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Zamil Steel is committed to producing marketing literature that contributes to the education of all parties involved in the purchase of a Zamil Steel pre-engineered steel building. Every effort is made to update this literature on a regular basis.
Certified builders are independent contractors that are an extension of Zamil Steel in specific sales areas. They have one or more high level managers with extensive experience in pre-engineered steel buildings.
Green timber should not come into contact with galvanized steel or ZINCALUME® zincaluminium alloy coated steel, due to acidic substances in the timber which have a corrosive effect on the metallic coating. The use of kiln dried or appropriate dried timber species is therefore recommended for any situation where intimate contact between the metallic coated steel and timber is considered.
Copper/chrome/arsenic (CCA) timber cladding used in a run-off situation, can result in a corrosive leachate from the timber containing copper, which if it contacts galvanized, or ZINCALUME® steel will promote corrosion.
If CCA treated timbers must be used then the timber and/or steelwork should be sealed by fully painting the material prior to installation.
B3. What is EPDM (Ethylene Propylene Dimonomer) Seals.
In 1984 - 85 EPDM (Ethylene Propylene Dimonomer) became the seal of choice with the leading roof fastener manufacturers. This terpolymer elastomer is particularly well suited for sealing washers due to its resistance to water, chlorinated water, dilute acids, alkalines, ozone and oxidizing chemicals. It has a negligible absorption rate, is not susceptible to swelling, and can withstand temperatures up to 100°C
The range of employment and durability of EPDM elastomer seals is as follows:
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Temperature resistance
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-40° to 100° C
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Tensile strength
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Good
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Impact elasticity
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Good
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Abrasion resistance
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Good to Very Good
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Residual compression set
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Very Good
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Flame resistance
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Low
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Water resistance
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Very Good
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Acid resistance
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Good to Very good
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Alkali resistance
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Very Good
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Ozone resistance
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Good to Very good
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Weathering resistance
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Very Good
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Contact stains
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None
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Migration stains
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None
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Animal and vegetable oils
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Very Good
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Ageing in sunlight
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Very Good
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Ageing in heat
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Very Good
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Ultraviolet resistance
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Very Good
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The EPDM seal can be inseparably bonded to washers of galvanized carbon steel, aluminum or stainless steel, or loose. Both provide a leak free and long lasting seal.
Leading Panel manufacturers recommend the used of EPDM seals, not Neoprene, and further recommend that the sealing washers are low in carbon black, particularly for marine environments.
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Zamil Steel recommends that you follow our simple maintenance recommendations for steel buildings. By doing so you will substantially enhance the life of your investment.
Frequency of maintenance is dependent upon the environmental zone in which the building is located.
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Building Location
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Maintenance Period
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Within 5 km of the sea.
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Every 3 months
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High pollution industrial area.
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Every 3 months
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Medium pollution industrial area.
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Every 4 months
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Areas of high humidity.
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Every 4 months
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Low pollution industrial area.
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Every 6 months
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Dry desert regions.
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Every 6 months
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Cautions and Safety Notes
- Extreme caution should be exercised when working on roofs.
- Professional maintenance staff shall be used for maintenance works.
- Access ladders shall reach at least one meter above the step off point.
- Ladders shall be secured to the building, and shall be on a firm base.
- Do not step on skylights.
- When walking on the roof, step in the valleys of the panel, not on the ribs.
- Whenever possible, walk on the purlin line, (screw line).
- Areas of roof subject to frequent access shall be protected by temporary or permanent walkways.
- When maintaining overhead crane runways, immobilize the crane before commencement of work.
Exterior Maintenance Procedure
- Preventive maintenance shall commence immediately after a project is erected or modified.
- Debris and small items such as screws, pop rivets, drill bits, or any ferrous objects shall be removed by sweeping with a soft nylon brush. Large items such as sheet metal cut-off shall be removed by hand to avoid damaging the surface of the roof panels. Such debris shall be removed after any trade, (e.g. electricians, plumbers, air conditioning technicians and steel erectors) has worked on the roof.
- Sand and dust retain salt and moisture, which will eventually breakdown the paint and zinc layers, resulting in corrosion of the base metal. Sand and dust shall be removed by washing with clean potable water and a soft nylon brush, working from the highest point to the lowest, followed by a final rinse using a hose and clean potable water.
- The most vulnerable areas of the building are gutters, roof sheets, sheltered areas under eaves or canopies, and upper portions of walls or roof extensions.
- For buildings located in high pollution industrial areas, or close to marine environments, water alone may not be sufficient to remove saline deposits that have become encrusted on the panels. In such cases, a mild detergent should be added to the initial washing water. Panels shall be washed with the mild detergent solution and a soft nylon brush, working from the highest point to the lowest, followed by a final rinse using a hose and clean potable water.
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Important Site Storage Instructions
These products were dispatched from our factory in good condition. To maintain this condition, we recommend that the bundles of sheets, purlins or channels are stored 150mm clear of the ground, with a slope of 1:25, to allow for water drainage. Cover the stack with a waterproof cover, leaving the ends open to allow for air circulation.
Upon receipt of materials, it is recommended that bundles of panels be checked. If any water is entrapped between sheets, the sheets should be carefully dried, and then re-stacked allowing for air circulation.
It is recommended that panels be installed as soon as possible after delivery. Extended site storage is not recommended.
Zamil Steel accepts no responsibility for staining of Galvanized, Zincalume® or Aluminum products, or deterioration of Painted products due to incorrect site storage.
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Zincalume®
Zinc / Aluminum alloy-coated steel or Zincalume® steel is composed of 55% aluminum, 43.5% zinc and 1.5% silicon which provides a superior coating for steel. The aluminum in the coating provides barrier protection to the steel whilst the zinc component provides sacrificial cut edge protection. This double protection mechanism is the secret behind Zincalume® steel's superior corrosion performance.
Comparative coating loss of galvanized and Zincalume® steel
at sites ranging from rural to severe marine.
Extensive research has proven that Zincalume® performed the desired non-corrosive functions far better than the Galvanized steel. Actual field testing after 20 years have also shown that the roof made from Zincalume® steel is still in good condition, while the roof made from galvanized steel shows significant red rust.
Myth:
Decision makers in the building industry usually specify building materials that are most cost effective. There is a perception that galvanized materials are cost effective. The reality is that roofs and walls made from Zincalume® steel have a far more superior performance over galvanized steel and are very cost competitive. It is very clear that Zincalume® out perform galvanized steel. At the same time, Zincalume® also offers comparable corrosion resistant performance compared to Aluminum and stainless steel, in various environments.
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For safety reasons there are precautions that need to be taken during erection.
- Make daily check on all lifting equipment.
- Make daily checks on all lifting slings, check for fraying and kinking.
- Check that all access equipment is in good condition, including scaffolding and ladders.
- Check weather conditions, strong winds are dangerous during erection and sheeting.
- Check for overhead electric lines before moving in with a crane.
- Check that all erectors have the correct personal safety equipment, hard hats, boots, safety harness etc.
- Check electric cables for hand tools, discard frayed or split cables.
- Ensure that materials are correctly stored.
- Ensure that there are sufficient guy wires on site for temporary bracing.
- Ensure that erection always starts at a braced bay.
- Ensure that permanent bracing and flange stays are installed as work proceeds.
- Ensure that high strength bolts are used where indicated.
- Ensure that high strength bolts are correctly tightened.
- Maintain a clean and tidy site, thus avoiding material loss or accidents.
- Tie down sheeting once the bundle is opened.
- Sweep roof sheeting at the end of each days work, drill swarf will corrode the panels if not removed.
- When walking on the roof, step in the valleys of the panels, not the ribs.
- Use the correct tools for the job, wrong tools will damage materials and produce poor quality work.
- Finally, take out Contractors All Risk Insurance, even the best can have an accident!
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This information has been compiled to indicate the correct way of installing roof sheeting. By following the details and advice given, roof leaks will not be encountered.
Prior to commencing, the erector should ensure that he has all the necessary tools to do the job. Here is a list of essentials.
- Electric screw gun with torque or depth sensitive adjustment. Speed 0 – 2500 RPM
- 8mm socket for the screw gun.
- Electric drill.
- 3.5 & 5.5mm drill bits.
- Electric nibbler for cutting profiled panels.
- Aviation snips, left and right cut.
- Pop rivet puller.
- Vice grips.
- Chalk line
- Measuring tape.
- Caulking gun.
- Sweeping brush.
- Power source, mains electric or mobile generator.
- Extension leads for power tools.
The erection crew should be familiar with the details and should study the Erection Drawings before commencing.
Where endlaps of panels occur, an additional angle is fixed to the purlin at that location. To save time, and for ease of fixing it is preferable to screw the angle to the purlin before erecting the purlin.
To prevent purlins from “rolling”, it is recommended that timber blocks 200mm long be used to temporarily support the purlins at the rafter positions. After sheeting is completed they can be removed. This is specially recommended with bay spacing greater than 7500mm.
Set the first panel square to the eave strut, with the correct overhang dimension of 65mm.
Set a line along the eave strut with a parallel dimension of 65mm. this helps to keep the panel line straight and avoid a sawtooth effect.
Temporarily clamp the panel to the purlin in its correct position using vice grips.
Check that the screwgun is correctly calibrated for tightening the self-drilling screws. Screws, which are too loose or too tight, can result in leaks. The screwgun should be adjusted so that the EPDM washer compresses to 1mm wider than the steel washer at the head of the screw.
Not tight enough…..adjust
Too tight…….readjust
Just right……..Proceed.
Using a chalk line, mark the centre line of the purlin, this will avoid the possibility of the screw missing the purlin.
Note the positioning and number of screws at eave strut, intermediate purlins, and endlap condition.
Fixing self drilling screws, cutting or drilling sheets causes small amounts of swarf to be deposited on the surface of the panel; this should be swept away with a soft brush as work progresses. If left, surface rust stains will occur in the presence of rain or high humidity.
Bead mastic is placed between the endlaps of panels to prevent the ingress of moisture and dust. The mastic should be carefully unrolled, following the profile of the corrugations, do not stretch the mastic over the ribs as it may break when the next panel is placed on top, thus creating gaps in the seal, and providing a chance for moisture to enter.
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B9. Why Zamil Steel changed the method of fixing roof screws from rib to valley:
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Due to continuous product improvement, Zamil Steel opted to change the method of fixing roof screws from rib to valley fixing.
The main reasons behind the change are as follows:
- There have been major improvements in the design and manufacture of the sealing washers used on self-drilling screws. The EPDM material now used for the bonded washer is far superior to the old type of neoprene. EPDM does not become brittle or crack due to weathering, and will remain watertight, provided it is correctly tightened.
- Fixing in the valley gives a much more positive fixing than fixing in the rib. The solid purlin gives much more torque resistance for the sealing washer to spread the EPDM material, and seal evenly on the sheet, without any deformation of the profiled sheet.
- In rib fixing it was possible to deform the rib of the panel through over-tightening, which caused the panel to dimple, and thereby create possible future leakage. In valley fixing this cannot occur, as explained in (2).
- Valley fixing ensures tighter nesting of the panels at the end-laps, thus reducing the possibility of leakage by capillary action.
- Shorter valley fixed screws will not be subjected to the forces of wind, and temperature fluctuations imposed on longer rib fixed screws.
- Shorter screws are easier to control during installation. This will ensure that they are fixed at the correct angle, and will reduce the risk of missing the purlin.
There is a cost saving which can be passed on the customer.
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