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«Prefab Instruction Manual TABLE OF CONTENTS A. Site and Foundation Preparation 1. General Information 2. Squaring of ...»

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Prefab Instruction Manual

http://www.muellerinc.com

TABLE OF CONTENTS

A. Site and Foundation Preparation

1. General Information

2. Squaring of Foundation

3. Anchor Bolt Settings (Pgs. 3,4)

B. Building Delivery and Storage

1. Unloading and Preparation of Parts for Assembly

2. Unloading, Handling, and Storage of Materials

3. Location of Building Parts

4. Care and Handling of Mueller Sheet Metal (Pgs. 4-6) C. Erection of Primary and Secondary Structural

1. General Information

2. Tools and Equipment Required (Pgs. 2,3)

4. Typical Building Parts

5. Raising Rigid Frames (Pgs. 5-9)

10. Erecting Column and Beam Endwalls

11. Erecting Remaining Frames (Pgs. 11,12)

13. Assembly of Brace Cables

14. Installation of Wind Bracing (Pgs. 14-17) D. Connection Details

1. Endwalls (Pgs. 1,2)

3. Column/Rafters for Main Frames

4. Individual Connection Details (Pgs. 4-15) E. Insulation

1. Wall Insulation (Pgs. 1,2)

3. Roof Insulation (Pgs. 3-5) F. Sheeting

1. Fastener Layout

2. Aligning the Girts

3. Screw Alignment (Pgs. 3,4)

5. Installation of Wall Panels (Pgs. 5-10)

11. Preparing the Eave (Pgs. 11,12)

13. Installation of Roof Panels (Pgs. 13-25)

26. Skylight Installation (Pgs. 26-29) G. Trim

1. Flashing

2. Peak Sheet Ridge Installation

3. Typical Screw Placement for Peak Sheets/Ridge Roll

4. Tape Sealant Application at Ridge Flashing

5. Rake Trim

6. Corner Trim

7. Eave Trim (Pgs. 7-9)

10. Gutter (Pgs. 10-15)

16. Door Trim (Pgs. 16,17)

18. Overhang Trim Details H. Doors and Accessories

1. Personnel Doors (Pgs. 1,2)

3. Roll-Up Doors (Pgs. 3,4)

5. Windows (Pgs. 5,6)

7. Ridge Vents (Pgs. 7-10)

11. Pipe Deck Flashing I. Glossary

1. Metal Building Terms and Definitions (Pgs. 1-9) Section A Site & Foundation Preparation

PREPARATION OF SITE AND FOUNDATION

1. General Before the Mueller prefabricated steel building arrives, the site and foundation should be prepared. This includes leveling the terrain and constructing the foundation. Mueller buildings are typically designed to be placed on a permanent slab. A concrete contractor is highly recommended for this phase of the construction.

2. Procedural Steps A. Remove trees, debris, and other items from the building location.

B. Smooth and level the ground where the foundation is to be made.

C. Construct the foundation using the materials recommended by your cement contractor.

A-1

SQUARING OF FOUNDATION

For proper building erection, it is critical the foundation is square. The following examples are suggested to ensure square foundation.

–  –  –

It is extremely important that anchor bolts be placed accurately in accordance with the anchor bolt setting plan. All anchor bolts should be held in place with a template or similar means, so that they will remain plumb and in the correct location during placing of the concrete. Check the concrete forms and anchor bolt locations prior to the pouring of the concrete. A final check should be made after the completion of the concrete work and prior to the steel erection. This will allow any necessary corrections to be made before the costly erection labor and equipment arrives.

–  –  –

Building Delivery And Storage

UNLOADING AND PREPARATION OF PARTS FOR ASSEMBLY

The vehicle transporting your building parts must gain access to the building site from the adjacent highway or road. Such access should be studied and prepared in advance of arrival. All obstructions, overhead and otherwise, must be removed and the access route graveled or planked if the soil will not sustain the heavy wheel loads.

A forklift or other type of power loader may be required to unload the truck and move the heavier parts to the proper locations.

When the truck arrives with the building, unload the truck promptly, stack the steel parts evenly on blocks and protect them from the weather.

Unloading and placing the steel parts of the building in the most convenient places for assembly will make the process easier and faster.

After unloading the truck and before the driver leaves, ensure that all parts have been delivered.

1. Check each part against the delivery receipt. Each part is marked for identification.

2. Sign the delivery receipt if all parts are delivered.

3. If any of the parts are missing, notify the driver and note the missing items on the delivery receipt before signing.

4. Check with your salesman regarding the missing parts.

–  –  –

A great amount of time and trouble can be saved if the building parts are unloaded at the building site according to a pre-arranged plan. Proper location and handling of components will eliminate unnecessary handling.

Blocking under the columns and rafters protects the splice plates and the slab from damage during the unloading process. It also facilitates the placing of slings or cables around the members for later lifting and allows members to be bolted together into sub-assemblies while on the ground. Extra care should always be exercised in the unloading operation to prevent injuries from handling the steel and to prevent damage to materials and the concrete slab.





If water is allowed to remain for extended periods in bundles of primed parts such as girts, purlins, etc., the pigment will fade and the paint will gradually soften reducing its bond to the steel. Therefore, upon receipt of a job, all bundles of primed parts should be stored at an angle to allow any trapped water to drain away and permit air circulation for drying. Puddles of water should not be allowed to collect and remain on columns or rafters for the same reason.

All primer should be touched up as required before erection.

–  –  –

Place the parts around the foundation so that they will be in the most convenient locations for installation. For example: place the end columns and rafters at the ends of the building and the mainframe columns and rafters at the sides.

Place the bolts and nuts in a place where they will be accessible to the parts.

You may want to screw the bolts and nuts together and place them with the corresponding parts. This will save time as you begin assembling the parts.

Purlins and girts, depending on the number of bundles, are usually stored near the sidewalls clear of other packages or parts.

Sheet packages are usually located along one or both sidewalls off the ground and sloping to one end to encourage drainage in case of rain.

Accessories are usually unloaded on a corner of the slab or off the slab near one end of the building to keep them as much out of the way as possible from the active area during steel erection.

–  –  –

Delivery: Mueller takes every precaution to insure that material is delivered to the customer damage free and fully protected from the elements during shipment.

When the material is delivered to the customer it then becomes the customers responsibility to protect the material from the elements, possible theft, and other

damage. The following guidelines are recommended:

HANDLING: Proper care is required in unloading and handling panel bundles in order to prevent damage.

1. Bundles should remain banded (if possible) during the unloading process.

Bundles should never be lifted by the banding material.

2. Lift each bundle as close as possible to its center of gravity.

3. If the bundles are to be lifted with a crane, use a spreader bar of appropriate length and nylon band slings (do not use wire rope slings as they will damage the material).

4. Depending on the panel length, some bundles may be lifted by a forklift.

When using a forklift, the forks should be spread to their maximum spacing, and the load centered on the forks. Sheets over 25’ long require two forklifts.

5. After panel bundles are opened, individual sheets must be handled carefully to prevent panel buckling or damage to the panel coating. When removing a sheet from a bundle it should be rolled off the bundle to prevent scratching of the next sheet. Never drag or slide one sheet over another sheet. Sheets should not be picked up by the ends. Instead, lift the sheet along its longitudinal edge and carry in a vertical position. For sheets over 10’ long, two or more people may be required to carry the sheet.

6. To avoid permanent black “finger printing” of Galvalume sheets, soft gloves must be worn.

B-4 WALL AND ROOF PANELS

Mueller’s wall and roof panels including color coated, galvalume, and galvanized provide excellent service under widely varied conditions. All unloading and erection personnel should fully understand that these panels are quality merchandise which merit cautious care in handling.

Under no circumstances should panels be handled roughly. Packages of sheets should be lifted off the truck with extreme care taken to insure that no damage occurs to ends of the sheets or to side ribs. The packages should be stored off the ground sufficiently high to allow air circulation underneath the packages. This avoids ground moisture and deters people from walking on the packages. One end of the package should always be elevated to encourage drainage in case of rain.

All stacked metal panels are subject, to some degree, to localized discoloration or stain when water is trapped between their closely nested surfaces. Mueller, Inc. exercises extreme caution during fabricating and shipping operations to insure that all panel stock is kept dry. However, due to climatic conditions, water formed by condensation of humid air can become trapped between stacked sheets. Water can also be trapped between the stacked sheets when exposed to rain. This discoloration caused by trapped moisture is often called wet storage stain.

The stain is usually superficial and has little effect on the appearance or service life of the panels as long as it is not permitted to remain on the panels. However, moisture in contact with the surface of the panels over an extended period can severely attack the finish and reduce the effective service life. Therefore, it is imperative that all panels be inspected for moisture upon receipt of the order. If moisture is present, dry the panels at once and store in a dry, warm place.

B-5 STORAGE: It is recommended that sheets be stored under roof if at all possible.

If sheets are to be stored outside, the following precautions should be observed:

1. The storage area should be reasonably level, and located so as to minimize handling.

2. When stored on bare ground, place a plastic ground cover under the bundles to minimize condensation on the sheets from ground moisture.

3. Store bundles at least 12 inches above ground level to allow air circulation beneath the bundle, and to prevent damage from rising water.

4. Elevate one end of each bundle slightly to permit runoff of moisture from the top of the bundle or from between sheets. A waterproof cover should be placed over the bundles to allow for air circulation under the cover.

5. Inspect stored bundles daily and repair any tears or punctures in the waterproof cover.

6. Re-cover opened bundles at the end of each workday to prevent subsequent moisture damage.

Checking order at time of delivery

Check each order carefully, as it is unloaded. Report any obvious damage or shortages to the carrier immediately. If damage or shortages are noted after delivery (at time of unpacking) notify your Mueller representative immediately.

Have invoice numbers and detailed descriptions of the damage or shortage available. These procedures are for your protection. A shortage or damage discovered later, can be caused by theft, misplacement, mishandling or other causes and is not the responsibility of Mueller, Inc.

–  –  –

Many methods and procedures are in use for erecting the structural portion of metal buildings. The techniques of raising frames vary from erecting small clear spans and endwall frames in units to erecting the larger clear spans and modular frames in sections. The erection methods used depend strictly on the type of building, the available equipment, the experience level of the crews, and the individual job conditions.

The variations in these factors preclude the establishment of a firm or specific set of erection rules and procedures. Consequently, the erection operation must be tailored by the erector to fit individual conditions and requirements. However, there are certain erection practices, pertaining to structural members, which are in general use and have proven sound over the years. Descriptions of these follow.

Erectors are cautioned not to cut primary members (rigid frame columns, rafters, end bearing frame rafters, interior columns). These are the primary support members for the frame and are designed as such. Any cutting of these members may affect the structural stability. A representative of Mueller’s must be consulted prior to attempting alterations of these members.

C-1 TOOLS AND EQUIPMENT REQUIRED

The types of tools and equipment required in order to assemble and erect the building depend on the size of the building purchased. This part of the instruction manual lists the tools and equipment that are normally required for most buildings. You may wish to use more or less power equipment or different tools than are listed as the need dictates. Whatever tools are used, it is important to remember that using the recommended tools will enable the least effort and best manner of erecting the building.



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