M A N U A L

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January 2002
‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬
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Chapter Section Description Page No
1 Pre- Erection Steps

1.1 The Engineering Document
1.2 Anchor Bolt Setting Plan
1.3 Cross Section
1.4 Roof Framing Plan
1.5 Roof Sheeting Layout
1.6 Sidewall Sheeting & Framing
1.7 Other Drawings
1.8 Bill of Materials
1.9 Pre-Erection Checks
1.10 Receiving Materials
1.11 Unloding Containers
2 Erection Procedure
2.1 Preparation
2.2 Erecting Main Frames
2.3 Mezzanine Floors
2.3 Crane Beams
2.4 Sheeting Preparation
2.5 Sheeting - Walls
2.7 Sheeting - Roof
2.8 Miscellaneous
2.9 Fascia
3 Handling of Sheeting
3 Care & Handling
3.1 Unloading
3.2 Storage
3.3 Handling
3.4 Cutting and Fixing

3.5 Completion and Inspection
3.6 Paint Repair
3.7 Water test procedures for Roofing
3.8 Leakage Testing
3.9 Summary
4 Safety & loss prevention

Precautions
Check-List
1
E R E C T I O N
January 2002
Introduction
This Erection Manual is designed to assist Zamil Steel builders and erection Contractors,
who are engaged in the erection of Pre-Engineered Steel Buildings, to understand some
basic and safe working practices. The manual is also intended to assist them in controlling
building quality and developing the erectors craftsmanship.
Even thogh it is not posible to indide all steel builders erecting practices in this manual
Zamil Steel based on its intensive experience in this fold recammanders careully following
the erection proceses illustrated in this publication It important to not that Zamil Steel issues
this publication as a guide for erection, we keep it up to the erection to learn from the tips
and advice in this manual Zamil Steel becous us responsibility whatsoeva for an erection
to been that meny an se live to improve erection It is worth noting that no matter how good
the design and the fabrication may be it is the perfect erection and the finishing of the
building that remains visible for many years to come.
Erection of pre-engineered steel buildings maid be a simple operation if the basic prin-
ciples are followed and sensible decisions are made at the time of erection.
A clear understanding of the sequence of erection is necessary together with careful

planning. The erection drawings and bills of material (BOM) supplied by Zamil Steel shall
be studied thoroughly before commencement of erection work. erectors shaled familiarize
themselvs with the various components of the steel building and their weights, evaluate the
site conditions, and decide where to start, bearing in mind that a braced bay must be
erected first.
The major components comprise of, rigid frame columns and rafters, eave struts, purlins and
girts, flange braces, endwall columns and bracing systems which may be cables, rods,
angles or portal.

The lighter built-up cold formed members used in pre-engineered steel buildings require
less crane capacity but will need more temporary bracing during the erection stages. Due
to the synergic design, temporary bracing must be left in place until sufficient components
have been fully assembled.
N M A N U A L 2
January 2002
1 Pre-Erection Steps
1 Understanding Zamil Steel Engineering

Document
It is essential to have a clear understanding of the
engineering documents prior to commencement of
erection work. In the case of erection, the Engineering
Documents are referred to specifically to as “Erection
Drawings” and “Bills of Material (BOM).”
Lay-down area
1.1 The Erection Document
Erection Drawings used at site are the ones. marked as
“Issued for Construction.” Ensure that you are using
the latest revision. Drawings marked as “Approval
Drawings” shuld never be used for site works.
The revision boxes at the bottom right corner of each

sheet indicate the latest status of each drawing, i.e.,
“For Approval,” “Issued for Construction,” “Revised as
Noted,” etc.
Checking of Anchor Bolts

Erection drawings are not to scale, so do not attempt to
scale any dimensions. all dimensions on the drawing
are in Millimeters unles clearly mentioned otherse.
Sheeting with one elevated end
Wrong usage of Nylon Ropes
3
E R E C T I O N
January 2002
1 Pre-Erection Steps
1.2 Anchor Bolt Setting Plan The details along the bottom of the plan show bolt
The Anchor Bolt Setting Plan drawing shows the layout configuration and bolt projection. If grout is required
of all anchor bolts in a building the plan world under columns, (this applies to fixed base columns and
normally be on one sheet, however, for very large crane columns), the grout thickness is also shown.
buildings, the layout could be on two or more sheets.
It is extremely important to adhere to the dimensions.
The Anchor Bolt Setting Plan layout contains the In all case deviation shuld not exceed 6mm.
anchor bolt schedule, which is in the form of a table at
the bottom left corner showing quantities and sizes. The details along the bottom of the plan show bolt
configuration and bolt projection. If grout is required
The key plan shows out-to-out dimensions, bay under columns, (this applies to fixed base columns and
spacing dimensions, anchor bolt setting details and crane columns), the grout thickness is also shown.
critical dimensions for the building span.
It is extremely important to adhere to the dimensions.
In all case deviation shuld not exceed 6mm.
ANCHOR BOLT KEY PLAN
ANCHOR BOLT SCHEDULE

ANCHOR BOLT KEY PLAN AND DETAILS
ANCHOR BOLT SCHEDEULE
N M A N U A L 4
January 2002
1.3 Cross Section The Cross Section drawing may be typical, throughout,
The Cross Section is one of the most important draw- in standard buildings. In large and more complex jobs,
ings as it contains a lot of vital information. Columns there may be several Cross Section drawings identified
and rafter references, connection details, bolt sched- by grid numbers.
ules and flange brace schedules where applicable
details of and other details, strut tubes and flange brace
details are all illustrated.
In conjunction with the Bill of Materials (BOM), it is

possible to determine the weight of individual mem-
bers or a combination of members. This is important
for the planning of erection and also to determine the
capacity of the crane to be used during the erection
process.
Materials Assembly
CROSS SECTION ‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬
CROSS SECTION
E R E C T I O N
January 2002
1.4 Roof Framing Plan
The Roof Framing Plan shows all the purlins and roof
bracing details. The part numbers for purlins, bracing
and eavestruts are clearly indicated including sag rods
and strut tubes (if avilble).
The Roof Framing Plan has to be studied carefully,

otherwise, it is possible to overlook certin details such
as nested purlins, strut purlins, strut clips, etc.
Erection of the 1st Braced Bay
ROOF FRAMING PLAN
ROOF FRAMING PLAN
N M A N U A L
January 2002
1.5 Roof Sheeting Layout
On this layout, all roof panels are shown by length and
by part number. The panel laps are clearly indicated. If
the building has skylights, gutters and downspouts then
their positions would be shown clearly on the drawing.
Standard details of fasteners, trims and insulation are

also included as
An important point to check is the starting dimension

of the sheeting from the end wall steel line. If the start-
ing point is not strictly followed, the corner trims would
not fit.
Pops between Girts
ROOF SHEETING LAYOUT
ROOF SHEETING PLAN
E R E C T I O N
January 2002
1.6 Sidewall Sheeting & Framing
Depending on the job, sidewall framing and sheeting
may be on one drawing or more.
The framing elevation shows the position and part

numbers of girts, eave struts will bracing and sag rods.
The sheeting elevations show the panel positions with

lengths and also part numbers. Eave trims, gutters and Wall Sheeting
downspouts are shown and then part numbers clearly

indicated. Standard details are included to indicate fas-
teners and trimming details.
SIDWALL SHEETING
SIDWALL FRAMING AND SHEETING ELEVATION
N M A N U A L
January 2002
Chapter 1 Pre-Erection Steps
1.7 Other Drawings

Other drawings may include crane beam layouts and
details; mezzanine layouts and details; accessories
such as sliding doors, roll-up doors, personnel doors,
windows, louvers and ventilators.
Temporary Bracing
Completion of the Main Frames
Sheeting- Roof
Louvers Sliding Door and Ventilators
5 E R E C T I O N
January 2002
1.8 Bill of Materials (BOM) 4 - Revision number

The BOM comprises a cover sheet that indicates job 5 - Description of part
number, Building number, phase number, customer name, 6 - Color
locations and building size. The cover sheet also shows 7 - Length of item
the number of phases in the building, any revisions 8 - Weight of item
plus any special notes. 9 - Total weight of line item.
The second page has an index of the various sub- The sub total of weight is shown at the end of each
areas. Each sub-area then has its Bill of Materials (BOM) sub-area and also the total number of items. The last
on the remaining sheets. page indicates the total BOM quantity of items and
weight.
The BOM has 9 columns indicating:
The BOM is a reference to the items shown on the
1 - Line number Erection Drawings and must be used to double check
2 - Part number items against the packing list. It is also used to identify
3 - Quantity frame weights for crane capacities.
N M A N U A L 6
January 2002
1.9 Pre-Erection Checks

Check the anchor bolt settings for compliance with the
details provided on the Anchor Bolt Setting Plan. The
tolerances are given in the General Notes on the draw-
ing.
Check the foundation levels. The buildings that require

grout, shim pads are leveled and placed in the center
of the bolt pattern. The Buildings without crane systems Mezzanine Floors
generally do not require grout, but variances in con-

crete levels may necessitate the use of shims if the
concrete is outside the stated tolerances. Due to design
requirements on certain buildings, double nuts must be
used in place of shim plates.
1.10 Receiving Materials

Receiving and unloading of materials shall take place
as near as possible to the place of erection. The laydown
area shall be cleaned and leveled. Fascias
A 3-ton forklift is ideal for unloading. A mobile crane is

also equally suitable. In either case, extra care is to be
taken in handling the various components and bundles,
to avoid damaging paint of the steel. To protect cold-
formed members such as purlins, girts, and channels
from weather conditions, store the bundles inclined to
permit water drainage. It is strongly advisable to tightly
cover with a tarpaulin. Bundles of sheets shall be stored
properly.
Fascias
In the same way, keep the bundles inclined and clear

off the ground. Check materials against the Packing
List.
Crane
7 E R E C T I O N
January 2002
1.11 Unloading Containers
Good preparation will make container unloading a
straightforward operation. Prepare a firm, level, asphalt,
concrete on compacted area. Unloading will be con-
siderably easier if a small step out of ___? wood is
made so that the inside base of the container is lev-
eled with the external ground. Unload the container
from the trailer using a mobile crane and four leg slings
or chains. Set the container on the ground, and level it, Fixing Crane
open the doors before final positioning.
Sliding tracks are provided in the container for with-

drawing the skid. Pull out the tracks, lay them on the
leveled ground, and align them with the tracks inside
the container. Secure the tracks by nails or steel pins.
The tracks must be continuous from the container to
end of the runway to the length of container.
Attach chains to the front of the skid in the container,
and then attach it to the pulling vehicle. Take up the
Correct
strain on the chains, and steadily pull the skid from the
container. When the materials are clear off the con-
tainer, remove the skids from the container floor.
Cutting Profiled Sheets using Nibblers
Aviation Snips
N M A N U A L 8
January 2002
2 Erection Procedure
2.1 Preparation
Prepare all materials for the first bay erection. Identify
the rafter sections required by part number, assemble
the rafter sections as near as possible to their lifting
positions. The splice connections are made with high
strength bolts; the sizes are shown on the drawing cross
section, identified as S1, S2, S3 etc. Tighten the splice
bolts and check for correct torque value using a cali-
brated torque wrench, or by turn of nut method. Attach
for very large buildxxxxxxxxxings, could be on 2 or more sheetsxxxxxxxxx.
eave strut clips using high strength bolts. Fix flange Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
attempxxxxxxxxxxxx arexxxxxxxx xxxxxxxxxxx xxxxxxxxxxx xxxxxxxx
braces to the rafter using machine bolts, the flange
brace positions and part numbers are shown on the
drawing cross section. Flange braces are fitted on one
side of the rafter only. For uniformity it is preferable to
maintain the same side throughout the building.
Temporary guy wires are attached to the rafter, manila

or nylon ropes are not recommended for temporary
guying, they can stretch and break. They are also un-
suitable for aligning purposes.
Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
Prepare the mobile crane and Forklift for erection.
2.2 Erecting Main Frames

Erect the first four columns at the braced bay, verify the
part number and orientation, and position over the
anchor bolts. Adjust the columns for plumb by tighten-
ing or loosening the anchor bolts.
Positions the crane for lifting the assembled rafter sec-

tions. Check that slings, chain and shackles are in good Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
condition and of adequate capacity for the weight.
The chains, or slings should be long enough to provide ‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬
sufficient spread, at an angle of not less than 45 de-
grees. The spread of the slings is normally claculated
by dividing the member length by four, which will give
the distance of the lifting point from each end.

E R E C T I O
8
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January 2002
This formula may require some adjustment depending
on rafter weight and configuration.
Flange clamps are a safe lifting device which also mini-

mizes damage to paint. When using clamps, always
install temporary bolts in the purlins holes, or use “G”
clamps to prevent the clamps from sliding. If clamps are
not available, conventional slings may be used, in which
case timber or other protection should be used on the
flanges.
Commence lifting the rafter, previously attached hand

ropes will help to guide the rafter to its position.
Carefully lower the rafter to the column cap plates, and
position using spud wrenches. Spud wrenches are an
invaluable tool for aligning members and holding in
position whilst bolting up.
Install the high strength bolt nuts and washers in the
knee connection, K1. The bolt is normally placed from
the top, with the nut and washer on the underside.
Hand tighten the bolts. Ratchet pullers are attached to
the guy wires, and connected to suitable
stable objects, anchor bolts are most suitable for this

purpose. The rafter is now aligned by means of the
guy wires and ratchet pullers, once all guy wires are in
place it is safe to release the crane. Erect the
second rafter and hold in place with the crane, at the
same time position the purlins and bolt up using
12x35mm machine bolts. Connect the previously
attached flange braces to the purlins with 12x35mm

machine bolts. The eave strut is also erected now, but
unlike the purlins the eave strut requires 12x35mm high
strength bolts.
N M A N U A L
January 2002
Chapter 2 Erection Procedure
Complete the purlin installation and then install the

diagonal bracing in the roof. Before tightening the
diagonal bracing, ensure that the lip of the hillside
washer is correctly seated in the web slot.
Adjust the tension of the bracing, at the same time

adjust the rafter alignment.
Fix the wall girts to the columns for additional stability.

The girts are attached with machine bolts. Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
The completed braced bay should now be aligned. A

theodolite should be used for plumbing, if available, if
not, for buildings of low eave height, a spirit level or
Plumb bob will suffice. A tolerance of 1 in 300 is
allowable.
After completing the first bay alignment the high
strength bolts at the knee connection are fully
tightened to their respective torque values. Times spent
on correct alignment of the first bay will reap benefits Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
as work proceeds with the remaining bays.
The remaining bays are erected following the same

procedure. All components are installed as work
progresses, including crane beams.
Multi-span frames provide a degree of flexibility in

erection in that partial spans may be erected if site
conditions dic tate.

When the main frames are all completed, the endwall Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer

framing is erected. Pre-assembly of columns and girts
on the ground saves time and is more efficient. Endwall
posts are connected to the purlins by post spanners
using high strength bolts.

9 E R E C T I O N
January 2002
The complete frame should now be checked for plumb

and alignment. Adjustments can be made by tighten-
ing or loosening bracing, or by ratchet puller,
After completion of all checking, bolt tightening can

commence. Air or electric impact wrenches may be
used and checked with a torque wrench, or they can
be tightened manually using the “Turn of Nut Method”.

The Turn of Nut Method is achieved by bringing all Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
the bolts in the pattern to a snug tight position, using a
normal spud wrench. Match mark the nuts against the
connection plate, and then apply a further one third
turn to all the nuts.
Finally, framed openings for sliding doors are installed,

this includes door jambs, brackets and header.
2.3 Mezzanine Floors
When mezzanine floors are provided, they are erected Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
with the main frames, generally prior to sheeting.
Start with mezzanine columns if any, otherwise mezza-

nine beams are installed by connecting to the col-
umns with clips and high strength bolts as indicated
on the drawing details.
The joists are then placed between the beams and

connected with clips and machine bolts. An edge angle
is then screwed at the perimeter of the mezzanine
area, prior to laying and screwing the decking panels. Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
The decking panels are attached by 32mm self drilling ‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬
fasteners without washers. Openings for stairs and pen-
etrations are framed before fixing the reinforcement.

N M A N U A L 10
January 2002
It is important to advise the concreting crew about

placement of concrete, particularly if a pump is to be
used. The concrete should be evenly spread; concen-
trated piles of wet concrete could cause deflection in
joists or decking.
2.4 Crane Beams

Special care should be taken in buildings with crane
runways, the column supporting runway beams should Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
be erected on shims provided, to zero tolerance. If not,
the performance of the overhead crane will be ef-
fected.
Alignment of crane beams is very important, the cen-

tres of the crane beam webs should be equal to the
centres of the crane wheels, the maximum tolerance is
10mm.
Alignment is achieved by setting each end of the beam
to the correct dimension as shown on the drawing, and Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
stretching a line from end to end, alternately, a theodo-
lite or lazer beam can be used if available.
The crane beam brackets have slotted holes to assist

with alignment, if the building has been carefully
plumbed, adjustment will be minimal. During alignment
install the “T” brackets and shim plates, and install the
angle braces from column to beam.
Once final alignment is confirmed, fully tighten all high

strength bolts to the required torque. Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer

2.5 SHEETING Preparation
The base angle is fixed to the concrete slab by means
of masonry nails. Power actuated tools are preferred for
fixing. The fixings for the base angle are provided by

11 E R E C T I O N
January 2002
the erection contractor, to ensure compatibility of nails

and fixing tools.
The base angle should be set 200mm from the column

flange, the same as the wall girt line.
Girts may sag under their own dead lod, to over come
this the girts are temporarily supported in a horizontal
line with timber props from floor to girt, girt to girt, girt
to eave strut. The props remain in place until the wall Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
panels are screwed, they can then be removed and
relocated to the next bay, the girts will remain straight
and horizontal after the panels are installed. In bays
over 8.5m, sag rods are provided and these are used
to align the girts.
Before commencing with sheeting check the details

on the drawings. A starting position will be given in
relation to the steel line, mark the starting position, and
then mark out the guage of the sheets along the for very large buildxxxxxxxxxings, could be on 2 or more sheetsxxxxxxxxx.
concrete notch.This will provide a check against “creep” Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
or “bunching” of the panels, an important point in or-
der for the corner trims and accessories to fit as de-
tailed.
Insulation is more convenient to handle if unrolled on

the ground and pre-cut to the required lengths, a full
length piece is used from eave to floor, with an allow-
ance top and bottom for folding over.
A chalk line is essential for marking the girt position

and thus maintaining a straight screw line. Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
All screws are self drilling and require an electric screw- ‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬
gun with a speed of 2000 to 2500 RPM. Depth sensi-
tive or torque regulated screw-guns should be used to
control the screw
regulated screw-guns should be used to control the

screw tightness. The EPDM washer should be com-
pressed 1mm wider than the steel washer when cor-
rectly tightened.
2.6 Sheeting - Walls

N M A N
Double face tape is applied to the eave strut and the U A L 12
January 2002
base angle, this is used to hold the insulation in place.
The insulation must be kept vertical, and pulled taught.

Remove the fibres from the allow-ance at top and bot-
tom and fold the white facing before placing the wall
panel.Place the panel in the pre-marked position, plumb
it clamp it,them screw it.
The second “drop” of insulation is fixed to the double

faced tape and then the side tabs are stapled together
at 300mm centres, folded and stapled again in be- for very large buildxxxxxxxxxings, could be on 2 or more sheetsxxxxxxxxx.
tween the previous staples, thus providing a closed Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
joint and vapour barrier.
The second panel is installed and so on……… Endwall

panels are pre-cut in the factory, and no further cutting
is necessary. The panels are stepped, the steps being
covered by the gable trim. (Field cutting may be nec-
essary on steep slopes).
The preferred procedure is to complete all wall sheet-
ing before starting the roof, as the eave trim covers the for very large buildxxxxxxxxxings, could be on 2 or more sheetsxxxxxxxxx.
top of the wall panel and fits under the roof panel. Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
Outside foam closures are placed between the wall
panel and the eave trim to provide a dust free junction.
2.7 Sheeting - Roof

Prepare the roof panels by segregating to the lengths
shown on the roof sheeting plan. The sequence of roof-
ing is from ridge to eave on both slopes finishing with
the ridge panel.

To commence, it is advisable to temporarily fix one run Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer

of panels to walk on. The insulation can then be un-
rolled on the “walkway”
Double faced tape is applied to the eave struts, or an

intermediate purlin if the roll does not cover the full
width of the building. The insulation is lifted into place
and is retained in place by the double faced tape.
Before placing the roof panel, the insulation end should
be folded over to be concealed at the eave. It is nec-
essary to scrape away the fibres on the folded portion.
The inside foam closure is placed on the fold, and the Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
panel is then positioned. Adjust the squareness and
line of the panel to avoid “saw-toothing” at the eave
13 E R
line. Use a nylon line projected from the eave strut byE C T I O N
January 2002
65mm to give the correct distance and line.
Clamp and screw the panel. Move progressively panel

by panel up to the ridge. After completing several runs
of panel, the temporary “walkway” can be lifted, insu-
lated, and re-fixed.
Panel end-laps require bead mastic. This should be

carefully unrolled from the release paper, over the panel
corrugations, do not stretch the bead, otherwise it may
break when the panel is nested over it.
Make sure that the panel ribs are kept in a straight
line from eave to ridge. Use a chalk line to mark the
purlin location and maintain a straight line of screws,
thus avoiding mis-drilling and possible leakage. The
endlap detail must be carefully followed
Proceed with the next run of insulation, stapling the

side tabs together, before placing the next run of pan-
els. When both slopes of the roof panel have been
fixed, the ridge panel. connects both slopes.
As work proceeds, it is important to keep the roof area
clean, a soft brush should be readily available to sweep
off drill swarf, which if left will cause surface corrosion.
Stitch screws are fixed at panel side-laps at 750mm

centres, or as detailed.
2.8 Miscellaneous
Having completed the roofing,gable trims are installed,
outside foam closures are used against the end-wall Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer

panel, the stitch screws securing the gable trim also
keep the foam closures in place.
Eave gutters are spliced using two runs of flowable

mastic and pop-rivets,the gutter is then hung by means
of gutter straps which are screwed through the roof
panel with 57mm screws
Down spout connections are cut with aviation snips, in

locations shown on the roof plan. The down spouts are
assembled in straight sections and a shoe, the com- Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
plete unit is then attached to the gutter by pop rivets,
and to the wall panel by straps and rivets.
N M A N U A L 14
January 2002
Personnel doors are supplied in knock-down form and

are generally field located. The frame is assembled
and positioned, the wall panel is carefully cut using an
electric nibbler, final cutting and fitting of head trim
should be done with aviation snips. The galvanized
threshold support is fitted and screwed to the concrete
before the frame is connected to the girt by clips, and
anchored to the floor with expansion bolts. Check that
the frame is plumb and square before final fixing. Head
trim, jamb trims and the door leaf are now fitted. Per- Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
sonnel doors have the option of standard hardware or
panic hardware.
Sliding doors leafs are assembled on the floor, the

framing members are connected by machine bolts and
clips. The sheeting is also fixed before hanging the
door. The trolley trucks are located in the top member
of the door leafs, if T1 or T2 are being installed, the
adjusting nuts on the trolley trucks should be set equally,
final adjustments can be made after hanging the doors.
Bottom running doors (B1) have wheels fixed in the
bottom member of the door framing
Once the doors are hung, stoppers are installed,also

the handles and the door hood trims, note that there is
an inner and outer hood trim, complete details are on
the drawing.
2.9 Fascia
Fascia posts are bolted to the brackets, fascia girts are Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer

then attached to the posts. The girts consist of “C” and
“Z” sections, which must be correctly aligned and lev-
eled before commencing sheeting the fascia. Prepare
for the sheeting by installing the sill trim on the bottom
girt.
Check the starting dimension from the corner of the

framing, offer up the first panel, clamp it with Vice grips
until finally adjusted to its correct position, mark the
girt line with a chalk line and then screw the panel to
the girt. Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
15 E R E C T I O N
January 2002
Continue installing panels on each elevation until com-

plete. The back-up panels are installed next, they are
attached to the top girt, and overlap the valley gutter at
the base. The external corner trims are installed using
4.8 x 20 self drilling screws. The Cap flashing is in-
stalled using 4.8 x 20 self drilling screws, make sure
that the flashing slopes into the building as shown on
the detail. The overlapping joints of the flashing should
be sealed with flowable mastic.
The soffit panel edge trim is fitted to the wall panel,
make sure that it is level with the sill trim, and is leveled
around the building. Starting the soffit in the correct
place is important, if the soffit panel and wall/fascia
sheets are the same type, the ribs should be aligned.
Align the ribs, and fix the panels as shown in the de-
tail. Corner soffit panels should be mitered.


N M A N U A L 16
January 2002
Chapter
3 Care & Handling of Zamil Steel Sheeting
3. Care & Handling of Zamil Steel Sheeting

Nibblers or snips shall be used for cutting sheets. A
grinding disk should not be used for cutting sheeting.
Drilling of holes or installing self dailling fastener pro-

duces very hot metal chips (swarf), which should be
removed from the panel. This should be done immedi-
ately, if possible, and the work area should be swept
with a soft broom at the end of each day work.
Care should be taken in walking on roof panels. Work-
ers or visitors should use soft footwear. Metal studs or
heel tips will cause damage to the panels. It is impor-
tant to walk in the correct place on roof panels. Always
step on the low portion of the panel, which is in con-
tact with the purlin Standing on the high corrugations
may result in deformation of the panel.
Other useful tips in achieving a quality job are: Use a
torque or depth sensitive screwgun this will ensure cor-
rect fixing of fasteners and avoid sheet damage. Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
3.1 Unloading
Sheets are packed in bundles, and may be unloaded
by a suitable forklift truck or crane. Care must be taken
not to “break the back” of the sheets when unloading.
use a spreader if necessory Do not use chains or cable
slings for unloading, unless good protection is provided
for the the corners of the bundle.


3.2 Storage
Packs of sheets should be stored in a safe area of the
site. They should be stored clear of the ground and
elevated at one end to allow for water drainage. Prefer-
ably, the bundles should be loosely covered with a
tarpaulin, this will afford additional protection but allow
air circulation.
3.3 Handling
Care should be taken when handling sheets. Erectors Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
should use clean gloves to avoid dirty marks, oil or
grease stains on sheets. When handling individual
17 E R E
panels from the stack, each panel should be lifted clear, C T I O N
January 2002
dragging will cause scratches.
Chapter 3 Care & Handling of Zamil Steel Sheeting
3.4 Cutting and Fixing

Only proper tools should be used for cutting
profiled sheets. An electric nibbler should be
used for cutting across the ribs, or along
Use a torque or depth sensitive screwgun, this will

ensure correct fixing of fasteners and avoid sheet
damage.
3.5 Completion and Inspection
O n c o m p le t i on , t h e s h e e te d a re a s hou l d b e
inspected. Any ferrous objects such as pop-rivet,
mandils stalks, bolts, nails, screws etc. left on the
roofing should be removed.
Any accidental scratches, minor damage or should

be touched-up with the appropriate paint. The area
should be left clean.
3.6 Paint Repair
For minor scratches, a small brush can be used to
apply touch-up paint of matching color to the
damaged area.
I f da m a ge h a s a f fe c te d t h e ga l va n i z e d
coating, then the damaged area should be coated
w i t h s p e c i a l p r i m e r fo l lowe d by a m at c h i n g
polyurethane finish coat.

3.7 Water test procedures for Roofing
There is really no better way of water testing a roof
than actual rainfall, as to simulate even fall or wind
blown rain is impossible.
If medium to heavy rain has fallen after completion

of roofing, and no leakage is visible then the roof
should be considered tested and satisfactory.

N M A N U A L 18
January 2002
If the roofing has been completed during a dry sea-

son, and testing is required, then the following test can
be carried out:
A 25 to 30mm diameter hose will be required with

sufficient mains pressure, or a tank and electrical pump.
Two tests can be done.
1. The hose should be positioned on the ridge, or high-

est point of the roof. The water should then cascade Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
down each slope, down each valley between panel
ribs. The hose should not be deliberately directed at
the panel endlaps and sidelaps.
2. The second and longer test can be carried out if

desired by attaching a rotary garden sprinkler to the
hose and allow the whole roof to be systematically
“watered “.This is the nearest method of stimulating rain-
fall as the sprinkler system causes the water to bounce,
thus finding any weakness in lap conditions.


19
E R E C T I O N
January 2002
3.9 Reminaers
1. Check starting position for roof and wall panels.
2. Panels should be plumbed and held in place by

Vice Grips before screwing.
3. The panel gauge should be marked on the sheeing

notch.

4. A line should be used to maintain a straight sheet- Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
ing line at the eave.
5. A chalk line should be used to ensure the screws

are installed in a straight line, and avoid misdrilling.
6. Roof sheets should be undamaged.
7. Endlap mastic must be carefully placed over the
corrugations.
7. Foam closures are not well fitted. Erection drawingsxxxxxxxxxx are not to scale, so nevxxxxxxxer
8. The screws are loose.
9. Roof panels are not fully screwed.
10. Screws are overtightened.
11. The wrong installation of fiberglass roof insulation.

insulation hanging into the gutter will act as a sponge,
eventually becoming waterlogged.

12. Flowable mastic sealant is not placed between the
overlapping gutter sections.
13. Incorrect projection of roof panel at the eave.

N M A N U A L 20
January 2002
Chapter
4 Safety & loss prevention 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 condi

tion, including scaffolding and ladders.
• Check weather conditions, strong winds are danger attempxxxxxxxxxxxx arexxxxxxxx xxxxxxxxxxx xxxxxxxxxxx xxxxxxxx
ous 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 for very large buildxxxxxxxxxings, could be on 2 or more sheetsxxxxxxxxx.
or split cables. attempxxxxxxxxxxxx arexxxxxxxx xxxxxxxxxxx xxxxxxxxxxx xxxxxxxx
• 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 indi for very large buildxxxxxxxxxings, could be on 2 or more sheetsxxxxxxxxx.
cated. attempxxxxxxxxxxxx arexxxxxxxx xxxxxxxxxxx xxxxxxxxxxx xxxxxxxx
• Ensure that high strength bolts are correctly tightended. ‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬
• Maintain a clean and tidy site, thus avoiding meterial
loss or accidents.
• Tie down sheeting once the bundle is opened.

21
E R E C T I O N
January 2002
Chapter 4 Safety & loss prevention for safety reasons there are precautions that need to be taken during erection.
• Sweep roof sheeting at the end of each day works,

drill swarf will corrode the panels if not
removed.
• When walking on the roof, step in th valley of the

panels, not the ribs.
• Use the correct tools for the job, wrong tools will
damage materials and produce poor quality.
• Finally, take out contractors all Risk Insurance, even
the best can have an accident.


N M A N U A L 22
January 2002
C heck list
Job No: Bildings. No: Site Location:
Customer: Inspection Date:
Yes No
1.1 Is the roof & wall bracing installed
1.2 Is the bracing tight
1.3 Are the flange braces installed at rafters & columns
1.4 Are the eave strut & purlin clips fitted (where required)
1.5 Are all high strength bolts fitted in correct locations
1.6 Are the washers installed with H. S. B.
1.7 Is the thread projection correct
Framing
1.8 Are the H. S. B’s crrectly tightened
1.9 Are the main frames correctly plumbed & aligned
1.10 Are the crane beams braced & aligned
1.11 Are stoppers installed on crane beams
1.12 Are purlins & girts straight & aligned
1.13 Are all machine bolts correctly fitted in secondary framing
1.14 Has primer paint been touched-up
2.1 Is the base angle securely fastened to concrete
2.2 Are the sheets fastened in the correct location
2.3 Are the sheets fastened with correct lenght fastener
2.4 Are the sheets plumbed
Wall sheeting 2.5 Are the sheets correctly lapped
2.6 Are the corner trims crrectly fitted & fastened

2.7 Are the gable trims correctly fitted & fastened
2.8 Are the external form closure fitted at eave & gable
2.9 Are the internal form closures fitted at base angle (if no INS.)
3.1 Are the sheets correctly lapped at sides & end
3.2 Is the tail line at eaves straight
Roof sheeting 3.3 Has endlap mastic been installed
3.4 Have the correct fastners been used
3.5 Have the fastners been fixed in correct location
23
E R E C T I O N
January 2002
Check list
Yes No
3.6 Has the roof been cleaned

Roof sheeting 3.7 Have sheets been crimped at vents or lean-to connection
3.8 Have the external foram closures been installed where required
4.1 Is the insulation taut and not sagging
4.2 Has the insulation been properly stapled at side tabs
Insulation
4.3 Has the insulation been properly fixed & folded at eaves
4.4 Has the insulation been properly fixed at skylight frames
4.5 Has the insulation been properly fixed at the base angle
5.1 Has sealant been applied at endlaps
5.2 Have the correct number of rivets been used at joints
Gutters
and 5.3 Have the outlets been sealed & rivetted
Downpipes 5.4 Are the downpipes plumb and correctly fastened
5.5 Have the gutter endcaps been fitted, sealed & rivetted
6.1 Are personnel doors operating correctly
6.2 Are locksets, panic devices, closers correctly adjested
6.3 Are the sliding door operating smoothly
6.4 Are the roll-up doors correctly tensioned & operating smoothly
Accessories
6.5 Are the windows sliding freely & locking correctly
6.6 Are ridge vent dampers operating correctly
6.7 Have ridge vent flashing & closures been installed
6.8 Have roof curb or penetrations been sealed
7.1 Has the work been cleaned of, specially roof & gutters
7.2 Has touch-up painting been done (where required) ‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬
7.3 Have all trims and flashings been installed
7.4 Are all flashing self draining
General
7.5 Have cap trims been sealed at overlaps
7.6 Has trimming been neatly executed
7.7 Are fassias, (where fitted) in line
7.8 IST the general appearance pleasing
N M A N U A L 24
January 2002
HEAD OFFICE
PO Box 877 Dammam 31421
Saudi Arabia
Phone (966 3) 847 1840
Fax (966 3) 847 1291
saudimarketing@zamilsteel.com
www.zamilsteel.com
EGYPT
PO B0x 11 Main Post Office
6th of October City Egypt
Phone (20 11) 34 1250
Fax (2011) 34 1247
egyptmarketin@zamilsteel.com
VIETNAM
Noi Bai Industrial Zone
Quang Tien Commune
Soc Son District Hanoi
Phone (84 4) 885 0800
Fax (84 4) 885 0801
vietnammarketing@zamilsteel.com
CHINA
2605 Jin Mao Tower
88 Shi Ji Avenue
Pudong Shanghai 200120
Phone (86 21) 5047 2600
Fax (86 21) 5047 2606
zsshanghai@zamilsteel.com
INDIA
Nelson Tower
4th wing 117 Nelson
Manickam Road
Aminijikarai Chennai
Phone (91 44) 374 3316
Fax (91 44) 374 3315
zscchennai@zamilsteel.com
AREA OFFICES

Saudi Arabia (Dammam, Riyadh & Jeddah)
Kuwait (Kuwait City), Bahrain (Manama), Qatar

(Doha), UAE (Dubai & Abu Dhabi), Oman
(Muscat), Yemen (Sanaa)
Jordan (Amman), Lebanon (Beirut), India

(Chennai), Pakistan (Lahore), Sri Lanka
(Colombo), Bangladesh (Dhaka), Czech
Republic (Prague), Romania (Bucharest),
Greece (Athens), France (Paris), Poland
(Warsaw)
Egypt (Cairo, Alexandria, Port Said & Assuit),

Sudan (Khartoum), Ethiopia (Addis Ababa),
Ghana (Accra), South Africa (Johannesburg)
E R E C T I O N
January 2002
www.zamilsteel.com

M A N U A L

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N

1 Pre- Erection Steps

‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬

4 Safety & loss prevention

A clear understanding of the sequence of erection is necessary together with careful

‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬

1 Understanding Zamil Steel Engineering

The revision boxes at the bottom right corner of each

Checking of Anchor Bolts

Sheeting with one elevated end

‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬

Wrong usage of Nylon Ropes

ANCHOR BOLT SCHEDULE

ANCHOR BOLT SCHEDEULE

In conjunction with the Bill of Materials (BOM), it is

The Roof Framing Plan has to be studied carefully,

Erection of the 1st Braced Bay

ROOF FRAMING PLAN

ROOF FRAMING PLAN

Standard details of fasteners, trims and insulation are

An important point to check is the starting dimension

ROOF SHEETING PLAN

The framing elevation shows the position and part

The sheeting elevations show the panel positions with

downspouts are shown and then part numbers clearly

SIDWALL FRAMING AND SHEETING ELEVATION

1.7 Other Drawings

‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬

Louvers Sliding Door and Ventilators

1.8 Bill of Materials (BOM) 4 - Revision number

1.9 Pre-Erection Checks

Check the foundation levels. The buildings that require

generally do not require grout, but variances in con-

1.10 Receiving Materials

A 3-ton forklift is ideal for unloading. A mobile crane is

‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬

Sliding tracks are provided in the container for with-

Cutting Profiled Sheets using Nibblers

‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬

Temporary guy wires are attached to the rafter, manila

2.2 Erecting Main Frames

Positions the crane for lifting the assembled rafter sec-

for very large buildxxxxxxxxxings, could be on 2 or more sheetsxxxxxxxxx.

Flange clamps are a safe lifting device which also mini-

Commence lifting the rafter, previously attached hand

stable objects, anchor bolts are most suitable for this

‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬

Complete the purlin installation and then install the

Adjust the tension of the bracing, at the same time

Fix the wall girts to the columns for additional stability.

The completed braced bay should now be aligned. A

After completing the first bay alignment the high

The remaining bays are erected following the same

Multi-span frames provide a degree of flexibility in

for very large buildxxxxxxxxxings, could be on 2 or more sheetsxxxxxxxxx.

‫ﻣﺟﻣﻭﻋﺔ ﻣﻬﻧﺩﺳﻳﻥ ﺍﻟﻣﻧﺷﺄﺕ ﺍﻟﻣﻌﺩﻧﻳﺔ‬

for very large buildxxxxxxxxxings, could be on 2 or more sheetsxxxxxxxxx.

The complete frame should now be checked for plumb

After completion of all checking, bolt tightening can

for very large buildxxxxxxxxxings, could be on 2 or more sheetsxxxxxxxxx.

Finally, framed openings for sliding doors are installed,

Start with mezzanine columns if any, otherwise mezza-