Tag: metal roof installation

Using Personal Protective Equipment (PPE) to Safely Install Metal Roofs

Posted on by David Lester

Anyone who has installed a metal roof knows it can be a dangerous business. With risks ranging from slips and falls to debris and even skin damage as a result of sun exposure, the installer needs to be cognizant of all safety considerations to mitigate personal injury. The good news is that wearing the proper Personal Protective Equipment (PPE) can greatly reduce the risk—and severity—of potential injuries.

Here we’ll review gear that can help ensure personal safety on jobsites and recommend equipment to always have on hand.

Standard Construction Safety Equipment

 

Safety Gear Recommendations:

Gloves—the thicker the better for optimal protection from cutting one’s hand on the sharp edges and corners of sheet metal. According to the Metal Construction Association’s (MCA’s) Metal Roof Installation Manual, clean leather gloves that allow for a good grip are the the best injury protection. (Dirty gloves can soil and scratch the panel surface.) Gloves also protect hands from burns when handling materials heated by sun exposure.

Hard Hats—according to OSHA, when exposed to the possibility of head injuries, hard hats should be worn. Roof work, especially handling metal materials, does raise the possibility. It is critical to ensure the hard hat fits properly to maximize their protective effectiveness.

Eye Wear—ensure protective eyewear features side shields to prevent metal shavings or any other airborne debris from damaging the eyes.

Fall Protection—slips and falls are, perhaps, the most obvious risk when installing metal roofs. Recommended gear includes a tie-off safety harness, non-skid footwear and mesh netted “Fall-Saver” insulation laid underneath the roof to help prevent falling through.

Toe Protection—in addition to being durable and having non-slip soles, steel-toed boots can help protect installers’ toes from injury.

Forearm Guards—Even lightly brushing against an exposed metal panel edge can result in serious injury. Forearm guards made of chainmail or Kevlar are recommended to prevent wounds.

Reflective Vests—these are a key piece of safety wear critical for alerting others to a workers’ presence. This is particularly important if there are vehicles or mobile machinery on site.

Proper Clothing—perhaps the most obvious recommendation is to wear fitted clothing. Loose clothing can get caught on sharp material and in machinery, which can cause serious, irreversible injury. Long-sleeved shirts and pants should be worn to protect skin from metal shavings and sun damage.

 

 

 

General Construction Site Safety:

In addition to the specific PPE listed above, the saying “Better safe than sorry.” can’t be overstated. The following is a checklist of common-sense equipment and other items that should always be on every construction site:

  • First-Aid Kit
  • CPR/AED kits
  • Fire extinguisher
  • Working access to /communication with Emergency services
  • ICE (In Case of Emergency) contact information for all personnel
  • Water
Additional Resources:

To learn more about PPE and safeguarding against injury when installing metals roofs, OSHA construction site safety guidelines and Metal Construction Association’s Metal Roof Installation Manual (Chapter 9: Safety Issues) are great resources. You can also learn more about metal panel installation considerations from our recent blog post. And, of course, the American Building Components team is always available to answer questions and provide guidance.

 

When to Call a Metal Panel Manufacturer: Part II

Posted on by Ken Buchinger

In Part 1 of this series, the success of a metal roof or wall project can rest heavily on the installer’s ability to recognize issues. When that happens, calling the manufacturer is not just suggested, but imperative to ensure any potential problem is averted before it’s too late. In addition to issues like damage to the physical panel or problems with the fasteners discussed previously, let’s take a closer look at a few other common circumstances under which ABC recommends reaching out to the manufacturer:

Alignment and Substrate Issues

The installer is responsible for verifying the condition of the substrate and checking for proper alignment before attaching any sheeting materials. If the installer notices any issues like this (either before installation or once they begin laying panels), they should stop and address them immediately. This might include oil canning or other irregularities in panel appearance. The installer should investigate the source, and—if unable to identify and properly remedy the situation on their own—they should call to the manufacturer’s support team. They may be able to suggest ways to identify source of the problem—whether it be installation or manufacturing—and from there, make suggestions on how to best address the situation.

 

Accessories

Adding penetrative accessories such as snow guards or mechanical curbs to a roof or installing doors, windows or louvers to walls can impact the system, its weather-tightness and appearance. Oftentimes, accessory installers with little or no knowledge of metal sheeting systems come onto the job to perform accessory installation. In these cases, it’s wise to visit with manufacturer prior to installation of these accessories and to alert the non-metal panel installer of precautions the manufacturer suggests be taken.

The image at left represent several installation issues that could have been avoided by calling the metal manufacturer prior to installation. The piping used is not compatible with metal roofing and was not installed in such a way to prevent issues with roof performance, including leaking and water damage.

Manufacturer recommendations can vary based on the panel type and building slope, as well as on the accessory and fastener type, and installation location.

Another factor to consider when adding accessories to your metal building is that some material types can react negatively with the installed metal system and lead to damage as well as void manufacturers warranties. Since accessories can be make of many different types of material, any potential accessories should always be researched prior to installation to ensure the material type is compatible with your metal roof and/or wall system.

 

Panel Engagement

Panel systems are designed and engineered to attach and engage one another to ensure optimal performance. These specification are outlined in the manufacturer’s installation manuals and project drawings. If at any point the panel does not engage as depicted in the details, installation should be halted and reviewed to determine the cause. This can require a call to the manufacturer to help determine if the matter is site- and/or substrate-related or if it’s a manufacturing issue requiring replacement material.

Panel engagement issues that warrant ceasing installation and making a call to the manufacturer include:

  • laps are not nesting properly
  • clips are not engaging as they should
  • panel modularity can’t be controlled
  • panels aren’t “resting” on the substrate—causing excessive bowing and stress

Once the material is completely installed, it is much more difficult to determine the cause of a problem and is potentially more expensive to remedy. Additionally, in many cases, full installation constitutes acceptance of the product and the manufacturer’s hands could be tied or extremely limited in being able to assist in remedying after the fact.

By knowing when to be proactive with a call to the manufacturer, installers can mitigate many types of potential pitfalls. And if you’re just not sure, it’s best to call.

For more information on metal roof and wall products, visit us online or reach out to your local representative today!

When to Call a Metal Panel Manufacturer: Part 1

Posted on by Ken Buchinger

Each metal building installation is unique and even the most experienced of installers can run into trouble on a job. Whether a panel isn’t engaging properly, it’s not meeting stated tolerances or fasteners are missing or not working, anyone who takes on the task of installing metal panels needs to know when to call a metal panel manufacturer for support, guidance and resources at any time to ensure the success of their project.

ABC Blog: When to Call a Metal Panel Manufacturer

Manufacturer Resources:

While it’s not the manufacturer’s responsibility to guarantee their panels are installed correctly, reputable manufacturers should set installers up for success. They can do this by providing product resources and recommendations on how to alleviate or mitigate potential pitfalls, and by sharing tips on how to avoid common mistakes that other installers have made.

  • Product Installation Manuals and Construction Drawings: Before installation begins, the product installation manual and detailed construction drawings should be reviewed by the installer—especially if this is his or her first time working with the product. These resources contain all the product information needed as well as installation best practices. American Building Components makes product details and installation information available to metal panel dealers and distributors through shop.abcmetalroofing.com. If you’re a dealer or distributor, click here to learn more and sign up for an account!

Installation techniques can vary based on the unique dimensions of the panel as well as on the actual building design. When an issue arises that is beyond an installer’s expertise, it’s in the best interest of everyone involved to call a metal panel manufacturer for input before permanent mistakes are made.

When to Call a Metal Panel Manufacturer

Examples of when American Building Components recommends that an installer immediately call a metal panel manufacturer are:

  • Product Damage: Building owners may not always be able to recognize material damage and understand how it can be detrimental. Therefore, installers should always evaluate all building materials before any installation begins. If—after review—damage is suspected, the building owner should take pictures of the damage and notify the manufacturer immediately. The manufacturer will advise if the issue is minor and installation can begin, or if the panels should not be installed. The last thing you want to do is install damaged panels and have to uninstall them and wait for new materials. The impact of removing and replacing panels like this will significantly increase cost and delay the construction schedule.
  • Fastener Issues: The type of fastener used depends on the material they will be fastening to (substrate). If the substrate differs from what’s stated in the project details, check with the manufacturer to verify that the provided fasteners can be used. If the screws aren’t engaging properly, or there any problems with the fastener type. The manufacturer can advise how to move forward based on the project details. In short, substituting fasteners with ones not supplied by the manufacturer is never recommended.

Remember: no problem is too small to call a metal panel manufacturer for advice! In part two of this series, we’ll share more situations when calling the manufacturer will save time, money and headache. For more information on metal roof and wall products, visit us online or reach out to your local representative today!

Concealed v. Through-Fastened Metal Roof and Wall Panels: How to Choose

Posted on by Tyler Roose

All metal panels—whether for commercial, residential, industrial or agricultural applications—are attached to the structure using either fasteners, clips or a combination of both that keep them in place. Vertical panels, in particular, are often categorized by the type of fastening method used to attach them, which is most often either using hidden/concealed fasteners or using an exposed (through-fastened) method. Here we’ll look at the benefits your customers can experience when using these common fastening types, as well as their differentiators, including price/budget, durability, aesthetics and ease of installation.

Concealed-Fastened Roofing Panels

Concealed-fastened panels are attached to the substrate with clips, which means the panels are not pierced to secure the connection. The clips and fasteners, therefore, are concealed underneath the metal panels when properly installed—arguably making the roof more aesthetically pleasing. These panels are offered in various styles, depending on which options your customers choose and additional job-specific considerations. This method is common in architectural and residential applications where a clean appearance and protection from environmental exposure are priorities.

Through-Fastened (Exposed) Roofing Panels

Through-fastened panels are generally attached with screws or nails, which puncture the overlapping roofing sections to lock the panels into place. They are also installed using washers, which provide leakage protection around the puncture hole. The fasteners are on the outside face of the panel and are visible even after the installation is complete.

So, how do your customers decide which option is right for their project? See below for some factors that can help them choose between a concealed- or through-fastened approach.

Key Considerations

Price/Budget:

Concealed: Typically, concealed-fastened panels can be more expensive overall due to the longer installation time required. In addition to increasing the labor cost, this installation method also takes longer, which affects your customer’s project schedule. However, ABC’s SL-16® panel can be installed faster and for about the same cost as exposed-fastened panel systems.

Through-fastened: While less expensive, through-fastened applications are more prone to issues. For example, if a washer fails, the screw can pop, which allows water in and can cause leaks and corrosion. While washer material is of a higher quality and more dependable than in the past, this is still a concern.

Durability:

Concealed: Because concealed fasteners have limited weather exposure, they therefore generally have a longer lifespan than panels with exposed fasteners. Additionally, there is less wear and tear since concealed panel fasteners are not as affected by the metal panel expansion and contraction that occurs when temperatures fluctuate as exposed-fastened panels are.

Through-fastened: Because concealed fasteners have limited weather exposure, they generally have a longer lifespan than panels with exposed fasteners. Additionally, there is less wear and tear since concealed panel fasteners are not as affected by the metal panel expansion and contraction that occurs when temperatures fluctuate as exposed-fastened panels are.

Aesthetics:

Concealed: Aesthetically, the main question is whether your customers want the screws to be visible or if it’s important that they are hidden. A concealed-fastened application is considered more aesthetically pleasing, as the lack of visible fasteners, creating a smooth, clean appearance. Generally, residential and architectural buildings favor concealed-fastened roofing panels.

Through-fastened: As stated, the hundreds of fasteners required to secure panels are exposed and visible on the outside of the panels. This method is often used on agricultural and industrial buildings, as clean aesthetics are usually less important for customers in these markets.

Ease of Installation:

Concealed: Installing concealed-fastened metal panel systems is time-consuming and complicated as compared to through-fastened. In fact, the complexity of the process dissuades many DIY installers from taking on the task.

Through-fastened: Exposed-fastened metal panel systems require less installation time as each fastener is drilled directly onto the outside of the panels. This makes it the method of choice for the majority of DIY installers. Overall, this method works well with simple structures but can be difficult to use on more complex projects. It should also be noted that through-fastened panels should be installed with care so that there is proper sealing. There also may be length limitations due to thermal movement.

Conclusion

The type of fastener system your customers choose for a given metal panel project will depend on a wide array of factors—budget, durability, aesthetics and ease of installation. Making the right choice is one step in ensuring the success and integrity of their building for years to come.

For more information on ABC’s concealed and through-fastened metal panels, visit our website. As always, our team is ready to help with your metal panel needs, so reach out to your local representative today!