Sandwich panel cutting at construction site
We will cut. Just what?
The panels must be cut strictly horizontally. The horizontal control of the lines of the upcoming cut is carried out on both sides of the panel with a building level. First, the metal is cut, then the insulation layer.
When using a grinder, a high temperature arises at the cut site, which can lead to a fire insulation. In addition, overheated metal loses its corrosion resistance, so only a circular or band saw for metal or a jigsaw is used to cut sandwich panels. As an exception and only for small volumes of work, electric shears for metal are allowed.
With panels where wood or PVC is used as a shell, everything is easier. they are cut with an electric jigsaw or an ordinary hand saw.
Avoiding mistakes and mistakes
A large number of errors during the installation of sandwich panels are associated with inattentive, fluent reading of the accompanying design and installation documentation, and in fact it often contains comprehensive information about panels and connecting elements.
But even strict adherence to the instructions cannot insure against some installation errors, namely:
- Metal sandwich panels must be free from damage and corrosion. The metal frame on which the fastening will be made should be in the same condition;
- If the panels are attached to a timber frame, it must be impregnated with antiseptics and insecticides;
- Contaminated sandwich panels must not be cleaned with detergents containing alkalis, acids and abrasives;
- The protective film should not be exposed to direct sunlight. It should also be protected from solvents;
- The protective film must be removed from the sandwich panels no later than a week and a half after installation, but this cannot be done in very hot and very cold weather;
- You cannot walk on sandwich panels, put various objects on their surface and attach anything to them.
Strengthen, but in moderation
Fasteners for sandwich panels are selected taking into account the type of structure and its thickness. As a rule, self-tapping screws (self-tapping screws) are used for this.
Their length is the sum of the thickness of the panel, the frame and the compensation for the height of the rubber washer (5 mm). The latter is mandatory for use with self-tapping screws. it prevents the metal head from damaging the panel when screwing in and seals the attachment point.
The panel 6 m long is fastened with six self-tapping screws, 4 m long and less. four, more than 6 m long. eight. Self-tapping screws are fastened with a screwdriver with a pre-adjusted tightening force.
When properly tightened, the washer does not deform and at the same time is sufficiently tightly pressed against the metal. Too tight tightening crushes the washer, not tight enough does not ensure the tightness of the fastening. The oblique landing of the self-tapping screw is categorically unacceptable.
How to properly lift and install panels?
A transport package with sandwich panels (read about the technical characteristics of these products in this article) is lifted to the mounting height with special equipment. vacuum lifters.
If a conventional crane is used for these purposes, a number of measures must be taken to prevent damage to the panels:
- Soft slings are used to lift the transport package. In this case, the seizure of the package itself by the slings is not allowed. The locking parts of the panels are protected from possible damage by slings, spacer bars, at least 122 cm long, evenly spaced above and below the package;
- The sandwich panel cannot be lifted directly from the pallet.
Also, in the process of work, you should adhere to the following rules:
- The panels must be joined strictly at an angle of 180 degrees, i.e. vertically. Docking at a different angle can lead to deformation of the locks;
- Installation should be carried out with extreme care to avoid damage to the protective coating. Otherwise, the service life of the panels will be significantly reduced.
How to cut and fasten a sandwich panel. the nuances and features of installation
Installation of sandwich panels is a very important stage in the construction of a building, and just as important. The important nuances here are not so much how to fix the sandwich panels, but in accordance with the implementation of their installation to the technological process. Their service life and the energy efficiency of the building as a whole depend on this.
Vertical and horizontal mounting
Fastening of sandwich panels to metal structures can be carried out in two directions: vertical and horizontal. Both mounting methods have their advantages and disadvantages.
If the floor has a low height (from 3 to 6 m), vertical installation is used. In this case, the panels are attached only to the guide profiles of the floor and ceiling, and are rigidly connected to each other. The integral and sturdy structure created at the same time is free from “cold bridges” and does not have heat losses. During installation, significant funds are saved, since there is no need for lifting special equipment and scaffolding.
However, you cannot do without them if the floor height is more than 6 meters. Perhaps, instead of scaffolding, a carriage will be required to ensure facade work at a height. All of them, moreover, are unthinkable without the use of a truck crane. Additional costs are also required to strengthen the metal frame of the building to prevent sagging of tall panels.
The level of costs at such a height of the walls can be reduced by horizontal installation of sandwich panels. They are laid out one on top of the other and attached with the edges to the columns of the frame. This also creates a continuous skin. However, to use horizontal installation, it is necessary that the distance between the columns of the building frame is no more than 6 meters.
When installing sandwich panels, either horizontal or vertical method should be used. Their combination is unacceptable.
You can see how to properly mount the panels in the video below:
The nuances of installing sandwich panels
With the vertical installation method, the panel is laid out first from the corner, abutting against the joint. With horizontal. first, the first row from the base is performed, and only after it is the next one. Regardless of how to mount the sandwich panels, the work ends with the installation of an additional panel. If necessary, it can be dimensioned on site by cutting.
The sandwich panels must not come into direct contact with the supporting structure. To avoid this, a seal gasket is performed. If the panels have polyurethane foam insulation, polyurethane foam is used; if made of mineral wool. the same material. Polymer tape and silicone sealant are also used.
With vertical installation, it is necessary to achieve the most tight connection of the locking part of the panels as possible. However, be very careful to press down on the panels so as not to damage them. With horizontal installation, the tightness of the joining of the locking parts is ensured by their weight.
To seal the connection from the outside, silicone sealant must be added to the lock, but so that it does not react with the coating of the panels. Adjacencies from external influences are protected by special additional elements. cover strips.
Preparatory work before installing wall panels
- The preparation of the material begins with the removal of the protective film from the surface of the web.
- To keep the anti-corrosion coating intact and intact, it is recommended to lay the material only on wood or foam pads.
- You should inspect the locking parts of the cladding. the insulation should in no case protrude. If it does protrude, you need to eliminate the flaw with a wooden scraper.
The protective film is removed only before installing the cladding
Where to start installation work
Fastening of sandwich panels is carried out directly not on the surface, but on a special supporting structure. a frame made of a certain material.
The main point in the construction of the frame should be the fact that its vertical and horizontal steps must correspond to the dimensions of the sandwich panels. Of course, all the slats must be oriented strictly according to the level, otherwise all the material will skew or begin to bunch together.
Since the cladding will be installed with joints and indents from the edges of 5 cm, it is necessary to provide for these features when installing the frame for a sandwich panel.
Frame made of metal beams and profiles
First of all, you need to clean the surface of any contamination, be it dirt or dust. Then it is treated with antiseptics and a layer of anti-corrosion composition. For subsequent work, you need to choose which frame will be erected.
Supporting structures are of the following types:
- A wooden frame is the most affordable, but at the same time the most fire hazardous option. For fastening in this case, ordinary self-tapping screws are used for sandwich panels for wood.
- A reinforced concrete frame is a durable but heavy option that is not suitable for every type of foundation. Dowels and anchors are used for fastening.
- A metal frame is the most preferable option, in which the installation of wall sandwich panels will be the best way. Self-drilling screws will be used for fastening in this case. Before screwing them in, the support elements are pre-drilled with holes of slightly smaller diameter than necessary. Screws are then screwed into these holes.
The main nuances when cutting material
In most cases, to complete the installation, it will be necessary to cut the panels to a convenient size for us.
Cutting plastic blades with a jigsaw
How to cut a variety of sandwich panels. the processing method differs depending on what material was used in the manufacture of the product:
- plastic products are sawn with a simple hacksaw or jigsaw. With the help of the last device, the cutting process is much easier, moreover, the quality of the saw cut is higher;
- steel blades are cut with metal scissors. You can use a jigsaw or circular saw, which are designed for cold working. Since steel is always covered with a protective layer, during cutting it is necessary not to allow it to overheat. this excludes the use of grinders, grinders and plasma cutting;
- SIP panels must be cut taking into account in order to keep the edge of the product intact and to ensure the possibility of even connection. Do not use a jigsaw. Circular electric saws or hand tools are recommended for use.
DIY sandwich panel installation. types of fasteners, cutting methods and installation tips
DIY sandwich panel installation
One of the fairly popular materials for prefabricated buildings are wall sandwich panels.
This material is used not only for cladding, but also for insulation. You can also use it not only for facade, but also for roofing or interior work, such as making ceilings or partitions.
In this article, we will consider the installation of sandwich panels with our own hands from the preparation stage to the post-surface treatment stage.
Why choose this kind of finish? At least because the installation can be carried out without the use of rare tools or inaccessible devices. For example, skilled workers are quite capable of paneling up to 500 square meters of facade per day.
Possible types of fasteners
The sandwich panel installation technology assumes either horizontal or vertical installation. Combining these two methods for decorative purposes is unacceptable. however, this drawback is completely leveled by a variety of color and texture solutions.
If the storey level has a size of three to six meters, you need to make a vertically oriented installation (in some cases, a horizontal orientation will also work).
How to fix the cladding in this case. the sandwich panels are connected to the guide metal profile and the upper surface (ceiling), you also need to connect the elements together.
Partition attachment point for vertical installation
The sealing compound is laid on both sides. The resulting structure with these manipulations relieves you of cracks and perfectly protects the house from severe frosts. No special equipment and scaffolding is required, which reduces financial costs by a fairly large amount.
If the height of the storey exceeds six meters, then the vertically oriented installation is complicated by the fact that the work cannot be carried out without the use of a crane and scaffolding. In addition, the upper parts of the vertical canvases will tilt under their own weight, which will require additional reinforcement. All this makes vertical installation in this case impractical.
The lifting of wall panels can be carried out in several ways.
To prevent the above problems, it is recommended to use horizontal cladding. At the same time, separate wall canvases will lie on the upper one on the lower one, and fastenings will be carried out to the frame columns.
The output will be a beautiful solid cladding. For horizontal installation there is a mandatory requirement. the horizontal step of the frame should not be longer than 6 meters.
Installation and fastening highlights
After installing the frame, for further work, self-tapping screws are used to fasten the panels.
Fasteners must be tightened so that they protrude from the frame by 1-2 cm.It should also be mentioned that a sealing tape should be installed on the columns of the frame, which extends along the entire height.
With a horizontal method of installation, you need to start from the bottom up, with a vertical one. from left to right from the corner of the building. This approach eliminates the formation of gaps at the joints. The grooves for horizontal installation must be placed at the bottom. so it will be easier for the water to flow down. Fasteners for sandwich panels are the same for any type of installation.
If installation without special equipment is difficult due to the height of the building, then basement substructures, lifts and grippers are necessarily used.
Self-tapping screw used for fastening cladding sheets
With the help of a lift, you can lift the material, and then lay them on the same substructures. After that, it is necessary to check the treated wall for the absence of drops, and the canvas itself. for compliance with the building level.
The first panel should be carefully leveled, since the quality of all subsequent works depends on it.
General diagram of the fastening of the mounting device for lifting material
Even the slightest deviation of the starting panel will lead to an increase in the error with the installation of each subsequent element, as a result of which it will take at least an uneven appearance in the upper part of the wall, and in the worst case, gaps are formed at the joints, which is undesirable for thermal insulation.
We have already mentioned the need for fastening to the frame more than once, now it is time to make it unfastened. Making all these manipulations, it is important to carefully monitor that the sandwich panel is not damaged.
Each subsequent canvas is attached similarly to the first, but even despite the maximum accuracy of the installation of the initial strip, check everything according to the level after installing every third element.
Example of correct and incorrect seating of screws for fastening
In terms of observing other nuances, the question of how to mount a sandwich panel comes down to organizing reliable joint seams. The panels are tightly connected in locks. each ledge must fully fit into the corresponding groove, otherwise the structure will collapse immediately after commissioning, and sometimes even before it.
Depending on the severity of the climate, the silicone sealant should be applied only on the inside, or on the inside and outside. Adhesive and sealant are applied right before the panel is installed.
The temperature range allowed for it is always indicated on the sealant. Please note that the sealant is really suitable for your weather conditions.
An example of the correct joint of two wall panels
The transverse joints are sealed with mineral wool. The use of polyurethane foam is allowed. Some types of insulation lose their properties due to exposure to moisture. To prevent this nuance, the attachment points must be treated with waterproofers.
If the length of the material does not exceed 4 meters, then the recommended joint width should be more than 15 mm. If the length is more than 4 meters, the seam must be at least 20 mm.
After finishing the installation work, you need to mask the seams. For this purpose, shaped elements are used, the installation of which starts from the basement ebb. The masking is fastened using small screws or rivets. The shaped element is treated with a sealant from the back side.
Care tips and important installation rules
At the end of the main installation work, it is time to talk about caring for the finished cladding. Note that some problems are easier to prevent than to fix the imperfections later.
For low-rise buildings, installation can be done with a minimum number of people.
Therefore, we will mention some of the installation features:
- if mineral wool is used as a heater, installation work is carried out only in a respirator. This material is very undesirable to enter the respiratory tract. Allergies and irritations are the least to get;
- do not install structures with mineral wool in high humidity. the insulation will swell and lose its properties. And we have already mentioned the need to use a waterproofing sealing tape;
- if the protective layer of the cladding was not damaged during installation, then the facade should be protected from influences and subsequently. for this, you simply should not lean against the walls elements of construction equipment, temporary supports, stairs, etc. steadily;
- a visual inspection of the surface should be carried out at least once a year. Remove dirt with a soft brush and soapy water. A variety of damage to the protective layer can be repaired with repair dyes.
Thus, compliance with all recommendations for installation and maintenance will lead to the fact that the protection and beauty of the house for tens of years will be ensured by a once-made installation of sandwich panels.
Installation of sandwich panels
Sandwich panel buildings are warm and light.
In order for them to provide maximum comfort during operation, have a long service life, special attention must be paid to their installation.
During the installation of pre-fabricated premises, the quality of sandwich panels and additional elements is of great importance.
In addition, the construction of structures of this type must be trusted by experienced professionals with the necessary qualifications.
Panel cutting and drilling
The basic rule of assembly cutting of sandwich panels is the use of tools that perform exclusively cold sawing.
Excessive heating of metal surfaces can lead to a violation of the protective polymer coating.
It is recommended to use jigsaws and circular saws for cutting sandwich panels.
It is also possible to use scissors for metal, but subject to separate cutting of each metal surface.
It is forbidden to apply markings before assembly cutting or drilling and any other marking on the surface of the sandwich panels using sharp objects.
After each cutting or drilling, all joining surfaces and panel joints must be completely cleaned of metal shavings.
Lifting and installing sandwich panels
Lifting and installation into the mounting position of a separate sandwich panel is carried out exclusively with the help of special load-gripping mechanisms, which are divided into:
- mechanical grippers with through-hole drilling of the panel;
- mechanical grips fixed in the panel lock;
- special grippers with vacuum suction cups.
When lifting, it is also recommended to additionally use textile slings to strap the panel and prevent a possible fall when moving.
Removal of safety straps is carried out immediately before installing the panel.
The procedure for laying sandwich panels
Organization of the transverse joint of wall panels.
The seam between the panels is sealed with mineral wool, and its size should be 20 mm.
Seams are closed with shaped elements.
The installation of fittings should be carried out from the bottom up.
The overlap between the elements must be at least 50 mm.
Shaped elements must be attached to the panels with self-tapping screws or rivets with a pitch of 300 mm.
Organization of the transverse joint of roofing panels.
The overlap of the transverse joints of roofing panels should be selected depending on the roof slope:
- with a slope of 5-10 degrees, the overlap length should be at least 300 mm;
- with a slope of 10-20 degrees, the overlap length must be at least 250 mm.
At the upper panel of the transverse joint, it is necessary to cut the lower steel sheathing by the amount of overlap and remove the insulation layer.
Apply sealing tape to the top steel panel of the bottom panel.
Next, the panel is fixed to the frame.
An application for the installation of sandwich panels can be sent electronically to the company’s mail email@example.com or call us at 7 (495) 118-36-14.
Site condition and preparatory work
When preparing for installation work, you must make sure that the construction site is suitable for the work, which includes:
- Availability of a reinforced road surface to provide access to the construction site for freight transport with a permissible payload of up to 40 tons, as well as truck cranes of appropriate carrying capacity;
- Availability of appropriate working platforms with a level surface with sufficient bearing capacity for the approach of equipment;
- Availability of the necessary storage areas near the place of work and for the placement of materials;
- The ability to connect to power grids or access to electricity 220V;
Before starting installation work, it is necessary to obtain project documentation containing:
- Layout schemes for wall or roof panels, as well as the specification of these panels, indicating their type, thickness, length, type of profiling and quantity;
- Descriptions of the method for attaching panels to supporting structures with designation of the type, location and number of connecting elements;
- Detailed drawings of individual assemblies for fastening panels to supporting structures, including special instructions for installation;
- Drawings and specifications of fittings;
- List of sealing and sealing materials;
- Installation instructions and wiring diagrams.
Before starting the installation of wall and roof sandwich panels, it is necessary to check the quality of the installation of load-bearing metal structures in accordance with the project documentation and the relevant SNiPs.
for the installation of sandwich panels
per sq. We guarantee high quality of work.
The cost of work is formed from:
- Remoteness of the object;
- Manual assembly or using power engineering;
- Altitude and the need for climbing equipment;
Why make up a PPR for the installation of sandwich panels
The main goal of developing a production project is to prove the compliance of all work performed with regulatory and technical documentation. This is necessary in order to ensure the safety of the erected building or structure for finding people in them. If a situation occurs in which the mounted structures are subjected to deformations exceeding the standard values, it is possible to identify who will be responsible for this according to the PM. Using a manufacturing project has a few more implications.
- An indicator of the organization’s competitiveness. If the company has a PPR, then it is already ready to start installation work. Also, such documents are taken into account when certifying the quality system.
- Rationalization of the resources used, including time, production capacity and labor of workers. According to a typical project, the construction process always proceeds in accordance with the time allotted for it.
Why else is a work production project needed?
When carrying out construction processes, it is important to ensure not only the compliance of the installation with the rules and regulations, but also the safety of workers on the construction site. To do this, in the project for the production of works, the technology for their implementation must be indicated. This helps to minimize possible risks of damage and hazardous situations. Other tasks of compiling the PPR:
- admission to the production of work, including the installation of panels;
- saving costs associated with the selection of material and technical resources (machines, tools, inventory, technological equipment, etc.);
- determination of the most effective methods for performing construction and installation work;
- assessment of the conformity of the quality of work to the requirements of design documentation.
Project for the production of PPR works for the installation of sandwich panels
Such enclosing structures are easy to install, but the process has its own characteristics that must be taken into account. This is helped by PPR for the installation of sandwich panels. The abbreviation stands for a project for the production of works. According to SP 48.13330.2011 “Organization of construction”, the development of PPR is an obligatory part of the preparation of organizational and technical documentation for any type of work.
What works indicate in the PPR for the installation of sandwich panels
The first section provides general data for the production project. The next paragraph provides a list of regulatory documents that were used in the preparation. The next in the PPR for the installation of sandwich panels are several more important sections.
- Organization and technology of work. This section reflects several construction processes.
- Preparatory work. The section contains recommendations for preparing the site for installation: providing temporary approaches, clearing debris and arranging fences.
- Basic work. They relate directly to the installation of sandwich panels. This includes panel lifting, assembly cutting, drilling, installation and fastening.
- Requirements for quality and acceptance of works.
- Description of safety and labor protection at the construction site.
- Work schedule.
STO 43.99.50 INSTALLATION OF GUARDING STRUCTURES FROM SANDWICH PANELS
|DEVELOPED AND INTRODUCED FOR THE FIRST TIME
Effective date: “01 November 2012”
Based on the Order of 12/18/2012
4.1. Responsibility for meeting the requirements established by this service station is borne by:
4.2. Control over compliance with the requirements established by this service station is carried out by:
5.4 When binding this standard to a specific object and construction conditions, the following are specified: the amount of work, labor costs, means of mechanization and equipment.
Terms, definitions, designations and abbreviations
This standard uses terms in accordance with the City Planning Code, GOST 16504-81.
3.1. Terms and Definitions:
Standard: a document that establishes product characteristics, implementation rules and characteristics of design (including survey), production, construction, installation, adjustment, operation, storage, transportation, sale and disposal, performance of work or provision of services for the purpose of voluntary reuse. The standard may also contain rules and methods of research (testing) and measurements, rules for sampling, requirements for terminology, symbols, packaging, marking or labels and rules for their storage.
Building frame: load-bearing internal structure of the building structure.
Supporting structure: a set of building structures that withstand loads, provide strength and stability of the building.
Specification: the main design document defining the composition of the assembly unit, complex, kit
Sandwich panel: a building material with a three-layer structure, consisting of two sheets of rigid material (metal, PVC, fiberboard, magnesite board) and a layer of insulation between them. All parts of the sandwich panels are glued together using hot or cold pressing.
Tooling: a set of labor tools, devices designed for installation, fastening of workpieces and tools.
Scaffold means: any temporary structure (stationary, suspended and mobile) and its supporting components that are used to support people and materials or to provide access to any such structure and which are not lifting mechanisms.
Insulation: a structural element that reduces heat transfer.
Clamp: a type of auxiliary tool used to fix any part.
Slinging of loads: technological operation of fastening the structure to the hook of the crane for lifting.
Scaffolding: a temporary auxiliary structure for placing workers or materials during construction, installation and other work.
Lanyard: pulling device.
Sealant: paste-like or viscous composition based on polymers or oligomers, which is applied to joints in order to prevent leakage of the working medium through the gaps of the structure.
Seal: a device or method to prevent or reduce the leakage of liquid, gas by creating an obstacle at the junctions between the elements.
STO. organization standard;
PPR. project of the production of works;
POS. construction organization project;
Coolroom Panel Cutting.mp4
ITR. engineering and technical workers;
University. higher education institution.
This standard has been developed taking into account the requirements of the following regulatory documents:
If the reference document is replaced (changed), then when using this STO one should be guided by the replaced (changed) standard. If the referenced document is canceled without replacement, then the provision in which the link to it is given applies in the part that does not affect this link.
Organization and technology of work
6.1 Process preparation conditions
Before starting work, you must:
a) panel layouts;
b) methods of fastening and the number of fasteners;
c) solutions for the junction points of the panels;
d) specifications of panels, shaped and additional elements;
e) wiring diagrams.
6.2 Unloading panels.
6.3 Storage of panels
Warehousing of SANDWICH panels shall be carried out in open storage areas, provided that the original packaging is preserved and the bags are protected from precipitation with a waterproof material. The storage areas should be covered with crushed stone, 200 mm high and planned with a slope of 1 0.
The storage areas are separated by through passages with a width of at least 1.0 m every two stacks in the longitudinal direction and every 25.0 m in the transverse direction. For the passage to the ends of the products, gaps equal to 0.7 m are arranged between the stacks. A gap of at least 0.2 m in width is left between the individual stacks in order to avoid damage to the elements during loading and unloading operations. Panel mounting markings must face the aisle.
Packages of wall and roof panels should be stored stacked in one or several tiers, the total height of which should be no more than 2.4 m. providing a slight slope of the panel packages during storage, for the free flow of condensate. When storing panels packed in boxes, the height of the tiers is not limited.
Figure 3 shows a diagram of the storage of panels packages.
The shelf life of the stored packaging should be no more than 1 month in order to avoid fungus in the filler and, as a result, the loss of the main properties of the product.
To prevent strong adhesion of the protective film to the surface of the panel under the influence of sunlight, it is necessary that the surface of the panels is closed from their penetration.
It is recommended to cover the panel packages during storage with a tarpaulin so that there is a possibility of ventilation, see fig. four.
The factory markings of the elements must be readable. If necessary, the marking should be duplicated on surfaces that are open for viewing.
Instructions for storing and storing panels
6.4 Organization and technology of the construction process
6.4.1 Installation of wall sandwich panels
Professional staff of the link
The work is proposed to be carried out by a sequential method by a unit of 4 people of the following professions:
Two installers are on the ground doing all the preparatory work, the other two installers are installing and fixing the panels.
In the absence of the above specialties and qualifications of workers, before starting the production of work, it is necessary to conduct their training and certification.
Composition and sequence of works
Before starting the installation of wall panels, carry out the final leveling with the placement of the bottom of the panels on all columns, mark the top and bottom of the panels on the window, door girders and the top of the panels under the roof, taking into account the installation size of the panel, the gap between the panels and taking into account the panel lock. In order to avoid mistakes when installing panels.
Before installing the first wall panel, install and fix the plinth strip on the basement of the building.
Immediately before starting the installation, the M4 installer checks the integrity of the panel, locking parts, checks the color of the panel. Removes the protective film from the locking joints, the places where the panel meets the supporting structures, and from the locations of the fasteners.
Installation of wall panels is carried out from the outside of the building frame using inventory means of paving or mobile lifts. When installing inventory scaffolding, it is necessary to leave a gap between the building frame and the scaffolding of at least 400 mm for the installation of panels.
To grip and move panels use:
clamps with safety slings of a vice or clamping type (see Fig. 5);
a mechanical gripper that drills through the panels (in this case, pay attention to drilling the panel for the pin. The hole must be located strictly perpendicular to the surface of the panel cladding), see fig. 6;
special mechanical grips, which are fixed in the “lock” of the panel, see fig. 7;
vacuum lifter, see fig. 8.
In order to prevent the panel from falling when lifting when using mechanical grips, it is necessary to use safety belts (textile slings) that will wrap around the lifted panel. They need to be removed right before installing the panel in the design position. At this point, the panel will only be held by mechanical grips.
In case of vertical assembly of panels with a length of 6 meters or more, in order to avoid breakage and deformation of the panel, it is recommended to use a vacuum lifter, see fig. 8. In those places where the vacuum gripper will be attached to the metal surface, you need to remove the protective film.
Attention: When gripping the panels with load-carrying devices, make sure that the surface of the panel in the place where the load-carrying devices are fixed is clean.
3.1 Horizontal installation of wall panels
Technological sequence of works:
When installing wall panels horizontally, start the panel assembly from the bottom upwards from the basement:
Stick the sealing tape on the metal frame in the places where the plane of the panels adjoins the frame elements, see fig. 9.
Place the bottom panel in the design position and fix it with self-tapping screws. Then unbind the panel. The panel groove (the convex part of the lock) must be on top, see fig. ten.
Drilling holes in the panels for fastening self-tapping screws should be performed in the places for further installation of fasteners or in places covered by edging, cover strips after installing the panels. Install self-tapping screws in the horizon of the wall panels, 2 in each wall girder. The distance from the edge of the panel to the self-tapping screw must be at least 50mm, see fig. eleven.
Increasing the distances at the junction of the panels and the distance between the screws and the joint is unacceptable. since the shaped elements covering this joint are designed specifically for these dimensions, and in the event of an increase in the distance, the head of the self-tapping screw will interfere with the normal installation of the shaped elements.
Insert a tubular seal or sealant into the lower locking part (groove) from the room side, see Fig. 12.
tubular sealant (sealant).
Mount the panels of the adjacent span, insulate the joints of the panels, and the abutment to the basement of the building, mount the strips, see Fig. 13. The overlap of one strip on the other is at least 50mm. Fasten the strips with self-tapping screws with a pitch of 300mm.
3.2 Vertical installation of wall panels
The main differences between vertical and horizontal installation is the great complexity of installation work.
Technological sequence of works:
When installing wall panels vertically, start panel installation from the corner of the building exactly from the panel that will abut against the joint, see fig. 14.
Stick the sealing tape on the metal frame in the places where the plane of the panels adjoins the frame elements.
Place the first panel in the design position and fix it to the metal frame using a self-tapping screw at a distance of 20 mm from the end edge of the panel. A sealing tape must be glued between the panel and the frame, see fig. 15.
Lay the joint part of the mounted panel (groove) with a tubular seal on both sides or sealant. Place and fix the next panel in the design position, before fixing the second panel to be mounted, firmly press against the first panel. It is imperative to ensure that the tubular sealant (sealant) is firmly in the lock and does not interfere with the installation of the second panel. Installation direction, see fig. 16.
For a tighter connection of the panels, use a persistent lanyard, see fig. 17.
In the same way, all facade panels are mounted, the joints of the abutments are stuffed with insulation and the necessary cover strips are installed.
3.3 Organization of joints of wall panels
Sealing of panel joints and installation of strips is carried out only after the installation of all wall and roof panels is completed.
When organizing the longitudinal joint of wall panels, lay a tubular seal on both sides or a sealant into the locking part of the mounted panel (groove)
Arrange technological joints between the wall panels in the transverse direction, which in the future will be closed with shaped elements.
sealant (polyurethane foam, mineral wool);
The step of fixing fittings with self-drilling screws. 300mm.
Carefully check the filling and sealing of the mounting gap of the overhang strip mask. Fasten the corner strips from the bottom. On the strips, trim the ends for a tight and tight fit of the joints and joints. Cover strips for windows, doors, gates, start mounting from the bottom strip. Apply sealant from the inside with a width of 10-15 mm. on all edges of the strips facing upwards to prevent water penetration.
After the installation of the external flashing strips, seal those mounting gaps from the inside of the room with mounting foam that were not sufficiently sealed outside the building. After the foam has hardened, its excess is cut off and the internal flashing is mounted in the following sequence:
Perfect cuts: The new Panel Cutter TruTool TPC 165
-Internal corner strips.
After the completion of all installation work, the protective film is removed from the panels and strips both outside and inside the building. Wash off traces of dirt on panels and strips with a damp cloth. If this method is ineffective, use a cloth soaked in solvents. white spirit, 646 or acetone. No more than 40 reciprocating movements at a time, if the traces of dirt are not removed, repeat after 30-40 minutes.
3.4 Fastening the panels of the supporting structure with self-tapping screws
The self-tapping screws are tightened until the bend of the metal washer is eliminated. The self-tapping screws for fixing the panels must not be overtightened, as this may deform the panel. Check the sufficiency of the tension by the deformation of the rubber seal of the washer, see Fig. 17.
In order to avoid deformation of the sealing washer, it is necessary to set the value of the screw tightening torque on the screwdriver.
Always start fixing panels from the top end of the panel and continue fixing to the crossbars, going down.
All connecting elements should be located at an angle of 90 ° C. Anything that does not meet this parameter should be considered defective.
Do not leave the panels loose or partially fixed, as this may lead to panel breakage. The ends of the panels must not be left open; at the end of the shift, they must be closed with polyethylene. The cover strips should be secured with Phillips-head pan-head self-tapping screws.
Panels joining a window, door, gate require special attention due to joining with crossbars and adjacent panels. These panels sometimes require cutting out a part of the panel under the opening. Cutting is done on site with an electric jigsaw after marking. Cutting panels using abrasive wheels is prohibited due to damage to the paintwork due to local overheating. After cutting, the surface of the panel cladding must be cleaned of metal shavings and basalt dust.
When marking, it is imperative to take into account mounting gaps of 20-30 mm between panels and window or door blocks. After checking the horizontalness of the cutting lines with a building level on both sides of the panel, a cut is made on both sides, the mineral wool is cut through and a piece of the panel is removed. If it is impossible to cut on the mounted panel (protruding parts of the girder inside the panel, close arrangement of structures, etc.), the panel is marked on the inside of the panel directly at the installation site, without fixing the panel with self-tapping screws. Then the panel is removed and placed on special stands. The markings are transferred to the outside. The panel is cut on both sides, according to the marking, with a jigsaw, after which the wool is cut with a sharp knife and a piece of the panel with mineral wool is removed. Lifting the panel with a cutout to the installation site should be done with extreme caution, since the panel has lost its initial bearing capacity.
Then the next panel is inserted into the lock with the previously mounted panel (while the verticality of the panel is controlled) and fixed with screws, similar to the previous one. During installation, it is necessary to monitor the tightness of the spike in the panel locks.
3.5 Assembly cutting of panels
Assembly cutting is performed using scissors and saws that allow extremely cold cutting (jigsaw or hand-held circular saw). In the event that overheating of the metal coating of the panel occurs, the anticorrosive layer may be disturbed.
It is forbidden to use grinders, plasma cutting devices, which lead to significant heat generation and sparking.!
If the volume of cutting is not very large, then manual or electric metal shears can be used. With this option, both metal panel skins must be sawn separately.
It is necessary to clean the surface of the panels from metal shavings after each cutting or drilling.
Do not mark with sharp objects on the surface of the panels!
6.4.2 Installation of roof panels
Before starting work, clean the locking parts of the panels from protruding glue and insulation. Remove excess with a wooden scraper. On the supporting structures of the roof, it is necessary to arrange a working flooring from a board.
Installation of roofing panels must be started in rows from bottom to top towards the ridge, see fig. 22.
Roof panel slinging is carried out at the on-site warehouse using clamps or vacuum gripper. When slinging and lifting the panel, make sure that the panel is not damaged.
Roofing panels are mounted in such a way that the upper row of panels overlaps the lower one, the amount of overlap is 150-300mm, depending on the slope of the roof, see table. 1. Before installation, make a cutout of the panel insulation, taking into account the overlap, see fig. 23a, 23b. The trimming of the panels of the second and subsequent rows must be done at the installation site of the panels, for this it is necessary to cut the bottom sheet of the panel to the required distance and cut out the insulation. Particularly careful cutting of the core must be done in trapezoidal corrugations.
It is necessary to lay sealing strips or mastic on the panel of the first row. Fixing the panel at the joint is done only after fixing the panel with self-tapping screws to all elements of the frame. Further, the panels are attached in the same way.
Movement on the mounted panels is allowed only with the use of decks, in order to preserve the integrity of the panel covering.
Technological sequence of works:
Check the order of installation of panels according to the wiring diagram. Check the location of the first panel; it is recommended to make the necessary marks on the supporting structure;
Stick the sealing tape on the roof girders;
Install the first (end) roof panel.
Mount the first panel with an open wave towards the end of the building. Attach the clamps to the panel (see Fig. 24) should be at a distance of 1 / 4-1 / 5 L from both ends, the center of the pressure plate should be located between the first and second or second and third corrugations. Tie nylon cables to the edges of the panels to stabilize the panel when moving to the installation point. Holding the panel, lift the panel with a crane to the installation site. Align the edge of the panel with the end of the building, along the outer edge of the wall sandwich panels. Set the overhang of the panel to the distance specified in the project. Check the parallelism of the end edge of the panel with the axis of the building by pulling the cord along the ridge, and if there is no joint between the panels, then along the facade of the building.
The gap in the lock joint between the panels is 1-1.5mm. It is forbidden to exert excessive pressure when joining the panels; there must be a guaranteed gap between the panels in order to avoid buckling of the lock joint;
Mark the drilling site. Fasten the panel with self-tapping screws and sealing washers. The number of self-tapping screws on the sides of the roof should be selected at the rate of 3 self-tapping screws per girder panel. The self-tapping screws are tightened until the bend of the metal washer is eliminated. Screws are installed along the tops of the waves of the upper panel skin.
Cut along the longitudinal edge the lock of the upper casing in the plane with the panel core, as it will interfere with the installation of the end strip.
Install the next panel. The panel is laid with a protruding corrugation on the same corrugation of an adjacent panel and in a circular motion is placed in the design position, see Fig. 25a, 25b.
Beforehand, a vapor barrier rubber seal is placed in the lock of the bottom sheet of the mounted panel, and silicone sealant is applied to the groove of the lock corrugation, with a bead diameter of 5 mm, see Fig. 26.
Attention! The sealant is applied just before the installation of the roof panel.
The panel is fixed in the same way as for the first panel. After that, the panels are connected to each other by means of self-tapping roof screws with a sealing rubber washer. The screws are installed on the crest of the corrugation with a pitch of 300mm.
After installing the panels, mount the necessary cover strips, snow retainers and drainage systems, according to the project documentation.
Attention! Installation of roofing panels is not recommended in the cold season when ice forms
After the installation of all roofing panels is completed, the installation gaps are filled with sealant and mineral wool. After that, cover strips are installed on the mounting clearances.
6.4.3 Finishing and repairing damaged panels
It is not recommended to remove the protective film on the surface of the panel until after the installation of the panels. To facilitate the removal of the protective film, it is recommended to tear it off in the places where the strips are attached, see Fig. 27.
If the panel surface is scratched during installation, it is recommended to clean the scratched surface and paint the surface with a spray gun with paint in the panel color.
For dents up to 5 mm deep, it is recommended to use fillers when restoring the surface.
If the panel is severely damaged that cannot be repaired, it is recommended to replace the panel.
Replace non-recoverable wall panels in the following technological sequence:
For dismantling the wall panel, see fig. 28.
To dismantle damaged panels, the same tools and mechanisms are used that are used to assemble panels. An important condition for this type of work is the mandatory sealing of the junction of the panels to each other from the side of the room.
If the roofing panels are severely damaged, do the following:
For the replacement of roof panels, see fig. 29.
Replace roofing panels carefully without damaging entire adjacent panels. To move around the panels, it is necessary to lay wooden bridges or other protective material