installation handling & installation - barbour product …€¦ · · 2018-04-28the...

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Packing, Delivery, Off-loading& Site Storage 617

Site Handling & Installation 618

Product Health & SafetyData Sheet (C.O.S.H.H.) 620

Ridge Safety System 621

Method Statement 622

Kingzip Installation Methods and Tools 625

Handling &Installation

615

For more information on Kingspan Insulated Panels visit www.barbourproductsearch.info

http://www.barbourproductsearch.info/kingspan-insulated-panels-comp107529.html

Safety should be an inherent part of any workplace, especially when one of the

greatest risks relates to working at height

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616


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617

Packing, Delivery, Off-Loading & Site Storage

PackingAll Kingspan panels are packed in the factory and protected to ensurethey arrive on site in first class condition. The packing details vary from product to product because of theirshapes, and details of each can be found on the product data sheetswithin the relevant roof or wall section. In all cases however the panels are packed horizontally, with panelslying one on top of another, with additional anti damage protection toall sides and ends. The entire pack is wrapped in plastic film to keepthe panels clean.The number of panels in each pack varies depending on panelthickness, and customer requirements. Normally the maximum heightof each pack is approximately 1100mm. Each pack is labelled withthe customers name and contentsFully timber crated packs are available on projects requiring delivery bysea freight shipping at additional cost.

When hoisting packs or panels into position protect the edgesif necessary to avoid damage. Use flat slings and not chainsfor hoisting.

Using lifting beam with panels over 6 metres long

✓

✗

Spreader barwith slings

Using forklift with panelsunder 6 metres

2m Max 2m Max3m Max 3m Max

Delivery & Off - LoadingPanels are normally delivered to the site by road transport, thenumber of packs depending on panel and pack size. The packs areseparated with timber bearers which create gaps between the packsto allow lifting straps or forklift tines to be inserted.It is the customer’s responsibility to arrange lifting equipment andlabour to unload the packs. This usually requires using a crane, withor without a lifting beam, or a forklift, depending on panel length andweight.

• Store packs in a secure area, where they will not be damagedor stolen.

• Inspect the storage site and the packs regularly to ensure thepanels remain in good condition.

• Do not store packs where people will walk across them.

Site StorageIt is often necessary to store packs of panels on site for a periodbefore they are fixed. To ensure that the panels remain in primecondition until they are installed the following precautions shouldbe taken.• Store packs off the ground and on a slope, so that should rain

water penetrate the wrapping water will drain away. Support thepacks evenly with timber bearers spaced at 1.5 metres. Bearersshould always be placed one directly above another.

• If packs cannot be kept in a building they should be coveredwith a weatherproof sheet ensuring that the sheet drains wateraway effectively and does not allow ponding on top of the pack.It should also allow air circulation through the stacks of panels.


Site InstallationThe installation of Roof and Wall cladding on a particular buildingmust be planned carefully to ensure the work can proceed in safety.The contractor normally prepares a method statement for his client,which indicates who is responsible for safety, what equipment andparticularly what safety equipment, will be used for each stage ofthe work, and the sequence of installation.

The actual technique for fixing KS1000 RW and KS600/900/1000MR/EB/FL-S/MM/CX/WV Kingspan panels is described, but anumber of general principles apply:• Ensure that the purlins or cladding rails have been installed toprovide a level fixing plane for the panels.• Fasten the first panel at the edge of the roof or wall area to beclad, ensuring it is correctly aligned and the right way round forlapping etc, and then fix as indicated in the construction details. It is desirable to arrange the panels so that any side laps are notexposed to the prevailing wind.• Install the recommended fasteners in their correct positions to fixthe panel to the steelwork. Note that the number of fasteners mayhave to vary depending on the wind suction load. Fasteners shouldbe installed in the direction of lay.• The fasteners must be installed correctly in order to weather sealcorrectly, and any drilling swarf must be removed from the panel toprevent damage to the coating.• When sealants are applied at laps or joints, ensure surfaces areclean and dry, apply the tape seal to the surface before removingbacking paper, and cut (do not tear) the sealant at the end of a run.• If the panels have to be cut on site always use a reciprocatingtype saw (jigsaw or similar), do not use abrasive wheel cutters. Aftercutting remove swarf from the panel surface, and any burrs from thecut edges. Eye protection should always be worn when cutting ordrilling. (See Health & Safety Data Sheet).

618

Site Handling & Installation

Site HandlingPacks of panels up to 6 metres long can be lifted either with aforklift, or by crane with lifting straps, as shown below. Care must betaken to ensure the forklift tines do not damage the bottom panel,and similarly when using straps, protect the edge of the panels toprevent local damage.

Individual panels should always be lifted from a pack and notdragged over others.The weight of individual panels for lifting can be determined fromthe information in the Product Data pages for the individualproducts.

Generally, however, it is normal to man handle roof panels up to15 metres long into position, whereas for walls the limit is typically8 metres. For panels longer than this the contractor wouldnormally arrange to use a crane, hoist, or other equipment to helplift the panels into position.

Individual panels should always be handled carefully to avoiddamage. In particular Roof and Wall panels should not be lifted bythe side or end lap. Sliding panels on top of the other should beavoided, especially at edges.

Gloves should always be worn to avoid cuts and abrasions tooperatives. Installers should always wear rubber soled footwear toavoid damage to the panel coating when installing roof panels(See Health & Safety Data Sheet).

Protecting FilmWhen panels are supplied with a plastic protective film this shouldbe removed immediately after site installation.

1m Min

Fork Lift

Lifting Straps

Lifting Beam

2m Max 3m Max 3m Max

2m Min

6m Max

Packs longer than 6 metres should be lifted by crane with a liftingbeam with straps at a maximum of 3 metres centres.


Site Installation

Roof & Wall PanelsInstallation Procedure KS1000 RWThese panels lap at the sides and ends, so they must be fixed insequence to ensure reliable performance.1. Start with the eaves (or bottom) corner panel, with theprojecting side and end laps to the outside of the building. Installfasteners and apply sealant as specified.

2. Locate the second panel upslope or above, so that it overlapsthe first, adjusting its position carefully before contacting thesealant. Repeat up to the ridge or eaves/gable.

1

1

2

13

2

3. Start the second tier from the eaves (or bottom), side lappingthe first panel, sealing and fixing, as specified. Repeat theprocedure for the complete roof or wall.

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619

Architectural Wall SystemInstallation Procedure KS600/900/1000 MR/EB/FL-S/MM/CX/WV & OptimoHorizontally Laid

1. Fixing always starts at the lowest panel ensuring that the sillflashing and panel bearers (at max. 1.5m centres) are level. Sit thepanel on the bearers and fix the top edge to the rails using 1 or 2fasteners depending on panel span and wind loading. See designexample on page 121 in the Building Design section.

2. Sit the second panel on the tongue of the first, ensuring theends are correctly aligned andsealed, and the joint width is parallel. Fix the panel to thesteelwork as before. The side joint contains a factory applied sealand no further sealing is required.

3. Continue the same procedure to the top ofthe wall, cutting the top panel along its length if necessary. Thetop edge of the top panel must be fixed to the steelwork at500mm centres maximum.

4. Where through fasteners are used at panel ends or edges, atcorners or around doors, windows etc, they should be concealedby a flashing, to maintain a secret fix appearance.

KS600/900/1000 MR/EB/FL-S/MM/CX/WV Vertically Laid

1. Ensure the bottom rail is permanently or temporarily supported,and level, along its full length before starting installation.

2. Fix the sill flashing to the bottom rail, ensuring it is straight andlevel.

3. Position the first panel with the groove side at a corner, makingsure it is vertical before installing. Use concealed fasteners at thetongue edge and through fasteners at the corner. Use either 1 or 2fasteners at each position depending on the panel span and windloading.

4. Engage the side of the second panel into the tongue of thefixed panel, making sure the joint is parallel and consistent for thefull height of the panel. Install fasteners into the leading edge ateach rail position, using the specified number of fasteners.

5. Continue until the wall is completed.

6. Where necessary, panels can be cut down their length atopenings and corners. In this case through fasteners must beused, but these should be concealed by the flashings/trims.

Flashings / TrimsFlashings and trims must be carefully fixed, ensuring they arealigned, correctly sealed and their edges are straight and notdistorted. (See construction details).


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Product Health & SafetyData Sheet (C.O.S.H.H.)

Kingspan Insulated Roof & Wall SystemsData References• Consumer Protection Act 1987• Health and Safety at Work Act 1974• Control of Substances Hazardous to Health

(COSHH) Regulations 1999• Environmental Protection Act 1991

UsesThe products are used for roof and wall cladding industrial andcommercial buildings.Refer to Kingspan installation instructions for use. To be used inaccordance with approved practices and building regulations.If any other use is to be considered please contactKingspan Technical Design Bureau.

CompositionPanels comprising coated steel or aluminium outer and linersheets autoadhesively bonded to a rigid urethane core.

Health HazardsConsideration of the composition of this product indicates that innormal use it does not present a health hazard. The reaction of theinsulation core has no known toxic effects.

Fire HazardsIt is prudent to take precautions against ignition, fire and smokehazard.In fire situations beware of low visibility due to soot and avoidsmoke inhalation. Smoke contains carbon monoxide and othergases, which may be injurious to health if inhaled. If smoke orfumes are inhaled seek fresh air and medical assistanceimmediately.Panel which may have been subjected to very high temperaturesmay lose their normal strength.

Storage, Handling and UseThe panels insulation core is a combustible product whenexposed to a direct flame of sufficient intensity and thereforeshould be handled accordingly. Precautions must be taken tominimise the hazards in storage, handling and use.Good practices suggest the following precautions:

Storage1. Store in a location free from any ignition hazard such as openflames, cutting and welding torches, high surface temperatures,electric heaters and other forms of direct radiant heat.

2. Do not stack more than 2.5 metres in height. Ensure stability ofstack and provide adequate aisle space for access betweenstacks.

3. Store packs off the ground and on a slope, so that should rainwater penetrate the wrapping water will drain away.4. Support the packs evenly with bearers spaced at 2m. Bearersshould always be placed one directly above another.

Installation1. During the fixing operation or whilst handling, laceration of the

skin is possible on the edge of the sheet.

2. Product is supplied in heavy bundles and injury may result fromincorrect lifting or handling.

3. Cutting the product may cause flying swarf which could injureskin, particularly eyes. Cutting can also produce dust whichcan cause irritation if inhaled.

4. If hot working using flame or other ignition hazard must bedone near exposed urethane core, the product should beprotected with a heat resistant material.

Precautions• Protective clothing particularly gloves should be worn to avoid

skin lacerations.• Eye protection should be used when cutting.• Handling sheets and bundles should be in accordance with

HSE recommendations.• Do not use flame cutting equipment, blow lamps or any high

temperature equipment or process near the panels.• If subject to abnormally high temperatures ensure adequate

ventilation.• In a fire, breathing apparatus should be worn.

COSHHEmployers must ensure that there are measures in place that willcontrol or limit the exposure of their employees to any substancehazardous to health.Occupational Exposure Standards (O.E.S.) for nuisance dusts, e.g.urethane foam, are detailed in Health and Safety ExecutiveGuidance Note EH 40 (current issue).Further information on dust hazards may be obtained from EH44/84 ‘Dust in the Workplace’ - general principles of protection.

Disposal PrecautionsWaste foam should be disposed of regularly in a designatedlocation in accordance with the requirements of Local Authoritiesand the Environmental Protection Act 1991. It is important that theaccumulation of waste foam is avoided to prevent wind dispersal.Packaging material is combustible. Store away from sources ofignition prior to disposal.

Ensure polythene wrapping/packaging is kept away from children.Observe usual precautions with polythene bags.


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621

Ridge Safety System

IntroductionThe Saferidge Safety System when installed with the KS1000 RWroof panel system, will provide a secure mobile attachment eye,which will allow maintenance operatives safe access to both roofslopes for the length of the ridge while being securely attached.The Saferidge Safety System combines the weatherproofcharacteristics of a traditional ridge flashing without introducingcold bridges to the construction.

SpecificationThe Saferidge comprising a plastic coated steel sheet, isolatinglayer and powder coated extruded aluminium section. The mobileeyebolt is manufactured from anodised aluminium extrudedsections complete with stainless steel eye piece and ancillary partsrunning on plastic covered roller bearings.

AuthorityWhen correctly specified and installed the system offerscompliance with the relevant Class D requirements of RegulationEN795, 1996.“Protection Against Falls from a Height” Anchor Devices -Requirements and Testing.It is essential for the correct operation of the system that theoperative wears a harness and lanyard fitted with a shockabsorber all in accordance with EN358, 1993; EN360, 1995 andEN362 Connector.

TestingIn accordance with good practice and the recommendationscontained within EN795 it is recommended that the installation beexamined and tested on an annual basis by our Technical Staff toensure that the Saferidge is suitable for continued use.Further advice regarding the correct application and installationmay be obtained by contacting Saferidge Limited on: 0141 954 2666

Ridge flashing

Stainless steel bolt

Extruded aluminium traveller

Internal ridge flashing

Purlin

9mm x 3mmButyl rubbersealant

Sealed profiled filler Site applied insulation by others

Extruded aluminium section

Cleat

Cast stainless steel eye

Stainless steel nyloc nut


622

Method Statement

Product : KS1000LP Lo-Pitch InsulatedRoof SystemThe following detail shows the correct method that should befollowed to ensure that the panel end-lap is correctly installed.

Prior to InstallationCheck that the panels supplied (panel B) have:(i) End lap stitching plate factory applied (when requested /ordered), panels will be marked in the factory to identify that it is apanel with an end lap stitching plate (see detail 1).

Detail 1This ensures that when the panels are lapped, the end-lapstitching screws (5 number) engage into the plate and provide aclamping action for the two number 0.5mm thick external weathersheets, (see detail 2) with the 18mm x 4mm U section butyl rubbersealant.

Panel A

End lap stitching plate

Panel B

Joggle

Swage

Cover cap complete withjoggle factory applied

3rd Fix2rd Fix 1st Fix 2rd Fix 3rd Fix

End lap

End lap stitching plate

18mm x 4mm U sectionbutyl rubber sealant

Detail 2(ii) The upper most profile of the panel side joint has been joggled(see detail) at the flush end of the panel, this item is an automaticfactory operation and does not have to be requested / ordered.This ensures that when the upper panel (panel A) is end lapped tothe lower panel (panel B) it sits correctly.

(iii) The side of the panel side joint, on both sides of the panel,above the “groove” has been swaged at the flush panel end(see detail 3).


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623

Method Statement

Detail 3This item is an automatic factory operation and does not have tobe requested / ordered. The swaging allows the upper panel toend-lap the lower panel without distorting the panel profile andease the installation.

Joggle

18mm x 4mm Usection butyl

rubber sealant

Joggle

SwageSwage

InstallationAfter the above items have been checked and the usual steelworkline / level checks have been carried out, the following installationprocedure for correct panel end-lapping should be adopted.

(i) Position lower panel A in the first tier at the required positionensuring that the flush end of the panel is bearing onto the purlin bya minimum of 30mm.

(ii) Install fixings at every side joint / purlin junction except the flushend.

(iii) Ensure that the external panel surface across the whole panelprofile is clean and dry for the first 75mm from the panel flush end.Apply the end-lap seal (18mm x 4mm U section butyl rubbersealant) starting at the top of the side joint is not to be side jointedand working the butyl across the full profile until the opposite sidejoint is reached. Ensure butyl seal is not stretched during installation,and is in continuous contact with the profile, sealant should bepositioned so its bottom edge is 75mm from the flush end.

(iv) Remove backing paper from the butyl sealant. Check to ensurethat the underside of the end-lap on panel B is clean / dry, andposition over the previously installed panel. Ease one side of theend-lap into position (the side that is not to be side joined).

Joggle

Swage


End lap

Adjustable panelclamp

Timber packer

Detail 4(v) Using a timber packer position as shown on detail resting onthe end lap purlin. Position the panel clamp directly over the end-lap and tighten so that the two grooves meet, leave clamp on (see detail 4).

(vi) Push down the opposite side joint at the end-lap withoutdamaging the butyl sealant, and again using a timber packerposition as (v) and resting on the end-lap purlin. Position the panelclamp directly over the end-lap and tighten so that the twogrooves meet, leave clamp on.

(vii) Install primary fixings through the panel side joint at everypurlin position including the end-lap purlin.

Apply ‘foot pressure’ at the panel end-lap starting in the middle ofthe panel and working towards each side joint. Apply stitchingscrews as shown on detail starting at the middle of the panel andworking towards each side.

Remove panel clamps and timber packers.

(viii) Position lower panel (Panel B) in the second tier ensuring thatthe flush end of the panel is bearing onto the purlin by a minimum30mm.

(ix) Using panel clamps positioned at a maximum of 3 metres anddirectly over the purlins, draw panel into position and fix at everyside joint/purlin junction except the flush end. Remove panelclamps (See Detail 5).


624

Method Statement

(xiv) Position panel clamps at a maximum of 3 metres and directlyover the purlins, draw panel into position.

Fix panel at every side joint/purlin junction including the end-lap.

(xv) Apply ‘foot pressure’ at the panel end-lap starting in themiddle of the panel and working towards each side joint. Applystitching screws as shown on detail starting at the middle of thepanel and working towards each side.

Remove panel clamps and timber packers.

(xvi) Repeat (viii) to (xv)

For all other junction details, sealants and profiled fillers, refer toour technical design manual.

For further assistance contact: Kingspan Technical Design Bureau.Tel: 01352 716101 Fax: 01352 716111email:[email protected]

Joggle

Swage


End lap

Adjustable panel clamp

Detail 5(x) Repeat as item (iii).

(xi) Remove backing paper from butyl sealant. Check to ensurethat the underside of the end-lap on Panel A is clean/dry, andposition over previously installed panel. Ease one side of the end-lap into position (the side that is being side jointed).

(xii) Position the panel clamp directly over the end-lap and tightenso that the two grooves meet, leave clamp on.

(xiii) Push down the opposite side joint at the end-lap withoutdamaging the butyl sealant, using a timber packer position as (vi)and resting on the end-lap purlin. Position the panel clamp directlyover the end-lap and tighten so that the two grooves meet, leaveclamp on.


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625

Installation Methods & Tools

Roof PenetrationsPenetrations and junctions as well as architectural features can bedealt with by the following alternative measures dependant upondesired aesthetic finish as well as budget.

Site WeldingOn-site TIG welding of aluminium Kingzip end laps, upstands, soilvent pipe penetrations, hips, hip valleys and other features can becarried out by the following experienced companies. It is alwaysnecessary with standing seam systems to consider the design,logistics, co-ordination and cost of penetrations / features at anearly stage. Early contact with a recommended company by thedesigner and subsequent cladding installation contractor isnecessary to ensure the project proceeds smoothly, safely and tobudget, and to ensure co-ordination with other trades.

Melvyn Rowberry Welding Services LimitedUnit 6, Worcester Trading Estate,Blackpole, Worcester. WR3 8HRTel: 01905 755055, Fax: 01905 755053Email:[email protected]:http://www.rowberrygroup.comContact:Mr Chris Pomphrey, National Sales ManagerEmail: [email protected]

Sureweld & Roof LimitedBall Mill Top,Hallow, WorcesterWR2 6LSTel: 01905 641104, Fax: 01905 641135Email: [email protected]: Mr Darren Powell, Director

Site Installed SoakersThe following companies can provide colour coated soakers,upstands, sleeves flashings and features with proven long termweathering performance and to suit aluminium or coated steelKingzip insulated standing seam panels. Again, early contact witha recommended company by the designer and subsequentcladding installation contractor is necessary to ensure the projectproceeds smoothly, safely and to budget, and to ensure co-ordination with other trades.

"Aperture PU or Aperture 185 Seamless Cold Applied Systems"from:-

ApertureUnit 0,Springfield Trading Estate,Samuel Street, Failsworth,Manchester. M35 OGATel: 0161 681 4455, Fax: 0161 688 8625Email: [email protected]:www.aperturesp.co.ukContact Mr Michael Philbin, Operations Manager

"GRP System of Standard and Purpose Made Weathering" from:-

Jones & Woolman (UK) LtdCroxtalls Road,Bloxwich, Walsall, West Midlands. WS3 2XUTel: 01922 712111, Fax: 01922 712539Email: [email protected] Mr Darren Jones, Sales Director

Factory Manufactured SoakersKingzip single-skin stucco-embossed mill finish aluminium outerprofile or insulated panel can have upstands factory welded intoplace by Kingspan Limited (or alternatively factory welded by oneof the previously mentioned site welding companies). Earlydetailed ordering of the upstands by the Customer are necessaryto have them prepared to suit the site programme, i.e.single-skinor panels have to be manufactured prior to fabrication work onupstands / soakers.Polyester powder coated aluminium upstand soakers can besupplied by Kingspan Limited to suit coated steel Kingzip panels.Again fully dimensioned details of the soakers are needed as earlyas possible from the Customer for Kingspan to provide timelymanufacture. Order forms are available from Kingspan Limited

Power Seamer Eaves Seam Starter Tool


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