TECHNICAL HANDBOOK

20067 TRIBIANO, Milan Phone +39 02 906951 - Fax +39 02 90634238

WALL-PANELS
HORIZONTAL ASSEMBLING

METECNO INDUSTRIE S.p.A.

Phone +39 02 906951 - Fax +39 02 90634238 www.metecno.com - info@metecno.it

POLYURETHANE OR ROCK WOOL SELF-SUPPORTING INSULATING METAL PANEL

ENG

WALL-PANELS
(horizontal assembling)

TECHNICAL MANUAL This document has been drawn up to help you in using the following panels.
MONOWALL A-B / B-B SUPERWALL ML SUPERWALL HF HIPERTEC WALL HIPERTEC WAND SOUND ROCKSTEEL WALL H-WALL 8P / 8M / 10P / 10M FIREMET WALL

Before using the products, we suggest to take some of your time to carefully read the present manual to refresh your technical and operative knowledge. This manual is divided into several sections, which are identified by a number. Each section is subdivided into numbered chapters.

For any information or suggestion, please send your mail to:

METECNO GROUP sales conditions apply to all aspects that are not covered by the present technical manual.

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(horizontal assembling)

1.
1.1

GENERALS
COMPOSITION AND USE All the wall panels from Metecno are composite panels, formed by two metal sheets linked by a layer of insulating material, which can be manufactured upon request: with combined insulation with mineralwool with polyurethane foam
Monowall A-B / B-B Superwall ML H-Wall 8P H-Wall 10P Hipertec Wall Rocksteel Wall Superwall HF H-Wall 8M H-Wall 10M FIREMET Wall

When the panel is laid horizontally, no secondary purlin structures (wall stringers and secondary columns) are necessary, since panels are directly fixed to the main columns. The shape of the panel longitudinal joint is such as to house the fastening screw, when using douple span or multi span. wich is then hidden inside, making panel more pleasant and elegant looking In addition to the economic benefits for the structure costs, this solution is an innovative architectural alternative. (only for panel type: Superwall ML / HF ; H-Wall 8P / 8M) Due to its geometrical configuration, the panel may also be assembled in a vertical wall position in the presence of the secondary purlin structures.

1.2

STANDARD SIZE Panels are manufactured in 1000 mm wide modules, their length depends on the specific design requirements and the feasibility of the manufacturing factory. Please request for that.

Monowall A-B 1000 250 250 250 250

S 62,5 62,5
Gasket (polyurethane version only)

Monowall B-B 62,5

S 1000

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(horizontal assembling)

SUPERWALL ML / HF
1000 25 S 62,5 Gasket (polyurethane version only)

HIPERTEC WALL / HIPERTEC WALL SOUND / ROCKSTEEL WALL / FIREMET WALL 1000 62,5

62,5

62,5

62,5

3
H-Wall 8P / 8M 20

125 62,5
Gasket (polyurethane version only)

1000

H-Wall 10P / 10M 18

100

62,5 1000
Gasket (polyurethane version only)

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1.3

REACTION AND RESISTANCE TO FIRE Contact METECNO for detailed information.

1.4

FASTENERS When panels are laid horizontally, they require the following type of fastening.
le n g t h o f t h e s c r e w * v is ib le F ix in g p a n e l ty p e t h ic k n e s s panel t h ic k n e s s a t t h e p o in t w e re th e s c re w is lo c a t e d [m m ] 20 25 30 35 45 55 75 95 115 135 145 25 30 35 40 50 60 80 100 120 140 150 60 80 100 120 50 80 s t e e l c o n s t r u c t io n > 1 ,5 m m s c r e w w it h f in e t h r e a d [m m ] 45 50 45 60 70 80 100 120 140 160 170 50 55 50 65 75 85 105 125 145 165 175 80 100 120 140 70 100 le n g t h o f t h e s c r e w * h id d e n f ix in g p a n e l ty p e t h ic k n e s s panel t h ic k n e s s a t t h e p o in t w e re th e s c re w is lo c a t e d [m m ] 46 66 86 106 40 70 s t e e l c o n s t r u c t io n > 1 ,5 m m s c r e w w it h f in e t h r e a d [m m ] 60 80 100 120 60 90 w o o d e n c o n s t r u c t io n >50m m s c r e w w it h c o a rs e th r e a d [m m ] 105 125 145 165 100 130 w o o d e n c o n s t r u c t io n >50m m s c r e w w it h c o a rs e th r e a d [m m ] 85 90 95 100 110 120 140 160 180 200 210 90 95 100 105 115 125 145 165 185 205 215 120 140 160 180 110 140

[m m ] M o n o w a ll A - B 25 30 35 40 50 60 80 100 120 140 150 25 30 35 40 50 60 80 100 120 140 150 60 80 100 120 5 0 /7 0 8 0 /1 0 0

M o n o w a ll B - B F ir e m e t W a ll H ip e r t e c W a ll

S u p e r w a ll

H - W a ll 8

[m m ] S u p e r w a ll 60 80 100 120 5 0 /7 0 8 0 /1 0 0

H - W a ll 8

w a s h e r w it h d ia m e t e r o f 1 6 o r 1 9 m m * r e c o m m e n d e d m in im a l le n g t h o f t h e s c r e w T h e a d v e r t is e d le n g t h o f t h e s c r e w d e p e n d s o n t h e s t e e l t h ic k n e s s o f t h e s u p p o r t c o n s t r u c t io n a n d d if f e r e n s e b e t w e e n t h e v a r io s s c r e w s u p p lie r s I f y o u u s e s e lf d r illin g s c r e w s , p le a s e c o n t a c t u s b e f o r e .

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2.3

HANDLING AND STORAGE Package handling and storage is a very delicate phase, in which panels can get damaged. For this reason, a label with the following instructions is applied to each package:

WARNING ! Carefully follow these handling and storage instructions

Sling the package by using a rocker arm and min. 200 mm-wide nylon belts. Insert min. 200 mm-wide wooden boards between the package and the belts. The wooden boards will have to be approximately 2 cm longer than the package width. Do not store more than three packages one on top of another, and place spacers or boards between them.

min. 5% lope Slight s

3

200

. min

L 1/5
L

/5L

5
Place the package on a flat and rigid surface, and position 50 mm-thick and 200 mm- wide polystyrene spacers or wooden boards at max. 1 m intervals. Panels will have to be stored slightly sloping in order to help possible condensation flow and to prevent backwater. Store packages under cover; if this is impossible, protect them with rainproof membranes. Make sure that the goods are appropriately aerated. Any protective film should be not exposed to direct sunbeams and, in any case, should be removed within 45 days after the date when the panels are prepared.

- m in . S light s lope

5%
er der cov eep un ams - K e to sunb expose Do not

1m

1m

1m

Remove protection

NOTE: The extendable polyethylene forming the external wrap of this package is not suitable for a long exposition outdoor, since sunbeams change its properties.

When panels have to be moved one by one due to building yard needs, they should be always carried as shown in the illustration.

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3.

ASSEMBLY TOOLS

PORTABLE DRILLING MACHINE Portable drilling machine with max. 8-mm diameter spindle and relevant helical drills.

ELECTRIC SCREW-DRIVER Reversible electric screw-driver with relevant bushes.

HACK SAWING MACHINE

RIVETING MACHINE Riveting machine for 2.5-5 mm diameter rivets and relevant rivets.

VACUUM CLEANER

RELEASE PINCERS

PLIERS

HAND LEVER SHEARS

(right and left)

SLEDGE HAMMER

SCRAPER OR SPATULE

PLUMB LINE

SPIRIT LEVEL

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4.
4.1

ASSEMBLY INSTRUCTIONS
PRELIMINARIES a) b) c) d) e) f) g) h) Check that the storage has been carried out according to the directions in chapter 2. Check that the panel support structures are level. Position the packages of panels near the points of use. Prepare a fixed or cradle scaffold, according to the working height, 30/40 cm far from the external edge of the main columns and comply with the rules on safety in the workplace. Control that all workers are equipped with individual safety equipment according to current regulations. Prepare all the power supply lines for tools according to current regulations. Prepare the panel lifting vehicles. In addition to the traditional scaffolding, when assembling wall panels horizontally, automatic scaffolds with platform can be profitably used. These platforms may be either the type with masts starting from the ground or the selfpropelled type with telescopic arms.

4.2 4.2.1

PREPARING PANELS Before the assembly, the polyethylene protecting film must be taken away from the entire panel. Thoroughly check that no traces of residual glue of the protecting film are left on the surface. In case, remove them using a detergent in a waterbased solution. If the panel surface shows clear damages in the sheet, set the panel aside and use it when undersizes are required.

4.2.2

4.3

WALL WITH HORIZONTAL PANELS IN GENERAL

4.3.1 Metecno wall panels, depending on the distances between centers of the main columns (Figure 5), can be assembled on single, double and multiple spans. Due to space limitations, only the assembly on double spans is illustrated here. For single and multiple spans, adopt similar assembly methods.

Main column

Main column

Main column

Main column

Drip

Main column

Figure 5

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(horizontal assembling)

4.3.2

When panels are assembled horizontally, the purpose of the base flashing is draining the water flowing along the faade (Figure 6). In order to guarantee that the wall is perfectly horizontal, the base substructure (tube) must be positioned using the traditional floor control level. Once the base flashing and/or, if required, also the internal flashing is assembled (Figur e 6), install the U-shaped zinc-plated steel profile (Figure 6a) on top of the above mentioned base substructure, which is suitable to house and block the panel without using the screw (Figure 6a).
Main column Tube Internal flashing Base flashing Panel blocking profile

Drip

Drip

Figure 6 4.3.3

Figure 6a

Based on the executive drawings, find out the starting point of the initial bottom panel and position it on the prepared U shaped profile (Figure 7), holding it to the columns by means of release pincers (Figure 8).

Main column

Main column

Main column

Main column

Main column

Panel U-shapped profile

Base flasing

Drip

Figure 7

Main column

Main column

Release pincers

Panel

Drip

Main column

Figure 8

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(horizontal assembling)

4.3.4

After checking that the panel is horizontal, fix the top joint to the main columns (Figure 9) according to the scheme indicated at point 1.7 (Figure 4). Remove the release pincers, control that the panel is level and then assemble the panel.
for example: panel type Superwall (horizontal assembling)

Figure 9 4.3.5 4.3.6 Before assembling the second panel, check that the joints are thoroughly clean. For an easy and proper assembly, the second panel must be approached to the fixed panel from above and slipped into the joint (Figures 10-11).
for example: panel type Superwall (horizontal assembling)
Drip

Figure 10

Figure 11

WALL-PANELS
(horizontal assembling)

Figure 12 4.3.8 When the wall is higher than 5 m, we suggest you to proceed simultaneously on all sections forming the building wall by assembling 4-5 panels for each section, so that you can always monitor the horizontal level of the panels of the various sections (Figure 13).

for example: panel type Superwall (horizontal assembling)

4.3.7

Verify that the joint is perfectly executed by checking that the lengthwise edges of the two adjoining panels are perfectly in touch. If necessary, change the horizontal level of the panel by holding it with the release pincers and fix it (Figure 12). Proceed as above with the remaining panels until the first wall section is completed.

10

Drip

Figure 13 For the distance between the edges of the panels of two adjoining sections, stick to the indications given at point 4.3.11.

WALL-PANELS
(horizontal assembling)

4.4

FASTENING AND SCREW CONNECTION FOR THE DIFFERENT PANEL TYPES

4.4.1 Type Superwall

Fixing with a screw in the joint

Fixing with a screw and a load distribution plate in the joint

It is necessary to prepair the fixing connections between column and panel with gaskets before, to obtain a rain- and windproof wall (vapour barrier) . Please be shure, that you installed the panels in the right direction. The panel on the top must overlap the joint of the panel below, for the correct water-bearing on the surface of the building.

cover-flashing

11

supporting structure (concret column)

supporting structure (steel column)

HTU-bar

Gasket

insulation

the joint-distance depends on type of the cover-flashing

insulation

the joint-distance depends on type of the cover-flashing

WALL-PANELS
(horizontal assembling)

4.4.2 Type H Wall 8

1 Fixing with a screw in the joint

2 Fixing with a screw and a load distribution plate in the joint.

It is necessary to prepair the fixing connections between column and panel with gaskets before, to obtain a rain- and windproof wall (vapour barrier) . Please be shure, that you installed the panels in the right direction. The panel on the top must overlap the joint of the panel below, for the correct water-bearing on the surface of the building.

cover-flashing

1a Visible fixing in the valley (if necessary)

12

supporting structure (concret column)

supporting structure (steel column)

HTU-bar Gasket

insulation

the joint-distance depends on type of the cover-flashing

insulation

the joint-distance depends on type of the cover-flashing

WALL-PANELS
(horizontal assembling)

4.4.3 Type H Wall 10 / Monowall / Hipertec Wall / Rocksteel Wall / Firemet Wall
for example: panel type H-Wall 10 (horizontal assembling)

1 Fixing on both sides near the joint

slot (top)

key (down)

supporting structure (concret column)

supporting structure (steel column)

HTU-bar Gasket

insulation

the joint-distance depends on type of the cover-flashing

insulation

the joint-distance depends on type of the cover-flashing

for example: panel type Monowall (horizontal assembling)

It is necessary to prepair the fixing connections between column and panel with gaskets before, to obtain a rain- and windproof wall (vapour barrier). Please be sure, that you installed the panels in the right direction. The panel on the top must overlap the joint of the panel below, for the correct water-bearing on the surface of the building.

cover-flashing

13

WALL-PANELS
(horizontal assembling)

4.5 4.5.1

VERTICAL WALL JOINT When the first wall section is assembled, move the scaffolding for assembling the panels of the second section (Figure 14)
First panel section

Second panel section

Drip

Figure 14 4.5.2 Before assembling the second panel section, check again that the first panels is in level and than assemble the following panels.

Corrugated sandwich wall panels (H-Wall 8P / 8M / 10P / 10M)

4.5.3 The vertical joint between the panel end sections is placed in front of a main column. The gap between panels should be 40 mm (Figure 15).

Main column

14
First section panel Second section panel

40

Joint gap

Figure 15 4.5.4 Position a distance-holder (previously prepared in the building yard) consisting of a 3-4 m long and 40 mm wide ( tube made in aluminum or another material, vertically in contact with the edges of the first section panels that have been already assembled (Figure 16). If the panel lengths are slightly different from the nominal value (anyway within the standard tolerance), a template of a slightly different size may have to be used.
Main column

First section panel

20 40

d i s t a n c e - holder

Figure 16

WALL-PANELS
(horizontal assembling)

4.5.6 Control that the distance-holder is perpendicular and position the first panel of the second section against the wall, push the edge against the prepared template (Figure 17).

Main column

First section panel

Second section panel

20 40 T emp late

Figure 17 4.5.7 Control that the panel is horizontal and aligned with the already assembled adjoining panel. This operation may be easier if a mark and/or an alignment line is drawn on the distance-holder (Figure 18).

15
Main column Alignment line T emp late

Assembled panel

Panel to be assembled

for example: panel type H-Wall 8 (horizontal assembling)

Figure 18 4.5.8 Fix the panel to the column with the release pincers and fasten it (Figure 19) according to the scheme described at point 1.5 (Figure 4).

WALL-PANELS
(horizontal assembling)

4.5.9 After assembling all the panels of the section covered by the template, take the template out of the joint area and reposition it into the following vertical wall joint.

Screw 20 20

Main column Screw

First section panel

Second section panel

20 T emp late 40

Figure 19

4.5.10 Assemble the next panels following the same method until the various panel sections forming the faade are finished. 4.5.11 Always check the horizontal direction of panels in order to keep them perfectly aligned. 4.5.12 Once two panel sections are assembled, the joint profiles connecting the base gap between panels can be assembled, so that the faade wall looks continuous. This operation may be carried out by another team of workers, while the panels of the next sections are laid. 4.5.13 The profiles for the vertical joint are in different solutions possible, some examples are shown in the pictures below. Standard Joint (Figure 20) Special Joint (Figure 21)

16

S + 40

Figure 20

Figure 21

WALL-PANELS
(horizontal assembling)

4.5.17 Insert the supplied insulation element into the joint gap, as explained in point 4.3.11 (Figure 22).

Figure 22 4.5.18 Apply the joint profile, on whose sloping sides two self-adhesive gaskets must be stuck (Figure 23). Insert the profile into the joint gap and fix it to the high peaks of the panels by (in case, pre-painted) rivets (No. 0.8/m) (Figure 24).

Gasket

Gasket

Figure 23

17
Rivet
Gasket

Rivet

Figure 24 4.5.19 With this operation, the gaskets prepared on the profile are compressed and seal the corrugated side of the panels quite effectively.

Figure 25

WALL-PANELS
(horizontal assembling)

Low profiled sandwich wall panels (Monowall / Hipertec Wall / Rocksteel Wall / Firemet Wall)
4.5.21 The assembling steps principaly are the same like the instruction point 4.4 ff. The only difference in the construction detail for the vertical joint (low profiled sandwich wall panels like the types Monowall, Hipertec Wall, Rocksteel Wall and Firemet Wall) is the use of a different cover-flashing be able to cover the screw-heads at the panel near the joint. The cover flashing is to be fixed with self cutting screws or rivets on the panel, like shown in the picture below.

Main column

gasket 10/20 or 20/20

insulation

18
cover flashing

20mm

Figure 26

WALL-PANELS
(horizontal assembling)

5.

LIFTING PANELS
USEFUL CONSIDERATIONS In the assembly stage of the Metecno wall panels, especially when they are handled along the wall, considering their horizontal size, special lifting devices can be used, like:

5.1 5.2

a suitably sized device with clamps, which in its turn is held by a lifting device (Figure 29) one of the most innovative lifting tools is a retaining jig with pneumatik air sucker (Figure 30)
Holding ring Spring

Steel rope

Figure 30

Figure 29

6.
6.1

CUTTING PANELS
If panels need to be cut to make openings or passages, proceed as follows (Figure 31): Protect the surface to be cut with adhesive tape. Draw the cut to be made on the tape using a felt-tip pen. Cut using a hack sawing machine. Clean the surface from the shavings formed during the cutting, because they can cause corrosion over time. Remove the adhesive tape.
Adhesive tape

19

Hole

Cutting line marked with a felt-tip pen

Panel cut made with a hack sawing machine

Figure 31

WALL-PANELS
(horizontal assembling)

7.

CONSTRUCTION DETAILS
Some construction details relevant to the individual points of a wall formed by Metecno wall panels are enclosed to the present document.

NO. 12 DRAWINGS
(annexed to the present manual)

20

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(vertical assembling)

8.
8.1

PANEL MAINTENANCE
For the good panel maintenance, two phases must be distinguished: First phase: regards the time necessary to assemble the panels. Second phase: regards the use of the building, to which the panels have been assembled. In the first phase, in order to maintain panels undamaged, you should take care of what follows: the handling during the unloading operations from vehicles must be carried out with suitable means and appropriate protections, in order to prevent panels from being indented or scratched. the handling during the removal of the protective film and the distribution near the works. In this stage, we always suggest that the panel and sections are controlled to remove any excess of the insulating material for the benefit of the perfect execution of the panel coupling joint. the lifting operations near walls, to be carried out with suitable means and safety systems for the staff. the assembly stages, taking particular care to the fastening operations, immediately removing all the shavings caused by drilling from the panel surface. In order to insert screws and avoid indentations to the panel, use screwdrivers that are equipped with a depth limiting device. when, during the distribution of panels, stains or deformations (indentations) that cannot be easily fixed are found, avoid to assemble such panels and set them aside for use as undersize elements, where possible.

8.2

If the above-mentioned recommendations are truly complied with, they guarantee the product integrity and avoid the annoying building yard objections that very often translate into unpleasant financial costs. The second stage regards the panel maintenance, which is the final users task, in order for the panels of his building to maintain their original look and have the building look pleasant. The consequences of a slow degradation of the pre-painted external sides are mostly originated from the contact with aggressive substances contained in corrosive air and gaseous emissions from surrounding activities. Therefore, periodical inspections to the panels should be planned in order to find possible corrosion; if it is found, action should be taken immediately, starting protective cycles to stop the process. In the long run, smog deposits on painted surfaces and may create a dirt film, and the walls will have to be cleaned with water jets. The existing seals will have to be controlled, verifying that they are still airtight and waterproof, which otherwise may cause deterioration. All the fastenings will have to be controlled to verify that they are still in good conditions. Any scratches of the paint that may have been caused accidentally will have to be protected by retouching: cleaning and painting. In case of large size dents caused by impacts, the panel will have to be replaced. DISPOSAL In case of yard working wastes and/or dismissal, the panel disposal shall only be entrusted with authorized companies and carried out in compliance with the current laws in each country.

8.3

34

8.4

8.5

WALL-PANELS
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9. SAFETY INFORMATION
Each user and/or worker must be aware of all the problems connected with the assembly of these panels, and should prepare a SAFETY PLAN in order to prevent dangerous situations. THEREFORE, WE REMIND YOU TO STRICTLY COMPLY WITH THE REGULATIONS ON SAFETY IN WORKPLACES, BUILDING YARDS AND EQUIPMENT SAFETY.

35

IMPORTANT The information contained in this manual has been prepared in connection with our customers needs. It has been processed based on our know-how at the time of publishing and, therefore, it is subject to changes without any prior notice. For the same reason, this is not a full guide to installation, use and maintenance of METECNO products. In case of doubt or difficulty, the user must seek for METECNOs advice before proceeding. METECNO does not accept any responsibility for damages to individuals or properties, caused by faults in assembly or installation, by improper use and wrong maintenance of Superwall ML sandwich panels. Metecno trademark Metecno copyright

METECNO S.p.A. Via Per Cassino, 19 20067 TRIBIANO, Milan Phone +39 02 906951 - Fax +39 02 90634238 www.metecno.com METECNO INDUSTRIE S.p.A. Via Per Cassino, 19 20067 TRIBIANO, Milan Phone +39 02 906951 - Fax +39 02 90634238 www.metecno.com - info@metecno.it