PORTABLE ROLLFORMING, APPLICABLE ENGINEERING
Transcription
PORTABLE ROLLFORMING, APPLICABLE ENGINEERING
PORTABLE ROLLFORMING, APPLICABLE ENGINEERING & INSTALLATION DETAILS PORTABLE ROLLFORMING, APPLICABLE ENGINEERING & INSTALLATION DETAILS SFM07A Credit: 1 AIA HSW CE Hour © Ron Blank & Associates, Inc. 2012 Sheffield Metals International 5467 Evergreen Parkway Sheffield Village, OH. 44054 jhock@sheffieldmetals.com 904-451-5989 AN AMERICAN INSTITUTE OF ARCHITECTS (AIA) CONTINUING EDUCATION PROGRAM AIA Approved Promotional Statement: Ron Blank & Associates, Inc. is a registered provider with The American Institute of Architects Continuing Education System. Credit earned upon completion of this program will be reported to CES Records for AIA members. Certificates of Completion are available for all course participants upon completion of the course conclusion quiz with +80%. Please view the following slide for more information on Certificates of Completion through RBA This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA or Ron Blank & Associates, Inc. of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. AN AMERICAN INSTITUTE OF ARCHITECTS (AIA) CONTINUING EDUCATION PROGRAM AIA Course Format: This is a structured, web-based, self study course with a final exam. Course Credit: 1 AIA Health Safety & Welfare (HSW) CE Hour Completion Certificate: A confirmation is sent to you by email and you can print one upon successful completion of a course or from your RonBlank.com transcript. If you have any difficulties printing or receiving your Certificate please send requests to certificate@ronblank.com Design professionals, please remember to print or save your certificate of completion after successfully completing a course conclusion quiz. Email confirmations will be sent to the email address you have provided in your RonBlank.com account. Please note: you will need to complete the conclusion quiz online at RonBlank.com to receive credit COURSE DESCRIPTION COURSE DESCRIPTION During this one hour online course, design professionals will gain insight into the benefits of portable rollforming including efficiency, flexibility, and sustainability. We will review applicable engineering, testing standards, and installation details and conclude the course with a brief 10 question quiz. LEARNING OBJECTIVES OBJECTIVES Upon completion of this course, the design professional will be able to: Explain the benefits of Portable Rollforming. Discuss how a UL 90 rating is achieved and what to look for in UL Construction Numbers. Specify applicable uplift testing requirements based on the project deck assembly. Recognize the appropriate cost effective installation details to utilize based upon job specific conditions. INTRODUCTION INTRODUCTION Metal roofing has been around for centuries. However, the process to make the finished roof panel has evolved greatly. Metal roof panels were originally made by hand and the panels were bent into the proper configuration. When metal brakes became available, they were used to bend the panels but the length of the panel was limited to the length of the brake. Fixed in place Rollformers solved this problem by producing a machine that manufactured the panel for you and provided panels at any length that could be shipped to a project. With today’s advances, Portable Rollforming equipment is available and able to produce multiple panel profiles at any length anywhere. Before we get into the benefits of Portable Rollforming, let’s first discuss how the process works. WHAT IS ROLLFORMING? WHAT IS ROLLFORMING? Rollforming feeds a continuous sheet of material (i.e. steel, aluminum, copper) via an expandable die-coiler through a series of rollers and Rollforming dies that bend the material slightly at each pass to form a particular metal roof panel profile. WHAT T YPES WHAT T YPES OF OFROLLFORMERS ROLLFORMERSARE ARETHERE? THERE? There are two types: 1. 2. Fixed in place – Rollforming machine is stationary, panels are produced in a warehouse environment and then crated and shipped to the customer. Portable – Rollforming machine is mobile, usually on a trailer that can be brought to the project where the panels can be produced on site. WHAT TTYPES YPES OF OF ROLLFORMERS ARE ARETHERE? THERE? Fixed in place Rollformer Portable Rollformer HOW PORTABLE ROLLFORMING WORKSWORKS HOW PORTABLE ROLLFORMING 1. Coil is fed to the machine. 4. Formed panel exits the machine and is cut to length by a guillotine. 2. Coil goes through forming dies inside the machine to form the panel. 3. Panel quantity and length are controlled by a batch computer. HOW PORTABLE ROLLFORMING WORKSWORKS HOW PORTABLE ROLLFORMING Portable Rollforming is used to produce Standing Seam Metal Roof Systems (SSMRS) in mechanically seamed, various snaplock and face-fastened panels. Can produce panels in steel, aluminum, stainless steel, copper and zinc. Produces 60 to 80 feet of formed panel per minute. Can have the capability to switch out forming dies to form a different type of SSMRS. Can have the ability to run off a gas or electric motor. Can be controlled manually or used with a batch computer. HOW PORTABLE ROLLFORMING WORKSWORKS HOW PORTABLE ROLLFORMING This is an example of what the forming dies in a Portable Rollformer could look like. As the flat, metal coil enters the machine, it passes through a series of forming dies. These dies slowly form the panel through each stage. Once the metal has finished going through the forming dies, a rigid, finished panel exits the machine ready to be cut to the desired length. The type of forming dies that are installed in the Portable Rollformer determine which roof panel profile is made. Many Portable rollformers have the ability to switch the forming dies to produce a variety of roof panel profiles. BENEFITS OF PORTABLE ROLLFORMING BENEFITS OF PORTABLE ROLLFORMING It’s GREEN Besides metals’ already eco-friendly properties, Portable Rollforming allows you to ship metal coil rather than shipping formed panels. This reduces cost and protects the product from being damaged during transit. This also limits the amount of trucks necessary to ship the material reducing emissions. BENEFITS OF PORTABLE ROLLFORMING BENEFITS OF PORTABLE ROLLFORMING VS Formed metal panels being shipped to project Metal coils on pallets BENEFITS OF PORTABLE ROLLFORMING BENEFITS OF PORTABLE ROLLFORMING Easy Storing Large project sites have limited storage space and many different trades working simultaneously. Portable Rollforming eliminates the need of onsite storage and, in turn, limits the handling of formed panels, reducing the chance of damage. BENEFITS OF PORTABLE ROLLFORMING BENEFITS OF PORTABLE ROLLFORMING More control of your project Portable Rollforming allows the contractor to take control of the product. If a panel is damaged on the project, it can be replaced on site with no wait. It also allows the contractor to adjust panel length and quantity on the fly if there are discrepancies on the project. BENEFITS OF PORTABLE ROLLFORMING BENEFITS OF PORTABLE ROLLFORMING Panels at any length Factory formed panels are limited to the length of the truck that they can be shipped on. Portable Rollforming allows a continuous panel to be formed onsite which can speed installation and reduce cost. BENEFITS OF PORTABLE ROLLFORMING BENEFITS OF PORTABLE ROLLFORMING Getting the panels on the roof All panels have to get on the roof somehow. With a Portable Rollformer, instead of craning panels a little at a time to the roof, the Rollformer itself can be lifted and angled to shoot the panels from the machine directly onto the roof. This is especially helpful when dealing with large projects and long panels. BENEFITS OF PORTABLE ROLLFORMING BENEFITS OF PORTABLE ROLLFORMING BENEFITS OF PORTABLE ROLLFORMING BENEFITS OF PORTABLE ROLLFORMING Engineered Systems Most Portable Rollformer manufacturers have UL Construction Numbers to go along with the profile their machines can produce. The more popular panel profiles usually have various UL Construction Numbers for use with different material and being installed over various deck assemblies. UL CONSTRUCTION NUMBERS NUMBERS UL CONSTRUCTION As we just covered, most Portable Rollformers come with their own UL construction numbers. So let’s talk about how a UL 90 rating is achieved. WHAT IS UL 90? WHAT IS UL 90? UL 90 is the highest of the three ratings that can be achieved during a UL 580 uplift test. It does not correlate to a wind speed but rather the test relates to uplift pressures and loads measured in pounds per square foot. The test pressure for a UL 90 rating is a 105 psf. This number does not include a safety factor which is 50% of the test pressure. In this case, the design pressure with safety factor would be –52.5 psf. HOW TO HOW ACHIEVE A UL 90A UL 90 RATING TO ACHIEVE RATING UL 90 is part of the UL 580 uplift test. UL 580 is a test procedure for the uplift resistance of roof assemblies. To better understand how this rating is achieved, you must first understand how the UL 580 test is performed. HOW TO HOW ACHIEVE A UL 90A UL 90 RATING TO ACHIEVE RATING To perform a UL 580 test a 10’ x 10’ test specimen is made consisting of the deck assembly and panel profile. The specimen is then placed into a test chamber where positive and negative pressure is applied to the test specimen to determine uplift resistance. HOW TO HOW ACHIEVE A UL 90A UL 90 RATING TO ACHIEVE RATING Test specimen example HOW TO HOW ACHIEVE A UL 90A UL 90 RATING TO ACHIEVE RATING UL 580 test chamber with test specimen in place HOW TO HOW ACHIEVE A UL 90A UL 90 RATING TO ACHIEVE RATING UL 580 test chamber lid being removed after test HOW TO HOW ACHIEVE A UL 90A UL 90 RATING TO ACHIEVE RATING Once the test starts the specimen is tested in three classes: Class 30, Class 60 and Class 90. Each class has five phases and lasts 80 minutes. You must pass each phase of the test in order to move forward to the next class. In other words, the test specimen must pass class 30, then pass class 60, then class 90. You cannot get a UL 90 rating without first testing to class 30 and class 60. Load table examples for Class 30, 60 and 90 UL CONSTRUCTION NUMBERS NUMBERS UL CONSTRUCTION Now that we have covered how to get the UL 90 rating, we will go over a UL Construction Number and what to look for when reading it. Reading a UL Construction Number is pretty basic, but there are two key factors that need to be considered when specifying the Construction Number. Both of these are under the deck assembly section. UL CONSTRUCTION NUMBERS NUMBERS UL CONSTRUCTION First thing to look at is how the deck is attached? The deck needs to be attached per the UL Construction Number in order for the engineering to be valid. OR UL CONSTRUCTION NUMBERS NUMBERS UL CONSTRUCTION For example: Most plywood decking is usually nailed to the supports using ring shank nails, however, if the UL Construction Number calls for the decking to be screwed down, then that’s how it will need to be installed for the engineering to be valid. UL CONSTRUCTION NUMBERS NUMBERS UL CONSTRUCTION The second thing to look at is if the decking is sealed For example a UL Construction Number could read: “All joints to be sealed with one part urethane sealant feathered out from the joint.” UL CONSTRUCTION NUMBERS NUMBERS UL CONSTRUCTION For example: The plywood decking on a project would have to have all the seams caulked where the plywood butts up to one another so no air could pass through for the engineering to be valid. During the UL 580 test, the sealed joints stop the positive pressure from coming through the decking to get to the roof panels. Example of sealed joints on plywood decking UL CONSTRUCTION NUMBERS UL CONSTRUCTION NUMBERS Why does this matter? UL CONSTRUCTION NUMBERS NUMBERS UL CONSTRUCTION First – Increased project costs and time Labor is always more expensive than materials. Depending on how much extra labor will be needed to install the substrate appropriately, project costs could go up. Extra labor requires extra time which should be taken into consideration for scheduling. UL CONSTRUCTION NUMBERS NUMBERS UL CONSTRUCTION Second – Void of engineering Specified or not, if a roof failure should take place and the decking is not installed per the UL Construction Number specified, then it is automatically a bad installation. UL CONSTRUCTION NUMBERS NUMBERS UL CONSTRUCTION In a perfect world, this would not be a concern, but because the deck attachment is commonly overlooked, it is important to cover this. If anything should happen, the person who will feel the full effect of the situation is the building owner. Roof decking blown off during Hurricane Charley APPLICABLE TESTING APPLICABLE TESTING Now that we have covered UL 90 Ratings and UL 580 testing, let’s discuss the differences between the types of uplift tests typically specified and if they are applicable to your project. APPLICABLE TESTING APPLICABLE TESTING UL 580…What is it? APPLICABLE TESTING APPLICABLE TESTING UL 580 -Test for Uplift Resistance of Roof Assemblies over a solid substrate: Scope 1.1 The method of test specified in this standard is intended to determine the uplift resistance of roof assemblies consisting of the roof deck and roof covering materials. It is applicable to any type of roof assembly which is adaptable to the test equipment. Tests to evaluate other potential hazards of roof assemblies are not within the scope of these requirements. 1.2 The purpose of this test is to evaluate the comparative resistance of roof assemblies to positive and negative pressures. 1.3 The test evaluates the roof deck, its attachment to supports, and roof covering materials. It does not evaluate roofs adjacent to chimneys, overhanging eaves, or similar construction, connections of the assembly to main structural supports (girders, columns, or other supports), structural integrity of secondary supports (purlins, joists, bulb tees, or the like), or deterioration of roofing materials. APPLICABLE TESTING APPLICABLE TESTING The short version APPLICABLE TESTING APPLICABLE TESTING UL 580: UL 580 is an uplift test for a SSMR installed over solid substrate i.e. plywood deck, B-deck, B-deck with ISO, etc. UL 580 tests to three different classes; 30, 60 and 90. UL 90 is the highest rating available in the UL 580 test protocol. APPLICABLE TESTING APPLICABLE TESTING UL 580 test specimen example APPLICABLE TESTING APPLICABLE TESTING UL 1897…What is it? APPLICABLE TESTING APPLICABLE TESTING UL 1897 - Uplift Tests for Roof Covering Systems Scope 1.1 The test method specified in this Standard is intended to provide uplift resistance data for the evaluation of the attachment of roof covering systems to roof decks by using differential air pressures. It is applicable to any type of roofing system which is adaptable to the test equipment. 1.2 The test evaluates the roof covering systems method of attachment, including all components such as base sheets, ply sheets, slip sheets, membranes, etc. and insulation, if used. Supporting roof decks are evaluated only with respect to span conditions and physical properties such as gauge, yield strength, grade, size and/or species of lumber and related factors which affect fastener attachment or bond strength. APPLICABLE TESTING APPLICABLE TESTING Scope 1.3 This test method provides a comparative measure of the uplift resistance for roofing systems by means of static differential pressure. The method does not necessarily simulate the actual dynamic uplift pressures encountered by roofing systems. Uplift pressures on a roofing system are dependent upon many factors such as wind gusts, building shape, edge configuration, and the terrain surrounding the building. A method to calculate the uplift pressures on roof assemblies is contained in the Standard for Minimum Design Loads for Buildings and Other Structures, American Society of Civil Engineers, ANSI/ASCE 7. 1.4 The purpose of this test method is to provide data regarding the securement of the roofing system to the roof deck based upon a short-term static load. For information regarding uplift resistance of complete roof deck assemblies including the roof deck and its attachment to supports refer to the subject category Roof Deck Construction (TGKX) in UL's Buildings Materials Directory. APPLICABLE TESTING APPLICABLE TESTING The short version APPLICABLE TESTING APPLICABLE TESTING UL 1897 UL 1897 is an uplift test for a SSMR installed over solid substrate. It is the continuation of the UL 580 test after the test specimen has reached UL 90. After successful completion of UL 90, the pressure is increased in the test chamber by set increments until the test specimen experiences ultimate failure, i.e. panels disengaging, clip disengaging or permanent kinks in the vertical seam of the roof panel. APPLICABLE TESTING APPLICABLE TESTING UL 1897 test specimen example over plywood APPLICABLE TESTING APPLICABLE TESTING UL 1897 test specimen after ultimate failure inside test chamber APPLICABLE TESTING APPLICABLE TESTING ASTM E 1592…What is it? APPLICABLE TESTING APPLICABLE TESTING ASTM E 1592 - Standard Test Method for Structural Performance of Sheet Metal Roof and Siding Systems by Uniform Static Air Pressure Difference Scope 1.1 This test method covers the evaluation of the structural performance of sheet metal panels and anchor-to-panel attachments for roof or siding systems under uniform static air pressure differences using a test chamber or support surface. 1.2 The provisions of this test method are applicable to standing seam, trapezoidal, ribbed, or corrugated metal panels in the range of thickness from 0.012 to 0.050-in. (0.3 to 1.3mm) and apply to the evaluation of uniform pressure applied to single-skin construction or one sheet metal layer of multiple-skin construction. They do not cover requirements for the construction of a specimen to determine the load sharing that can occur with either composite or multiple-layer construction such as: (1) metal cladding over wood sheathing; or (2) field assemblies of insulation sandwiched between corrugated or formed metal panels. 1.3 Proper use of this test method requires knowledge of the principles of pressure and deflection measurement. APPLICABLE TESTING APPLICABLE TESTING Scope 1.4 This test method describes optional apparatus and procedures for use in evaluating the structural performance of a given system for a range of support spacing's or for confirming the structural performance of a specific installation. 1.5 The values stated in inch-pound units are to be regarded as the standard. The metric equivalents of inch-pound units are approximate. 1.6 The text of this standard references notes and footnotes exclusive of those for tables and figures. These notes and footnotes provide explanatory material and shall not be considered as requirements of the standard. 1.7 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. For specific precautionary statements, see Section 7. APPLICABLE TESTING APPLICABLE TESTING The short version APPLICABLE TESTING APPLICABLE TESTING ASTM E 1592 The test is performed on a 12’ x 24’ apparatus where a SSMR is installed over purlins. The test specimen is then pressurized to simulate the effects of wind pressure on a rooftop. The exact point of failure is determined when the test specimen fails to maintain its integrity, i.e. panels disengaging, clip disengaging or permanent kinks in the vertical seam of the roof panel. APPLICABLE TESTING APPLICABLE TESTING ASTM E 1592 test support structure example APPLICABLE TESTING APPLICABLE TESTING ASTM E 1592 test specimen installed over support structure example APPLICABLE TESTING APPLICABLE TESTING ASTM E 1592 ultimate failure example APPLICABLE TESTING APPLICABLE TESTING So now that we have covered the three most prominent uplift tests, let’s give some examples of what test would be applicable to different deck assemblies. APPLICABLE TESTING APPLICABLE TESTING Q: Which test would be applicable to a project consisting of a metal B-deck with 4 inches of ISO installed? APPLICABLE TESTING APPLICABLE TESTING A: UL 580 or UL 1897, either of these tests would be applicable. The one specified would be determined by the uplift requirements for the project. APPLICABLE TESTING APPLICABLE TESTING Q – Which test would be applicable to a project consisting of a plywood deck and requiring a UL 90 uplift rating? APPLICABLE TESTING APPLICABLE TESTING A: UL 580, this test is applicable due to the solid substrate and the UL 90 requirement. APPLICABLE TESTING APPLICABLE TESTING Q: Which test would be applicable to a project consisting of open framing with purlins spaced at 2 foot on center? APPLICABLE TESTING APPLICABLE TESTING A: ASTM E 1592, this test is applicable due to the SSMR being installed over purlins. INSTALLATION DETAILS INSTALLATION DETAILS In this section we are going to look at some different installation details used throughout the industry and the options to provide a watertight installation while also taking into consideration project costs. INSTALLATION DETAILS INSTALLATION DETAILS The first example is a standard gable detail Gable detail 1 Gable detail 2 INSTALLATION DETAILS INSTALLATION DETAILS Both details shown are appropriate for use on a gable installation and both would be approved for use on a project requiring a weathertight warranty; however, Gable Detail 1 has five extra accessories that would need to be purchased and then installed to complete the assembly. Gable Detail 2 has less pieces to buy and install which would bring down project costs. INSTALLATION DETAILS INSTALLATION DETAILS Another way to break it down is to look at it like this: For Gable Detail 1, you are using 4 feet of product per linear foot plus 5 fasteners per linear foot with 2 pop rivets every 3 linear feet. For Gable Detail 2, you are using 1 foot of product and 2 fasteners per linear foot. INSTALLATION DETAILS INSTALLATION DETAILS Example 2: High Side Eave Detail ENER O.C. High Side detail 1 High Side detail 2 INSTALLATION DETAILS INSTALLATION DETAILS The example for the High Side Eave shows the same circumstances as the Gable Detail in example 1. By knowing the installation options available, it is possible to reduce the project costs without sacrificing the weathertight integrity of a project. INSTALLATION DETAILS INSTALLATION DETAILS The previous examples shown are just a few options of installation details and how they can reduce project costs. Let’s now move onto deck penetrations (i.e. pipes, curbs) and their proper installation to maintain weathertight integrity. INSTALLATION DETAILS INSTALLATION DETAILS Curb penetrations through a panel seam. Curb for roof penetrations VS Approved Sealant Fastener 4” O.C. Cont. butyl tape sealant Pre-fab curb Seam cover. Set in butyl. Caulk around panel at open end and fasten 2’ O.C. w/sefl sealing fasteners Approved adhesive sealant Stainless Washer Fasteners, 4’ O.C. Cont. butyl tape sealant Fasteners, 4’ O.C. Cont. cleat, mitred at corners Set curb on panel w/(2) cont. strips of butyl tape sealant INSTALLATION DETAILS INSTALLATION DETAILS CURB EXAMPLE 1 Panels are pinned by multiple exposed fasteners which stop the expansion and contraction of the metal. Expansion and contraction of the panel increases the risk of a fastener failure which could cause potential leaks. Panel seams on the front side of the curb are left exposed relying solely on sealant to maintain the weather-tight integrity. Curb for roof penetrations Approved adhesive sealant Stainless Washer INSTALLATION DETAILS INSTALLATION DETAILS CURB EXAMPLE 2 This installation uses offset cleats on the sides and back of the curb. This allows the panel to expand and contract how it should. It also allows for snow and water to escape down the back and sides of the curb. Exposed fasteners are minimized to the front of the curb, limiting potential leaks from exposed fasteners. Approved Sealant Fastener 4” O.C. Cont. butyl tape sealant Seam caps are used at the front of the curb to stop any water intrusion between the panel seams. Pre-fab curb Seam cover. Set in butyl. Caulk around panel at open end and fasten 2’ O.C. w/sefl sealing fasteners Fasteners, 4’ O.C. Cont. butyl tape sealant Fasteners, 4’ O.C. Cont. cleat, mitred at corners Set curb on panel w/(2) cont. strips of butyl tape sealant INSTALLATION DETAILS INSTALLATION DETAILS Pipe penetrations through a seam VS INSTALLATION DETAILS INSTALLATION DETAILS PIPE EXAMPLE 1 Pipe boots are not designed to go up and over the vertical leg of a standing seam panel. This installation does not provide a tight seal against the panel and you are relying solely on sealant to keep the area weathertight. There is a possibility for the cut roof panel to slice the pipe boot and cause a leak. The cut may be on the underside of the boot and is not visible from the top. INSTALLATION DETAILS INSTALLATION DETAILS PIPE EXAMPLE 2 Pipe boot is sealed to a flat surface as it was designed to do. Panel can expand and contract without damage to the pipe boot. Pipe boot can easily be replaced if necessary for repairs or maintenance. SUMMARY SUMMARY There is always more than one option when it comes to how things can be done. The topics that have been covered are intended to show how Portable Rollforming, proper test specifications, the use of UL Construction Numbers, and different installation details can affect the cost, schedule and performance of a metal roof system. By being aware of all the different choices, you are able to choose the best options available to meet your needs. COURSE SUMMARY COURSE SUMMARY The design professional will now be able to: Explain the benefits of Portable Rollforming. How UL 90 is achieved and what to look for in UL Construction Numbers. Specify applicable uplift testing requirements based on the project deck assembly. Recognize the appropriate cost effective installation details to utilize based upon job specific conditions. P O R TA B L E R O L L FO R M I N G , A P P L I C A B L E E N G I N E E R I N G & I N S TA L L AT I O N D E TA I L S PORTABLE ROLLFORMING, APPLICABLE ENGINEERING & INSTALLATION DETAILS SFM07A Credit: 1 AIA HSW CE Hour © Ron Blank & Associates, Inc. 2012 Sheffield Metals International 5467 Evergreen Parkway Sheffield Village, OH. 44054 jhock@sheffieldmetals.com 904-451-5989