Ondatherm 900 Installation Guide - PGA Consultants

Edition: October 2011
Installation guidelines
System: ONDATHERM 900 C
ArcelorMittal Construction International
Industriestrasse 19
8112 Otelfingen / Zürich
Switzerland
www.arcelormittal.com/arval
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Javier Cirauqui

Summary
1. Basic principles ........................................................................................................ 3
2. Documentation ......................................................................................................... 3
3. Building site conditions............................................................................................ 3
3.1. Lifting the material ....................................................................................... 4
3.2. Packaging and storage on site....................................................................... 4
3.3. Un-packaging................................................................................................ 5
3.4. Protective film .............................................................................................. 5
4. Safety........................................................................................................................ 5
5. General rules............................................................................................................. 6
5.1. Inspection of existing works......................................................................... 6
5.2. Inspection of installation work ..................................................................... 6
5.3. Structure alignment ...................................................................................... 6
5.4. Installing the panels...................................................................................... 6
6. Cutting and drilling during installation .................................................................... 7
6.1. Cutting .......................................................................................................... 7
6.2. Drilling ......................................................................................................... 7
7. Anchoring, fixing and connecting the panels during installation............................. 7
7.1. General.......................................................................................................... 7
7.2. Fixations and how to fix ............................................................................... 7
7.2.1. Screws....................................................................................................... 8
7.2.2. Blind rivets ............................................................................................... 8
7.2.3. Considerations .......................................................................................... 8
8. System fixation description ...................................................................................... 9
8.1. Installation .................................................................................................... 9
8.2. Width of support........................................................................................... 9
8.3. Alignment of the panels................................................................................ 9
8.4. Fixings and connections ............................................................................. 10
8.5. Sealing strips .............................................................................................. 10
8.6. Fillers for profiles sheeting......................................................................... 10
8.7. Drainage...................................................................................................... 11
8.8. Overlaps...................................................................................................... 11
8.8.1. Side laps.................................................................................................. 11
8.8.2. End lap.................................................................................................... 12
8.9. Direction of installation.............................................................................. 12
8.10. Securing for uplift................................................................................... 13
8.11. Holes....................................................................................................... 13
8.12. Design of flashings ................................................................................. 13
8.12.1. Flashings overlap.................................................................................... 14
Annexes .......................................................................................................................... 15
I. Templates ....................................................................................................... 16
I.1. Checking lists templates ............................................................................. 16
I.2. Cutting list templates.................................................................................. 17
I.3. Curved cutting list templates ...................................................................... 20
II. Installation ratios ............................................................................................ 21
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Javier Cirauqui

1. Basic principles
Every project has requirements according with national and local regulations.
These regulations must be taken in consideration to select a system with the
right performances to fulfil the requirements of the project.
Safety, thermal and acoustic comfort, or energy savings may fail if not properly
selected.
Before ordering any material, it must be checked that the selected system
performances are in accordance with the requirements for the project.
1.1. Load bearing of the system support
1.2. Load bearing of the external skin
1.3. Thermal insulation
1.4. Noise insulation
1.5. Acoustic absorption
1.6. Fire behaviour
1.7. Air permeability
2. Documentation
For any project it is necessary to prepare a basic documentation to verify that
the building can be erected in accordance with client’s performance
requirements:
• Installation drawings with the layout of the roof or façade and indications
about the position of any profile and the direction of installation should be
a must before starting the erection.
• Details showing how flashings should be positioned, sealed, and fixed.
• Cutting list to have a reference of the materials we have ordered and
ease following of the layout
3. Building site conditions
A necessary task that can save time and money during the erection of the
building is to do a visit to check if:
• Site is in conditions to receive and storage the materials properly
• Free space to place and move the cranes, platforms, scaffoldings, etc.
• Safety measure can be installed
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3.1. Lifting the material
Bundles must be handled properly to avoid damaging the material.
Bundles can be handled with:
• Sling belts
• Sling belts and spreader beam
• Fork lift
3.2. Packaging and storage on site
Avoiding the retention of water between sheets and panels is a must to avoid
corrosion.
Bundles must be stored with a slop of 1% to facilitate the evacuation of the
water.
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The materials must be distributed on site as close as possible to the area where
they will be installed.
Bundles can not be stacked on top of each other on the construction site.
They can be delivered stacked but they must be unloaded and stored
separately.
When lifting the bundles to the roof, you must secure them to avoid sliding
sheets or panels.
Before leaving bundles on the roof, you must check with the contractor that the
structure can support the bundled weight.
3.3. Un-packaging
When you unpack the materials you have to take care about the risk of
displacements of the materials or up-lifting them due to the wind action.
Waste material has to be taken to the proper place to avoid dirty and risk of
accidents.
3.4. Protective film
Coated products are supplied with a removable
protective film to prevent mechanical damage
during transport and assembly. This film must
be removed 15 days after outside storage
exposed to weather and/or immediately after
installation, whichever is soonest.
4. Safety
The work site must have the collective protective measures installed properly
before starting the works.
These protections must be defined according with the requirements of the
safety project created by the General contractor.
Employees must be equipped with the individual protections appropriated for
the job that they are doing.
Some of the protections are: helmets, gloves, boots, harness, etc.
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Javier Cirauqui

5. General rules
5.1. Inspection of existing works
Before starting the installation, it is necessary to check the works and analyze if
there are deviations in the existing works (structure alignment, dimensions, etc.)
that could concern your own works and stop you installing materials properly.
5.2. Inspection of installation work
Your own works must be inspected regularly to verify that all the works are
being developed according with the manufacturer’s instructions and the
construction rules.
When works are done professionally, we all will get the customer satisfaction
and reducing the claims.
The checking list documents provided in this document can help to do it.
5.3. Structure alignment
If the structure is not properly aligned, the roof will not be with the right pitch.
Every error in the structure will be transmitted to the roof.
When defects in the alignment, etc. the contractor should correct the defects or
installing a substructure prior starting our works.
Maximum deflection of purlins must be considered to avoid water retentions on
the roof.
5.4. Installing the panels
Panels have to be installed according with the layout drawing prepared for this
job. It must be done in the direction indicated in the drawings.
Before interrupting the day works, profiles must be secured to avoid uplift due to
the wind action.
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6. Cutting and drilling during installation
6.1. Cutting
Panels can not be cut with abrasive tools.
Most kinds of saws are suitable to cut steel
sheets and panels if they don’t burn the
material as abrasive tools.
Metal shavings have to be removed from the
area to avoid adverse optical and warranty
issues.
During the cuts, the area where the saw tool
can scratch the sheet must be protected.
6.2. Drilling
Metal shavings from these operations have to be removed to avoid optical and
warranty issues.
7. Anchoring, fixing and connecting the panels during
installation
7.1. General
Depending on the final use of the sheet / panel, its dimension and the
supporting structure, several fixings systems can be used.
Fasteners must have an appropriate corrosion protection for the environment
where the buildings are located.
Installation and dimension of the fasteners is described in the next points
7.2. Fixations and how to fix
The next points will describe the possible fasteners, how they must be fitted and
the field of application.
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7.2.1. Screws
Screws can be used to fix cladding panels.
Two types of screws are acceptable:
• Self-drilling
• Self-tapping
Tools, power and speed must be fitted according with the technical
recommendations of the screw manufacturers.
In the case of self-tapping screws, the diameter of the hole must be in
concordance with the instruction of the screw manufacturer to keep the loadbearing
capacity.
If the screws have a sealing washer, it is recommended to use a depth stop to
keep the waterproof properties.
No water tight Correct Too tight Oblique
7.2.2. Blind rivets
Blind rivets can be used for stitching two sheets together for side laps,
flashings, etc.
Load-bearing capacity and diameter of the drilled hole must be considered from
the recommendations of the rivets manufacturer.
7.2.3. Considerations
Expansion and contraction of the materials due to the changes of temperature
must be taken in consideration when the type of fixation is decided.
Our technical assistance can support you to choose the right fastener and
indications about how to install it properly.
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8. System fixation description
8.1. Installation
Every system has its own way of installation.
In this case, you must follow the
recommendations below:
• Installation of consecutive panels
• Installation of the distribution plate and
fixing it in the central hole or two
external holes (depending on uplift
loads) with a screw diameter 6.3 mm x
L
• Installation of a thermal insulation
between the two ribs.
• Installation of the cover plate clipping
to the ribs and hiding insulation and fixation.
8.2. Width of support
Width of the support must be confirmed according with the product we are using
and, material of the structure and the wind loads
In general, you can consider that for steel structure we need a minimum width:
• End support: 40 mm
• Intermediate supports: 60 mm
Performances of the panels change considerably when we increase the width of
the supports.
8.3. Alignment of the panels
The ribs of the profiles of every row must be aligned on whole surface.
The first panel must be properly vertical or horizontal installed because it is the
reference for the whole roof.
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8.4. Fixings and connections
The number of fixings must be calculated per project to ensure the resistance of
the roof / façade to the wind actions.
The selection of the fasteners has to be done according with the thickness of
the structure and the grade of steel.
All the fixings must be protected against corrosion, stainless steel or bichromium
protection.
When water runs off on the fixings, a waterproof washer is a must.
8.5. Sealing strips
End laps must be sealed and also flashing laps
8.6. Fillers for profiles sheeting
Fillers for profiling sheets or panels must be installed properly to avoid dropping
out.
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8.7. Drainage
Dimensions of gutters and outlets must be done in accordance with the
technical standards.
Solutions for overflows must be designed an installed when inside mounted
gutter.
8.8. Overlaps
Overlaps must be done according with professional rules to keep the water
tightness under every action.
Panels can be prepared with two types of overlap depending on the slope that
will be placed, right and left overlap. The reason of both overlaps is to allow the
continuity of the ribs from one slope to the other slope at the ridge.
Right overlap
Left overlap
8.8.1. Side laps
As consequence of cover plates, it is not necessary to seal side laps
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8.8.2. End lap
End lap must be sealed with a row of
8mm diameter PIB butyl strip positioned
maximum 15mm from the edge of the
under lapping sheet or using butt straps to
achieve a flush joint use tapes as above.
It is not necessary to stitch it.
Cover plate overlap must be displaced 500 mm upstream from panel overlap to
avoid water infiltrations.
8.9. Direction of installation
Installation must be done in the direction of the predominant winds. Every
product has its own direction of installation and must be consider before starting
installing it.
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8.10. Securing for uplift
Products must be fixed as soon as they are placed on the roof or façade to
avoid any uplift due to the action of the wind.
Before interrupting the work, it is necessary to check that all the products are
properly fixed and the bundles are also fixed with some straps to avoid risks of
falling materials.
Direction of installation is important for an easier secure.
8.11. Holes
Pipe penetrations must be properly made in concordance with the design taking
in consideration that:
• Pipes can not transmit forces to the façade
• Reduction of the thermal bridges is a must
• Flashings must be water and air tight
8.12. Design of flashings
Flashings must be defined following some recommendations:
• Flat surface shouldn’t be larger than 250 mm to keep the flatness
• Small slope is recommended to avoid water retention.
• Drip is recommended in any flashing to reduce the dirty on the façade.
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8.12.1. Flashings overlap
Laps can be done:
• Overlapping the flashings 100 mm and adding a sealant butyl tape 15
mm from the end and in front of the stitching screws or using butt straps
to achieve a flush joint use tapes as above
• Joining obtusely to an underlay sheet with sealant tapes 15 mm from the
ends of the two pieces of flashing and in front of the stitching screws.
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Annexes
The next annexes are showed as example and orientation, ArcelorMittal
Construction is not responsible about the right use of them.
Other alternatives are possible and the customer must check if the information
is enough for his company.
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I. Templates
I.1. Checking lists templates
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Only if cutting list,
drawings have been
made by AMC
Only if installation is
supervised by AMC
Check list
Site
Tidy and clean
Y N
Delivery On time
Y N
Number of times
Packages properly storages
Y N
Material properly lifted from packet to site
Y N
On time
Y N
Delays
Y N
Roof
Fixation to the roof Y N
Are properly Junctions
Y N
done Ends
Y N
Gutters
Expansion joints
Y N
Are they Shavings
Y N
clean bubles
Y N
Are installed Joints
Y N
properly mouths
Y N
Aligment of the gutter and ridge
Y N
Undulations, scratchs, dents, material properly managed
Y N
Roof is lengh enough at the gutter
Y N
Overlaps of the roof are properly done
Y N
Fixations are enough and well positioned
Y N
Roof material properly fixed
Y N
Ridge properly installed
Y N
Ridge joints properly installed
Y N
End of the roof material is properly folded
Y N
Fixation of flashings properly done
Y N
Every solution is water proof
Y N
Holes revised and properly done
Y N
Protected film properly retired and storaged
Y N
Roof cleaned
Y N
Façade
Material properly lifted from packet to site
Y N
Material without bubles and undulations
Y N
Fixations are enough and well positioned
Y N
Drip and façade are properly leveled and aligned
Y N
Doors, Windows and holes properly done and flashings installed
Y N
Overlaps or vertical joints properly installed and sealed
Y N
Drip is properly aligned
Y N
Corners are properly aligned
Y N
Windows are properly aligned
Y N
Flashings properly designed
Y N
Flashings properly sealed and fixed
Y N
Drip flashing doesn't have any dent
Y N
Safety
Installers have finished the safety training
Y N
Safety speach has been done to the installers
Y N
Collective safety measures are installed
Access to the roof is safe
Y N
Electricity wires are at the right distance and properly insulated
Y N
Electrical box containers have a "gadget that cut the electricity if contact with metal" Y N
Installers have the right tools for the installation
Y N
Material packets are properly placed and/or fixed
Y N
Scaffolding and platforms are safe
Y N
The ground permits the movement of the platforms
Y N
The roof holes are protected aganist fallings
Y N
Working area is properly indicated
Y N
Installers have the individual safety elements
Y N
New installer in the work site has been trained in safety
Y N
Components installation
The insulation is properly installed according with the system description
Y N
The spacers are properly installed and fixed
Y N
Vapour barrier is installed properly
Y N
Are there thermal bridges visibles
Y N
I.2. Cutting list templates
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Panels cutting list
Customer
Work reference
Location
Delivery address
Number of order
Date
Number of
position
Product
Core
Panel
thickness
Number of
units
Lenght
External face
Internal face
Steel thick Coating Colour Steel thick. Coating Colour Layout drawing position
Signature
Stamp
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Javier Cirauqui

Flashings cutting list
Customer
Work reference
Location
Delivery address
Number of order
Date
Flashing name
Number of pieces
Lenght piece
Number overlap pieces
Coating
Colour
Steel thickness
Layout drawing position
Flashing name
Number of pieces
Lenght piece
Number overlap pieces
Coating
Colour
Steel thickness
Layout drawing position
Flashing name
Number of pieces
Lenght piece
Number overlap pieces
Coating
Colour
Steel thickness
Layout drawing position
Signature
Stamp
Flashing name
Number of pieces
Lenght piece
Number overlap pieces
Coating
Colour
Steel thickness
Layout drawing position
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I.3. Curved cutting list templates
Curved steel profiled sheets cutting list
Customer
Work reference
Location
Delivery address
Number of order
Date
Internal face
Number of
position
Product
Thickness
Number of
units
Internal
Radius
Angle
External face
(to be filled if different of back coating)
Coating Colour Coating Colour Layout drawing position
Signature
Stamp
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II. Installation ratios
Installation ratios are given in hours per man and square meter.
In general, we can consider that installation must be done by teams and every
team is composed by three members: two handling and fixing and the third one
preparing the material at the position.
Element
Rate
(Hours / (man · m 2 )
Panel 0.08 hours / (man · m 2 )
Flashings 0.2 hours / (man · m)
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