded to a member to prevent buckling.
Stitch Screw
:
Used to fasten side laps of panels.
Truss
:
Structural member made up of several individual parts welded or bolted together, the completed unit acting as a beam.
V.G.
:
Valley Gutter.
ASSY
:
Assembly
BT PLT
:
Bent Plate
BOTT’M
:
Bottom
CC
:
Center to Center
CONC
:
Concrete
CL
:
Centre Line
DET
:
Detail
DRG
:
Drawing
DSD
:
Double Slide Door
EW
:
End Wall
EXP’N
:
Expansion
FO
:
Framed Opening
FNB
:
Fin Neck Bolt
HSB
:
High Strength Bolt
INT
:
Internal/Interior
LG
:
Long
MB
:
Machine Bolt
NS/FS
:
Near Side / Far Side
OA
:
Overall
OC
:
On Centre
O/O
:
Out to Out
PL-PLT
:
Plate
P&B
:
Post and Beam
R.F.
:
Rigid Frame
RUD
:
Roll-Up Door
SHT
:
Sheet
SHT’G
:
Sheeting
SDS
:
Self Drilling Screw
STS
:
Self Tapping Screw
SSD
:
Single Slide Door
STIFF
:
Stiffener
SW
:
Sidewall
TC
:
Tempcon
THK
:
Thick
TYP
:
Typical
TYP UN
:
Typical Unless Noted
ZS
:
Zamil Steel
Zamil Steel Pre-Engineered Buildings I Erection Manual
Commonly Used Abbreviations
58
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