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Erection of sandwich panels

Before any erection work, it is necessary to provide a quality technical preparation of assembling and of construction site.  Technical preparation for erection is to provide design and erection documentation.  The specialized companies that have all necessary tools, equipment and trained professionals should execute the erection works. 
Before erection works, it is necessary to check the quality of load-bearing structure (metal frame) for compliance with design documentation (installation dimensions, linear and vertical dimensions of the beams, framing deviation from parallelism, horizontality, verticality, straightness and flatness of its base surface)/  This is the most important prerequisite for high-quality panel installation. 

Packages with the panels should preferably be in the place of erection, in accordance with CPD, designs layouts (beginning of erection) and the marking of panels along their façade s.  The wall panels of hinge zone "spike", should be directed to the side of the façade  to reduce the number of manipulations during the ascent.  The crane boom should ensure the delivery of the panel from storage to the place of erection without intermediate reloading.  When moving, tilting and supplying panels to the erection site, it is necessary to eliminate panels warping, which can lead to deformation of the hinge side, peeling claddings from an insulator or even a fracture of EPS insulation. 

Before the erection, the panels need to be cleaned, the surface of the panel and the connecting locks have to be cleaned from all possible contamination, and the necessary cutting of panels performed, if it is provided by the project. 

For cutting panels, it is recommended to use tools that prevent cladding from excessive heat: electric hand shears, circular saws, electric jigsaws with a fine tooth profile.  After cutting, it is necessary to remove chips off the panel’s surface carefully with a brush, not damaging the paint-and-lacquer coating. 

ATTENTION: CUTTING OF SANDWICH PANELS with flame-cutters, tools with abrasive wheels, (to prevent paintwork damage, caused by local overheating), as well as carrying out welding, working with grinders in close proximity to the panels, as high temperature and sparks flow can damage the polymer coat of panels’ cladding is PROHIBITED.  Cutting of panels is performed on horizontal racks lined with soft material, excluding damage to coatings.  First the cladding is trimmed, then the insulator. 


In roof panels, in place of the roof overhang trimming it is necessary to remove the cut cladding and insulation.  During the erection, make sure to pay attention that the roof panels can have left and right trimming. 

If necessary, on completion of panels’ erection, other works, such as cutting windows, doors, doorways, vents, various slants and other trimming could be done in accordance with working drawings. 

Lifting of panels has to be implemented, using special mounting devices, G-cramp or a lever-type clamp, and vacuum suction with safety belt. 

It is recommended to start panels’ erection with the corners with the lowest panel according to the orientation given in the working drawings. 

During the erection works, it is not allowed to have gaps in the interlocks.  Sealing of joints in the interlock is not required under the normal climatic conditions.  With the strict requirements for containment of docking units, it is recommended to apply a silicone sealant or water repellent non-hardening sealant, to the inner or outer rail of the interlock.  Then the next panel is inserted into the lock of previously erected panel (you need to control the vertical and horizontal bar).  The erected panel is pressed against the crossbars, half-timbered uprights using special clamps, it is necessary to make sure that they did not damage the panel. 

After fixing with clamps, a panel is attached to metalwork with the self-tapping screws, which you turn perpendicular to the panel.  The length of a self-tapping screw depends on the thickness of the panel; the number of screws is given in the plan.  The joint between adjacent panels must be plugged with foam (as a rule, a gap of 20 mm is left between the panels), or mineral wool (mostly at the ridge of the roof or in the place of adjacency to the wall) in accordance with the planned packing of docking units. 

The amounting of shaped elements (flat strips) should be conducted in accordance with the schemes of standard junctions.  The step of self-tapping screws and rivets is 0.25 - 0.3 m.  While mounting the fire barriers of wall panels it is possible to mount flat strips on the panel’s longitudinal joint (lock) to maximize the security, integrity and fire resistance of buildings.  In docking places between the columns, beams, purlins and a panel, a sealing tape can be installed to prevent contact of interior panels’ cladding with the bearing structures of the metal frame, if provided in working drawings.  No hits on the panels during the erection, mounting of fasteners and sealing of joints and junctions are allowed.  Along horizontal and vertical layout of the panels, a girder should be installed every 8 - 10 m.  The surface of the steel cladding panels should be cleaned of dirt and dust using the detergents that do not cause damage to protective coatings. 
It is not recommended to do the assembling works, if the wind speed is above 9 m/s, as well as during precipitation or fog, it is recommended to maintain safety precautions and safe working conditions, approved by the organization.  Sandwich Panels are also used as vertical and inclined curtain walling, so fixing of ladders, industrial wiring, process equipment and fixtures, drainage devices to the panels, is not allowed. 


Fasteners


For fixing
СПС and СПК panels, it is recommended to use self-tapping screws of stainless steel or carbon steel with sealing washers that provide direct mounting on the metal frame of up to 12.5 mm, without prior drilling.  When choosing self-tapping screws it is necessary to consider type of base (metal, wood, etc.), diameter and length of which depend on the thickness of the panels. 
When choosing fasteners it is recommended to use the Table No. 1.

Table 1: Fasteners

Panel thickness, mm 50 80 100 120 150 175 200
Screw diameter, mm 5.5 5.5 5.5 5.5/6.3 5.5/6.3 6.3 6.3
СПС L, mm 90 120 140 165 190 215 240
СПК L, mm 125 155 175 195 225 250 275
 
L – length of self-tapping screw (mm)

d - diameter (mm)

 

 

See the estimated weight of self-tapping screw at Table No. 2

 

Table 2: Estimated weight of self-tapping screw

Size, mm 5.5х25 5.5х87 5.5х90 5.5х100 5.5х130 5.5х150 5.5х150 5.5х190 5.5х230 5.5х285
Weight, kg/1000 pcs 4.73 15.50 15.90 17.70 22.92 26.45 28.25 33.52 40.60 50.40

 

Estimated weight of self-tapping screws for other diameters and lengths are counted empirically.  Pay attention to the efforts applied to wrap the self-tapping screws.  Avoid excessive tightening of fasteners; it can damage the panel’s cladding.  The first sign of too much tightening is the appearance of dents on the surface of the panels’ cladding. 

 

Installation and mounting of flat strips is performed in a strict accordance with the documentation. 

Use of similar fasteners of other companies, provided the same strength characteristics and corrosion resistance is possible.