Metal Roof Installation Manual
Total Page:16
File Type:pdf, Size:1020Kb
Metal Roof Installation Manual ACKNOWLEDGEMENTS The Metal Construction Association (MCA) would like to gratefully acknowledge Ken Buchinger, Jim Bush, Bill Croucher, Rob Haddock and MCA technical director Scott Kriner who have given generously of their time and talent in the production of this Training Manual. Additionally, we would also like to thank the Metal Building Manufacturers Association (MBMA) for granting permission to utilize their 2012 Metal Roofing Systems Design Manual as a source document for this Training Manual, with information being excerpted from the following chapters: Chapter 1-Systems Components; Chapter 2-Substrates; Chapter 4-Retrofits; Chapter 7-Installation and Maintenance; and Chapter 12-Metal Roof Details. That material is reprinted with permission and as noted in Training Manual Chapters 10, 11, 12, 13 and 16. The complete MBMA reference is available at www.mbmamanual.com. We would like to further acknowledge the following individuals and organizations that contributed images to this manual. All images were reprinted with permission. Ken Buchinger, MBCI Figures 2-3b Figures 3-5, 3-11, 3-12, 3-13, 3-14, 3-15, 3-16 Figures 4-17 Figures 7-4, 7-8, 7-9, 7-12, 7-13 Figures 8-8, 8-9, 8-12, 8-15, 8-17, 8-25, 8-28, 8-29, 8-30 Figures 10-22, 10-40, 10-41 (partial), 10-42, 10-44, 10-45, 10-46, 10-48, 10-49, 10-59, 10-67 Figures 12-3a, 12-3b, 12-10 Figure 13-1 Figures 14-6, 14-26, 14-27, 14-28, 14-29 Figures 16-2, 16-21, 16-22, 16-23, 16-24, 16-31 (partial), 16-32 Figures 17-3, 17-4, 17-9 Figures 19-2, 19-11, 19-12 (partial), 19-13 (partial), 19-14, 19-16 (partial) Jim Bush, ATAS International, Inc. Figure 4-10 Figures 5-11, 5-19, 5-20 Figures 8-34, 8-35 (partial) Table 10-1 Figure 13-7 Bill Croucher, Fabral Figure 8-19 Rob Haddock, Metal Roof Advisory Group, Ltd. Figures 2-5, 2-6, 2-7, 2-8 Figures 3-1, 3-2, 3-4, 3-7, 3-9, 3-10 Figures 4-4, 4-5 ACKNOWLEDGEMENTS Figures 7-14, 7-17 (left), 7-20 Figures 8-13, 8-14, 8-18, 8-19, 8-20, 8-22, 8-23, 8-33 Figures 9-10, 9-17 Figures 10-23, 10-31, 10-32, 10-33, 10-35, 10-37, 10-43, 10-47 Figures 11-5, 11-6, 11-7, 11-8, 11-12, 11-18 Figures 12-11, 12-12 Figures 15-1, 15-2, 15-3, 15-4, 15-6, 15-8, 15-9, 15-15 Figures 16-25, 16-26, 16-29 Metal Building Manufacturers Association Figures 6-2c, 6-9 Figures 8-10 Figure 10-2, 10-4, 10-40,10-71,10-72,10-73,10-74,10-80 Figure 13-13, 13-14,13-15,13-16,13-17,13-18 Figures 14-1, 14-20, 14-22, 14-25 Figures 16-14, 16-17, 16-18, 16-27 Figures 20-2, 20-3, 20-4, 20-5, 20-12 (top), 20-13, 20-14 National Roofing Contractors Association Figures 4-1, 4-13 Figure 5-16 Figures 8-3, 8-4, 8-5, 8-6 Figures 10-3,10-9, 10-10,10-14,10-15,10-24,10-25,10-26,10-27,10-28,10-34,10-36,10-50,10- 51,10-52,10-53,10-54,10-55,10-56,10-57,10-58,10-60,10-61,10-62,10-63,10-64,10-65,10- 66,10-68,10-69,10-70,10-75,10-76,10-81,10-82 Figures 13-19a, 13-20, 13-21, 13-22, 13-23 Figures 14-21, 14-23, 14-24, 14-32, 14-33, 14-34 Figures 15-10, 15-13 Table of Contents Chapters: 1. INTRODUCTION 2. METAL ROOFING: A FAMILY OF PRODUCTS / HISTORY OF METAL ROOFING 3. INTRO TO METAL ROOFING MATERIALS 4. PANEL TYPES 5. PANEL ATTRIBUTES / PROFILES 6. ROOF DECK SUBSTRATES 7. PANEL CONNECTIONS 8. COMMON ROOF ACCESSORIES 9. SAFETY ISSUES 10. ROOFING DESIGN 11. DELIVERY, RECEIPT, STORAGE, AND HANDLING OF MATERIALS 12. TOOLS AND FIELD OPERATIONS 13. SEALANTS 14. FASTENERS 15. SEAM JOINING 16. PANEL INSTALLATION 17. MAINTENANCE 18. CODES / STANDARDS AND SPECIFICATIONS 19. INSTALLER CHECKLISTS 20. RE-ROOFING Appendices: 1. GLOSSARY 2. ABBREVIATIONS AND ACRONYMS 3. RESOURCE MATERIAL 4. DISCLAIMER Chapter 1: Introduction Chapter Contents 1. Introduction ....................................................................................................... 1-1 1.1 MCA Installer Training Manual .................................................................. 1-1 1.1.1 Purpose of the Manual .................................................................... 1-1 1.1.2 Using This Manual ........................................................................... 1-1 1.1.3 Skill and Knowledge Requirements of the Installer ..................... 1-1 1.1.4 Responsibility of the Various Trades ............................................ 1-2 1.1.5 Timeliness of Information ............................................................... 1-2 1.2 Development of the Training Manual ....................................................... 1-2 1.3 Acknowledgments ..................................................................................... 1-2 INTRODUCTION: CHAPTER 1 metal roofing products when following the 1. INTRODUCTION manufacturer's installation instructions; This installation training manual addresses the installation of metal roofing material and • Promote installer safety practices. related accessories. It includes information pertaining to both new construction reroofing 1.1.2 Using This Manual and retrofit projects. This installation training manual was developed to provide information regarding Important Note: Different roof types the installation of most metal roofing require specific installation techniques. The products, and to serve as a reference for information provided in this manual does not most types of metal roofing products and supercede installation instructions provided applications. This manual does not address by the manufacturer. Always consult the the unique characteristics of factory manufacturer's instructions. assembled insulated metal panel roofs or special environments such as cold storage. 1.1 MCA Installer Training Manual The manual provides an overview of information relating to: 1.1.1 Purpose of the Manual • The MCA installation training manual was The History of, and Introduction to, Metal developed to improve the installation of Roofing Products and Materials metal roofing within the construction • Panel Attributes industry. The goal is to eliminate avoidable • problems and reduce the need for additional Roofing Design work due to callbacks. • Sealants and Fasteners This installation training manual is intended • Installation of Products for installers of metal roofs, related products • Common Accessories and accessories. • Specifications and Codes Other professionals involved in the • Final Cleaning and Inspection construction industry can benefit from this training manual. This includes architects, • Re-roofing specification writers, contractors, building • Installer Checklists owners, manufacturers, and numerous others. 1.1.3 Skill and Knowledge Requirements of the Installer The specific objectives of the MCA installation training manual are to: This installation training manual assumes that the installer possesses the following • Promote consistent, high quality basic knowledge and skills: installations; decreasing installation deficiencies; minimizing product failures 1. Basic measuring skills and callbacks; while promoting energy 2. A basic understanding of construction efficiency and, thereby, lowering the methods and techniques ultimate cost to the consumer. 3. An understanding of the proper use of • Provide installers with the basic knowledge tools normal to the roofing trade necessary for proper installation of typical The contributors to this document attempted to include the basic information needed. 1-1 INTRODUCTION: CHAPTER 1 However, it is not practical to include all 1.1.5 Timeliness of Information information related to each product and its design options. In the event that an installer This manual provides information which is has any questions, or faces a situation not current as of the date of publication. Always addressed in these materials, it is check the manufacturer’s instructions and imperative that such uncertainties be current information provided by the building resolved through consultation with the and roofing industry for updates. responsible parties before work is begun. 1.2 Development of the Installer 1.1.4 Responsibility of the Various Trades Training Manual For the purpose of this training manual, an The installation training manual is based on installer is defined as someone who sets, industry-accepted practices and principles anchors, seals, and/or applies metal roofing that have been developed over the years by products and necessary flashing and trim. members of the MCA (Metal Construction No differentiation is specified between a Association) This association recognizes the new construction installer and a need for consistent installation practices and replacement (retrofit) installer in this is dedicated to the development of installation manual. Some of an installer’s tasks may best practices. The best practices developed be performed by other individuals. As an have allowed for the creation of this training example, one party may dry-in the roof by manual offered by the MCA. applying the peel and stick underlayment, another install the panels, and a third party Experienced individuals and experts in the install pipe penetrations and pipe boots. field provided input throughout the development of the installation training Although the installer is responsible for the manual. A team of individuals from MCA quality of the work performed, others was formed to assist in developing the (building contractor, developer, architect, manual based on material submitted or etc.) are often the "approving authority" or recommended by the MCA. "responsible parties” that make specific decisions that affect the installation. The In addition, this training manual incorporates approving authority is responsible for information offered by MCA members who coordination and checking the quality of the are manufacturers and/or suppliers. Much work done by the various trades associated of the information provided was incorporated with the roofing. The construction sequence, into the language and graphics. proper coordination, and proper integration of all of the various building components are 1.3 Acknowledgments essential to the long-term performance of This installation training manual was any completed installation.