Introduction to Metal Buildings.pdf

INTRODUCTION TO METAL BUILDINGSM e s c o B u i l d i n g s S o l u t i o n s Introduction to Metal B uildings NCI Building Systems, L.P. 7301 Fairview Houston, Texas 77041 713-466-7788 Copyright 2001 R-2/09-2003 This publication is a general guide to the Metal Building Industry and should not be relied upon for specific engineering, technical or legal problems, or legal advice. In no event will Mesco Building Solutions or NCI Building Systems, L.P. be responsible for any special incidental or consequential damages incurred by the reader for any reason. Strict adherence to the manufacturer's installation/erection manual is required. Further, this manual is intended as an instruction aid in the assembly of metal buildings and components. The Introduction to Metal Buildings manual is not being offered nor should it be construed as a comprehensive analysis of all aspects of the metal building assembly and safety issues. Neither Mesco Building Solutions, NCI Building Systems, or any of their affiliated entities intend the presentation of this manual as an exhaustive study of all safety issues involved in the assembly of metal buildings, and expressly disclaim any liability therefore. Prior to beginning any construction project, a builder should familiarize himself with all applicable metal building assembly installation and erection procedure as well as all applicable safety laws and regulations. Table Of Contents Introduction Successful Selling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Functions of a Builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 The Introduction to Metal Buildings Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Introduction to Metal Buildings Has Application Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Mesco - The Builder - The Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Corporate Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 The Builder Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Mesco's Building Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Design Build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Mesco and the Builder as a Sales Team . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Competition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Lesson One: The History of Metal Buildings Building Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Construction Material Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Fundamental Factors Affecting Building Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Design Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Resistance of Material to Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Column Reactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Load Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Building Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Steel Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Minimum Loading Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Lesson One: Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Lesson Two: The Building System Standard versus Non-Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Pricing and Design Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Primary Framing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Secondary Framing Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Lesson Two: Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Lesson Three: Building Types Clearspan Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Modular Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Lean-to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Endwall Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Endwall Cost Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Long Bay® System Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Conventional Steel Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Lesson Three: Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Lesson Four: Introduction to Covering Systems Performance of Covering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 The Components of a Covering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Lesson Four: Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Table Of Contents Lesson Five: The Roof System The Built-Up Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Single-Ply Roofing Membranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Metal Roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Standard Screw Down Roof Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Standing Seam Roof Panel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Roof Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Wind Uplift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Expansion and Contraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Retrofit Roofing Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Sales Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Lesson Five: Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Lesson Six: The Wall System Types of Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Mesco Wall Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Wall Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Panel Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 IPS - Insulated Panel Division of NCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Concrete Wall Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Performance Characteristics of Tilt-Up and Precast Wall Systems . . . . . . . . . . . . . . . . . . . . . . . . .72 Lesson Six: Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Lesson Seven: Metal Building Accessories Roof Ventilators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Light Transmitting Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Liner Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Louvers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Walk Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Open Wall Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Lesson Seven: Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Lesson Eight: Project Planning and Construction Pre-Construction Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Concrete Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Floors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Pre-Erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Erection of the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 Location of Building Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 Storing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Tips to Keep Erection Costs Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Lesson Eight: Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Glossary Basic Terms Used in the Metal Building Industry A - Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95-109 Answers to the Self-Tests Lesson 1 through Lesson 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110-111 Introduction Introduction Successful selling today does not depend as much on B. Product Knowledge - You must learn the sources working harder than your competitors, but rather on of information and sales features of your products being "smarter" in selling. As in other fields, the effort and services, and how they help your prospective you put forth is important, but what really count are the customer. results you obtain. Today's successful Builders are those who take a consultant approach to establishing C. Product Application - You must be able to select and solving the building needs of customers. the best possible building solution to meet the specific needs of the customer. If you have chosen to become a Builder, it carries two implications. It implies that you desire to acquire the D. Pricing - You must be able to calculate the prices necessary knowledge and skills to become a reputable of your products. Builder. It also implies that you are willing to accept the E. Inside Work - You must be able to file your infor- responsibilities inherent in marketing a product and mation and working materials systematically, service involving a major capital investment by your handle job correspondence, and organize other customer. information pertinent to the job. Successful Selling F. Competition - You must know the strengths and weaknesses of competitor's building materials and The buying motives of an individual contemplating the building systems so you can plan the sales purchase of consumer goods, such as an automobile or strategy effectively. a household appliance, are often personal and primarily G. Construction - You must have a basic knowledge emotionally based. The individual buys for increased of construction in order to convert the customer's convenience, comfort, or prestige. In contrast, the busi- needs into construction requirements. nessman anticipating a capital expenditure for building construction makes his/her decision based on his evalu- H. Selling - You must find and qualify prospective ation of what will best serve the needs of the business customers, build customer confidence, develop and offer the greatest value per dollar of investment. solutions and proposals, and gain the acceptance Although he/she will be influenced by personal desires to of those proposals. some degree, he/she is usually more concerned about The successful Builder maximizes selling effectiveness, the value of his purchase as a business investment. remains active in the learning process, and continues to Often the customer is investing capital funds in an area develop and utilize specific job skills. in which he/she is not an expert. Because of this, Where does a new Builder start? You have already he/she turns to the Builder for information and assis- started, because this manual is an introduction to the tance. The success of a sales effort then depends metal building industry. The purpose of this manual is to largely upon the ability of a Builder to: introduce new employees in this industry to the role • Establish Dealer Confidence played by Mesco and the Builder, with emphasis on product knowledge and application. • Ascertain Needs and Desires • Develop the Best Solution The Introduction to Metal Buildings • Gain Acceptance of the Proposal Manual Functions of a Builder As you read this manual, you will notice that it is written for the Builder and his employees. To maximize your overall effectiveness in selling, you The Manufacturer-Builder relationship is based on team- must fulfill the following job objectives: work. In order for this relationship to function correctly, it A. Orientation - You as the Builder must relate your is helpful for all employees, even those not in the sales own opportunities to the opportunities of the manu- department, to have a general knowledge of the industry facturer, the prospective customer, and the industry. and the manufacturer's products and services. Introduction to Metal Buildings 7 Introduction Introduction to Metal Buildings Has tems for commercial, industrial, agricultural and community service purposes. NCI markets its building Application Knowledge systems through a sales force and Authorized Builder Organizations. The purpose of this manual is to enhance your knowl- NCI Building Systems was founded in 1984. In 1989, an edge of the industry and our products, increasing your opportunity appeared to acquire a related business. A sales and revenue. It is important that you be able to financial group was assembled to help the company project to prospective customers the image of the capitalize on that opportunity, which launched NCI Manufacturer as a long-established, reliable firm that Building Systems on its accelerated path of success. In has proved itself worthy of the customer's confidence. April 1989, NCI Building Systems leased and assumed Projecting a favorable image of the relationship operations at the Houston facilities of the Mid- between the Manufacturer and you, the Builder, is even West/Metallic division of American Buildings Company. more important. The NCI family now consists of several divisions and During the study of Introduction to Metal Buildings, you principal subsidiary companies, each offering a cus- will learn about the basic relationship between Mesco tomer building solutions that are faster and more and the Builder. The manual introduces you to some of economical than traditional construction methods. NCI the principles of building design, sales aids, and the also operates its own coil coating facilities. With more sales information system. Introduction to Metal than 3.0 million square feet of operating space across Buildings also provides an opportunity for you to the United States, NCI's divisions and subsidiaries now become acquainted with the major product systems, offer complete or partial pre-engineered metal building components, and basic construction methods. It is the packages in all sizes, a full range of metal building stage for developing sales points you can use to sell components, self-storage buildings, doors and light- your products and services. gauge steel studs. NCI markets building systems and The more sales-oriented each member becomes, the building systems components under several well more effective the team will be in accomplishing respected trade names. common goals. If you are not employed as a salesperson, don't let this diminish your enthusiasm for The Builder Organization pursuing Introduction to Metal Buildings. As you study this material, you will find many things useful for your Much of the success of Mesco Building Solutions can job and for your association with this industry. be attributed to its Builders. Mesco and the Builder have worked closely together through the years to establish If you find something you don't understand, make note themselves as a team whose activities are well known of it and discuss it with your supervisor or your District in the construction industry. Manager. Also, the Mesco Training Department wel- comes any questions, comments, and/or suggestions Shortly after World War II, various individuals wanted to that might help improve this manual. buy the rigid frame buildings that were such an important part of the shelter solution during the war. These Mesco - The Builder - The Industry individuals sold hundreds of buildings for a wide variety of uses. This was the start of the dealer program. As the As a Builder, your knowledge should be sufficient to end uses increased, the need arose for more complete enable you to project an image of the Buildership as a construction packages. capable and a reliable business. To do this you must be The dealers began taking more responsibility, including able to answer questions intelligently concerning Mesco, the foundation, steel erection, insulation, masonry work, the Builder organization, and the industry. It is only interior finishing and mechanical trades. It soon became appropriate to start with some general information about evident that those dealers were simply more than the company that provides the Buildership with many of dealers in material - they were Builders of complete the products utilized in construction projects. The buildings. Thus in 1955, the word "dealer" was replaced Standard Specifications on your Information Systems by the more appropriate term "Builder". CD gives a brief history of Mesco building systems. Traditionally people think of building construction as the Corporate Operations process of pouring some concrete, laying bricks or blocks, and installing a roof that will keep out the rain. The various Building Divisions of NCI Building Systems When you really give thought to the matter, this is a very design, manufacture, and market metal building sys- tedious and complicated way to build. It means that all 8 Introduction to Metal Buildings Introduction the various raw materials involved must be obtained Gable Unsymmetrical: A ridged (double slope) from numerous suppliers, each delivering their own building where the ridge of the roof is off-center. materials to the building site. After delivery the material must be cut, welded, mixed, and fitted in accordance with the architect's design or at the contractor's discre- tion. With the evolution from "dealer" to "Builder" comes the growth of a modern and more efficient construction method. With this modern system of construction, most materials are ordered from Mesco, saving the owner in delivery costs. Each piece of Mesco's material is designed and pre-engineered to expedite the erection process. This insures better erection with materials being assembled in accordance with the total design. Pre-engineered materials like Mesco's are checked by exhaustive quality control techniques. This ensures better quality materials versus those fabricated in the Single Slope: A sloping roof in one plane. The slope is field. Also, factory fabricated materials mean savings in from one sidewall to the opposite sidewall. construction cost because labor and time involved at the job site are reduced. Mesco's Building Systems With the development of Mesco's diverse building systems line, the prospective customer is offered more choices in the design, appearance, and value of his building. This enables the customer to select a system that provides the performance characteristics that best meet his building requirements. Mesco's building systems include: Gable Symmetrical: A ridged (double slope) building where the ridge of the roof is in the center of the building. Lean-To: Ideally suited to give you that extra space you need alongside your building. The lean-to attaches at or below the eave of your building, and can provide shelter for a variety of uses, from just a covered area to a completely enclosed addition to your building. Introduction to Metal Buildings 9 Introduction Long Bay® System Buildings: The Long Bay® System Hybrid Structures: Hybrid structures blend the advan- is ideal for manufacturing, warehousing/distribution, tages of metal building system construction with the and retail applications requiring a large area of open strength of conventional steel members. Hybrid struc- floor space with few interior columns. The result is a tures meet heavy loading requirements by providing the lightweight, strong framing system that is superior to most effective design possible - the best of both worlds. conventional structures with the inherent benefits of The advantages include: metal building systems. The Long Bay® System pro- • Design flexibility vides a clean, uncluttered interior. The term Long Bay generally refers to sidewall bay spacing greater than 30 • Single source responsibility feet. • Fast, easy construction • Cost effectiveness Conventional Structural Steel: A conventional structural steel building is pre-designed and pre-defined by an engineer that has been carefully appointed by the Mesco designs and engineers virtually every element architect or owner for specific needs for that building. required for hybrid structures, no matter how large or Mesco Building Solutions has formed the Steel complex. The company has complete in-house engi- Structures division, which specializes in structural proj- neering and computer design groups dedicated to ects and special construction needs. hybrid structures. When it comes to large, tough construction jobs, the hybrid building approach provides a cost-conscious alternative. Crane Buildings: With the end use of metal building systems dominated by the manufacturing and warehousing sector, building cranes become an important element of the structure. Mesco recognizes the need to properly integrate the design of the metal building system with the building crane specifications. The building crane is a complex structural system consisting of the crane with trolley and hoist, cranes rails, crane runway beams, structural supports, stops and bumpers. 10 Introduction to Metal Buildings Introduction The cranes typically found in metal building systems such as brick, stone, precast concrete, or glass, the include: structure can be aesthetically appealing while providing the perfect solution to aviation needs. • Bridge Crane • Top Running • Underhung • Monorail • Jib • Stacker • Gantry Mesco understands crane usage frequency and severity classification as indicated by the Crane Manufacturer's Association of America. This is critical to the design. Mesco designs each metal building and Design Build crane support system to meet the specific requirements of the project. Increased consumer demand for better building solutions has stimulated Mesco and its Builder organization to move closer to a complete building service. This service is called Design Build. Design Build is a modern, recognized, logical way to build. Under this system the planning, specifying, designing, estimating, and construction are combined under a single source of responsibility. This provides the prospective customer with a better building solution, more predictable quality, and better value than any other method of construction. Many of our Builders are Design Build Contractors. For this modern method to be effective, a team effort is required. The combination of the Manufacturer and the Builder system of construction can offer the total con- Aviation Facilities: Aircraft hangars are individually struction from the foundation to the door key, but engineered to meet specific requirements and are flex- customers wanted more service. The Design Build ible enough to satisfy even the most complex aviation System offers not only total construction, but the Builder need. The hangars may be designed using gable sym- also assumes responsibility for the design phase. metrical, gable unsymmetrical or single slope structural systems. Mesco and the Builder as a Sales These cost effective, functional structures have many Team advantages: Why are all the things we have presented about the • Design flexibility manufacturer and the Builder organization important to • Fast, easy construction you? Because you can help prospective customers recognize the respect and esteem commanded by the • Reduced maintenance costs Buildership and the Mesco name by customers and Clearspan design provides column-free interiors for competitors alike. For example, emphasize strengths wide-open floor space and eave heights that can such as: accommodate today's larger aircraft. The structures Authorized Builders: We have the finest Builder allow for a variety of door options including bi-fold, bi- organization in the industry, and each year the company parting, and stack leaf designs.By combining the metal joins efforts with its Builders - taking the working rela- building system with conventional exterior materials tionship to new levels. This teamwork approach is the Introduction to Metal Buildings 11 Introduction most important aspect of Mesco's relationship with its By working for the good of the entire industry, MBMA Builders and is the foundation of the company's contin- has created greater markets and more sales. It is impor- uing development and success. tant to know your competitor's strengths and weaknesses. A list of members of the MBMA consisting Suppliers: Mesco has perfected the concept of busi- of the major fabricators can be found on the internet at ness based on strategic alliances. We promote www.mbma.com. It is necessary that you become partnerships between the Manufacturer and suppliers knowledgeable regarding those companies that serve by including them in our goal to provide the finest quality your area and are competition. and competitive prices in the industry. Employees: We have employees with years of metal building experience, led by seasoned management. Their common goal is to provide the finest metal building systems in the industry. Strong Financial Footing: Mesco has a dramatic financial position allowing us to develop new products and plants, and to expand facilities. The Builder's single source of responsibility - it offers the customer convenience and economy because he/she will be working with one firm instead of many. It is a sound, tested, predictable way to build. The Builder's Reputation and Record: The local image can be very influential. Past jobs represent proof of the Builder's ability. Special awards - Builder of the Year, Million Dollar Club, and local club memberships - represent the integrity of a Builder and his standing in the community. The Builder's Service: The Buildership is the Builder's whole means of livelihood and he/she expects to be there tomorrow to continue to serve his customers. This is vital to a building prospect. You can sell all these things. They can be door openers, interest retainers, or order clinchers - great contributors to the total sale. Competition Of course, like any other good business, there is competition. There are many fabricators of metal buildings and components, and they range from small shops to large companies. In 1956, producers of metal buildings formed the Metal Building Manufacturers Association (MBMA) for the purpose of: 1. Establishing design standards and criteria. 2. Assuring certifiable product quality (AISC) 3. Collectively participating in pro-active building codes and insurance standards. 4. Continuing to progress in standards and practices 12 Introduction to Metal Buildings Lesson 1 Lesson One: The History of Metal Buildings Building Forms Post and Beam Our ancestors used natural shelters, such as caves, for refuge. Their first efforts to construct a man-made shelter probably resulted in a lean-to of branches and leaves. This developed into the simple post and lintel system of LEAN-TO construction where two or more vertical members supported a horizontal member spanning between them. The roof, of course, completed the structure. Although post and lintel was the descriptive term for this type of construction, the present day term is beam instead of lintel. Lintel continues to be an architectural term, but it is primarily used for the structural member above doors and windows. SIMPLE POST AND LINTEL The Arch Early Romans readily adopted materials to perfect the arch for spanning large areas without the necessity of posts and beams, thus introducing a building form that was both functional and architecturally beautiful. The arch has a building design concept that does not exist in the post and beam - the side thrust. There are two ways to meet the side thrust: 1. External abutments ARCH THRUST 2. Downward pressure of massive walls against COUNTERACTED BY ABUTMENTS which the thrusts operate We have mentioned the post and beam and the arch because both forms are still in popular use today. The post and beam, even though a very simple design, will be important to you in sales presentations. The arch principle is pertinent because it is closely related to the rigid frame primary structural system that will be one of your "best sellers". Despite limitations of available materials and design know-how, early Builders continually looked for ways to ARCH THRUST obtain greater and greater clearspan (areas without COUNTERACTED BY MASS supporting members). The construction and design principles were based on the use of load-bearing walls and of thrust counteracted by weight and mass. These Today, a popular and practical structural scheme is that principles endured for a very long time, but eventually consisting of a skeletal framework with a variety of the introduction of steel and reinforced concrete external materials attached. This provides an endless brought about many new possibilities of construction. variety of buildings forms and styles. Introduction to Metal Buildings 13 Lesson 1 Construction Material Requirements and economy. However, its basic requirement must be one of protection. Consider some of the key factors that influence the You might analyze this a step further and really consider selection of construction materials by the manufacturer, two kinds of protection. the designer and the user. One type is protection against forces or loads that may STRENGTH is a very important factor. be exerted upon the building. Unless the structure can offer adequate resistance against various loading con- AVAILABILITY of material influences its selection, ditions, the safety of persons and the value of property cost of material and final in-place cost. are endangered. This is where sound design consideration must be given as to the strength of the building To facilitate design and fabrication, a material must and particularly to the structural system. possess a good degree of WORKABILITY. Another kind of protection is protection against rain, WEIGHT and BULK become important from a wind, heat, and cold. Any of these can contribute to the handling and shipping standpoint. discomfort of persons and cause a decrease in the value of contents. The degree of protection against DURABILITY of the finished product is measured them is determined by the weather tightness and in terms of its resistance to wear and destruction thermal efficiency of a building. These things, of course, from all causes. greatly influence the design of roofs and walls - also known as the covering system. Materials must be capable of presenting a pleasing APPEARANCE. Design Loading Steel is used extensively in many segments of con- If you were to ask an engineer to design a structure of struction, especially in standard structural members. a certain size, he/she would first have to know what When you hear a construction worker refer to "red iron", loads would be imposed upon the building - their type he/she is talking about steel. and magnitude. Only with this basic information will The primary advantage of steel is its strength. The he/she be able to design a building that will meet the material, as it comes from the mills, has very exacting prospective customer's exact needs for loading condi- specifications, enabling engineers to design structures tions, it is important that you have a basic with a high degree of accuracy. In addition, steel is a understanding of design loading. plentiful and well-accepted material. It has a high A load is a force exerted upon a structure or one of its degree of workability because it can be cut, welded, members. There are many different kinds of loads that shaped, and formed to meet a great variety of needs. must be taken into consideration in various situations, Steel can also take a great deal of abuse and wear. but only those that are of prime importance will be cov- The greatest disadvantage of steel is that it will rust - ered at this time. deteriorate by a process of oxidation - when exposed to Dead Load: The weight of the metal building system, the elements. This is prevented, however, by the appli- such as roof, framing, and covering members. cation of protective finishes and paints. Although steel will not burn, it is not classified as fire- proof because it can become distorted, lose its structural strength, or even melt - depending on the intensity of the heat. Nevertheless, compared to many materials, steel offers a great deal of fire resistance due to the large amount of heat needed to cause it damage. Fundamental Factors Affecting Building Design Buildings provide shelter for persons and property. A building must have many desirable characteristics such as an attractive appearance, long life, flexibility of use, Dead Load 14 Introduction to Metal Buildings Lesson 1 Live Load: Any temporary load imposed on a building Seismic Load: The load or loads acting in any direction that is not wind load, snow load, seismic load or dead on a structural system due to the action of an earth- load. A few examples of a live load are workers, equip- quake. ment, and materials. Live Load Seismic Load Snow Load: The vertical load induced by the weight of snow, assumed to act on the horizontal projection of the Auxiliary Loads: All dynamic live loads such as cranes roof of the structure. and material handling systems. Snow Load Auxiliary Loads (Note: Very wet snow 6" deep is equal to one inch of water. One inch of water on a square foot of surface weighs five pounds.) Wind Load: The forces imposed by the wind blowing Collateral Load: The weight of additional permanent from any direction. materials, other than the weight of the metal building system, such as sprinklers, mechanical and electrical systems, and ceilings. Wind Load Collateral Load Introduction to Metal Buildings 15 Lesson 1 Resistance of Material to Forces For an illustration of a few of these terms, take a simple rubber eraser and draw evenly spaced straight lines Loading has been defined as a force exerted on a across its width as shown in Figure A. building. Such forces, in turn, are transmitted through joints and connections to individual parts or components. This eventually leads to a consideration of the properties of materials to resist forces in order to provide the engineer with a basis for subsequent design calculations. You are not expected to be an engineer in order to sell Figure A buildings, nor does this manual intend to delve deeply into technical subjects. By the same token, the more By grasping the eraser in both hands and pulling understanding you have of building design and terms, (Figure B), you are exerting tension on the eraser. Its the better job you will do working with engineers, archi- resistance to breaking is its internal resistance. This is tects, or other technically minded individuals. indicated by the widening of the spaces between the Stress: The force acting on a member divided by its lines drawn on the eraser. area. Tension Tension: Stresses acting away from each other that produce a uniform stretching of a member. Force Force In Tension Figure B Using the eraser again, grasp it in both hands and push towards the center of the eraser (Figure C). Notice how Compression: Stresses acting toward each other that the lines tend to become closer to each other. This is causes a member to compress. compression. The internal resistance of the eraser prevents its parts pushed together. Force Force Compression In Compression Shear: Stress that tends to keep two adjoining planes of a material from sliding on each other under two equal and parallel forces acting in opposite directions. Figure C As an example of both tension and compression, grasp Force the eraser in both hands and bend it (Figure D). Notice Force that the top part of the eraser is stretching and is in tension, while the bottom part of the eraser is pushing together and is in compression. Tension Force Compression Force Shear Figure D 16 Introduction to Metal Buildings Lesson 1 Column Reactions The load at the base of the column will be a vertical load and also a transverse thrust or "side kick". These trans- Any structure placed on a foundation causes a load to verse thrusts can become very sizeable figures and be imposed on that foundation. All buildings have these must be taken into consideration when designing foun- loads imposed by the columns on the foundation. These dations for rigid frame buildings. loads are called column reactions. Column reactions are often expressed using the term "kip". A kip is a commonly used engineering term for LOAD 1,000 pounds, derived from the contraction of the words Kilo (1,000) and Pound. Framing structures exert a load on a foundation both vertically and transversely. The vertical load is the result of the dead weight of the structure, and other loads such as snow on the roof, wind loads, crane loads, or seismic loads. THRUST The transverse load is the result of wind loads or seismic loads, and also produces the tendency of the base of rigid frame columns to spread apart under vertical load. A wind load on the sidewall of the rigid frame structure may produce uplift on the main frame as well as trans- A third type of load arises from framing systems, which verse thrusts. have fixed base columns. A streetlight or a flag poll is a common example of a fixed base column. When this type of column is subjected to wind loads, the foundation of such columns must be designed to resist the wind's effort to overturn them. This overturning force is called a moment. WIND Engineers usually express the overturning moment as "foot-kips". As an example, assume that the wind load THRUST against the wall of the building creates an effective force of 2,000 pounds against the top of a 12' column. The foundation must be designed to support not only The resulting moment at the base would be an over- vertical loads, but also the transverse thrust. turning force or moment of 24 -ft- kips (2,000 Pounds or Building Codes 2 kips x 12 feet = 24 -ft- kips). You needn't understand the total engineering involved, but you should know that the loads exist, and how they Building code is a set of minimum requirements for con- are expressed. You'll find these loads shown on the struction covering safety and serviceability. This safety anchor bolt drawings. involves life, health, fire, and structural stability. Most areas have enforced codes governing construction in Load Transfer the community. They may be administered by a city, county, or state, or by a combination of the three. Regardless of the type of load or where it is exerted on Building codes are necessary since their purpose is to a rigid frame building, it is always transferred from part benefit the public by helping eliminate unsafe design, to part down to the foundation. poor construction practice, and unsightly buildings. Assume, for example, a man standing on the roof. His By the same token, they should be modern and clear. weight is directly on the panels, but this load is trans- They should also provide for updating. Unfortunately, mitted through the panels to the purlins - the closest many communities have codes that are old and obso- purlins taking the greatest part of the load. The purlins lete, and fail to recognize the parade of new materials transfer the load to the rafter, the rafter to the column, and designs. then the column to the foundation. Introduction to Metal Buildings 17 Lesson 1 A community may originate and write its own codes, but the old codes that were based on sustained wind generally it either adopts a recognized building code in speeds. This means that the code specified wind speed its entirety, or modifies it for its specific use. for the whole country will be higher than before. Also, unlike some earlier codes, it is necessary to specify Here are some authoritative and well-known codes in wind exposure categories and enclosure classifications. existence: The ground snow load maps in the new code are based THE UNIFORM BUILDING CODE, (UBC) com- on more recently accumulated data, but for most parts piled by the International Conference of Building of the country the starting snow load values have not Officials (ICBO). It is prominent on the West Coast changed that much. However, there are new unbal- and in some areas of the Midwest and South. anced snow load equations which drastically increase the roof snow load, especially for snow loads of 20 psf THE BOCA BASIC BUILDING CODE (formerly and greater. the National Building Code) is administered by Building Officials and Code Administrators The seismic provisions of the new code reflect the latest International (BOCA International) is primarily used research for earthquake loads. The new seismic maps the East of the Mississippi and North of measure "Spectral Response Acceleration" for 0.2 and Tennessee. 1.0 seconds. This is a completely new approach to this problem. The IBC seismic equations and maps result in THE STANDARD BUILDING CODE (SBC) covers substantially higher imposed loads. most of the Gulf Coast states and other Southern Because of all these changes, you must make sure to areas. Southern Building Code Congress use the new load maps whenever you are using the IBC International (SBCCI) sponsors it. codes. Over time, many areas have responded to There are many others, but these are the major ones. It unusual storms by increasing the base load to guard is important to note that it is not compulsory for com- against future collapses. Many of the wind and snow munities to adopt any of these codes. They were load provisions of the new code were written in compiled by groups of building officials, and are avail- response to such events. able for adoption by communities either in whole or in The snow provisions in the new code, for instance, may part. result in unbalanced loads more than twice the basic A building code is not intended to function as a building roof snow load, even with no high-low conditions. The specification, such as an architect would write for an minimum wind speed on the maps is now 85 mph, in individual structure. It is a legal document. The purpose lieu of the old 70 mph minimum that has been effect for of this document does not go beyond the establishment years. of those minimum design and construction require- Because of these changes, make sure to determine the ments that are essential to, and directly related to, the values for the wind, snow, and seismic loads for a safety, health, and welfare of the public. project only from the new maps. Over the past several years the three national model It is expected that the majority of state and local juris- building code bodies, SBCCI, BOCA, and ICBO have dictions will adopt this code during the next few years. been working together to produce a single code to be It is very important for each of our Builders to be in close used throughout the United States. The result of their contact with the local building officials to know when the labor is the International Building Code that was pub- new building code is going to be enforced. lished in 2000 as the IBC 2000. Codes are complicated and cover many phases of con- From a building design viewpoint, the IBC code has struction and differ from community to community. It is adopted new requirements for live, wind, snow, and necessary that you become familiar with the codes that seismic loads. The rules for applying and combining are applicable in your area. It is also advisable to dis- these loads are much more complex than in previous cuss the code official's interpretation of the codes. codes, and in many cases cause higher loads to be Interpretations of these codes can vary from official to used for designing the building. This can result in higher official. You must be able to propose buildings to cus- costs for building foundations as well as for the metal tomers that meet all the requirements. Since your building structure. customer may never have been involved in a construc- There are new load maps in the code for wind load, tion project before, he/she will depend on you to supply snow load, and seismic loads. The wind load maps are material that meets the codes and loads in his area. based on 3-second gust wind loads, unlike the maps in 18 Introduction to Metal Buildings Lesson 1 Steel Design Mesco is also a member of the Metal Building Manufacturers Association. Because of the many properties and characteristics of steel, many factors must be considered when designing both individual members and completed structures. Two organizations have published manuals that provide data and standards on which to base calculations for the design of steel: AISC - The American Institute of Steel Construction was originated Minimum Loading Standards by steel fabricators and is generally Our buildings are available for different loading require- concerned with hot rolled shapes ments in different geographical locations. In our and plates. continuing efforts to assure customers of high structural integrity, we screen incoming orders for design vari- ances, which could present problems. AISI - The American Iron and Steel Institute was originated by steel pro- With the MPact Pricing Software and special estimates, ducers and is concerned with the primary responsibility of using the correct codes and cold-formed steel structural mem- loads is the responsibility of the Builder. A Builder is bers. responsible for knowing and using the correct codes and loads for their local area. Any deviation from rec- Mesco's products, where applicable, are designed in ommended loading by Mesco is the responsibility of the accordance with AISI and AISC specifications. This is a Builder. A local code requirement of greater magnitude mark of sound design and engineering practices, and requested by the Builder, of course, will take prece- contributes to the high quality of our products. It is also dence. The U.S.A. Snow Load map is undefined in a sales feature that should not be overlooked. certain Western States and other mountainous areas. Mesco is an AISC certified MB Category manufacturer. Therefore, the Builder will determine the minimum This certification is obtained by passing annual audits of county load at the time of entering the order. both manufacturing and design practice by an inde- Assuming a clear loading deficiency exists, we will pendent engineering firm. The audits check for sound inform the Builder of the problem and suggest appro- engineering practice, proper application of pertinent priate corrective action. We will not accept an order building codes, and procurement of high quality mate- when the Builder has specified design loads less than rial. The material must meet the required specifications those indicated in the minimum load tables. and proper fabrication technique, especially in the Conclusion welding of structural components. It assures the customer that his building is of the highest quality and meets all applicable national standards. Remember, nothing being presented should be con- Other professional affiliations of Mesco: strued as an intention to train you to become an engineer. The materials presented, including technical portions, are merely fundamental and will provide back- Founding Member of the Light ground and basic training for improving your job skill Gauge Structural Institute (LGSI) level. ICBO (International Conference of Building Officials) certified CWB Canadian Welding Bureau certified CERTIFIED Introduction to Metal Buildings 19 Lesson 1 Self Test Lesson One: Self-Test 1. Our ancestors' first effort to construct a man-made shelter probably resulted in? A. An Arch B. A Metal Building C. A Lean-To D. A Conventional Stick House E. None of the Above 2. A building should have many desirable characteristics, such as a good appearance, long life, flexibility of use, and economy, but its basic requirement must be one of protection. A. True B. False 3. The introduction of what materials inaugurated many new possibilities for the construction industry? A. Thrusts B. Steel and Reinforced Concrete C. Clearspans D. Post and Beam 4. A load is simply a force that is exerted upon a structure or one of its members. Prime examples of different loads that can affect a metal building are: live, auxiliary, collateral, seismic, snow, and dead. A. True B. False 5. The primary advantage of steel is: A. Availability B. Workability C. Durability D. Appearance E. Strength 6. The primary disadvantage of steel is: A. Steel Rusts B. Bulk C. Weight D. Steel will not burn E. None of the Above 7. A seismic load is defined as the lateral load acting in any transverse direction on a structural system due to the action of a hurricane. A. True B. False 8. The early Romans perfected the arch for spanning large areas without posts and beams. What structural system is closely related to the arch? A. Post and Beam B. Purlins C. Girts D. Rigid Frame E. None of the Above 20 Introduction to Metal Buildings Lesson 1 Self Test 9. Red Iron refers to what? A. Wood B. Metal Sheeting C. Steel D. Zinc E. Aluminum 10. When you take an eraser in both hands and bend it downward, the eraser experiences this. A. Tension Only B. Compression Only C. Shear Force Only D. Both Tension and Compression 11. The code SBC generally covers the Gulf Coast states and is prominent in the Southern Region. A. True B. False 12. Mesco's products, where applicable, are designed in accordance with AISI and AISC specifications. A. True B. False Introduction to Metal Buildings 21 Lesson 2 Lesson Two: The Building System The building system consists of primary framing members, secondary framing members, roof system, wall system, and accessories. The prime objective of the building system is to provide a quality structure. Our buildings are available in a within the limits of what Mesco defines as "standard". range of configurations - from the small, standard struc- Any building that cannot be designed and priced by tures to maximum performance structures with creative MPact or Express must be sent into the main office for architectural refinements to satisfy the spectrum of the "Special Estimating" by our highly qualified staff of esti- owner's requirements. The variety of building configura- mators. When a building is designed and priced by tions and sizes offers many solutions to fulfill needs of "Special Estimating", the project can possibly take on the commercial, community, and industrial markets. the quality of "nonstandard". Standard versus Non-Standard The MPact software program is one of the most innovative design and estimating packages to be introduced You will hear the word standard used many times in our to the metal building systems marketplace. MPact is business. It is misunderstood more than any other flexible and user friendly, allowing the Builder to seek word. Certainly any manufacturer who designs and pro- the most efficient design in order to achieve the most duces parts that must fit together to provide a competitive price. MPact is the primary pricing tool used completed product has a definite direction or "stan- by our authorized Builders and our sales staff. dard", which is the base of normal application of the Approximately 90% of the building systems priced in the product. Consequently, standard items are considered market can be successfully designed and priced within to be those that are commonly manufactured on the MPact. MPact is available for purchase by an author- production line and those that are purchased by cus- ized Builder. To utilize MPact the Builder must attend an tomers. MPact Training Seminar. The seminar not only trains the Builder in how to operate MPact in the Windows However, if a situation arises involving something that is environment; it also spends a great deal of time "nonstandard", it is still possible and practical to meet enhancing the Builder's product knowledge. that need in many cases. Our engineers believe nothing is impossible but variation from a standard often means Express is used to price our smaller building systems. extra work, expense, and time. Sometimes this is negli- Using combinations of optional building widths, lengths, gible, but at other times it might be quite involved. and eave heights along with a wide range of accessories, unique and functional building layouts can be Usually, the information we present is on standard prod- designed and priced. The building systems are small ucts. Slight modifications of a product can be made to clean box buildings that are pre-engineered, with a four- meet the specifications needed by the customer. week delivery time frame. The Express program is Builders handle some variations by fieldwork. In other user-friendly, window based, and available to author- instances, we will make the modifications at the factory. ized Express Builders. The program not only designs It is important to note that any variation from the stan- and prices these smaller buildings, but also produces dard might have a serious effect on the design (loading, elevation drawings and anchor bolt drawings that a strength, etc.). Only qualified individuals should make Builder can print in his office. The quickest route to these variations and modifications. project completion is the Express Building. Owners get their buildings faster, and completion and occupancy Pricing and Design Programs occurs sooner. A satisfied owner is the result of the speed and quality produced by this Express Building Pricing a building manually can be time consuming, not System. to mention the designing phase. Mesco strives to make it as easy for the Builder as possible. Mesco Building Mesco continues to expand and refine both the MPact Solutions offers a computer pricing software program to and Express programs to help its Builders deal with the our Builders, MPact. ever-changing metal building market. Any authorized Builder interested in purchasing the MPact or Express This tool offers guidance in designing our buildings programs should contact his District Manager. 22 Introduction to Metal Buildings Lesson 2 Primary Framing System STIFFENER Primary framing furnishes the main support of a RAFTER WEB building. A bearing frame (post and beam) and a main frame (rigid frame) are examples of primary framing. In this text, we will not only be talking about the main HAUNCH PLATE frame as a primary framing system, but also about sec- COLUMN ondary framing members, and bracing that join with the main frames to make up a complete structural system. STIFFENER Roof Slope FLANGE FLANGE Roof-Slope is defined as the tangent of the angle that a STIFFENER roof surface makes with the horizontal, usually expressed in units of vertical rise to 12 units of hori- PERPENDICULAR CONNECTION zontal run. The roof slope of a building is expressed as ¹⁄₂:12, 1:12, 4:12, etc. A 1:12 roof-slope rises 1 inch in every 12 Knee/Haunch Area of Main Frame inches measured horizontally from the side of the building across its width to the peak of the building. The knee/haunch is that area of the eave where the column connects to the roof rafter. The knee/haunch Problem: If a 60' wide gable symmetrical building ties the members together rigidly and converts them is 12'-0" at the eave and has a 1:12 roof slope, into a single unit to carry all loads, vertical or lateral. what is the height at the peak. Notice that in the area of the knee/haunch, the main Solution: ¹⁄₂ building width (30) x unit rise (1) = frame (rigid frame) is deepest in section, which makes it inches of rise (30") the strongest area of the frame. Inches of Rise (30") + Eave Height (12'-0") = peak height (14'-6") This is required primarily because of the vertical load considerations, but at the same time it enables the The Main Frame frame to offer lateral strength. What does this mean? It means that the strength designed into the frame for ver- The main frame (rigid frame) is the primary structural tical loads is also available to carry lateral loads, which member of the building system. The main frame con- might be caused by high winds, earthquake shock, etc. sists of columns and rafters. Columns are used in a vertical position on a building to transfer loads from Because the inside flange of the knee is in compres- main roof beams, trusses, or rafters to the foundations. sion, a resulting thrust is produced at the inside corner, Rafters are the main beams supporting the roof system. which is upward and outward. Stiffeners are used to counteract the resistant thrust. Stiffeners are usually Strictly speaking, a main frame is structurally stable extended to the outside flanges and also serve to stiffen because of the rigidity of its connections. The main the entire web. The haunch connection also serves as frame members are connected in such a manner as to a stiffener. Main frames may be considered as arches in make the entire frame act as a single unit. Two common their action, in that they produced a transverse thrust at types of connections used to connect major parts of a their base or a tendency to kick outward. Under certain main frame are diagonal and perpendicular. loading conditions, however, an inward thrust might be STIFFENER WEB produced at the base. Main frames belong to a general class called continuous structures because the action RAFTER and stress travel throughout the entire structure, since COLUMN all joints are fixed in a structural sense. Because of this, engineers must analyze an entire main frame as a com- HAUNCH plete unit in itself, and not as an assembly of separate PLATE FLANGE members. FLANGE STIFFENER Visualize a big hand grasping the roof rafter of a single DIAGONAL CONNECTION main frame at the peak. The hand is alternately pushing down and pulling up on the frame. Since the member is Introduction to Metal Buildings 23 Lesson 2 a continuous structure, it is easy to see that the base of the two columns will tend to kick outward or inward, EW 25' MF 25' MF 25' MF 25' EW depending on the type of load being exerted. HALF FULL FULL FULL HALF BAY BAY BAY BAY BAY 100' These thrusts, however, are easily counteracted by a EW = Endwall MF = Main Frame properly designed concrete foundation. We have used the expression "easily counteracted " purposely because a qualified engineer can design an adequate The main frames indicated by MF in the drawing above foundation using the reaction charts supplied by the support a roof area of two half bays. The endwall manufacturer. There are many buildings, both over- frames indicated by EW, however, only support one designed and under-designed, in use today that have half-bay of roof load. improper foundations simply because the person designing the foundation was either unqualified or did From this you can readily see that the endwall frames not refer to the reactions furnished by the manufacturer. need not be as strong as the main frames. It is for this reason that in addition to expandable main frame end- The building drawings include reaction charts with var- walls, we offer lighter non-expandable mainframe ious loading conditions for standard main frames. The endwalls, or even lighter bearing frame endwalls, MPact pricing program produces preliminary mainframe depending on your customer's requirements. column reactions as well. Make these charts available to your architects and engineers so that foundations will RAFTER be priced properly and economically. Main frames are normally connected to the foundation by using the appropriate anchor bolts in a configuration COLUMN that is described as a pinned condition. This means that COLUMNS the loads transmitted to the foundation are vertical OR loads and transverse loads. POSTS VERTICAL ANCHOR LOAD MAIN FRAME BOLTS HORIZONTAL LOAD BEAM COLUMNS COLUMNS OR OR POSTS POSTS ANCHOR BOLT CONNECTION Endwall Frames Assume a building is 100' long, consisting of four 25' bays as shown above. BEARING FRAME 24 Introduction to Metal Buildings Lesson 2 The expandable main frame endwall is designed to EAVE STRUT support two half bays of roof load and can support an CLIP additional half bay in the future. The non-expandable main frame is designed to support one half bay of roof load and cannot support an additional half bay in the future. Main frame endwalls do not require any bracing and clear the endwall bays for large framed openings or open wall conditions. Secondary Framing Members Secondary framing members are those members that join the primary framing members together to form building bays and provide the means of supporting and attaching the walls and roof. Secondary framing mem- MAIN FRAME bers are: • Eave Struts Purlins • Purlins A purlin is a secondary framing member that serves to support roof panels and transfer the roof loads to the • Girts rafters. • Bracing The purlin is zee shaped as shown below. Purlins are available in 8", 10", or 12", depth, and are available in Eave Struts different gauges of steel 16, 14, 13, or 12 to meet various loading conditions. The eave strut is a roughly cee-shaped cold-formed member and is located as illustrated below. Cold- The continuous purlin is a zee shaped cold-formed forming is the process of using press brakes or rolling member 8", 10", or 12", depth with a 50 degree outer lip mills to shape steel into desired cross sections at room to facilitate nesting. The purlins are lapped at each inte- temperature. rior frame with the lap varying from 8" to 60" depending upon the conditions. Continuous purlins take into consideration the design advantage of continuous beams. The economy is based on using them on multiple bays EAVE STRUT where the overlapped splice of the purlin, continuous over the rafter, assists in supporting the load of the adjacent bay. PURLIN The eave strut provides an attachment and bearing points for the end of the roof sheets and wall sheets. RAFTER Eave struts are available in nominal depths of 8", 10", or 12" to match the purlin depth. Eave struts are prepunched at the factory for bolting to the main frames. CONTINUOUS PURLIN Introduction to Metal Buildings 25 Lesson 2 Girts Flush girts attach to the web of the columns, with the girt face in the same plane as the column face. Which pro- Girts are secondary framing members that run horizon- vides greater interior clearance. tally between main frame columns and between endwall columns. They are zee shaped members like purlins, also available in depths of 8", 10", or 12", and gauges of 16, 14, 13, or 12. MAIN FRAME COLUMN OR ENDWALL COLUMN Standard girt spacing is the first girt at 7'-4" above finish floor and a maximum of 6' there after. This standard spacing fits doors, etc., utilizing optimal design. Other spacing is available to satisfy design criteria. A low girt option is available on request at 3'-6", which stiffens the wall section, and is standard in high wind conditions. Girts and purlins are pre-painted at the factory. Mesco welds all girt attaching clips to the frames for easier and quicker erection. FLUSH GIRT GIRT FACTORY WELDED GIRT CLIP COLUMN In addition to playing an important roll in the structural GIRT stability of the complete building system, girts also serve the important means of providing the framing for the attachment of wall covering. Bracing Bypass girts attach to the shop welded clip on the out- In addition to main frames, endwall frames, eave struts, side flange of the columns creating a more efficient girts, and purlins, the building system must have ade- design. The girt is lapped at each frame and at the first quate bracing to make the system stable in a lengthwise interior frame from the endwall. Bypass girts are used to direction. Bracing systems transfer wind loads from take into consideration the design advantages of con- endwalls and sidewalls to the foundation. Wind bracing tinuous beams spanning from bay to bay. systems must include two types: MAIN FRAME 1. Longitudinal bracing, for wind on the endwall. OR ENDWALL COLUMN 2. Transverse bracing, for wind on the building sidewall. Requirements for bracing systems described on these pages are based on the specifications of applicable codes. A variety of methods are available for providing bracing for wind on the building endwall. Bracing systems of this type serve a secondary purpose of squaring the building. In addition to the standard method - diaphragm BYPASS GIRT action, alternatives include X-bracing (cable or rod), fixed base columns, portal frames, and wind bents attached to column When bracing must occur in bays where doors or other accessories are required, fixed based columns or portal frames should be used. 26 Introduction to Metal Buildings Lesson 2 Bracing Methods: columns will induce a moment to the foundation, thus requiring a special foundation design. Diaphragm Action Diaphragm action utilizes the diaphragm resistance of the wall panels to transmit lateral wind or seismic forces to the foundation. Diaphragm action utilizes undisturbed sheeting, floor to roofline, and assumes all wall panels are installed correctly. X-Bracing When diaphragm action of the panels is inadequate or not allowed, the first alternative is to provide cable or rod bracing between columns. X-Bracing transfers longitudinal forces to the foundation. Fixed Base Portal Frame If neither X-Bracing nor fixed base columns are accept- able, a portal frame (wind bent) can be used. A portal frame is an I-shaped section of built up material consisting of two columns and a rafter, running parallel to X-Bracing the sidewall, and attached to the web of the sidewall Cable or Rod columns. As a standard the portal frame usually does not induce a moment to the foundation. CABLE BRACE HILLSIDE WASHER FLAT WASHER BRACE GRIP HEX NUT EYE BOLT WEB OF FRAME CABLE BRACE TO FRAME CONNECTION Portal Fixed Base Columns Brace to Interior Main Frame A method of bracing used for an open bearing frame If the openings in the wall are such that they do not endwall is to provide bracing in the roof of the end bay. allow for the use of X-Bracing, then fixed base columns In this case, the lateral forces on the endwall are trans- may be used. A fixed base column is a column with spe- ferred to the first interior main frame. The main frame is cial base plate condition, which allows wind load to be then designed to resist this additional lateral force. transferred to the foundation. Therefore, fixed base Introduction to Metal Buildings 27 Lesson 2 provides a surface that is chemical and corrosion resistant. Therefore, it is not necessary to put an additional finish coat of paint on the framing members. However, if it is desired, finish paint may be applied over the red oxide in the field. However, consult with the paint supplier for the compatibility and proper preparation of steel before the application of any finish paint. It is also recommended that a test patch of the finish paint should be applied to test for compatibility. Secondary framing members are pre-painted by a company specializing in coating of metal products with a baked on red primer. Due to the special coating BRACE TO INTERIOR MAIN FRAME required for roll forming these members, they can be difficult to repaint. Flange Braces or Purlin Bracing Galvanized Steel Flange braces are structural members that attach For over 140 years, galvanizing has had a proven his- purlins, girts, and eave struts to primary structural tory of commercial success as a method of corrosion members (columns or rafters). Purlin bracing is an protection in a myriad of applications. Galvanizing can angle connecting the bottom flange of adjoining purlins be found in almost every major application and industry to prevent purlin roll. where iron or steel is used. The utilities, chemical Flange braces are used to prevent the main frame from process, pulp and paper, automotive, agricultural, and twisting or buckling laterally under the load. They are an transportation industries, to name just a few, have his- essential structural part and must be installed properly torically made extensive use of galvanizing for corrosion at all locations. Flange braces can also be very useful control. as an erection aid to align the purlins and eave struts for All of Mesco's buildings are also available in galvanized easier and lower cost roof installation. steel as a special option. Two types of galvanized material are used: PURLIN • Hot Dip Galvanizing • Pre-Galvanized Hot dip galvanizing is the process of applying a zinc RAFTER coating to fabricated iron or steel material by immersing the material in a bath consisting primarily of molten zinc. Mesco sends the fabricated material, such as, primary and secondary framing members, to the galvanizers. Pre-Galvanized material is used for secondary members only. The pre-galvanized material used is of 55 FLANGE BRACE grade and adheres to ASTM A653 specifications. The coil of pre-galvanized material is delivered to Mesco and then the pre-galvanized secondary members are fabricated. Structural Paint Conclusion All primary framing members are factory cleaned to This section has introduced you to the very basic remove loose dirt, grease, mill scale, etc. They are then building parts, which make up the primary and sec- painted with a red oxide primer. The purpose of this ondary framing. Bracing, structural paint, and primer is to provide temporary protection of the steel Galvanized steel have also been covered. From this members during transportation and erection. Touch up you should feel comfortable knowing what makes up a may be required after erection. Red oxide primer also building system. 28 Introduction to Metal Buildings Lesson 2 Self Test Lesson Two: Self-Test 1. Secondary framing members include purlins, girts, eave struts, bracing, and main frames. A. True B. False 2. The major parts of a main frame are: A. Web B. Flange C. Haunch Plate D. Stiffener E. All of the Above 3. What is the rise of the gable peak from the eave line of a 120' wide building with a 1¹⁄₂ on 12-roof slope? A. 8' B. 10'¹⁄₂" C. 100 D. 7'-6" 4. Main frame endwalls do require additional bracing A. True B. False 5. Which endwall is designed to support a future expansion? A. Bearing Frame B. Post and Beam C. Full Load Main Frame D. Half Load Main Frame E. None of the Above 6. Purlins and Girts are zee shaped, available in depths of 8", 10", or 12", and are available in gauges of 16, 14, 13, or 12. A. True B. False 7. As a standard Mesco's first girt is located at? A. 6' B. 7' C. 8'-4" D. 7'-4" E. 3'-6" 8. Which girt type has the girt face in the same plane as the column face and provides greater interior clearance? A. Bypass B. Flush C. Staggered 9. All primary framing members are painted with red oxide primer and can have a finish paint applied in the field. However, secondary framing members are pre painted by the supplier with a baked on red primer and can be very difficult to repaint in the field. A. True B. False Introduction to Metal Buildings 29 Lesson 2 Self Test 10. Transverse bracing on an endwall can use which of the following methods? A. Diaphragm Action B. X-Bracing C. Fixed Based Columns D. Portal Frames E. All of the Above 11. Bracing systems transfer wind loads from endwalls and sidewalls to the foundation. There are two types of wind bracing systems (1) longitudinal bracing or wind on the sidewall, and (2) transverse bracing for wind on the endwall A. True B. False 12. What part of the main frame is at the eave where the column connects to the roof rafter and ties the rafter and the column together rigidly? A. Base Plate B. Knee or Haunch C. Stiffener D. Web E. None of the Above 13. Fixed base columns are usually less expensive than portal frames, but increase the cost of the foundation. A. True B. False 30 Introduction to Metal Buildings Lesson 3 Lesson Three: Building Types There are many varieties of buildings that are constructed for specific needs and uses. This lesson will discuss a few of the different types of buildings for gaining general knowledge and understanding. Clearspan, modular, lean-to, Long Bay, and conventional structural steel buildings are covered. Some of these types of buildings can be used separately or together. Whatever requirements or needs the customer has, it is important to be familiar with types of CLEARSPAN WITH STRAIGHT COLUMNS buildings. LIMITED TO 80' WIDE OR LESS Clearspan Buildings Clearspan buildings allow for the maximum use of interior space, which is particularly important in manufacturing plants, warehouses, offices, and retail stores where uninterrupted space is required. Size flexibility also pays off outside where optimum land use is an equally important consideration. SINGLE SLOPE CLEARSPAN Virtually every symmetrical, unsymmetrical, and single WITH TAPERED COLUMNS AVAILABLE UP TO 150' WIDE slope building size and shape is possible as a standard 1/4 : 12 THROUGH 4:12 ROOF SLOPE product. Inside the clearspan building you have almost total flexibility in determining the height, width, and roof slope you want: building widths from 20' - 150'; eave heights from 10' - 30'; and roof slopes from ¹⁄₄:12 to 4:12. Building widths of 80' or less are available with the option of straight columns instead of tapered columns. Lean-tos are available for future expansion or additional space. A lean-to can be designed to match the eave height and roof slopes of the clearspan building if the building was originally designed to take on the loading SINGLE SLOPE CLEARSPAN WITH STRAIGHT COLUMNS of an additional lean-to load. Lean-tos are available in LIMITED TO 80' WIDE OR LESS widths from 8' - 60', eave heights from 8' - 30', and roof slopes from ¹⁄₄:12 to 4:12. LEAN-TO STRAIGHT COLUMNS LIMITED TO 60' WIDE OR LESS CLEARSPAN WITH TAPERED COLUMNS AVAILABLE UP TO 150' WIDE Note: All stated limitations and parameters are those 1/4 : 12 THRUOUGH 4:12 ROOF SLOPE standards imposed by MPact. Wider widths and greater roof slopes are available upon request. Introduction to Metal Buildings 31 Lesson 3 Modular Buildings A modular building (with interior columns) is specially designed for large buildings such as manufacturing plants, warehouses, truck terminals, and retail stores. Interior columns are either built up 'H' columns or pipe columns. 'H' columns are mandatory in a building with a top running crane. Modular buildings combine the proven practicality of a rigid frame with almost unlimited size flexibility. With a building that is 100' wide or less, the building can be designed with both clearspan frames and modular frames. This could serve the benefit of having a portion of the building with an unobstructed floor area while maintaining the cost savings of a modular building. Lean-to Modular buildings are also possible in any symmetrical, unsymmetrical, and single slope building size and The lean-to is ideally suited to give that extra space shape as a standard product offering. Inside the mod- needed alongside the building. The lean-to ties in at or ular building there is almost total flexibility in below the eave of the building and can provide a variety determining the height, width, and roof slope is wanted: of uses, from just a covered area to a completely building widths from 40' - 500'; eave heights from 10' - enclosed addition to your building. A lean-to structure 30'; roof slopes from ¹⁄₄:12 to 4:12; and interior module has only one slope and depends upon another structure spacing from 20' to 100'. Modules are defined as the for partial support. A lean-to can be located at eave or space between interior columns. MPact is limited to 8 below eave of the supporting structure. interior modules but more modules are available on TIE-IN GIRT MAIN FRAME request. Building widths of 40' - 80' are available with the option of straight columns instead of tapered columns. Lean-tos are also available for future expan- SHEETING ANGLE (IF SHEETED BELOW) sion or additional space if the original main structure had been designed to support the additional load of a lean-to. LEAN-TO PURLIN MODULAR BUILDING WITH 1 INTERIOR COLUMN LEAN-TO LEAN-TO BRACKET RAFTER (AT BY-PASS GIRTS ONLY) (2 MODULES) LEAN-TO CONNECTION A lean-to is limited to 60' wide as standard and only has a straight column at the low side and a rafter. The rafter attaches to the supporting structure's column. Therefore, it is imperative that the bay spacing of a MODULAR BUILDING WITH 2 INTERIOR COLUMNS (3 MODULES) lean-to equals the bay spacing of the supporting structure. Endwall guidelines for Lean-tos: 1. A lean-to with a bearing frame endwall may be attached to buildings having a bearing frame, an SINGLE SLOPE MODULAR BUILDING expandable main frame, or a non-expandable WITH 1 INTERIOR COLUMN (2 MODULES) main frame endwall. 32 Introduction to Metal Buildings Lesson 3 2. When the lean-to does not extend the full length of also serve as columns for attachment of the endwall the main building and begins or ends at an interior girts and transmit wind load into the foundation and main frame, the bearing frame endwall is the stan- structural system. Bearing Frame Endwalls also require dard condition but also could be a main frame a form of bracing, whether it be X-bracing, portal endwall if necessary. frames, or diaphragm action. 3. If an expandable or non-expandable main frame The use of a bearing frame endwall is a matter of endwall is used on both the lean-to and the main economy. You will usually find the prices of the bearing building the endwall may be completely open. frame endwalls to be less than one half the cost of the expandable main frame endwalls. Endwall Types Endwall Cost Considerations Endwalls are available in three basic types: It is important to recognize that the different types of • Expandable Main Frame endwalls can be interchanged to offer advantages in • Non-Expandable Main Frame specific applications. • Bearing Frame The expandable clearspan main frame endwall can provide an entirely open endwall up to 150' wide. This Expandable Main Frames could be the answer to a covered truck dock across the end of the building; or, total flexibility in placement of The expandable main frame endwall is a combination of framed openings. the standard main frame with endwall columns. The It is also possible to interchange the interior modular endwall columns do not support the rafter but serve only main frames comprised of different modular spacing. as columns for attachment of endwall girts and transmit For example: the wind load into the foundation and structural frame. The 120' wide building could have 3 - 40' wide modules The expandable main frame's largest advantage is that or 2 - 60' wide modules. By interchanging some 60' it provides for easy expansion. Since it is a main frame module frames within the structural system we can it will carry the design load of a full bay, and it can retain the lower cost of the interior columns yet provide remain in-place if the building is expanded. larger unobstructed areas. Non-Expandable Main Frames Also, using the 3 - 40' modular main frame endwall in place of the 2 - 60' module spacing, you would be able The non-expandable main frame endwall is still a main to place an overhead door in the center of the endwall frame with endwall columns, but cannot be used for without difficulty. future expansion. The non-expandable frame can only carry the design load of one half bay. Many times the ability to interchange frames and endwalls can bring about cost reductions, which will amount Both the Expandable and Non-Expandable main frame to several thousands of dollars. These can be very endwalls provide for more flexibility and ease in locating important savings if you are working against competi- large framed openings or entrance doors. Locate the tion or a low budget. Keep in mind the largest benefit of openings by simply adjusting the endwall columns our MPact Pricing/Design software is that you can spacing. Also, the main frame endwalls do not require process your project several different ways to arrive at any form of bracing, therefore, X-bracing or portal the most economical price without dedicating a lot of frames will not interfere with large openings. time or hassle. Bearing Frames Long Bay System Buildings ® A bearing frame (post and beam endwall) is our stan- Almost from the beginning of pre-engineered metal dard endwall condition. The endwall columns are buildings, designers and customers alike wanted to generally made of cee channel and at times can be push the limits of spans, heights, and loads. Expanding back to back cee channel. The bearing frame is sidewall bay spacing was one of the first limitations designed to support only one half bay of roof load, and challenged. Bays over 25' feet were pushed to 30' and cannot be used to expand the building in the future. later 35'-40' with the beefed up traditional "Z" or "C" sec- The endwall columns support the channel rafter and tion roof purlins (secondary framing). For bay spacing Introduction to Metal Buildings 33 Lesson 3 greater than 40' the only available option was to out- Long Bay® System buildings are easily adapted to tilt- source bar joists and substitute them for purlins. This wall, concrete block, or conventional metal wall often added costs and delays to projects and deliveries. systems. Single-ply, built-up, or Double-Lok® roofing In the summer of 1999 Mesco introduced the Long Bay® systems compatible with LBS offer customers complete System with it's open web purlin; such an innovative flexibility when planning new facilities. product that a patent is registered. The LBS open web purlin is fabricated of 12-16 gauge steel and custom designed web depths from 12" to 36", primed gray or red. Galvanizing is also an option. The open web purlin (OWP) or Long Bay® System MPact is used in the "Quotation Request" mode for cus- (LBS) allows sidewall bay spacing to be stretched to 60 tomer information, loads, codes, etc. that are necessary feet. The cold-rolled virtual square tube design is light, to assist and facilitate a manual estimate. Because of strong and straight and features bolted or welded con- the large size of these projects custom engineering and nections (to frames) and self-drilling fastener estimating is required. attachments for roofing. The most efficient design of LBS's buildings are modular frame buildings with a Cost efficient usage of the LBS is often but not limited 50'x50' grid. to large warehouses, distribution centers, and manufacturing buildings. High roof slopes, large clearspans, unusual shape, and small specialty buildings usually are not the most efficient use of the system. These building types will make up a major product line for you and your company, and will undoubtedly be a good part of your sales revenue. Our product line is well established in the market place and recognized for its quality, low cost, quick and easy erection, versatility, and adaptability. Conventional Steel Structures Mesco Building Solutions has formed the Steel Structures division, which specializes in structural projects and special construction needs. While the terms 34 Introduction to Metal Buildings Lesson 3 "structural steel" and "structural quality steel" are in common usage, there has never been a precise defini- Conclusion tion of these terms. In general, structural steel is defined This section covered the different types of buildings as a hot-rolled member that is formed while still in a "red your manufacturer has to offer in its standard product hot" state by pushing it through rolls that define the line. Clearspan buildings allow for the maximum use of shape. Cold-forming for structural sections uses cold- interior space, where the modular buildings use interior state material in a sheet or strip of uniform thickness columns to expand the standard width from 150' to 500'. and feeds it continuously through successive pairs of Both the clearspan and modular buildings are offered in rolls. The main difference between hot-rolled and cold- the gable symmetrical (a ridged double sloped building formed members is that hot-rolled are significantly in which the ridge is in the center of the building), the thicker. The process that is used to manufacture a gable unsymmetrical (a ridged double sloped building in member for a building depends on the requirements which the ridge is off-center), and the single slope (a and specifications for the building. sloping roof in one plane). When extra space is needed along the side of a building, a clearspan or modular building can be designed to support a lean-to. Mesco Building Solutions offers many different types of buildings as its standard product line. The product line is well established in the market place and is recognized for its quality, low cost, versatility, adaptability, and quick and easy erection. Being familiar with the standard product line will provide easy solutions that conform to customer's needs or requirements. Whether a pre-engineered metal building or a conventional structural steel building, Mesco Building Solutions has the solution. Buildings that people see and use everyday are usually pre-engineered or conventional buildings. The common denominator utilized in the construction of these buildings is steel. The concepts of these two types of buildings are quite similar in their overall function, but are built-up of different pieces and components. A pre- engineered building is usually designed by the metal building manufacturer (such as Mesco Building Systems), based on codes and loads given by the owner, architect, engineer, state, county or city. The steel that is utilized in the construction is mostly made- up of plate and cold-form materials. A conventional building is pre-designed and pre-defined by an engineer that has been carefully appointed by the architect or owner for specific needs for that building. The members that have been selected in the construction of this type of building are usually hot-rolled materials, such as wide flanges, pipes, tube steel, angles, and plates. Joists and truss girders are also commonly utilized with conventional structural steel structures. Introduction to Metal Buildings 35 Lesson 3 Self Test Lesson Three: Self-Test 1. What type of building allows for the maximum use of uninterrupted interior space? A. Modular Building B. A building with Interior Columns C. Lean-to D. Clearspan Building E. None of the Above 2. Clearspan buildings with tapered columns are limited to 180' as a standard. A. True B. False 3. A modular building with 3 interior columns will have how many modules? A. 1 B. 3 C. 2 D. 5 E. 4 4. The most economical endwall is a (this question is not considering the width of the building, endwall column spacing, or the loads of the building)? A. Expandable Main Frame B. Bearing Frame C. Non-Expandable Main Frame 5. Which type of building is not a self-supporting structure? A. Single Slope B. Gable Unsymmetrical C. Gable Symmetrical D. Lean-to 6. When a lean-to does not extend the full length of the main building and begins or ends at an interior main frame, a bearing frame endwall is the standard condition on the lean-to. However, a main frame endwall could be used if necessary. A. True B. False 7. Is it imperative that the bay spacing of a lean-to equals the bay spacing of the supporting structure? A. Yes B. No 8. Long Bay buildings refer to: A. Large clearspan structures B. Unobstructed craneway buildings C. Lengthening sidewall bay spacing D. Increasing interior module spacing 9. The best roof framing system for 50' sidewall bay spacing on a metal building is: A. 10"-12" Zee purlins 12 gauge B. Mesco's Long Bay® System C. Bar joists 36 Introduction to Metal Buildings Lesson 3 Self Test 10. When utilizing Mesco's Long Bay® System, which roof option is available? A. EPDM B. Awaplan single-ply C. Gravel ballasted built-up D. Machine seamed standing seam E. All of the above 11. Long Bay® System open web purlins are available gray, red primed and galvanized. A. True B. False 12. An octagonal clearspan church sanctuary with a 12:12 roof slope is a good candidate for LBS. A. True B. False 13. What process is used to manufacture structural steel members? A. Pressure pressing B. Cold-forming C. Hot-rolling D. Pressure rolling E. A & C F. B & C G. None Introduction to Metal Buildings 37 Lesson 4 Lesson Four: Introduction to Covering Systems Sam, a builder salesperson, and his neighbor, Joe, pre-engineered metal buildings because of these tradi- were driving out of town one weekend. Leaving the out- tional beliefs. Those prospects who do often base their skirts of a medium-sized town, they drove past a motives on a misconception that this is the cheapest recently completed building, a very attractive retail way to build. storefront. Your job as a salesperson involves enlightening people "That's one of our buildings. I sold that job." Sam about the modern way to build. One excellent way to proudly pointed out. begin is to point out the pre-engineered buildings in use in your area, as Sam did for Joe. This will help assure Joe was a little perplexed as he asked, "That's a metal front yard status for your building products and services. building?" "That is a metal building," Sam replied. Performance of Covering Systems Joe thought for a minute and then said, "I knew you sold The basic structural system of a building is designed to metal buildings, of course, but I didn't know you built resist forces imposed on it, such as live, dead, and wind anything like the one we just passed. I guess I had loads. In addition, the covering system of roof and walls something else in mind." provide a skin, which protects the building and its con- "You mean, like 'tin' sheds?" asked Sam. tents against the elements: rain, snow, ice, wind, heat, and cold. Joe laughed before his next remark. "Well, now that you mention it, I guess that is what I had in mind." Although the resistant and protective features of these two systems are of vital importance, the casual Sam settled back in his seat. "You know, Joe, most observer obtains his/her first and most lasting impres- people have the same reaction. And it is true that there sion of the building from its appearance, and are quite a few tin sheds around the country, especially appearance is an important function of any building's the ones built years ago. Originally, metal buildings complete covering system of roof and walls. (The term were used primarily as utility or backyard structures. "walls" includes both endwalls and sidewalls.) Many are still used this way, of course, but new and better material, plus advanced design and fabrication When evaluating a completed building, we tend to con- have introduced a modern way to build which has sider the roof primarily in terms of protection, and the become increasingly popular in many other building walls in terms of appearance. However, a successful markets." covering system must possess other, less obvious, but equally important features. As Sam continued to talk about his work, and about some of the buildings he had sold, one more person 10 Important Features of a Covering System became acquainted with today's modern way to build. Attractive in APPEARANCE This particular scenario is not necessarily a true story, Offers PROTECTION from the elements but the situation it describes is. If you have not yet had Possesses STRUCTURAL STABILITY a similar experience, you will. Every day, more and Withstands EXPANSION and CONTRACTION more uninformed individuals are surprised to learn that Insulates against HEAT and COLD many of the most attractive and functional buildings Controls MOISTURE condensation around them are basically factory engineered, fabri- Offers resistance to SOUND transmission cated metal structures and components. Why? It is simply because most individuals still visualize any metal Protects against FIRE building as a utility or backyard shelter made of plain ECONOMICAL to own and maintain corrugated metal sheets. Furthermore, they believe that Allows EASY INSTALLATION of accessories buildings used for commercial, community, or industrial Obviously, each of these important individual functions purposes must have massive walls to support the roof offers potential benefits to the building owner. Although and keep out heat and cold. all may not be required on any specific job, each should Unfortunately, many potential building prospects may be considered to meet the customer's needs and never give serious thought to contracting builders of desires. 38 Introduction to Metal Buildings Lesson 4 1. Appearance components can range from 10 degrees below zero to 140 degrees or more above it. Since cold Remember that most customers place a high value causes materials to contract, and heat causes on the appearance of a covering system. While them to expand, good building designs must take they usually direct most of their attention to the these factors into consideration. Concrete high- walls, some take a critical look at the roof as well. ways and steel bridges provide for movement Appearance is particularly important in commercial caused by expansion and contraction by means of and community installations, where the covering movable joints at regular intervals. The joints act system becomes the face of the building shown to as safety valves and allow controlled movement in the public and the image that the occupant proj- the structure. ects. Consequently, you will find many selling Well-designed masonry walls contain control joints situations where a great deal of time must be for the same reason. However, if too few of them devoted to the covering system, because appear- are used, or if they are improperly spaced, the wall ance is the customer's principal concern. will invariably crack as a result of temperature 2. Protection from the Elements changes. Such expansion and contraction cannot be eliminated; it can only be provided for in the Water is potentially the source of more mainte- building design with control joints and spandrel nance and repair problems than any other single beams. cause. 5. Insulation against Heat and Cold Whether in the form of snow, ice or wind-driven rain, water can find and penetrate the smallest Thermal transmission is the technical term gener- openings in a roof or wall. Result: damage to a ally used to describe heat flow. Roof and wall building's contents, discomfort for its inhabitants systems must be able to effectively resist the flow and eventual deterioration of the building itself as a of heat through them by possessing good insu- result of rot, corrosion or saturated insulation. lating characteristics. The entire covering system - panels, fasteners, To put it quite simply, a successful covering system sealants, flashings, and other components - must must do two things: work together to offer effective protection against A. Keep natural heat inside the building during the elements. winter, and 3. Structural Stability and Integrity B. Keep natural heat outside the building during All components of a covering system must have the summer. adequate strength and structural properties, since The total insulating value of the complete covering they are the first to offer resistance to loads and system must be known in order to calculate forces imposed on the building. heating and air conditioning requirement, and this The roof must be able to support its own weight, is often a key sales consideration. plus live loads, such as snow, ice, auxiliary and 6. Prevention of Moisture Condensation collateral loads, and be designed to resist wind. The wall system, on the other hand, must be Moisture condensation in a building can damage strong enough to resist predicted wind loads, wind both the structure and its contents by encouraging uplift, and abuse. rot, mildew and rusting. Condensation can even blister outside paints if the roof or wall does not Traditionally, many walls were load bearing to sup- contain a barrier (such as a metal sheet) to prevent port other components. One example is a concrete moisture penetration. block wall used to support the roof. The manufacturer's walls are designed as non-load bearing You are familiar, of course, with the formation of curtain walls and are not required to support the condensation on a glass of cold water or on a cold roof. windowpane. The same condition can occur on the inside of a building under similar conditions if it is 4. Expansion and Contraction not well designed with respect to insulation, A good covering system is designed to allow for heating and ventilation. expansion and contraction of its components as a The use to which a building is put may tend to reaction to temperature changes. In many parts of encourage or discourage condensation. For the United States, surface temperatures of building Introduction to Metal Buildings 39 Lesson 4 example, a laundry establishment represents high ering system, which the customer must consider in moisture occupancy, while a hardware or terms of his/her own particular operation and the end machinery warehouse usually has much lower use of his/her building. It is imperative that you become moisture content in the air. But the important thing as knowledgeable as you can about the covering sys- to remember is - water vapor is present in all build- tems. Only in this way will you be able to provide your ings. customer with the best solution to his/her building problem. Mesco covering systems incorporate some of the best insulating materials available. They employ efficient vapor barriers on the inside surface of The Components of a Covering roofs and walls to retard vapor penetration, which could saturate insulation and impair its efficiency. System 7. Resistance to Sound Transmission The remainder of this lesson will be devoted to identi- fying and describing the components, which make up a Sound waves that strike a surface are partially covering system. This will enable you to become reflected, partially absorbed and partially trans- familiar with the terms and specifications of various mitted through its mass, depending upon the type Mesco wall and roof systems to be presented later. of surface and the properties of the materials. You may have wondered why we refer to the covering 8. Protection from Fire as a system rather than simply walls and a roof. It is nat- Obviously, a desirable quality in a covering system ural to identify a particular wall or roof by naming the is its ability to prevent either the start or the spread basic material used in it. For example: a CMU, tilt-up of a fire. Its properties in this respect can have an wall, or metal roof. important bearing on insurance rates for the However, such a description is not complete, since building. In addition, fire resistance of materials most walls and roofs must consist of insulation, fas- generally must comply with local building codes teners, sealants, trim and finish, in addition to the basic and zoning laws. The fire protection classification material. Generally, the elements of a complete system, of construction materials is based on many factors, exclusive of accessories such as doors and windows, and the best source of information within your ter- will include some or all of the following components: ritory is that provided by local zoning and code authorities. • Structural Framing and Support 9. Economy of Ownership • Covering A good covering system can be economically eval- • Insulation uated in terms of a building's use and the value placed on it by the owner. Total cost of any system, • Joining and Fastening however, must include both the initial cost and the • Trim and Flashing long range or ultimate costs involved in maintenance, repairs, heating and cooling. As a salesperson, you will want to lead your prospect's Structural Framing and Support attention away from price only considerations and A covering system obtains its support and strength from toward the many benefits of Mesco products and either or both of two sources: services that add up to the lowest cost way to building well. 1. The Structural Frame 10. Easy Installation of Accessories 2. Its own Stability and Rigidity. The relative adaptability and workability of a cov- Mesco roofs are supported by, and attached to, purlins ering system for easy installation of such and eave struts. Mesco walls either hang on the struc- accessories as doors, windows and ventilators is tural framework or rest on the foundation, or both, and often an important consideration from the cus- attach to base angles, rake angles, girts and eave tomer's point of view. A good covering system must struts. possess enough flexibility to permit rapid installation of accessories, as well as easy relocation if the The role of structural framing is absolutely necessary, operations or use of the building should change. but the strength of the covering material itself is equally important. A properly designed covering system must These are the 10 performance factors of a good cov- have sufficient strength and rigidity to resist forces and 40 Introduction to Metal Buildings Lesson 4 transmit applied loads to the structural system. Light Roll-forming is a continuous process performed on a gauge metal covering materials are often fabricated machine consisting of a series of graduated metal rolls with corrugations or ribs or simply breaks in a specific arranged in pairs, (one on the top and one on the form or shape which will increase the strength, and also bottom) called stands. Instead of inserting single sheets enhance the appearance of the panel. of stock, metal may be fed through the rolls directly from coil stock, which may consist of hundreds of feet of con- The resulting form or shape of the metal sheet's cross- tinuous materials. As it progresses through the series of section is called configuration or panel profile. Shown rolls, each succeeding roll takes a comparatively below are three examples of Mesco's most common deeper bite to form the panel. wall panels, which are "PBR" panel, "PBA" panel, and "PBU" panel. "PBR" 36" 12" 1 1/4" COLOR "PBA" 36" 12" 1 1/8" COLOR "PBU" The roll-forming machine shown above has a number of stands, which enable gradual stages of forming. Each 36" forming stage should take only a slightly greater bite 6" COLOR 3/4" than the preceding stage in order to produce panels with precise tolerances and to avoid surface damage. The machine illustrated roll-forms the Mesco standard "PBR" panel. The panel is rolled from coil stock material The configuration of a metal panel, when properly that is Galvalume® Plus or has already been color designed and fabricated can provide substantial coated. The coil stock material is also illustrated below. increases in structural strength. Strong configuration of a metal panel is one of the major design factors employed in metal buildings. Mesco achieves many panel profiles or configuration by roll-forming the panel from pre-painted coils. Covering Thickness of material may be expressed in either inches or the decimal equivalent. Most of the time, Introduction to Metal Buildings 41 Lesson 4 thickness is referred to as a gauge, which is a standard good color finish. In any event, the first painted metal numbering system to designate the thickness of mate- buildings were coated by a standard procedure of rials. 29 gauge material is our lightest or thinnest gauge applying a good primer and then a good grade of com- used only for liner. Most of our standard panels are mercial paint. Generally, paint consist of three basic rolled with 26 or 24 gauge material, where all standing ingredients: seam panels are at a minimum of 24 gauge. The lower the gauge is the thicker the material. 1. Pigment - this gives the paint its color. 2. The vehicle or carrier - this provides paint with flex- Finishes ibility and offers protection of the pigment. Mesco's panels are available in three different finishes. 3. Solvent - this assures a compatible joining of the • Galvalume® Plus pigment and vehicle and proper curing. • Signature® 200 The wide selection and proportions possible with each of these basic ingredients are reasons why you see • Signature® 300 such a great number of paints available for so many different purposes. Galvalume® Plus Typical color finishes do not bond very well to metals, Recently a new development has introduced a new especially Galvalume® Plus steel is limited because of product called Galvalume® Plus. Galvalume® Plus is the the corrosion resistance. Therefore, it is necessary to trade name for a patented sheet steel product having a apply a primer to insure adequate adhesion of the highly corrosion resistant coating of 55% aluminum - system to the metal substrate and to obtain optimum 44% zinc alloy followed by a state-of-the-art polymeric corrosion resistance. passivation system. This newly developed passivation To capitalize and insure a quality product, in 1998 NCI system is a two component package consisting of an Building Systems purchased several coil-coating plants acrylic-based polymer resin system and an inorganic strategically located throughout the United States. corrosion inhibitor. These coil-coating plants use an innovative process of Galvalume® Plus is excellent where corrosion resist- oven-baking the finish on the coils. ance is required and can be used in high profile Coil stock goes through an exacting pre-cleaning and application like architectural panels and residential pretreatment process to insure proper adhesion of the roofing. Galvalume® Plus is also perfectly suited for Signature® 200 or Signature® 300 finish, uniformity of standing seam roofing applications. thickness, and flexibility for forming purposes. The fol- The base metal is 26 or 24 gauge Galvalume® Plus lowing is a typical process: steel. The base metal is pretreated and then primed 1. Coil stock starts by receiving a hot alkaline deter- with a primer for superior adhesion and superior resist- gent wash, under pressure, to remove oil and other ance to corrosion. The painted panels are available in residues. two finishes: Mesco's standard Signature® 200 or Mesco's premium finish Signature® 300. 2. Material is rinsed thoroughly. 3. A pretreatment coating system is applied. Signature® 200 and Signature® 300 4. The primer is roller coated on both sides. Appearance is one of the most important features of a 5. Polymer coat is oven-baked. covering system, particularly the walls. Nothing enhances the appearance of a wall more than the color 6. Final color finish is applied by roller coating to finish. In addition, the color finish of a building will often assure a uniform film of finish to the exterior sur- provide added protection against normal weathering. face and polyester baked to the interior surface. After early metal buildings were established as good utility buildings, people began to consider them for other 7. Finishes are oven-baked. uses. Galvanized steel was often painted to provide a A warranty is a very important sales tool. Almost as more pleasing appearance. This is certainly under- important as the warranty itself is the exacting means of standable, since color plays such an important role in judging whether or not the finish falls within the limita- our lives. Even bare wood or concrete block is not a par- tions of the warranty. A standard 20-year finish warranty ticularly attractive material unless it has been given a is available on all of our panels against peeling, blis- 42 Introduction to Metal Buildings Lesson 4 tering, cracking, fading, and chalking. This warranty manufacturer insulation, but the MPact program does covers cost of labor and material to repair, replace, or have the capability of pricing insulation within a building repaint material proved to be defective under the terms quote. The insulation is the standard white vinyl backing of the warranty. If you have never seen or heard of the in the thickness of 3", 4", or 6". However, it is good prac- 20-year finish warranty ask your District Manager to tice to work with a local insulation buyer in your area. supply you with a copy. Signature® 200 is Mesco's standard modified sili- Joining and Fastening conized polyester paint system. Most of Mesco's panels All the elements or parts that go together to make up a are available in the standard color offerings. Signature® complete wall or roof system must join and fasten 200 offers optimum exterior protection and resistance to together in such a manner to assure pleasing appear- chemical corrosion and ultraviolet radiation. This ance, good protection, and low maintenance. coating also offers excellent chalk, fade and mar resistance. Laps and Joints Signature® 300 is Mesco's premium fluorocarbon paint Lapping, tongue and groove, or snap down or mechan- system. Signature® 300 coating is formulated with ical seaming can be used to join the panel edges of two Kynar 500® /Hylar 5000® polyvinyulidene fluoride resin panels that are set side by side. and modified with a proprietary resin for toughness. This long-life finish offers the ultimate in color retention, film flexibility and durability. Fiberglass Another material available for use in the light transmitting panel is high strength translucent glass fiber LAP JOINT reinforced polyester. The light transmitting panels match the standard panel profiles and are ¹⁄₁₆" thick, weigh 8 ounces per square foot, and are white with a granitized top surface. Mesco's light transmitting panels are available in both insulated and uninsulated panels with a UL 90 Wind Uplift rating. Insulated light transmitting panels are available in "PBR" panel and Standing Seam Panel profiles only. The benefits of the use of light transmitting panels are obvious: TONGUE AND GROOVE • As light transmitting panels, the need for artificial SNAP DOWN SEAM light is reduced and electrical cost lowered. • As decorative panels, the appearance of a building is enhanced. Insulation It was mentioned earlier that one of the most important SNAP DOWN PROCESS jobs a covering system must perform is to retain heat inside a building during winter, and keep heat outside in MECHANICALLY SEAMED the summer. Heat flow cannot be stopped but it can be slowed considerably by using heat-reflective materials or colors, materials that are poor heat conductors, or by trapping still air. Therefore, a good insulation may have a reflective surface exposed to heat, plus many small cells or pockets to trap and hold air as still as possible. This explains why most good insulating materials are made of light, fluffy substances like fiberglass, organic MECHANICALLY SEAMING PROCESS fibers, cotton, cork or foamed plastics. Mesco does not Introduction to Metal Buildings 43 Lesson 4 Endlap an adequate distance, which is a 3" minimum overlap. Wall panels may also be lapped with the upper panel When two panels are to be joined together end to end, over the lower, although this is not a common practice. the intersection is identified as an endlap or end-joint Wall panels are cut to run continuously from floor to condition.The following illustration shows how the roofline. The standard maximum length panel is 50'. panels should be installed with back-up plates. Also However, longer panels are available upon request. shown is the sequence of installing the fasteners for endlap panels. Since sidelap and end-lap conditions occur in most covering systems, they deserve a substantial amount of COMPLETE ENGAGEMENT attention both in design and in selection of materials to OF BACK-UP PLATES do a specific job. It is important to note that the fewer the joints in any covering system, the less chance for problems of weather tightness to arise. Thus, the wider the panel, the fewer the sidelap conditions and the longer the panel, the fewer the end-lap conditions. Mesco's standard practice of roll forming from coil sheet stock has made it possible to reduce substantially the number of endlaps and sidelaps in the total covering system. Sealants Regardless of the joining and fastening method used in a covering system, a sealer, or sealant, is invariably used to provide added protection and weather tightness. Three basic types of sealants are: Tube Sealant: such as mastic from a caulking gun. Tape Sealant: Tri-Bead - often referred to as mastic tape. It is used at the eave, outside closures, endlaps, and trim connections. Minor Rib - used to fill voids at minor ribs of the panel at the eave. Factory Applied Sealant: a foam sealant that consists of a glue and gas mixture that is factory injected into the female leg of the standing seam panels. Fasteners The fastening or attaching of panels to structural members and to neighboring panels is of such prime importance that they are emphasized frequently in FASTENER # 1E selling situations. As the design and material of the cov- ALL LOCATIONS ering panels have improved throughout the years, so 4 have the methods of fastening. Standard fasteners come in two (2) types and groups, 7 1 3 2 5 6 8 various lengths and colors, and three (3) different grades. Using the correct fastener for the right job is vital. It is important to take into account the location, application, and circumstances when choosing the fastener that is best for the particular job. Joining is particularly important when weather protec- The two (2) types of fasteners are self-tapping and self- tion is being considered. Roof panels must always be drilling. The type that is used is determined by the joined so that the upper panel laps over the lower panel preference of the builder. The self-tapping screws 44 Introduction to Metal Buildings Lesson 4 require pre-drilling the panel/trim prior to applying the Again, the grade will be dependent on the specific fasteners. This step is not necessary for the self-drilling. needs of the customer and the building. The three The self-drilling fastener combines a unique non- grades are carbon steel or zinc capped head, which are walking point with a drill bit shaped tip to provide quick, also known as Long Life, and stainless steel. You positive penetration of both metal panels and steel should always use a Long-Life fastener (Zinc Capped or framing. The threads are engineered to maximize strip Stainless) when a finish warranty is desired. out and pull out values while avoiding over-driving torque. Electric Seamer Self-drilling fasteners should be used with unpunched panels and framing structural members. The self-drillers are now available in various sizes. Keep in mind that panel fasteners are used for two different purposes. One is for fastening the covering panel to the intermediate structural members. The second purpose is for attaching panels to one another, such as side-to-side or end-to-end. Panel screws are used for two (2) purposes. Depending on the use of the fastener, all fasteners will fall into one (1) of two (2) groups -- member screws and stitch screws. Fasteners used in panel-to-steel, trim-to-steel, and steel-to-steel applications are member screws. Mesco's mechanically seamed standing seam roof panel requires the use of an electric seamer. Unlike the other fastening systems, this system secures the panels side-by-side by seaming the panel edges together. A portable self-powered roll-forming machine MEMBER SCREW called the electric seamer does this seaming. Fasteners being used in panel-to-panel and trim-to- The electric seamer works at close tolerances and folds panel applications are stitch screws. The length of the the panel edges over twice creating a double standing member screws is primarily dependent on the thickness seam, which is weather tight. This mechanically formed of insulation used. Stitch screws are a standard length standing seam fastening system is a revolution in the (³⁄₄" for self-tapping and ⁷⁄₈" for self-drilling.) Fasteners metal roof industry. With the electric seamer, the cost of being used on colored panels or trim will match the the standing seam roof has been cut while its features color of the material, plain fasteners will be used on have been saved. Galvalume® panels. Trim and Flashing The final element of a good covering system is the method of handling its edges. For example, there must be some method of joining and finishing so that the tran- sitions from wall panels to roof panels offer both weather protection and good appearance. Flashing is a word used to describe a material for STITCH SCREW joining two components together to provide proper weather tightness. Fasteners come in three (3) grades. The grades apply Trim on the other hand, generally refers to a material or to the material of which the fastener is constructed. part used to finish out and cover a joint or juncture to Introduction to Metal Buildings 45 Lesson 4 EAVE TRIM GUTTER RIDGE FLASHING RAKE TRIM DIE FORMED RIDGE RAKE ANGLE PEAK BOX WALL PANEL FLASHING, GUTTER, AND TRIM NOTE: TRIM PROFILE MAY VARY improve appearance.Gutter refers to a channel member ments, all of which are very important to the complete installed at the eave of the roof for the purpose of car- building system. In presenting the various elements of rying water from the roof to the drains or downspouts. the Mesco covering system, we have tried to acquaint you with the terminology used in the metal building Conclusion industry. We have also tried to provide a brief description of the products and methods associated with the The purpose of this lesson was to encourage you to Mesco wall and roof systems. think of a covering system as possessing several ele- 46 Introduction to Metal Buildings Lesson 4 Self Test Lesson Four: Self-Test 1. Why do many potential building prospects never give serious consideration to a pre-engineered metal building? A. Traditional Beliefs B. Misconceptions C. Lack of knowledge of Pre-engineered Metal Buildings D. All of the Above 2. What are the two most obvious, but equally important, features of a covering system, (as stated in this manual)? A. Structural Stability and Resistance to Sound B. Economical and Easy Installation C. Appearance and Protection D. Control Moisture Condensation and Protect Against Fire 3. A properly designed covering system must have sufficient strength and rigidity to resist forces and transmit applied loads to the structural system. A. True B. False 4. Mesco's panels are available in what finishes? A. Galvanized Steel, Signature® 200, and Galvalume® Plus B. Galvalume® Plus, Galvanized Steel, and Kynar® C. Galvalume® Plus, Signature® 300, and Signature® 200 5. Roll-Forming is a continuous process performed on a machine consisting of a series of graduated metal rolls arranged in pairs, called stands. A. True B. False 6. An end-lap is when two panels join together end to end. Roof panels must always be joined so that the upper panel laps over the lower panel an adequate distance. What is the minimum overlap distance? A. 4" B. 10" C. 5' D. 3" E. 8" 7. Self-drilling fasteners should be used with pre-punched panels and framing structural members. A. True B. False 8. When fastening a wall panel to a girt, it is considered? A. Roof Panel to Panel B. Wall Panel to Panel C. Roof Panel to Structure D. Wall Panel to Structure Introduction to Metal Buildings 47 Lesson 4 Self Test 9. What word is used to describe a material for joining two components together to provide proper weather tightness? A. Trim B. Gutter C. Flashing D. Rake E. None of the Above 10. A complete covering system consists of several elements, such as, structural framing, covering material, insulation, joining/fastening finishes, and trim/flashing. A. True B. False 11. Water vapor is present in all buildings. A. True B. False 12. A wall system attaches to which of the following? A. Base Angles B. Rake Angles C. Girts D. Eave Struts E. All of the Above 48 Introduction to Metal Buildings Lesson 5 Lesson Five: The Roof System Throughout history man has had to satisfy the basic It is difficult to present information of a general nature need of a "roof over his head" to shelter himself, his on built-up roofs because so many types are available. family, and his possessions from cold, heat, rain, and A comparison of any two built-up roofs must take into snow. At first, this protection from the elements was consideration the relative quality of materials and work- very simple, even crude in form; but as man became manship, as well as any differences in basic design. more and more civilized he demanded better and more elaborate protection. Through succeeding centuries he Built-up roofing can be laid on decking made of wood, learned many things about shielding himself from the steel, gypsum, or concrete slab. Probably the most elements. Through trial and error, he has sorted through common roof in use today is installed on steel decking, a multitude of different materials, trying to find the ideal which is supported by a bar joist system. Bar joists are combination for roofing materials that were strong, but actually structural features and are not really pertinent not too heavy, and materials that were long-lasting and to a study of built-up roofing. However, it is important to resistant to weathering, and materials that would not note that they must be designed to span distances that leak, blow away, or fall apart. do not exceed the steel roof deck design conditions for live and dead loads. Steel roof decking is usually made Today, we see many kinds of roofs and roofing mate- of 22 or 24 gauge steel and is fastened to the bar joists rials; wood shingle, plastic or composition shingles, tar by welds or screws. Although different applicators might paper, tile, slate, built-up roofs, and various kinds of use a variation of materials and procedures, here is one metal roofs. For our purposes we need only study the example of a built-up roof on a metal deck. types most frequently used for nonresidential use: Built- Up Roofs, Single-Ply Roofs, and Metal Roofs. The Built-Up Roof INSULATION BOARD Built-up roofing is so called simply because it is a combination of layers of various materials built-up into a composite covering from a base or roof deck. This type of roof is particularly suitable for flat surfaces; and when made of good materials and properly installed, it may provide satisfactory protection from the elements for many types of commercial, community, and industrial buildings. METAL DECK ADHESIVE METAL DECK The first step involves the installation of rigid board roof insulation with screws or nails through disks or plates. If a second layer of insulation is specified the joints are staggered and a recommended adhesive or asphaltic bitumen bonds the two layers together. Once in place the insulation is mopped or strip coated in preparation for the next layers. Introduction to Metal Buildings 49 Lesson 5 Next, several layers of roofing felt are laid between Advantages of a Built-Up Roof mopped-on layers of heavy bitumen. Roofing felt is made of heavy paper or cloth, impregnated with water- 1. Built-Up roofs accommodate roof penetrations with proofing materials. Generally from 3 to 5 layers are relative ease. applied. The number of layers properly installed deter- 2. Built-up roofs have enjoyed public acceptance for mines the permanence of the roof system. many years. 3. Built-up roofs are well adapted to the construction of flat or very low pitch roofs FELTS TAR Disadvantages of a Built-Up Roof 1. Due to ultra-violet breakdown, the life cycle expectancy of this type of roof system is very limited. 2. Maintenance is often necessary and expensive. Tars and asphalts gradually lose their natural oils, dry out and crack with exposure to the natural elements. 3. The bonds or warranty on built-up roofs have many limiting conditions. INSULATION BOARD 4. They are not usually fire-safe. METAL DECK 5. Trouble spots and damage are not easily detected until it is too late to correct them economically. Single-Ply Roofing Membranes A new generation of roofing membranes has estab- TAR AND lished itself along side the traditional built-up roofs. GRAVEL Made of synthetic elastomers, the new materials are FELTS generally provided in preformed sheets. The preformed sheets are delivered to the site in rolls. The rolls are sometimes large enough to cover an entire roof area, but most of the time; successive strips are placed adjacent to one another and sealed where they overlap. The ability of elastomeric to elongate, even in sub- freezing temperatures, may be their greatest asset as roofing membranes. Substrate movement, a by product of normal building movement, is accommodated by INSULATION elastomeric roofing systems with its physical character- BOARD istics and installation techniques. Elastomeric roofing METAL DECK membranes are in general single-layered, synthetic polymer materials with elastic properties. Types of Single-Ply Roofing Finally, a protective-wearing surface of gravel, slag, marble chips, or a roof coating material is often spread Membranes: over the topcoat of tar. Shown is a cutaway view of the Neoprene: The first synthetic rubber. Neoprene various layers, which make up a typical built-up roof. exhibits good resistance to petroleum oils, solvents, Built-up roofs represent an area of considerable com- heat and weathering. petition, and you will find it beneficial to become knowledgeable on the various types and methods used EPDM: An elastomer synthesized from ethylene, propy- in your area. lene and a small proportion of a diene monomer. It has 50 Introduction to Metal Buildings Lesson 5 good resistance to ozone and is inexpensive, and light- directly on the substrate without attachment. There is no weight. bonding between the loose laid membrane and the substrate, except at the perimeter of the roof and at the roof Thermoplastic Materials penetrations. These areas require careful design and installation. If the membrane consists of more than one PVC (polyvinyl chloride): Through plasticizing and section, a sealing technique is applied to achieve a proper formulation, PVC materials can be obtained band at the laps. The ballast weight is typically specified which show elastomeric properties and ease of installa- between 5 and 10 pounds per square inch, depending tion. on the size and shape, and protects the membrane from the ultra violet rays of the sun and wind uplift. ECB: This thermoplastic material is a mixture of ethylene, copolymer, bitumen, and anthracite micro-dust. The membrane resists aging and the effects of weath- Partially Adhered ering, and can be repeatedly heat formed without The partially adhered is a modification of the loose laid detriment to its original qualities. system. The partially adhered system provides for a PVC and EPDM currently dominate the preformed restricted amount of movement and partial bonding is sheet market. achieved with the use of adhesive or with a combination of adhesive and mechanical fasteners. If adhesive is Methods of Erection Elastomeric Roofing the bonding agent, it is applied in strips to allow for a specified percentage of unbonded area. To separate Membranes Can Be Installed in One of Three sections of the membrane from the substrate, a bond Ways: breaker such as masking tape is sometimes used. 1. Loose Laid 2. Partially Adhered SINGLE PLY 3. Fully Adhered MEMBRANE ADHESIVE Loose Laid MECHANICAL FASTENER The loose laid system directly illustrates the principle (NAIL OR SCREW) behind elastomeric membrane design: floating free, the roofing membrane expands to accommodate substrate movement at any part of the roof. BALLAST SINGLE PLY INSULATION MEMBRANE BOARD METAL DECK If bonding with mechanical fasteners, generally nails or screws with disks or plates, are installed on top of the insulation and serve to attach the insulation to the roof deck (substrate). The membrane is then bonded to the disks or insulation board with the adhesive. INSULATION BOARD METAL DECK Fully Adhered The fully adhered system bonds the entire membrane to substrate with an adhesive and often with mechanical A typical loose laid system is held in place with ballast, fasteners as well. The fully adhered system functions preferably river bottom gravel. Insulation is placed very much like a conventional built-up roof. Introduction to Metal Buildings 51 Lesson 5 to both substrate and to the bottom surface of the membrane. The sheets bond directly to the substrate, and mechanical pressure is usually applied to assure bond SINGLE PLY strength. MEMBRANE ADHESIVE Heat welding is used with thermoplastic materials such as PVC. A controlled source of heat melts the material until it welds itself together. Solvent welding is again used with materials such as PVC and is a technique interchangeable with heat welding. The material becomes soluble in solvent cement and the seams are fused together. Immediately afterward mechanical pressure should be applied to achieve proper bond strength. Other methods are utilized with other materials, but the INSULATION methods just described are primarily used. BOARD METAL DECK Advantages of Single-Ply Membranes 1. Economical Installation 2. Roof Penetrations are Easily Accommodated The decks (substrates) commonly used with elastomeric systems are rigid board insulation with metal 3. Expansion and Contraction deck, concrete, and plywood. 4. Lightweight Seams Disadvantages of Single-Ply Membranes The integrity of elastomeric roofing systems is directly 1. Short Life Cycle (Ultra-Violet Breakdown) related to the proper installation of seams. Two types of seams are performed with elastomeric sheets, most 2. Dependency Upon Workmanship commonly lap seams and very infrequently, butt seams. 3. Susceptible to Foot Traffic Punctures 4. High Cost of Material 6. Material is Combustible Metal Roofs Even though we have frequently pointed to metal buildings as the "modern way to build", it is interesting to observe that metals have long been recognized as the best roofing materials. In order to obtain the many advantages offered by metal at a reasonable price, today's building owner can now LAP SEAM turn to roof panels made of either aluminum, aluminum- zinc alloy coated steel, or aluminum clad steel; all of which are available at relatively economical prices. Originally, metal sheets used for roofing were flat and it was necessary to join them by either welding or sol- Both sealants and sealing techniques must be compat- dering, or to introduce lap seams and joints. To facilitate ible with the membrane materials. The following is a list this type of installation, it became a common practice to of sealing methods and materials: crimp or flange the edges of the panels. Later, in order Adhesive is used with thermosetting materials such as to provide panels with greater strength, the metal sheet neoprene and EPDM. The adhesive is usually applied was formed so as to have ribs or corrugations. 52 Introduction to Metal Buildings Lesson 5 The illustration below represents an early application of 2. Die formed ridge saves time on installation. this principle of the continuous corrugated panel. Although largely replaced by more appealing configura- 3. The panel is available from all plants allowing low tions, it is still available through our components division freight to any location. and is known as the "C" and "D" panel. The "D" panel 4. Start installation at either end; therefore, allows has the extra purlin bearing leg for roof application. flexible installation. Standard Screw Down Roof Panel 5. The economical profile is cost effective. 6. Finish Warranty available. The panel has a 20-year To help achieve just the look you want in your new life span when used with long life fasteners. building, we have a selection of attractive, long-life, low- maintenance panel systems. 7. Wind Uplift Rating. The panel qualifies under several UL90 construction numbers. The deep-ribbed "PBR" panel is ideal for roof and wall applications. It provides an even-shadowed look 8. Profile light transmitting panels are available for designed for commercial and industrial applications. the "PBR" Panel. 9. Extra Purlin Bearing Leg ensures flush fit for better "PBR" Panel sidelap connections, and fewer leaks. "PBR" Roof Panel Installation 36" Coverage 12" 12" 12" It is recommended that both sides of the ridge of a building be sheeted simultaneously. This will keep the 1 1/4" 1" ³⁄₄" 4" 4" insulation covered for the maximum amount of time, COLOR and the panel ribs can be kept in proper alignment for the ridge panel or cap. As the sheeting progresses, ³⁄₁₆" 3¹⁄₂" 1³⁄₈" check for proper coverage. See illustration for panel "PBR" Panel sheeting sequence. Description: This purlin bearing leg panel is used for the roof, deep ribs create an even-shadowed appear- 13 1 ance. The area between the ribs is reinforced. 1 0 1 14 2 1 Gauge: 26 and 24 15 9 Length: 45' maximum is standard but longer lengths 6 8 available by special request. 5 7 3 4 Fasteners: Standard coated, zinc- aluminum cast 2 1 head, or stainless steel head screw. Dimensions: 36" coverage x 1¹⁄₄" deep. Finish: Galvalume® Plus and Commercial - Industrial Series. Usage: Roof or wall panel applications. As a roof panel the "PBR" panel offers the extra purlin bearing leg and offers more leakage protection. Ridge Panel/Cap Limitations: Not designed for coverage over bar joist. The ridge of the building is the horizontal line formed by Not designed to be used as rigid secondary. Five foot opposing sloping sides of a roof running parallel with on center purlin spacing. the building length. The ridge is covered by a transition Features and Benefits of the "PBR" Panel: of the roofing material, often called a Ridge Panel or Ridge Cap. When a ridge panel matches the configura- 1. 36" coverage allows ease of installation. tion of the roof panel, it is called a die formed ridge panel. Introduction to Metal Buildings 53 Lesson 5 Die formed ridge panels are to be installed as each side proof, since the only penetration made in the roof of the roof is sheeted. This aids in keeping both sides of during installation is in the eave panel, which is the roof aligned. See illustration for clarification. located outside the building shell. Standing Seam eliminates penetrations elsewhere in the roof, which are the major causes of leaks. DIE FORMED 3. Ideal Retrofit Roof System ROOF RIDGE FASTENERS Standing Seam systems are ideal for new building roofs, and as a replacement roof for older buildings having either a metal or built-up roof. In some cases standing seam panels can be installed without interrupting normal business operations. TAPE When retrofitting with standing seam, building SEALANT owners also have the opportunity to install additional insulation that can result in significantly lower heating and cooling costs. 4. Energy Efficient/Lower Operating Costs Standing Seam roof systems easily accommodate insulation material to provide a building that is highly energy efficient. When special insulation requirements occur, thermal barrier materials are RIDGE PURLINS TAPE SEALANT available for use over the purlins in order to effectively reduce heat transfer and maintain the thermal integrity of the roof system. Properly installed, a building with a standing seam Standing Seam Roof Panel Systems roof system can mean lower initial heating and cooling equipment costs, as well as lower fuel Mesco offers four different Standing Seam Roof Panel costs over the life of the structure. Systems: 5. Technical Support • Ultra-Dek® Mesco's technical staff supports the needs of • Double-Lok® architects, contractors and owners by providing detailed product specification information and • BattenLok® engineering or design assistance. The standing • SuperLok® seam roof systems are designed to meet the ever- changing AISI specifications and other industry The screw down roof is obviously the most economical codes. This technical support ensures that each choice for a roofing system. However, at times a roof roof is right for each building. may require a standing seam panel system, especially, 6. Longevity of Materials on a building with a roof slope of ¹⁄₂:12 or less. Overall benefits and selling points of a standing seam roof To ensure long life, all standing seam roof systems system are: are formed from 24 gauge Galvalume® Plus, an aluminum-zinc alloy coating applied to the steel 1. Unique Floating Clip substrate by the hot-dip process in accordance The standing seam system is designed to cope with ASTM A-792. with the forces of expansion and contraction with a When a painted finish is desired, Mesco offers their unique floating steel clip that allows the roof panels superior Signature® 300 fluorocarbon paint to move freely up and down the roof slope. The coating, formulated with 70% polyvinyulidene fluo- floating clip is also self-centering, insuring thermal ride resins. Mesco stands behind Signature® 300 expansion capability in either direction. painted panels with a comprehensive optional war- 2. Virtually Leak Proof ranty assuring protection for up to twenty years against blistering, peeling, cracking, chipping, The Standing Seam Systems are virtually leak excessive color fade and chalk. 54 Introduction to Metal Buildings Lesson 5 7. System Quality and Performance Limitations: Recommended for roof slopes of ¹⁄₄:12 or greater. When using the fixed clip we recommend Mesco systems and products are manufactured in for double slope buildings 200' wide or less, and single facilities that are Category MB quality certified by slope buildings 100' wide or less. (May vary upon the American Institute of Steel Construction. The extreme weather conditions). standing seam roof systems eliminate the need for through fasteners by interlocking panel edges at a raised seam, utilizing a factory applied sealant. 24" This, in conjunction with the floating action of the concealed clip assembly, is the basis of the supe- 3" rior performance of Mesco's standing seam roof COLOR systems. Combined with weather tight construc- 19³⁄₈" tion, excellent materials and overall strength these qualities result in a versatile, efficient and maintenance free roof system with a lasting appearance and structural integrity. SNAP DOWN SEAM Ultra-Dek® and Double-Lok® Panel Size: 24" wide, 3" high standing seam Configuration: The female leg is suitable to accept the other male leg and form a locking assembly or seam. SNAP DOWN ENGAGEMENT Gauge: 24 gauge structural quality aluminum alloy coated. Minimum yield stress of 50,000 psi. 22 gauge Features and Benefits of Ultra-Dek®: available upon request but not a standard offering. 1. No panel penetration is required inside the building Length: Recommended 55'-0" maximum. envelope other than at the endlaps connected by a Substrate: Galvalume® Plus compression joint, which seals out the elements. Standard Colors: Architectural Series 2. Panel side laps arrive at the job site containing factory-applied sealant, which contributes to the Warranty: 20-year available system's weather tight construction. Sealant: Factory applied mastic 3. Optional weather tightness warranty that assures Insulation: Can accept up to 6" of fiberglass and 1" that the roof system will remain weather tight for rigid thermal blocks extended service life. Wind Uplift: UL90 rated - tested in accordance with 4. May be factory notched at both ends, allowing for ASTM E283 and E331 for water penetration and air field installation to commence or finish from either infiltration. FM class 1 rated as well. end of the building. Endlaps: Prepunched endlaps ensure proper place- 5. Endlaps have a 16 gauge backup plate with pre- ment of fasteners. Mastic is applied between panels punched holes allowing for a solid connection at and secured with #¹⁄₄ - 14 x 1 1/4" self-tapping fas- endlaps and proper fastener spacing. teners through the panels and into the backup plate to 6. High or low clips accommodate a variety of insula- form a compression joint. tion systems, with up to 1" thermal spacers at the Fasteners: Standard coated, zinc- aluminum cast purlin. head, or stainless steel head screw. 7. UL 90 rated for lower insurance costs. Light Transmitting Panels: Optional insulated or 8. Does not use the mechanically seamed system. non-insulated This panel interlocks when snapped together; therefore, there is no need for seaming equipment, Ultra-Dek® allowing ease of installation. Usage: New and retrofit applications 9. Economical standing seam roof panel. Introduction to Metal Buildings 55 Lesson 5 Double-Lok® 8. 80% less exposed fasteners than traditional side lap panels and all fasteners are long life allowing Usage: New and retrofit applications. for increased weather tightness. Limitations: Recommended for roof slopes of ¹⁄₄:12 9. Panels available in low-gloss Kynar® paint with a or greater. When using the fixed clip we recommend 20-year finish warranty, which minimizes appear- for double slope buildings 200' wide or less and single ance of oil canning. slope buildings 100' wide or less (May vary upon extreme weather conditions). Oil canning is not a 10. The side lap has been tested for air infiltration and reason for rejection. water penetration under ASTM E283 and E331 methods. Minimal air infiltration and water penetra- 24" tion and acceptability among specifiers. 3" BattenLok® - Architectural Standing COLOR Seam Panel 19³⁄₈" 16" ¹⁄₁₆" COLOR 2" MECHANICALLY SEAMED Panel Size: 16 inches wide, 2 inch high standing seam Gauge: 24 gauge, 22 gauge available on request but not standard Length: Recommended 55'-0" maximum. MECHANICALLY SEAMING ENGAGEMENT Substrate: Galvalume® Plus Standard Colors: Architectural Series Features and Benefits of Double-Lok®: Warranty: 20-year available 1. No panel penetration is required over the building envelope other than at the end laps, which are Sealant: Factory applied connected by a compression joint, which is specially designed to seal out the elements. Insulation: Can accept up to 6 inches blanket fiberglass and 1 inch rigid board thermal blocks 2. Panel side laps arrive at the job site containing a factory pre-applied sealant, which contributes to Seamed: Roof is mechanically seamed in the field the system's weather tight construction. Wind Uplift: UL 90 rated 3. Optional product and weather tightness warranty is Concealed Clips: A choice of concealed fastening available, contributing to additional customer con- clips is available for this panel system including UL fidence. rated clips. These clips hold the panel firmly in place 4. May be factory notched at both ends allowing for without unsightly exposed fasteners. Each clip system field installation to commence or finish from either offers the ability to accommodate thermal movement. end of building or on both sides simultaneously Ideal Retrofit Roof System 5. Endlaps have a 16 gauge backup plate with pre- Usage: This panel is a structural panel that spans up punched holes allowing for a solid connection at to five feet on purlins, or can be used as an architec- endlaps and proper fastener spacing. tural panel over a solid deck. This flat panel is 6. High or low clips can accommodate a variety of designed with striations to minimize oil canning. It is insulation systems, including 1" thermal spacers at designed to meet the ever-changing AISI specification the purlins. and other industry codes. 7. UL 90 rated for lower insurance costs on Factory Limitations: Recommended for roof slopes of ¹⁄₂:12 Mutual class 1-rated projects. or greater. Oil canning is not a reason for rejection. 56 Introduction to Metal Buildings Lesson 5 Advantages of BattenLok®: 1. Aesthetically pleasing architectural design with vertical ribbed seams, which are easily custom flashed. 2. A great product for hip and valley, and turndown mansard application. The panels can be turned down over the eaves to form a wall panel appearance. 3. A feature of the BattenLok® is that the sidelaps are mechanically seamed with an electric seamer for a sure lock. 4. This system features easy to handle 16" wide panels with over 50 years of service in the marketplace. The proven durability and performance of the BattenLok® panel, with the factory-installed mastic and swaged endlaps, ensures weather tightness. 5. BattenLok® is a structural panel that spans up to five feet on purlins, or can be used as an architectural panel on plywood and felt substrate. 6. BattenLok® is a flat panel with vertical ribs creating no voids, therefore, no eave closure plugs are required 7. BattenLok® is designed to meet the ever-changing AISI specifications and other industry codes 8. The natural forces of expansion and contraction can cause roof leaks. The BattenLok® system is Battenlok® Panel Used in a Retrofit Roof installed using special clip assemblies that allow Application for roof movement. This system is designed to handle thermal shock; therefore, it won't crack, blister, absorb moisture or require painting, SuperLok® patching, or caulking usually needed with ordinary nonmetal roof system. 16" 2" ¹⁄₁₆ " COLOR Description: The SuperLok® standing seam roof system blends the aesthetics of an architectural panel with the strength of a structural panel. This panel has earned uplift ratings that are the highest in the industry for standing seam roofs, assuring the reliability of performance. This panel is Factory Mutual approved to satisfy stringent code requirements and is ICBO approved. Gauge: 22 and 24 (Minimum quantity may be required) Finish: Galvalume® Plus and Architectural Series Introduction to Metal Buildings 57 Lesson 5 Length: Recommended 55'-0" maximum. Roof Protection Fasteners: Concealed fastening system. A choice of concealed fastening clips is available for this panel By studying the details of various roof systems you will system including UL rated clips. These clips hold the acquire basic product knowledge that makes you panels firmly in place without unsightly exposed fas- familiar with the specifications, types of material, fasteners. Each clip system offers the ability to tening systems, options and applications of our different accommodate thermal movement. metal roof systems. The objective is to provide your customer with the best possible roof protection, equal Dimensions: 12", or 16" wide and 2" high with his/her needs and his/her budget. Usage: SuperLok® is a field-seamed panel that com- One of the most important functions of a building is to bines a slim rib with exceptional uplift resistance. This keep out the elements: rain, ice, snow, and wind. panel has been designed to withstand the most rigorous conditions. This system was designed to be Built-up roofs can, of course, be quite satisfactory, but installed over open framing, ⁵⁄₈" plywood, or a com- organic materials must eventually decay; therefore, it is posite roof assembly may be used as alternate necessary to establish a budget for periodic mainte- substructures. nance to assure the lasting weather tightness of built-up roofs. On the other hand, many building systems man- Limitations: Minimum recommended slope: ¹⁄₂ on 12. ufacturers make roofs of materials such as coated galvanized steel, aluminum, copper, aluminum coated Features and Benefits of SuperLok®: and aluminum zinc alloy. Inorganic materials take a 1. Can be installed over purlins and bar joists. firmer stand against the elements. 2. Factory notched for endlaps allowing ease of Even an inorganic roof that is weather tight at the time installation. of construction may cause the owner inconvenience and costly maintenance if the original design failed to 3. Clip allows 2" panel movement allowing for expan- consider the effects of wind uplift and expansion and sion and contraction. contraction. Wind Uplift 4. Sealant factory applied for less field labor and longer life. 5. Weather tightness warranty available When the wind blows over the roof of a building, suction is created. Similar to the airfoil effect on the wing of an 6. System qualifies for UL 90 wind uplift ratings under airplane, this exerts an upward pull, or wind uplift, on four types of construction including open framing, the roof. Therefore, the stronger the wind, the stronger composite, and solid deck methods. the upward force wanting to separate the roof from its 7. Metal Closures for longevity supporting framework. 8. Machine seamed which meets stringent code requirements, such as, Factory Mutual Oil Canning BattenLok® and SuperLok® panels have striated surfaces to meet the demand of any design challenge. While Mesco has recognized and responded to this requirement we have a responsibility to point out that a wide and perfectly flat appearance is not possible. In A key design factor in combating wind uplift is the some wide products, panel distortion, called oil canning, method of fastening the roof to the structure. Greatly will occur and tolerance and/or additional support due to superior fastening design implemented by behind the panel may be more visible under certain Mesco, all of the roof systems have withstood and lighting conditions. Minimizing foot traffic during and passed the rigorous testing required to meet after installation can eliminate the need for additional Underwriters Laboratories Class 90 wind uplift ratings support behind panel faces. and the Code of Engineers Guide Specification CEGS- 07416. 58 Introduction to Metal Buildings Lesson 5 Expansion and Contraction to the purlins without the need of any holes through the panel's roof surface. The floating clip allows the roof to Every roof moves due to expansion and contraction. move transversely 2" in each direction, accommodating Unlike the forces of wind uplift, you cannot resist the for the expansion and contraction imposed on the roof. forces of expansion and contraction without impairing the weather tightness of your roof. Therefore, your roof must be designed to allow for that movement. The most common damage that results from expansion or contraction of a building is cracked pavement. Leaving expansion joints between stretches of pavement is the most recognized solution for prevention of FLOATING CLIP SYSTEM this damage. Both Mesco's screw down and standing seam roof sys- However, with a standing seam roof, the purlins have a tems allow for roof movement transversely (across the bracing system of knock-in-bridging to reduce the nat- width of the building) and longitudinally (along the ural roll of the purlins. The standing seam roof clip is length of the building). attached to the purlins via self-drilling fasteners, and the clip is attached to the panel leg. The knock-in-bridging The screw down roof system allow for the transverse helps the purlin system to be more rigid. If the purlins movement by the panel corrugation, while the natural were to move the standing seam roof system would not roll of the purlin handles the movement in the other resist wind uplift or live load forces and the clips would transverse direction. When the roof contracts due to the not stay fastened correctly. cold, the purlins have a natural tendency to roll toward the ridge. When the roof expands due to the heat, the purlins have a natural tendency to roll away from the ridge. The forces of expansion and contraction would PEAK GING EAVE TO cause fasteners to be loosened, requiring annual main- INSTALL BRID tenance if Mesco did not allow for the transverse #12 X 1" S.D.S. BEND LEG OVER movement. W/O WASHER The standing seams roof systems allow for transverse movement in a much different fashion. The transverse movement in one direction is again handled by panel PEAK PURLIN corrugation, and the movement in the other direction is EAVE STRUT 1 X 1 X 14 GA ANGLE accomplished with a floating clip, which joins the panels When a building length gets over 600 feet, it may be necessary to also accommodate for longitudinal movement. Expansion and contraction of a buildings roof system causes lengthwise movement. Mesco may accommodate for longitudinal movement with an expansion joint and transition trim. An expansion joint is basically an extra slotted clip attached to the purlins, LOW FLOATING CLIP allowing the purlins to move in the longitudinal direction. 3 3/8" HIGH If longitudinal movement is not accommodated for the HIGH FLOATING CLIP sidelap of the panel system, it may have the tendency 4 3/8" HIGH to tear apart. Introduction to Metal Buildings 59 Lesson 5 metal roofs, but also a new roof solution for ordinary LONGITUDINAL construction. EXPANSION STANDING SEAM JOINT TRIM ROOF PANEL (2) 1/2" X 1 1/2" BOLTS WITH (2) NUTS (4)1/2"X 1 1/2" BOLTS Built-up Roof being Retrofitted with Standing Seam EXPANSION SIDE FIXED SIDE Roof System and added insulation. LONGITUDINAL EXPANSION JOINT All roofs are subjected to these different forces of nature; wind uplift, transverse movement and longitudinal movement due to expansion and contraction, live load, or snow load. The optimum roof system is one that is designed and constructed so that it is anchored securely to the building (to support wind or live load). However, the roof system should be able to move in any transverse or longitudinal direction (to allow for the Completed Retrofit using Standing Seam Roof transverse and longitudinal pushing and pulling of System. expansion and contraction). It should also maintain the complete weather tight integrity of the roof. Few built-up Re-roofing has often been thought of as a last resort. or traditional roofs can do that. Mesco has unique and Only after a present roof has been patched, repaired, patented roof systems that are designed and tested to resealed and repaired again, will a customer consider withstand these forces. installing a new roof on his/her present building. STANDING SEAM ROOF PANEL Retro-R® Panel INSIDE METAL 36" NET COVERAGE CLOSURE 12" 12" 12" TRANSVERSE EXPANSION JOINT TRIM 1¹⁄₂" 2" 2" 2¹⁄₈" ¹¹⁄₁₆" COLOR STANDING SEAM FIXED SIDE ROOF PANEL OUTSIDE Description: Retro-R®, the patented retrofit roof METAL system is the fastest and most economical solution to CLOSURE your re-roofing dilemma. This one-step setup is designed for easy installation over your existing metal TRANSVERSE roof. Retro-R® is cost effective with savings up to 50% EXPANSION JOINT over other roofing solutions. And because it is so easy EXPANSION SIDE to install, Retro-R® will not interrupt the normal course of your business. Retro-R® is available in a wide Retrofit Roofing Solutions variety of colors or with a Galvalume® Plus finish. Let Retro-R® save the day, by saving time and money. A significant market for the Mesco Builder organization Gauge: 29 has become available utilizing the Retro-R®, BattenLok®, Ultra-Dek®, and Double-Lok® roof systems Finish: Galvalume® Plus, and Commercial Industrial as not only a re-roofing solution, for both built-up and Series 60 Introduction to Metal Buildings Lesson 5 Fasteners: The manufacturer recommends a "Long for this reason that Mesco has devoted a considerable life fastener". The manufacturer does not recommend amount of time and money in the research, testing and self-drilling fasteners. design of roof systems. The challenge to you is twofold: Advantages of Retrofit Roof Systems: 1. Develop thorough product knowledge of all the roof systems you have to offer, and those offered by 1. Get rid of leaks for the long term. Compared to tra- your competition. Our components company, ditional roofing systems, Retrofit roofs provide MBCI, has even more roof systems to offer than superior weather tightness, effectively draining rain previously mentioned. For example: and snow. Unlike flat built-up roofs, Retrofit roof systems are sloped, so water doesn't stand. They • LokSeam® also drain to the building's exterior, further decreasing the chance of leaks. In certain environ- • QwikLok® ments, the life cycle of a Retrofit roof system can • FlexLoc® extend 40 years or more when properly main- tained. Contact your local Components District Manager for additional panel offerings. 2. Save on Maintenance. Materials in built-up roofs expand and contract at different rates during tem- 2. Make sure your customer knows the value of good perature changes, causing cracking, flaking and roof protection, particularly, through wind uplift and shrinking. Retrofit roof systems expand and con- the forces of expansion and contraction. tract at the same rate, minimizing damage. They Of course, almost every product feature and also resist corrosion thanks to the aluminum-zinc service that you have to offer can be an important alloy coating. consideration in a buying decision, but in most 3. Save on Energy Bills. When installed correctly with selling situations we find that a good roof presen- the proper insulation, Retrofit roof systems can tation is a key to successful sales. lower climate control costs, saving more money. 4. Fast, easy installation. Because the Retrofit roof Conclusion systems simply cover your existing built-up roof, The purpose for this lesson was to enhance your installation is fast, convenient and economical. awareness of the different types of traditional roof sys- There is no need to interrupt daily business activi- tems, such as built-up roofs, and single-ply membrane ties, and in some cases, can be installed with no roofs, but more importantly enhance your knowledge of on-site modification. the different type of metal roofs that Mesco has to offer: 5. Update Building's Exterior. With a Retrofit roof • Screw Down Roof Systems system, you can enhance an outdated roof, or simply dress up the building's appearance, quickly • "PBR" Panel and easily. Retrofit roof systems feature innovative • Standing Seam Roof Systems design details and adapt to facades and light transmitting panels. • Ultra-Dek® Fact is, even the best built-up roofs can leak, but a • Double-Lok® retrofit metal roofing system substantially lowers chances of roof failure due to atmospheric conditions. • BattenLok® With proper installation, these durable, weather tight • SuperLok® roofs can provide years of trouble-free protection. They go up over the existing roof so there's no troublesome • Retrofit Systems material tear-off or costly interruption of daily opera- • Retro-R® tions. What's more, a Retrofit system is an economical way to enhance the facility's exterior. The features and benefits of each roof panel, and the sales advantages of each system are to help aid you in Sales Approach selling the various different products Mesco has to offer. Finally, we covered the benefit of a newly emerging Because the roof is that portion of a building that protects market for Retrofit roof systems utilizing our standing occupants and contents from the elements, you and your seam roof systems to solve your customer's problems customer should give it the most critical consideration. It is of an old, leaky, run down traditional roof. Introduction to Metal Buildings 61 Lesson 5 Self Test Lesson Five: Self-Test 1. Which type of roof is not used in nonresidential construction? A. Wood or Composition Shingles B. Single-Ply Roofs C. Built-Up D. Metal 2. Which of the following is not a disadvantage of a Built-Up Roof? A. Built-Up Roof is not Fire-Safe B. Initial investment is generally reasonable unless a tear-off is required C. Maintenance is frequent and expensive D. Trouble spots are hard to detect 3. Which of the following is not a disadvantage of a Single -Ply Membrane? A. Lack of Design Criteria B. Dependency upon Workmanship C. Burns Easily D. Lightweight E. High Cost of Material 4. A built-up roof professionally installed is the most durable, reliable and maintenance free roof available today. A. True B. False 5. Which of the following is not a feature of Mesco's "PBR" panel? A. 36" Coverage B. Trimless Ridge C. Cost Effective D. Not Weather tight E. Extra purlin Bearing Leg 6. This roof panel interlocks when snapped together eliminating the need for seaming equipment. A. Double-Lok® B. "PBR" C. Ultra-Dek® D. BattenLok® E. None of the Above 7. This roof panel is a structural panel that spans up to five feet on purlins, or can be used as an architectural panel over a solid deck. A. Double-Lok® B. "PBR" C. Ultra-Dek® D. BattenLok® E. None of the Above 8. Every roof moves due to expansion and contraction. Mesco accommodates that movement by panel corrugation, natural purlin roll, floating clips, and expansion joints. A. True B. False 62 Introduction to Metal Buildings Lesson 5 Self Test 9. Wind uplift is when the wind blows over the roof of a building creating suction. This upward force wants to separate the roof from its supporting framework. Therefore, all of Mesco's roof systems have withstood and passed the rigorous testing required to meet Underwriters Laboratories Class 90 Wind uplift ratings. A. True B. False 10. A standing seam roof has a bracing system called knock-in-bridging. What is knock-in-bridging's function? A. Elevate Wind Uplift B. Control Expansion C. Control Contraction D. Reduce the Natural Roll of the Purlins E. None of the Above 11. Which of Mesco's roof systems is perfect to cover an existing built-up roof? A. Screw Down Roof B. Standing Seam Roof C. Retrofit Roof D. All of the Above E. B and C only 12. The ridge of the building is the horizontal line formed by opposing sloping sides of a roof running parallel with the building width. A. True B. False Introduction to Metal Buildings 63 Lesson 6 Lesson Six: The Wall System Most buildings erected today are designed with some the required thickness of walls and the weights brought degree of aesthetic appeal, whether a contemporary upon the foundations become excessive and uneco- office or a more traditional warehouse located in a nomical. And although this type of wall construction is heavy industrial area. Durable, functional and econom- still in use today, a more modern and functional system ical structures are still very important, but the customers has been introduced, called the curtain wall and frame are demanding more. They want their buildings to be system. aesthetically appealing as well. It has become a must to offer a striking design and Curtain Wall and Frame System visual appeal to sell any types or style of building in Curtain wall and frame construction is a popular way to today's market. Descriptive words such as, eye- build for commercial occupants. Not only can it be more catching, modern, attractive, elegant, and beautiful, economical, but also the unlimited selection of exterior appeal to the prospective customer. The increasing materials provides superior wall systems that are diffi- trend toward a more sophisticated design is one of the cult to surpass. Lighter weight and more economical greatest advantages in the marketing of a metal building walls offer better insulating efficiency as well. Greater system. The aesthetic design of a building becomes an flexibility in material and color selection is available. integral part of every sales proposal offered to a cus- And, in most instances, curtain walls are faster and tomer. As a Mesco authorized builder you can offer the easier to erect. most complete selection of the one product that contributes most to the visual appearance of a building, the exterior walls. Mesco Wall Systems While the roof provides overhead protection from the All of the Mesco wall systems are curtain wall and frame weather, and steel framing provides the supporting classification. Because wall panels play such an impor- framework, neither contributes as much to exterior tant role in the visual aesthetics of a building, it simply appeal as the wall system. makes good marketing sense to offer the customer a broad selection of wall systems to chose from, so that Types of Walls you can best meet his/her needs and desires. Although appearance is very important, it is usually not the only The types of wall materials available today are practi- objective. Performance and budgetary constraints must cally unlimited. They can range from wood, brick and also be important considerations. block, tilt up panels to metal panels. From the viewpoint of building construction, walls are divided into two major groups: load-bearing wall construction and skeleton- frame construction. Load-Bearing Wall Construction Load-bearing wall construction has been the method of structural design employed since the earliest days of the Roman Empire. In Lesson One: The History of Metal Selecting the right wall system to meet the needs for a Buildings, the thick walls of masonry used in the Arch specific building solution, and at the same time satisfy Design employ the same principle as that applied to both the personal wishes and business sense of the wall construction in today's common practice of load- customer is not an easy job. bearing wall construction. The walls support their own It will call for a careful study and analysis of your cus- weight plus the remaining load of the building. tomer's business, the building's end use, and what the In this method, roof beams and bar joists rest upon the customer considers to be attractive and functional in a exterior walls, which, in turn, transmit the loads to the wall system. One way to make this easier is to acquire foundations. It is evident that walls must be of sufficient a good knowledge of the various wall systems you have strength to carry resultant loads as well as their own available to offer your customer. The remainder of this weight. Consequently, as height of buildings increase lesson will be dedicated to introducing the different 64 Introduction to Metal Buildings Lesson 6 Mesco wall panels and the sales features and benefits • Slide Doors of each panel. • Light Transmitting Wall Panels (wall lights) Also keep in mind that a wall system consists of more than just the basic covering panel. A complete wall All of these accessories are covered in Lesson Seven: system must take these various components into con- Metal Building Accessories. Study the sizes and other sideration: specifications of these accessories. Learn to associate them with the wall system, because accessories are • Structural framing support often a requirement and a necessary part of the total wall system. • Basic covering material Liner panel and interior wall partitions are also available • Insulation utilizing the Mesco wall systems. Liner panel is often • Joining and fastening used for an interior application to protect blanket insulation in areas of high traffic where other abuse resistant • Exterior & Interior finishes interior finishes are not provided. Interior wall partitions • Trim, fascia, and flashing are often used to section off a particular part of a building for office space or other uses. Mention of the If the wall is to be insulated, standard white vinyl blanket liner panel and partitions are necessary here, to realize insulation in thickness of 3", 4", and 6" is often used. It that they are part of the entire wall system. See Lesson is field installed by sandwiching the roll insulation Seven: Metal Building Accessories for further explana- between the girts and the covering panels. See the illus- tion and illustration. tration below. The tabs of adjoining insulation rolls are folded and stapled to assure good vapor barrier. Panel Types BLANKET "PBR" Panel INSULATION WOOD BLOCK FOR INSTALLATION SUPPORT ONLY 36" 12" 1¹⁄₄" COLOR "PBR" Panel Description: This panel is used both for the roof and sidewalls; the "PBR" Panel's deep ribs create an ARCHITECTURAL even-shadowed appearance. The area between the WALL PANEL major ribs is reinforced with minor ribs. The "PBR" panel is one of the most economical wall covering systems. Wall Accessories Gauge: 29, 26, 24 and 22. Wall accessories are also a very integral and important Length: 45' maximum is standard but longer lengths selling point when a customer is considering a wall available by special request. system. All of Mesco's wall systems are available with the following wall accessories: Fasteners: Standard coated, zinc- aluminum cast head, or stainless steel head screw. • Personnel Walk Doors Dimensions: 36" coverage x 1¹⁄₄" deep. • Overhead Door Framed Openings Finish: Galvalume® Plus and Commercial - Industrial • Aluminum Horizontal Slide Windows Series. • Aluminum Narrow Lite Accent Windows Usage: Roof, wall, liner, mansard, and soffit panel • Louvers applications. Introduction to Metal Buildings 65 Lesson 6 "PBR" Panel Features and Benefits: 2. The striations reduce oil canning, textured appearance. 1. 36" Coverage for ease of erection. 3. Available in the standard Signature® 200, which is 2. Manufactured at all plants for low freight to any a silicone polyester color offered with a standard location. 20-year warranty. 3. Start installation at either end for flexible erection. 4. Single continuous panel to sill until panel exceeds 40'-0 length for attractive application with no end 4. Economical profile that is cost effective. laps, and ease of installation. 5. Finish Warranty - 20-year life when used with long 5. Signature® 300 premium finish optional for a finish life fasteners. with 20-year warranty, ultimate resistance to color 6. The panel provides diaphragm capabilities and girt change and chalk. stability in metal building construction. 6. Embossed texture available, embossing the metal 7. Profile wall lights are available for the "PBR" Panel. reduces glare and the potential for oil canning. 8. The panel can be reverse rolled putting the paint 7. Fire rating, the panel carries a UL "Class A" fire finish on the under side for installation as a wall rating. panel. "PBU" Panel "PBA" Panel 36" 6" COLOR ³⁄₄" 36" 12" 1¹⁄₈" COLOR "PBU" Panel "PBA" Panel Description: This utility panel with ribs 6" on centers is especially useful for liners, partitions, soffits, etc., Description: The Architectural "PBA" Panel for side- because of its shallower ³⁄₄" deep ribs and relative walls produces a decorative smooth shadow line ease of installation. creating a distinctive architectural effect with semi- concealed fasteners. Ribs are 1¹⁄₈" deep and major Gauge: 29, 26, 24, and 22. corrugations spaced 12" on center. The net coverage of panel is 3'-0". Finish: Galvalume® Plus and Commercial Industrial Series (29, 24, and 22 Ga. available in Polar White Gauge: 26 and 24. and Galvalume® Plus). Length: Maximum recommended 45'-0". Longer Length: Maximum recommended 40'-0". Longer lengths available on special order. lengths available on special order. Fasteners: Various, depending on application. Usage: Wall panel, liner panel, soffit panel, mansard panel face, and back sheet. Finish: Galvalume® Plus and Commercial - Industrial Series. "PBU" Panel Features and Benefits: Dimensions: 36" wide by 1¹⁄₈" deep. 1. Signature® 200 has 20-year warranty. Usage: Wall panel, liner panel, soffit panel, mansard 2. Reverse rolled profile that places color on the panel face, and back sheet. reverse side of the panel yields a flat profile Limitations: Installation may be difficult with very appearance with fasteners recessed in flutes. thick insulation. 3. Fire rating, the panel carries a UL "Class A" fire rating. "PBA" Panel Features and Benefits: 4. Single continuous panel eave to sill until panel 1. Semi-concealed fastener panel for attractive archi- exceeds 40'-0" length causing an attractive tectural application. 66 Introduction to Metal Buildings Lesson 6 appearance with no end laps, and ease of installa- Flat Panels - Artisan Series tion. 5. Signature® 300 optional finish that offers the pre- 12" mium paint finish with 20-year warranty, ultimate COLOR 1" resistance to color changes and chalks. L12 6. Face fastener that yields diaphragm capabilities and girt stability. 4" 4" 4" 7. Embossed texture optional, embossing the metal COLOR 1" reduces glare and the potential for oil canning. L12 with beads 8. Optional Perforated condition for ventilation or acoustical applications. Artisan Series NuWall™ Description: The simplicity of the Artisan Series panel is its best design feature. Uniform dimensions 12" and clean appearance allow the designer to plan modules, eliminate complicated pieces, and follow wall COLOR curvatures. 2¹⁄₂" Gauge: 26, 24, and 22 (26 and 22 Ga. may require minimum quantity). NuWall™ 1¹⁄₂" Finish: Galvalume® Plus and Polar White (Smooth or Embossed Texture with or without stiffener breaks), Commercial - Industrial Series. Length: Maximum recommended 20'-0" Rules of Description: NuWall™ combines the ease of installa- Thumb for Artisan Panel Lengths: tion in both new and retrofit applications with a pleasing aesthetic appeal. The shadow lines created Up to 4'-0" Long Use L12, L10, or L8 with the NuWall™ panel will enhance any structure's 4'-0" to 10'-0" Long Use L8 Only appearance. Installation of panels is performed com- Fasteners: Concealed fastening system Artisan pletely outside with no disruption of the workplace on Series panels use the Positive fastening method and the inside. are attached directly to the substructure. The fastener Gauge: 22, 24, and 26 (All gauges have a minimum is concealed behind the flush face. quantity required) Dimensions: 8", 10", and 12" wide by 1" high. Finish: Galvalume® Plus and Architectural Series. Usage: The Artisan panels are used for soffits and Length: Recommended 40'-0" maximum. interior liners. Fasteners: Concealed fastening system. The panel is Artisan Series Limitations: attached to the structure with self-drilling fasteners on one side of the panel only. No clips are required. The 1. The panel provides no diaphragm action due to the adjoining panel simply snaps into the previous panel, concealed fastener design. Installation over thick concealing the fasteners from view. or reinforced blanket insulation may induce oil canning. The product is designed for application over Dimensions: 12" wide 2¹⁄₂" high. rigid framing. Usage: NuWall™ is ideal for both new and retrofit 2. The product is susceptible to oil canning and applications. In retrofit applications, the NuWall™ should be sold in the heaviest gauge, embossed panel can be installed over an existing "PBR" or "M" and with grooves when possible. panel wall. This saves both labor and material. Other panel profiles and other forms of construction may 3. Not recommended for external wall application. require the use of sub-girts. Introduction to Metal Buildings 67 Lesson 6 Artisan Series Features and Benefits: the building with an expansion fastener. Both are positive fastening methods that create secure interlock 1. Factory applied sidelap sealant for watertight con- between panel and structure. nection. Dimensions: 16" wide by 3" high. 2. The panel sidelap has passed tests for air infiltration and water penetration per ASTM E283 and Usage: The ShadowRib™ panel can be used for E331 test procedures. walls, fascias, and equipment screens. Apply the panel over light gauge framing, purlins, girts, structural 3. The panels qualify for 1, 1¹⁄₂, and 2 hour UL fire rat- steel, and joists. In many instances, the panel can ings when installed under certain composite span from floor to ceiling without interior support, construction methods. This provides possible making it ready to apply a variety of insulation lower insurance costs, and meets code require- methods into the 3" cavity. ments. 4. Perforation available for ventilation or acoustical IPS - Insulated Panel Division of NCI applications. 5. The panel is available in the rock wall option, which is an aggregate coating for aesthetic applications. 6. Structural integrity due to panel depth and gauge availability, large spanning conditions are available. 7. Finish warranties available, a 20-year warranty is available for Galvalume® Plus and a 20-year warranty is available for Signature® 300. ShadowRib™ 16" IPS's Company History NCI Building Systems, L.P. acquired Insulated Panel COLOR Systems (IPS) in February 1997. IPS manufactures a 3" 1¹⁄₂" complete line of insulated panels for both wall and roof applications at the plant located in Stafford, Texas. IPS serves both the new and retrofit construction market. 5¹⁄₂" These products have undergone careful research and ShadowRib™ development. Testing consists of thermal resistance, air leakage, water penetration, strength, wind uplift, ignition properties, surface burning, room fire test, roof deck fire test, and roof covering fire test. Description: ShadowRib™ combines aesthetics, economics, and function to bring definition to metal Exclusively from Insulated Panel Systems is the "SSP" structures. ShadowRib™ is a proven performer and a roof panel. The "SSP" panels are ideal for temperature versatile tool to the designer. controlled roof systems and can be snapped together with IPS's patented Versalok™ sidelaps then mechani- Gauge: 24 and 22 (22 Ga. minimum quantity may be cally seamed. IPS's "EWP" Wall Panels, "ESP" Wall required). Panels, and the "IPP" Partition Panel system are all Finish: Galvalume® Plus and Architectural Series. thermally efficient, affordable, aesthetically pleasing products. All of the wall panels are available with our Length: Maximum recommended 40'-0". Rockwall™ system. The Rockwall™ process bonds real Fasteners: Concealed fastening system. Panels may stone aggregate to steel panels, combining the advan- be secured to the structure from outside the building tages of steel with the durability and beauty of stone with the ShadowRib™ concealed clip, or from inside aggregate. 68 Introduction to Metal Buildings Lesson 6 Insulated "EWP" Wall Panel maximum use of shadows and flat surfaces for strong vertical accents. Insulated "ESP" Wall Panel Description: "EWP" panels offer contemporary styling in an easily installed panel that is manufactured in the thickness of 2" or 4". "EWP" uses a joint with concealed fasteners. The ribbed profile gives the Description: This architecturally pleasing panel is building a strong vertical accent that is ideal for metal ideal for commercial applications. Low profile exterior building applications. Both exterior and interior metal structure and offset lap joint with concealed fasteners skins have stucco embossed pre-painted finish. The give "ESP" panels an attractive appearance for ver- panel is designed to module on 36" width. tical applications. The panel is designed to module on Gauge: 22, 24, and 26 (22 Ga. minimum order 36" width. required). Gauge: 22, 24, and 26 (22 Ga. minimum order Finish: Both faces are stucco embossed, Rockwall™ required). Stone-Coated, silicone polyester, and fluorocarbon Finish: Surfaces are stucco embossed, Rockwall™ polymer, See IPS Color Chart. Stone-Coated, silicone polyester, and fluorocarbon Length: Max 48'-0". polymer, See IPS Color Chart. Fasteners: Concealed with clips at side joints. Length: Max 48'-0". Dimensions: Width: 36"; Thickness: 2", 2¹⁄₂", 3", and Fasteners: Concealed with clips at side joints. 4". Dimensions: Width: 36"; Thickness: 2", 2¹⁄₂", 3", and Usage: Contemporary look and vertical linear profile 4". allow maximum use of shadows and flat surfaces to Usage: "ESP" is an architecturally pleasing econom- create a custom wall effect. ical insulated wall system. Limitations: Load/span tables for wind loads are Limitations: Load/span tables for wind loads are available upon request. available upon request. Insulated "EWP" Features and Benefits: Insulated "ESP" Features and Benefits: 1. Foam thickness of 2", 2¹⁄₂", 3", and 4" that provides 1. Foam thickness of 2", 2¹⁄₂", 3", and 4" for excellent excellent insulating properties providing R-values insulating properties providing R-values from 17.2 from 17.2 to 30.6. to 30.6. 2. Complete Load/Span tables available allowing 2. Complete Load/Span tables available, allows designer to make proper use of panel span capa- designer to make proper use of panel span capabilities. bilities. 3. Excellent test results for air leakage and water 3. Excellent test results for air leakage and water penetration through panel joint that confirms penetration through panel joint confirming weather weather tightness in compliance with specifica- tightness in compliance with specifications. tions. 4. Good Surface burning characteristics comply with 4. Good Surface burning characteristics, which model building codes for foam plastics. comply with model building codes for, foam plastics. 5. Concealed fasteners with clips provide a contemporary alternative to exposed fasteners. 5. Concealed fasteners with clips, which provides a contemporary alternative to exposed fasteners. 6. Lightly striated design gives a flat appearance for most architectural and commercial applications. 6. Vertical indented ribs at 6" centers which utilizes Introduction to Metal Buildings 69 Lesson 6 Insulated "IPP" Liner Panel uous uninterrupted partition walls capable of with- standing most interior design loads (5 psf). 8. Instant interior partition that is energy efficient. 9. Offset lap joint that retains high thermal properties. Insulated Rockwall™ Stone-Coated TecFoam Walls Description: Attractive flat embossed profile produced in thickness of 2" to 4". "IPP" utilizes a concealed fastener joint that retains the high thermal properties built into all IPS insulated panels. Easy to maintain finishes that adds to the appearance of your building. It is designed to module on 36" centers and has an USDA approved finish as a standard coating. Gauge: 22, 24, and 26 both faces (22 Ga. minimum Description: All of IPS's wall panels are available with order required). the Rockwall™ Finish system. IPS Rockwall™ gives you the advantage of steel wall panel construction Finish: Both faces are stucco embossed, Rockwall™ with the durable beauty of stone aggregate. The Stone-Coated, Signature® 200, and Royal K- 70®. See Rockwall™ process bonds real stone aggregate to IPS Color Chart. steel panels with a super adhesive system. A clear Length: Max 48'-0". sealer gives the finished panel a crisp glazed appearance. Fasteners: Concealed with clips. Concealed fastener installation hardware includes steel clips and screws. Gauges: 24 and 26. Finishes: Sand Rock, and Granite Rock. Dimensions: 36" Wide by 2", 2¹⁄₂", 3", and 4" thick. Length: Max 20' Fasteners: Concealed with clips. Usage: Interior partitions and ceilings - Can also be used as an exterior wall panel. Dimensions: Width: 36"; Thickness: 2"- 4". Limitations: Butyl side-joint sealant is field installed. Usage: The Rockwall™ finish is available on all IPS panel profiles: Insulated "IPP" Features and Benefits "RWP" Roof/Wall Panel 1. Foam thickness of 2", 2¹⁄₂", 3", and 4" for excellent "EWP" Wall Panel insulating properties providing R-values from 17.2 "ESP" Wall Panel to 30.6. "IPP" Partition Panel 2. Complete Load/Span tables available, allows Limitations: For wall applications only. designer to make proper use of panel span capabilities. IPS Rockwall™ Features and Benefits: 3. Excellent test results for air leakage and water 1. Foam thickness of 2", 2¹⁄₂", 3", and 4" for excellent penetration through panel joint confirming weather insulating properties providing R-values from 17.2 tightness in compliance with specifications. to 30.6. 4. Good surface burning characteristics complying 2. Complete Load/Span tables available, allows with model building codes for foam plastics. designer to make proper use of panel span capabilities. 5. Concealed fasteners with clips provide a contemporary alternative to exposed fasteners. 3. Excellent test results for air leakage and water penetration through panel joint confirming weather 6. Use of symmetrical mesa embossed surfaces on tightness in compliance with specifications. both sides creates uniformity in finish and color throughout the building's interior. 4. Good Surface burning characteristics that comply with model building codes for foam plastics. 7. 48'-0" maximum length which allows for contin- 70 Introduction to Metal Buildings Lesson 6 5. Concealed fasteners with clips provide a contem- wide. Panel heights are determined by building heights porary alternative to exposed fasteners. and frequently range up to 40 feet. Concrete Wall Systems General Information The concrete wall systems listed in this lesson are a group of economical wall systems that have been carefully selected and designed to be compatible with the Mesco Building Systems. The walls are constructed from components that are manufactured by universally accepted construction methods. The general categories of concrete walls described are tilt-up and precast. Concrete Tilt-up wall systems include load-bearing panels, non- load-bearing panels and wainscot panels. Concrete for tilt-up walls is often designed to have a minimum ultimate strength of 3,000 psi at 28 days. It Precast wall systems may be load-bearing or non-load- should be delivered to casting bed (a form used to pour bearing and include flat panels, flat panels with spandrel concrete into to obtain a desired form) with a slump (the beams, single-tee panels, double-tee panels, and wain- correct mixture of water and concrete to obtain a scot panels. desired strength) of 3 to 4 inches. Components used for each wall system include panels, joints, flashing and connections. Curing Curing of job-built panels is limited to the use of curing The buildings illustrated are typical of many being con- agents and membranes. structed in modern industrial parks. They demonstrate the use of precast flat wall panels with spandrel beams, The panel designer furnishes reinforcing steel specifi- tilt-up wall panels and precast tee panels. cations. Reinforcing is placed at mid-depth of panel. The amount of reinforcing that is required for tempera- Tilt-Up Wall Components ture and shrinkage is usually adequate for normal panel loading. Extra reinforcing is installed around openings Tilt-up wall components can be defined as those built by and at lifting inserts. the general contractor on the job-site using temporary casting facilities. They are usually wide, flat panels that Inserts span from grade to roof. The walls may be load-bearing or non-load-bearing and may act as shear walls to resist Inserts are installed in panels, prior to pouring concrete, wind and seismic forces. as necessary for the lifting operation and attachment to structure. Number and location of lifting inserts may be determined by the manufacturers of these items or by the contractor in association with a structural engineer. Tilt-Up Construction Planning Along with the decision to use tilt-up construction, the construction procedure should be established. Planning should involve everyone who will be associated with placing the walls. This includes those responsible for forming, placing concrete and reinforcing steel, finishing, erecting wall panels and erecting structural steel. The planning should consider the layout of the site and building and proper access should be provided. Common thicknesses of tilt-up concrete walls are 5¹⁄₂", Particular attention should be given to providing oper- 6", 7¹⁄₂", and 8". Typically panels are 20, 25, or 30 feet ating room for concrete trucks and erecting cranes. Introduction to Metal Buildings 71 Lesson 6 steam curing is widely used and is most effective. Reinforcement The type of reinforcing steel used varies widely with the precaster. Pre-stressing is usually provided. Pre-stress is the process to introduce internal stresses into (as a structural beam) to counteract the stresses that will result from applied load (as in incorporating cables under tension in concrete). Inserts Inserts or other lifting devices are used to lift panels The entire construction procedure should be organized from lifting beds. Top edge inserts are often used to to proceed in an orderly sequence. During space-plan- erect panels. Type of inserts and methods of lifting ning of the job site, it is often helpful to use scaled panels will vary among different precasters. model cutouts of wall panels and equipment on a print The details shown apply equally to precast panels as of the building floor plan. well as tilt-up panels. Use of precast wall panels often Tilt-Up walls are the most commonly used Concrete requires the utilization of a precast concrete subcon- Wall System in the erection of Mesco Building System's tractor in the builder's area. The type of wall panels or projects. sections used on a project depends on the types commonly manufactured and supplied by the local subcontractor. Double-tees, single-tees, or flat panels Precast Wall Components may not be available in all areas. A subcontractor usually supplies precast wall compo- Erecting precast panels is done after the primary struc- nents. They are manufactured off-site using permanent ture has been erected, which is just opposite of the casting facilities and transported to the job-site. Several tilt-up procedure. precast wall systems are flat panels, flat panels com- Performance Characteristics of Tilt- bined with spandrel beams, double-tee or single-tee panels and wainscot panels. Some precast wall systems are designed to be load- Up and Precast Wall Systems bearing. With appropriate design, economy may be achieved by replacing the perimeter steel framing with The performance characteristics of precast and tilt-up the precast wall system. concrete wall systems are outstanding in many important areas. Panel Sizes Thickness and configuration determine precast prod- Economic Considerations ucts available in the contractor's area. Typical flat The cost of concrete wall systems is low in comparison panels are 4 to 6 inches thick and are 4, 5, 6, 8, or 10 to masonry walls of similar or equal performance. feet in width. Typical flange thickness of tees range from 2 to 3 inches and flange widths are 4, 6, 8, or 10 feet in In many cases, tilt-up wall panels are the most cost width. Length of all wall components is determined by effective of the concrete wall systems. Load-bearing tilt- building heights and precaster's capability. up walls, which are designed to replace the perimeter steel columns and girders, provide the greatest cost Concrete savings. Concrete for walls is usually a high strength, typically In some areas of the United States, standard precast 4,000 to 6,000 psi. Vibration of casting beds increases single-tees or double-tees are used for wall panels and concrete density. are competitively priced. Curing Off-site precast flat panels are available in many areas of the country and use existing all-weather manufac- Curing of precast panels can be accomplished by turing facilities and local precaster experience and means of curing agents and membranes. However, techniques. A high degree of quality control plus addi- 72 Introduction to Metal Buildings Lesson 6 tional handling, loading and transportation requirements If a special color is important, the wall panels can will usually result in higher in-place panel costs in com- receive special paint or other applied finishes. parison to job-built tilt-up panels. The use of exposed aggregates combined with natural and colored cement result in an unlimited number of fin- Thermal Properties ishes and appearance options. Thermal properties of an uninsulated concrete wall system are adequate for buildings in some areas of the United States. The U-value for a 5¹⁄₂" thick wall is .064. If additional insulation or interior finish is required, rigid or batt insulation and gypsum board can provide a U- value of 0.16 and 0.05, respectively. Fire Resistance The market opportunities for Mesco Wall Systems are Concrete wall systems offer fire resistance in a range similar in many respects to those corresponding roof from incombustible for precast tees to 4 hour separation systems. However, the availability of multiple different for a 7¹⁄₂" thick flat panel. Low insurance premiums are wall panels from Mesco, MBCI, and IPS offers even assured for the owner. greater flexibility. The exact choice of the wall system that you decide to Weather Resistance present to your customer will probably not be made The stubborn resistance of concrete to all kinds of during the initial stages of the sale. The requirements of weathering is well known. Properly constructed con- the specific job, the individual customer, and the exact crete panels will provide a lifetime of service even in the selling or competitive situation will greatly affect the final most severe climates. selection. Only you and your customer can determine the correct Maintenance building solution and selection of wall materials. Concrete wall systems with natural finishes and long It would not be possible or practical to include a long list life, all-weather sealants provide many years of mainte- of competitors who make products similar to the wall nance free service. systems that have just been presented. The flexibility of Mesco's complete series of wall systems provides you Durability with a great market potential to out class your competitors. So far, no competitor has been able to offer a Concrete wall systems are highly resistant to damage comparable selection of walls. With the combination of resulting from physical contact. They withstand the hard Mesco, MBCI, and IPS we have the capabilities of day-to day usage present in many warehouses and offering our builders the advantage of a single source offer excellent security against theft and vandalism. supplier with the widest range of product offering in the metal building industry. Generally, you really do have a Sound Transmission great opportunity to sell smarter than your competitors. Concrete wall panels offer very good resistance to sound transmission. The resistance is in proportion to Conclusion the wall thickness. Sound transmission class varies Product knowledge is essential and you must continu- from 44 decibels for a 4" thick wall to 54 decibels for a ally keep up to date on Mesco's current product offering 7¹⁄₂" thick wall. These values exceed normal sound and new products that develop. The more familiar you transmission requirements for most types of buildings. become with what you are selling, the easier it will be for you to point out customer benefits. This will help you Appearance Options sell smarter and better. Concrete wall panels can be manufactured with appearance options related to specific project requirements. Where maximum economy is essential, the panels may be left with a smooth trowel or textured concrete finish. Introduction to Metal Buildings 73 Lesson 6 Self Test Lesson Six: Self-Test 1. Which of the following systems contribute the most to exterior appeal? A. Roof System B. Primary Framing C. Wall System D. Secondary Framing E. Both A and C 2. Which of the following is not a wall accessory? A. Walk Door B. Framed Opening C. Window D. Light Transmitting Panel E. Louver 3. Which of Mesco's panels can be used as a roof or wall application? A. "PBA" Panel B. "PBR" Panel C. "PBU" Panel D. Max-Span Panel E. Both B and C 4. The Architectural "PBA" panel for walls produces a decorative smooth shadow line creating a distinctive architectural effect with semi-concealed fasteners. A. True B. False 5. Which type of wall classification does the Mesco wall systems fall into? A. Load-Bearing Wall Construction B. Wood C. Brick D. Curtain Wall and Frame System 6. Which panel, when reversed rolled, offers a flat profile appearance with fasteners recessing in the flutes? A. "PBA" Panel B. "PBR" Panel C. Flat Panel/Artisan Series D. "PBU" Panel 7. IPS's Rockwall™ process bonds real stone aggregate to steel panels, combining the advantages of steel with the durability and beauty of stone aggregate. All of IPS's wall panels are available with the Rockwall™ system. A. True B. False 8. Concrete wall systems, such as tilt-up and precast wall systems, are not compatible with a Mesco Building System. A. True B. False 74 Introduction to Metal Buildings Lesson 7 Lesson Seven: Metal Building Accessories In addition to frame, wall, and roof systems, there are other components of a metal building system generally Light Transmitting Panel referred to as accessories. These include roof ventila- A "light transmitting panel" is a plastic roof panel tors, light transmitting panels, interior liner panels, installed to admit light. The acrylic modified, UV stabi- louvers, wall lights, wall openings, windows, pedestrian lized, SBS, light transmitting panels are high strength doors, overhead doors, fascias, mansards, canopies, translucent panels that are made of glass fiber rein- and trim in general. Any numbers of these items are forced polyester. The high strength translucent panels required to complete a metal building system. These match standard panel profiles, are ¹⁄₁₆" thick, weigh 8 individual components are also manufactured as inte- ounces per square foot, and are white with a granitized gral units for the metal building system. When installed, top surface. Insulated light transmitting panels are also they will be compatible in both design and appearance available. with the wall and roof systems that they penetrate. Light transmitting panels are installed using the same Roof Ventilators procedures as a steel panel. Care should be taken when installing fasteners in the light transmitting panels A roof vent is defined as an accessory, used on the roof to avoid cracking the material. Pre-drill ¹⁄₄" diameter fas- that allows the air to pass through. Gravity ridge roof tener clearance holes in the overlapping sidelap and ventilators are manufactured from Galvalume® steel, endlap. and maybe painted white. The ventilator body is made Do not under any circumstance step or walk on surface of 26 gauge steel and the skirt matches the roof slope. of light transmitting panel. If foot traffic is necessary Chain operated dampers are furnished when specified. over light transmitting panel, use walk boards that are Standard operators include cable, pulleys, cable properly supported by building purlins. clamps, and eyebolts. Three continuous vents may be operated from each operator. Each non-continuous vent requires an operator. Ventilators are equipped with standard bird screens and UPHILL riveted end caps. Ridge ventilators are 10' long and have 12" throat. Ultra-vents are 1'-11" long with a 12" 4 throat. 20" and 24" round ventilators are also available. 3 1 PEAK PANEL BIRDSCREEN 5 2 IN G E ET TION SH EC 10'-0" CONTINUOUS R DI VENT DOWN HILL ROOF PANEL Panels are installed in sequence that corresponds with 1, 2, 3, 4, and 5. END CAP OUTSIDE CLOSURE SKIRT WITH TAPE SEALER Introduction to Metal Buildings 75 Lesson 7 Liner Panel hardware, half screen, and the glass is available in a clear or bronze tint. The windows are self-framing and Liner panel is a metal panel attached to the inside self-flashing to the wall panels. Mesco's windows are flange of the girts or the purlins. The liner panel is used certified by Architectural Aluminum Manufacturers when it is desirable to protect the field installed insula- Association for the performance requirements of tion and improve inside appearance. Mesco's panels ANSI/AAMA. The aluminum horizontal slide windows that are available as liner panel are as follows: are available in the following sizes: 3'-0" x 3'-0" 4'-0"x 3'-0" • "PBA" Panel 4'-0"x 4'-0" 6'-0"x 3'-0" • "PBR" Panel • Artisan Series INSIDE CLOSURE Louvers GIRT Louvers are an opening provided with fixed or adjustable slanted fins to allow for the flow of air. Mesco's louver frames are of 18 gauge galvanized steel frame, painted to match the wall color with 20 gauge SILL ANGLE blades, and are self-framing and self-flashing. The louvers can come with fixed or adjustable blades. Standard JAMB ANGLE sizes are as follows: 2'-0" x 2'-0" 3'-0" x 2'-0" 3'-0" x 3'-0" 4'-0" x 3'-0" 3'-0" x 4'-0" 4'-0" x 4'-0" BASE ANGLE 5'-0" x 4'-0" Mesco also has a fixed 2'-0" x 7'-0" slim line window REMOVABLE available. This narrow, fixed window is perfect for an SCREEN INSIDE CLOSURE office environment to admit natural light. GIRT JAMB ANGLE WALL PANEL TAPE SEALER WINDOW WALL PANEL Windows BASE MEMBER Windows are openings in the wall of a building for the admission of light and air. The standard windows available through Mesco are horizontal slide units; with a mill standard finish with bronze painted finish as an available option. The windows are furnished with complete 76 Introduction to Metal Buildings Lesson 7 Walk Doors BASE ANGLE Walk doors are doors used by personnel for access to and exit from a building. Standard personnel doors are DOOR JAMB manufactured from 20 gauge galvanized steel with an embossed finish in white or bronze prime coat. The doors are flush and have vertical mechanical inter- THRESHOLD locking seams, which join both hinge and lock edges. The doors are provided with top and bottom inverted 16 gauge galvanized steel channels spot-welded within the TAMP-INS door. The door is reinforced, stiffened and sound dead- ened with impregnated kraft honey comb core TAPE completely filling the inside faces of the door and lami- SEALER nated to the inside faces of the panels. All doors are available with applicable hardware, such as panic hardware, mortice lockset, standard lever lockset, weather strip, closures, or keyed alike. The doors can be all metal, half glass, or narrow lite and available in sizes, 3'-0" x 7'-0", 4'-0" x 7'-0", or 6'-0" x 7'-0" (2 - 3 x 7 leaves, with one or both active). Glazing is by others. The doorframes are of 16 gauge galvanized steel, pre- Framed Openings/Overhead Door painted white with 8" standard jamb depth and Openings constructed for non-hand installation. The frames are provided with head and jamb flashing, optional weather Framed openings consist of framing members and strip, 1¹⁄₂ pair of 4¹⁄₂" x 4¹⁄₂" hinges, and reversible strike flashing which surround an opening for accessories plate. such as windows, louvers, fans, and roll up doors. Overhead door framing is designed to resist applicable Walk Door Framing System wind loads and consists of channel jambs with a structural header at the top of the opening. 26 gauge galvanized steel flashings, color coordinated with wall color is provided to conceal panel edges around the opening. GIRT EAVE STRUT DOOR FRAME GIRT WALK DOOR COLUMN HEADER ANGLE (WDA) USED FOR BRACING GIRT BASE ANGLE JAMB JAMB OPENING WIDTH The threshold of the door is aluminum and supplied with flat head screws and expansion shields for attachment to a masonry floor. Introduction to Metal Buildings 77 Lesson 7 Open Wall Conditions NAILER Mesco offers a wide range of wall panels for use on a BY BUILDER metal building; see the section on wall systems. However, there are many good reasons for using other types of materials in combination with metal panels or SPANDREL HEIGHT (OPTIONAL) by themselves to meet client's needs and/or desires. When a metal building is opened for collateral material it is considered an open wall condition. A few common collateral materials are masonry, glass, wood, and con- FINISHED FLOOR crete or any combination of these. Mesco has developed details for the integration of these materials into the building system. Refer to the following details. Tilt-Up (Spandrel Beam Optional) - Open for collateral material with a spandrel Typical Open Wall Conditions beam. Collateral materials are tilt-up walls or concrete block walls (CMU). The spandrel beam is designed to provide for support of collateral material that weighs 62.5 #psf, which is equivalent to 5" tilt-up or 8" hollow CMU. HEIGHT FINISHED FLOOR HEIGHT Remain Open - Open to remain open for passage or FINISHED FLOOR to the outside elements. Open For Glass HEIGHT HEIGHT FINISHED FLOOR FINISHED FLOOR Masonry - Open for masonry wall. Deduct Panels Only 78 Introduction to Metal Buildings Lesson 7 Canopies The function of the canopy is to provide shelter to areas 12 1 that require open access. Loading docks are prime examples of such open areas where a "roof overhead" is put to good use. Not only do canopies protect merchandise and supplies as they are loaded and unloaded but shelter and shade the crews during work opera- ELEVATION tions. PROJECTION A canopy over a doorway or walkway is especially appreciated during rain, sleet, or snowstorms, when people enter or leave a building. Below Eave Mesco offers three types of standard canopies on the sidewall-eave follow the roof, below eave, and box follow the roof. Refer to the following details. As a standard minimum canopy projection is 1' and maximum projection is 15'. Any canopy over 6' projection will utilize acantilever beam, see details below. ELEVATION PROJECTION Box Follow The Roof PROJECTION Eave Follow The Roof Examples of Canopies PROJECTION Eave Follow The Roof (Projection Over 6'-0") Introduction to Metal Buildings 79 Lesson 7 Mansards/Facades Simple Eave Trim Shown Trim Type and Style May The function of a mansard or facade is twofold, to pro- 3 Vary vide shelter for walkways, door entrances or areas that require open access, and to provide custom designed 12 appearance for impressive buildings. Whether they are large or small buildings, the addition of a mansard or facade can add a great deal of "eye appeal" to an otherwise plain structure. M INI M UM 2 '-0" A mansard or facade is defined as an architectural treatment, partially covering a wall, usually concealing the eave and/or the rake of a building. A mansard is a sloped architectural treatment, whereas, the facade is vertical. A mansard or facade can be located on the sidewall, the endwall, or both. As a standard mansards/facades are limited to 1'6" minimum projection, 6' maximum projection, and a maximum height of 9'. Refer to the following details for more information. Mansard - Sidewall Elevation Sidewall and Endwall 3'-0" M INIMUM Mansard/Facade HEIGHT The combination of the sidewall and endwall mansards/facades is a very simple installation. This condition utilizes basically the same beams, purlin extensions and other secondary structural members as in the separate mansards/facades. The main difference is in the pieces to form the corner, which joins the sidewall to endwall members. SOFFIT ELEVATION The mansards/facades, since they are most often used to enhance the appearance of the building, are avail- PROJECTION able with soffit panels and closure trims so the mansards/facades are "finished out", no unsightly red iron or exposed structural shapes. Facade - Endwall Elevation MINIMUM AT PEAK 3 6" Simple Eave Trim Shown 3'-0" MINIMUM 3'-0 MINIMUM 12 Trim Type and Style May HEIGHT Vary HEIGHT MINIMUM 2'-0" SOFFIT ELEVATION SOFFIT ELEVATION PROJECTION PROJECTION Mansard - Endwall Elevation Facade - Sidewall Elevation 80 Introduction to Metal Buildings Lesson 7 Examples of Mansards/Facades buildings have come a long way since their introduction to the market. It is very common to not even know that a metal building is a rigid metal structure, with all the accessories and auxiliary materials available to enhance and hide metal framing members. When to Sell Mansards/Facades The sale of a mansard/facade system is dependent upon the market opportunities for the sale of the main building. There are many items, however, when the mansard/facade broadens the acceptability of the product line and creates sales, which might otherwise be lost. Markets such as Sales and Service, Commercial Offices, Retail Stores, and Recreational Buildings are typical situations where appearance and "image" literally demand the use of distinctive mansards/facades. Conclusion It is to be understood that the lesson covering accessories of a metal building is just an introduction to the accessories available on a Mesco building. This lesson did cover the most common accessories used in the market today. Accessories can have a common use such as doors and windows or accessories can be used to "dress-up" the appearance of a metal building. Metal Introduction to Metal Buildings 81 Lesson 7 Self Test Lesson Seven: Self-Test 1. A mansard or facade is defined as an architectural treatment, partially covering a wall, usually concealing the eave and/or the rake of a building. A. True B. False 2. A standard roof vent operator does not include? A. Cable B. Pulleys C. Cable Clamps D. Handle E. Eye Bolts 3. Liner panel is a metal panel attached to the inside flange of the girts. A. True B. False 4. Which of the following is not a standard window size offered by Mesco? A. 3' x 3' B. 4' x 3' C. 4' x 6' D. 6' x 3' E. 2' x 7' 5. All of Mesco's windows and louvers are self-framing. A. True B. False 6. Which of the following is not a standard door size offered by Mesco? A. 7' x 4' B. 3' x 7' C. 4' x 7' D. 6' x 7' 7. Overhead door framing is designed to resist applicable wind loads and consists of channel jambs with a structural header at the bottom of the opening. A. True B. False 8. Which standard open wall condition would be used to open a building into another building? A. Open for Masonry B. Open for Collateral Material C. Open for Glass D. Open to Remain Open E. None of the Above 9. Any canopy with the projection of over 6' will be designed with a cantilever beam. A. True B. False 82 Introduction to Metal Buildings Lesson 7 Self Test 10. Which canopy has a face panel? A. Below Eave B. Box Follow the Roof C. Eave Follow the Roof D. All of the Above 11. When using a mansard/facade unsightly red iron or exposed structural shapes are visible. A. True B. False Introduction to Metal Buildings 83 Lesson 8 Lesson Eight: Project Planning and Construction NOTICE OF SAFETY DISCLAIMER: This manual is intended as an instruction aid in the assembly of metal buildings and components. The Introduction to Metal Buildings manual is not being offered nor should it be construed as a comprehensive analysis of all aspects of the metal building assembly and safety issues. Neither Mesco Building Solutions, NCI Building Systems, or any of their affiliated entities intend the presentation of this manual as an exhaustive study of all safety issues involved in the assembly of metal buildings, and expressly disclaim any liability therefore. Prior to beginning any construction project, a builder should familiarize himself with all applicable metal building assembly installation and erection procedure as well as all applicable safety laws and regulations. Most of the emphasis in Introduction to Metal Buildings struction of most buildings: The General Contractor and thus far has been on the presentation of product infor- Subcontractors. mation. Knowledge of Mesco products is probably the single most important job objective of any Builder who General contractors can be organized in two different is truly interested in becoming an effective building con- formats: Bid or Design Build. For the purpose of overall sultant. discussion general contractors will do both bid and design build work. The bidding general contractor bids on the total building project, with the use of relatively complete plans and specifications, usually prepared by an architect or engineer who has been retained by the owner, and arrives at the total selling price. If he/she receives the contract, he/she then awards bids to subcontractors who have agreed to perform their duties within a designated time, and of course, within the contract price. The general contractor is responsible for overall coordi- nation of the project, from clearing of the land to installing the lock on the front door, readying the building for occupancy. When a contractor has this full responsibility, many refer to it as a "turn key project". Most building projects will have one or more specialty An area that is particularly useful in building sales effec- builders, or subcontractors, who perform part of the tiveness is product application and construction. work. Following is a list of duties generally handled by Knowledge of construction is essential for the subcontractors: Buildership so that it can convert the customer's needs 1. Removal of existing obstacles and desires into building plans and specifications that can, in turn, be interpreted into preliminary building 2. Grading and excavation costs. This information is an important part of almost every building proposal. Apart from the fact that knowl- 3. Masonry edge of construction better equips you to convert needs 4. Electrical work and desires into building solutions, it also helps you understand plans and specifications. A factor that is 5. Heating and air conditioning equally important is that customers judge you on your 6. Plumbing knowledge of buildings and the building industry. Obviously, the better equipped you are to answer the 7. Finished floors, ceilings, etc. customer's questions and solve his/her building problems, the easier it will be to eliminate competition. The 8. Paving and landscaping result? Better use of your time to help the customer The general contractor usually does concrete and car- reach a favorable buying decision sooner. pentry work. However, on some jobs, the Two distinct working groups perform the actual con- subcontractors perform this portion of the job. 84 Introduction to Metal Buildings Lesson 8 The extent to which subcontractors are used on conditions, but similar scenarios do exist. A Builder does struction projects depends on the nature of the job, and not want to run into any surprises that will cause extra on the size and organization of the general contractor in monetary investment or physical labor to complete the charge. While a contractor on the construction project project. might serve as a subcontractor, on another job he/she might function as the general contractor. Building Codes The role that subcontractors play in the Mesco Builder System of construction depends on the organization of the Buildership, as well as the nature of the project. Some builder organizations subcontract all grading and excavation, concrete work for the foundation and the floor, and collateral masonry work, while others are equipped to handle virtually all functions except those normally handled by specialty trades, such as plumbing, heating, and electrical work. It is possible that two iden- tical projects will utilize subcontractors to a different degree due to job scheduling. For example, your Buildership may be equipped to con- Most cities and towns of any size have instituted struct foundations on one job, but it is determined building codes that protect the public against injury to beforehand that this same kind of work on another life and property. The types of construction, quality of project must be awarded to a subcontractor in order to materials, floor loads, allowable stresses and many meet the project completion date. There are no set rules other requirements relating to buildings are covered by governing where and how often subcontractors are uti- these codes. A building department or a local building lized. official generally administers codes, which examines The information presented in this lesson will not make and approves plans of proposed buildings. These offi- you a construction expert. However, if you become cials will visit buildings during construction to make sure familiar with the terminology and methods outlined, and the buildings are being constructed according to the periodically visit buildings during various stages of con- drawings the officials or the building department previ- struction, you will be surprised how quickly you develop ously approved. a good knowledge of the construction procedures. Codes vary widely in their requirements, from city to city, and county to county. It is important to become Pre-Construction Preparation familiar with the various codes and regulations enforced in your specific market area. One of the first prerequisites before actual construction begins is the thorough inspection of the conditions of A Builder is responsible for knowing and using the cor- the proposed building site. This is usually done well in rect codes and loads for their local area. Any deviation advance of the final planning stage since site conditions from recommended loading by Metallic is the responsi- affect the total costs that are to be included in the pro- bility of the Builder. posal. Zones Site Considerations Zoning should always be considered before the site selection is final. History Zoning ordinances regulate the size and use of build- The previous use of the land may not appear to be a ings and the use of land. There are four types of zones major consideration, as it will not affect the size or type generally recognized throughout a city: of proposed building. However, it may determine whether or not you want to build on that particular site • Residential at all. • Business Suppose you have the knowledge of an underground • Industrial stream located directly beneath the proposed building location, or you discover that the site was previously • Unrestricted used for the local city dump. These are not normal con- Introduction to Metal Buildings 85 Lesson 8 Business zones are areas incorporated within reason- Telephone and electrical lines provide more convenient able walking distances of residential areas for connections since they are usually exposed above the marketing and shopping. Industrial zones are areas ground. However, more and more telephone and elec- generally near waterways, railroads and other trans- trical cables are being installed underground as well. portation connections for manufacturing and Some zones even require all cables to be buried. commercial use. Outlying districts are zoned in the Excavation should never be attempted without notifying same manner to maintain them for present or future the local utility coordinating group to verify existing use. Each city or county has different zoning laws; utility locations. therefore, it is essential to become familiar with the zoning laws in your specific market area. Electrical subcontractors take care of all necessary wiring, but they do not make connections to the main Restrictions line. This is performed by the local power and light company, which inspects the electrical work before making Restrictions of a building site (as defined by codes and the final hook up. In most metropolitan areas, electrical zones) must be considered before final plans of a work is also subject to inspection by the local building building are completed, since they can affect the size official or department. and type of structure. Examples of typical restrictions may be: The telephone company usually handles telephone connections. The general contractor handles conduits • Buildings, as a rule, are not permitted to cover within the floor or wall system. the entire lot. Uncovered spaces, such as courts, yards, etc., must be provided so that light and air The exact location of service lines should always be are available to the occupants. This, of course, considered, since utility companies charge on the basis limits the square footage of possible floor space. of "distance from the nearest source" (power line, water main, and so on) to the buildings. This, of course, • Buildings also are restricted as to permissible affects the total cost of the project. height. Depending on the zone, taller buildings can be erected if portions of a building are set back a Soil certain distance from the street. It is essential to know the soil's characteristics before • Off-street parking requirements are another fre- building construction begins. Is it hard or soft? Is the soil quent restriction. composed of rock, boulders, gravel, sand, or clay? What are the specific sizes of the composition? Open • Availability of access to the building site can test pits, loading box and platform, and test borings are often be a safety restriction. The site might be three types of soil tests used to determine soil compo- located adjacent to a proposed interstate-highway sition. These tests establish the bearing value of the system which, when built, would limit convenient soil, which in turn determines the amount of weight the access to the property. soil will support. Building restrictions vary considerably from one com- Firms specializing in this service, such as testing labo- munity to another. A working knowledge of zoning laws ratories normally perform testing. and building codes will help you better serve your market area. It is not necessary that you know how to perform these tests, but you should become familiar with soil condi- Utilities tions in your area, and realize their importance to the total project. Many cities have established presumptive One of the first steps in the preparation of the site is bearing capacities, which determine the maximum consideration of the utility connections: water main, allowable loads that are placed on building sites. Soil sewer, gas main, telephone, and electrical service lines. tests are usually performed prior to foundation and Water, sewer, and gas mains are generally located in paving design. easements parallel to property lines or adjacent streets. Occasionally, they are located beneath streets or on the other side of the street from the site that require boring Site Preparation or tunneling for access. Prior to the actual construction of the building, the first step is the preparation of the site. The land is surveyed Permits are often required to connect to the main sewer to establish the exact boundary of the plot. In this line, water, and gas line. Inspections are required, and survey, the building is also located and the desired in some cases, "tap" fees are charged to connect. grade level is staked out. 86 Introduction to Metal Buildings Lesson 8 The exact elevation of the building, and the grade level, water from various locations. However, regulations are established by the use of a surveyor's instrument should be checked before any drainage system is called a level. The elevations are usually set in relation installed. This should be a part of any good site plan. A to the top of the road or nearby buildings. lot of foresight is necessary in considering drainage systems. It might prevent future problems and extra The land is then cleared of all obstructions, such as expense. trees or boulders, which interfere with the construction Concrete Work project. If it is necessary to remove any existing buildings, a wrecking or demolition contractor performs this work prior to the rough grading or rough leveling of the land. Grading Rough grading is leveling the site to conform to the designed building and site elevations. This is usually called the subgrade. The rich top layer is removed and saved to be spread over the area later. After the site has been leveled, the exact location of the building is marked. With the use of a transit and a meas- uring tape, the corners are located and staked out according to the plans. Excavation and Fill Concrete presents a substantial part of most building projects, regardless of the size. Like almost any other Excavation is digging out or hollowing the land to pre- material, it can give good service for years, or be a pare it for the necessary footings and foundations of the source of real problems, depending on the ingredients structure. There are two general types of excavation and care used in proportioning and placing it. performed on most construction projects: The two essential requirements of quality concrete are 1. General excavation - The bulk of the earth and strength and durability. A proper balance between these rock is removed to prepare for the footings and two characteristics is necessary in order to get a good, foundation walls of the structure. An amount suffi- strong foundation. In order to achieve this balance, four cient for back filling and final grading should be steps must be properly completed: retained. 1. Selection of materials 2. Minor excavation - Pick and shovel are used for trimming up trenches and footings prior to the 2. Proportioning of materials actual pouring of concrete. In some cases small 3. Placing and finishing of concrete machines may be utilized to handle minor excavation work. 4. Curing of concrete Fill or back fill might also be required in order to achieve Selection of Materials the necessary grade level. Filling is simply adding earth and rocks where void places exist. In cases where the The materials used in making concrete are water, slope of the land is abrupt, it maybe necessary to build aggregates (sand and gravel), portland cement, and walls to support this fill. When back filling the soil must admixtures. be well compacted or packed solidly in order to insure against future settlement. There are several types of portland cement available for different types of jobs. However, we are mainly con- Drainage cerned with the normal Type I portland cement, as it is the one most commonly used on construction of foun- Throughout the site preparation, excavations should be dation and floors. kept dry. Whenever ground water is present, it should be removed from the site, either by draining into pre- Together with the water, aggregate and cement, addi- pared pits, or by pumping out the water. Some site tional elements are sometimes required in the concrete locations might even require the placement of well to help make it react differently. These elements are points, where pipes are put into the ground to drain called admixtures. One such admixture is used to accel- Introduction to Metal Buildings 87 Lesson 8 erate the rate of early strength gain so that forms can be No element in the entire cycle of quality concrete pro- removed earlier. This reduces the time it usually takes duction requires a more careful consideration than the before concrete can be finished, also known as the final operation of placing and finishing. Placing and fin- appropriate curing time. ishing are both dependent on workmanship, so here, care and skill are especially important. In addition, there are other ingredients, which can be added, such as air infiltrating agents used for roadwork, Forms hold the concrete in place until it has hardened. where the concrete must be resistant to salts and They are usually constructed of wood or metal, and freezing. Retarders are sometimes used during hot must be rigid enough to support the weight of the con- weather so that concrete may be moved from the mixer crete without deformation or appreciable deflection, and to its final position before the initial set takes place. should be tight enough to prevent the seepage of water. The concrete is deposited uniformly in order to prevent Proportioning of Materials segregation of the aggregates and to make certain the reinforcing steel is completely covered without voids. Quality concrete inherently possesses high compres- Concrete is conveyed from the mixer to the forms by sive strength. If a tensile strength is desired, steel means of barrows, by inclined chutes, or is pumped. reinforcing bars must be embedded in the concrete to Normally, the concrete is vibrated by an electric or resist this tension. Tensile strength is the resistance to pneumatic vibrator or spaced to assure well, uniform stretching or drawing out of the concrete. The most coverage, and to prevent honeycombing from occur- important, single consideration in obtaining the desired ring. In placing concrete in deep layers, a gradual strength of concrete lies in the proper proportioning of increase in water content in the top layers usually the materials. results from the increased pressure on the lower portion. This excess water is called Latinate, and should be The compressive strength is usually defined in terms of removed before further finishing, because it produces so many pounds per square inch in 28 days, which is lower strength concrete in the upper levels if permitted the norm for concrete to reach its designed strength. A to remain. typical batch of concrete with a specified strength of 3,000 psi at 28 days would have approximately these When pouring concrete floor slabs, the surface is proportions: screeded prior to finishing. Screeding is the process of striking off the excess concrete to bring the top surface • Cement . . . . . . . . . .94 pounds to proper contour and elevation. A template is moved • Sand . . . . . . . . . . . . .185 pounds back and forth on the forms, with a sawing motion, to force concrete into the low areas. • Coarse Aggregate . .360 pounds After the foundation or floor is roughly leveled, the sur- • Water . . . . . . . . . . . .5¹⁄₂ gallons face is ready to be finished. Wood or metal floats are Practically all concrete is machine mixed in a rotating used initially to compact the concrete, forcing the larger drum cylinder, either in a "Ready-Mix" truck, or a similar aggregates below the surface. Steel trowels are then mixer on the job site. used to obtain a smooth surface and to compact it for a hard finish. If there are areas exposed to outdoor usage, such as walks or driveways, a broom finish is Placing and Finishing of Concrete recommended. The broom finish is simply taking a broom and wiping it across the concrete. This roughens the surface for a friction grip, so that the concrete is not slippery when wet. Curing of Concrete Concrete hardens because of the chemical reaction between portland cement and water. This process continues as long as temperatures are favorable and moisture is present. The quality of concrete, or the strength of the concrete, is dependent on the temperature and moisture conditions in which it cures. In addition, its resistance to abrasive action is also increased by these same ele- 88 Introduction to Metal Buildings Lesson 8 ments in curing. 2. Footings While it is important that the amount of water used in A foundation wall means any wall with a major portion mixing be controlled so that the consistency is as nearly located below the grade level. The wall serves as a normal as practical. It is just as important that concrete base support for other walls and columns. A footing is a is not allowed to dry out too soon or it will reach strength structural unit used to distribute building loads to the less than 50% of its potential. bearing materials. Temperature has a considerable effect on the rate of Foundations used for rigid frame buildings are consid- hardening. In the past, you could not pour concrete erably different from those normally required for during the winter season because the water in the mix- conventional structures with load-bearing walls. The ture would freeze and prevent the proper setting. But choice of foundation is determined in part by the basic now, construction operations may continue throughout loads, which need to be resisted. the year. The most favorable conditions are between 50 and 90 degrees Fahrenheit. However, good curing tem- Foundations for metal buildings are usually not subject peratures may range below 50º F and even below 32º to extremely heavy vertical loads; however; they are F, if the concrete is properly protected from cold air required to withstand transverse loads of considerable during the first 72 hours after being placed. magnitude. Transverse loads tend to push out the foundation, and if not adequately provided for, they could With suitable precautions, concrete can be placed cause failure not only of the foundation, but also of the during cold weather and have the same qualities as main structural framing members. These loads are concrete cured during the summer months. resisted by two methods: 1. Use of steel tie-bars. The reinforcing bars are con- Foundations nected to anchor bolts, providing a continuous tie between the column bases. A spread tie, or hairpin, which transfers the load from the column anchor bolts to the welded wire fabric (used in floor slab) is used where the transverse loads are not large. Basically, it utilizes the same design principle as the tie-bars. 2. Increasing size of footing. Increasing the size of the footing helps counteract the force exerted by transverse loads, thus preventing the movement of the foundation. This method is usually the most The actual construction of a building must obviously expensive. begin with the laying of the foundation, a necessary base for any structure. Because all ground, regardless The type of foundation depends upon the geographical of the bearing value of the soil, has a tendency to move, location of the building, topography of land, frame loads the building must be built on a good, strong foundation imposed on foundation, local building code restrictions that is designed for the anticipated loads. and architectural considerations. Generally, there are three types of foundations used with our building sys- The old saying, "a building is only as strong as its foun- tems: dation" is still just as true today as it was years ago when someone coined that phrase. While materials and methods are much improved, faulty foundations remain a paramount source of trouble for some building construction. Leaky basements, cracking walls, and settling floors are typical trouble spots. And once they exist, they can present some of the most difficult problems to solve. Foundations are actually broken down into two classifi- FLOATING SLAB cations: 1. Walls 1. Floating Slabs. Floating slabs consist of a concrete slab, monolithically poured with a continuous Introduction to Metal Buildings 89 Lesson 8 grade beam. The grade beam is either spread considered in order to establish the floor design. directly under the column or reinforced along the bottom to carry the vertical column loads. Many local building codes establish minimum floor- design loads for various end uses. Another consideration in the floor design is the type of joints used. A construction joint is simply a joint required where construction begins and ends, from one day's pour to the next. An expansion or control joint is used where the floor slab abuts a wall or where a steel column or pier passes through the floor. It is used to control the contraction that will occur, by merely forcing the crack to occur at a LOAD BEARING predetermined point. Actually, an expansion joint in a FOUNDATION WALL concrete foundation might better be classified as a contraction joint because during the curing process, the concrete shrinks in volume approximately the same amount that would normally result from a 100 degree drop in temperature. If the finished concrete floor is to be sealed, hardened, or waterproofed. Chemicals or additives are often applied during the final finishing or soon after curing to achieve the results desired. 2. Pier, Footing, and Grade Beam consist of a square Pre-Erection or rectangular footing and a grade beam wall. A In the pre-erection phase, there are several things that drilled pier may be utilized in lieu of the square or are necessary to consider: access to the site, assuring rectangular footing. Piers and footings carry most sufficient workspace requirements at the site, avail- of the vertical loads. ability of required utilities, a comprehensive safety awareness program, and a familiarity with the erection Floors drawings. A floating slab, or slab on grade, is the general type of The vehicle transporting your building parts must gain floor system often used with metal buildings. It is either access to the building site from the adjacent highway or poured monolithically with the foundation wall, or road. Such access should be studied and prepared in poured after the foundation wall is in place. In both advance of arrival. All obstructions, overhead and oth- cases, the concrete slab encases steel serving as rein- erwise, must be removed and the access route forcement. This steel reinforcing reduces the cracking graveled or planked if the soil will not sustain the heavy of the floor and helps control expansion and contraction. wheel loads. Where there are additional concentrated-load require- Inspect to insure that there is enough room to physically ments standard reinforcing bars are often necessary. perform the tasks required to erect the building. Application of sheeting and trim can be expensive when Many floor slabs are constructed with a vapor barrier to there is not sufficient working space because of the prevent passage of moisture from the soil through the proximity of adjacent buildings or other obstructions. concrete. The most common barrier used is a polyeth- ylene sheet material. This is placed on top of a gravel or The availability of any required utilities should also be sand base, with the concrete being poured directly over considered in advance. Take careful note of any over- the material. head electric lines or other utilities to avoid hazards and damage (notify your utility company when necessary). The type of floor system required and the thickness of floor depend on what loads are anticipated. The Develop a comprehensive safety awareness program in average of these floor loads is uniformly distributed. Any advance to familiarize the work force with the unique concentrated load, such as machinery or storage racks, conditions of the site, and the building materials, along and any moving load, such as forklift trucks, must be with the appropriate "Safe Work" practices that will be 90 Introduction to Metal Buildings Lesson 8 utilized. erection. Finally, before erection of the building can commence, Use the same lifting equipment to unload and erect you and your crew must familiarize yourselves with the structural parts of the building if possible. erection drawings furnished with every Mesco building. Combining the unloading process with the building erection usually minimizes lifting equipment costs. Each plan is specially prepared for each individual As soon as the truck is unloaded, the lifting equip- building and should be strictly adhered to. ment should start erecting the columns and raising the assembled rafters into position. Erection of the Building 4. CONSIDERATION OF OVERHEAD ELECTRIC The next stage in the construction process of a Mesco WIRES. OVERHEAD POWER LINES ARE A building is the erection of the structural and covering CONTINUING SOURCE OF DANGER. systems. We will merely discuss the general steps in EXTREME CARE MUST BE USED IN LOCATING this process. One of the best ways to become familiar AND USING LIFTING EQUIPMENT TO AVOID with this phase is to visit an actual construction job CONTACT WITH POWER LINES. within your local area. Select a building that is conve- 5. Schedule crew. Depending on the crew size, valu- niently located so that you can make several visits able time can generally be gained if the supervisor throughout the construction phases. If it is fairly small, plans and watches ahead instead of getting tied up most of the erection of the structural members, roof and with a particular unloading chore. walls can be completed in a relatively few days. 6. Check Shipment. When shipments are received in Unloading and Layout of Material the field, two inspections are necessary: Pre-planning of the unloading operations is an impor- a. When items, boxes, crates, bundles or other large tant part of the erection procedure. This involves components are received and unloaded for the careful, safe and orderly storage of all materials. carrier, they should be checked off from the Detailed planning is required at the job site where packing list. If during the inspection, damages, or storage space is restricted. Here, a planned separation shortages of items are found a report should be of materials in the order of erection process is neces- filed with the carrier immediately at the site. When sary to minimize the costly double handling of materials. damages are evident from the exterior of con- While set procedures are not possible in all cases, spe- tainers, they should be opened and inspected cial attention should be given to the following items: thoroughly at the time of receiving shipments. 1. Location of carrier vehicle during unloading. b. When bundles, crates, cartons, boxes, etc. are Unload material near their usage points to mini- opened following delivery, another check must be mize lifting, travel, and rehandling during building performed to determine the quantity received and assembly. their condition. If during this inspection damages or shortages of items are found upon opening the 2. Prepare necessary ramp for truck. The edges of crates or cartons, a written claim should be sent to the concrete slab should be protected to minimize the carrier no later than fourteen days after the danger of chipping or cracking from truck traffic delivery. If a shortage is discovered within a con- if the materials are to be laid out on the slab. One tainer, then a written notice should be mailed or important safety consideration is the fact that faxed to the manufacturer at the same time the materials stored on the slab may subject the claim is sent to the carrier. Unless these two impor- workers to possible injury from falling objects. tant inspections are made and any reports or claims are filed immediately, settlements become 3. Schedule lifting equipment. The manufacturer nei- very difficult and usually all parties suffer the loss. ther supplies lifting equipment nor labor to unload Location of Building Parts the truck. The type and size of lifting equipment is determined by the size of the building and the site conditions. The weight and size of the largest piece Columns and rafters are usually unloaded near their of structural steel is to be lifted as high as it has to respective installed positions on blocking on the slab in be lifted and the distance of the lift from the posi- position for easy makeup. tion of the crane all impact the selection of the crane or other lifting equipment. Length of boom, Endwalls are usually laid out at each end of slab with capacity and maneuverability of lifting equipment the columns near respective anchor bolts. will determine its location for both unloading and Introduction to Metal Buildings 91 Lesson 8 Hardware packages should be located centrally, usually a job, all bundles of primed parts should be stored at an along one sidewall near the center of the building. This angle to allow any trapped water to drain away and will minimize walking distances to other parts of the slab permit air circulation for drying. Puddles of water should area. not be allowed to collect and remain on columns or rafters for the same reason. Purlins and girts, depending on the number of bundles, are usually stored near the sidewalls clear of the other packages or parts. Wall and Roof Panels Sheet packages are usually located along one or both sidewalls off the ground and sloping to one end to DRAINAGE encourage drainage in case of rain. ELEVATE Accessories are usually unloaded on a corner of the slab or off the slab near one end of the building to keep them as much out of the way as possible from the active TARP area during steel erection. Storing Materials AIR CIRCULATION Structural Framing Members As previously emphasized, a great amount of time and Mesco's wall and roof panels including color coated trouble can be saved if the building parts are unloaded Galvalume® and galvanized, provide excellent service at the building site according to a prearranged staging under widely varied conditions. All unloading and erec- plan. Proper location and handling of components will tion personnel should fully understand that these panels eliminate unnecessary handling. are quality merchandise, which merits cautious care in Blocking under the columns and rafters protect the handling and storing. splice plates and the slab from damage during the Under no circumstances should panels be handled unloading process. It also facilitates the placing of roughly. Packages of sheets should be lifted off the slings or cables around the members for later lifting and truck with extreme care taken to insure that no damage allows members to be bolted together into subassem- occurs to ends of the sheets or to side ribs. Please note blies while on the ground. the designated "pick points" to prevent crimping damage during lifting of bundles. The packages should be stored off the ground sufficiently high to allow air circulation underneath the packages. One end of the package should always be elevated to encourage drainage in case of rain. All stacked metal panels are subject, to some degree, to localized discoloration or stain when water is trapped between their closely nested surfaces. Mesco exercises extreme caution during fabricating and shipping operations to insure that all panel stock is kept dry. However, XX due to climatic conditions, water formed by condensa- XX NOTE: Piece marks are stenciled on primary structural members, tion of humid air can become trapped between stacked 1'-0" from end. sheets. Water can also be trapped between the stacked sheets when exposed to rain. This discoloration caused by trapped moisture is often called wet storage stain. Use wood blocking to elevate and slope the panels in a If water is allowed to remain for extended periods in manner that will allow moisture to drain. Wood blocking bundles of primed parts such as girts, purlins, etc., the placed between bundles will provide additional air cir- pigment will fade and the paint will gradually soften culation. Cover the stacked bundles with a tarp or reducing its bond to the steel. Therefore, upon receipt of plastic cover leaving enough opening at the bottom for air to circulate. 92 Introduction to Metal Buildings Lesson 8 Metal Building Erection the building. Responsible personnel, experienced in rigging and 7. When the first bay is completed, the individual handling light steel members in a safe manner should frames are erected and tied together by skeleton complete the layout, assembly, and erection of the or lead purlins and the fill-in purlins are installed metal building. Improper handling can easily result in after the costly lifting equipment has been injury, delays and unexpected added costs. This is par- released. ticularly true when raising assembled rafters for wide 8. When the proper tools and equipment are avail- buildings. able in sufficient quantity and in good/safe working Mesco Building Solutions includes a Installation Manual condition. with each job. In addition, these manuals may be purchased from Mesco's Sales Department. The Conclusion Installation Manual is a guide for the erection process and reflects the techniques in use in the metal building The basics of metal building erection, from the primary industry believed to be most representative of good structures to the secondary structures, have been cov- erection practices. The erector should always use ered in this workbook. We have briefly encapsulated the proven and safe erection methods. Knowledge of basic sequence of events from construction site plan- and adherence to OSHA and other local codes or ning through erecting a Mesco Building System. Many laws governing jobsite safety is critical, and is the other phases, such as mechanical, electrical, interior responsibility of the erector. If any questions arise finishing and landscaping need to be done to finish and regarding erection questions on a specific building, the complete most projects. Although there are many other erector should contact Mesco's Customer Service events, procedures, and essentials that are involved in Department. the erection of a metal building, the brief overview Introduction to Metal Buildings provides will benefit not Tips to Keep Erection Costs Down only Builders but also their employees with knowledge to better serve the customer. Minimum costs should be obtained when the following conditions are met during the erection of a Mesco building: 1. When safety practices are discussed and initiated in advance of any work procedure. 2. When the overall work of erecting the building is divided into individual jobs, and when each job is assigned to teams of workers consisting of two to seven workers each, with three to five worker teams preferred. 3. When individual workers are properly trained and instructed in advance as to what they are to do and the safe way to do it. This eliminates time wasted while waiting to be told what to do next. 4. When building parts are properly laid out according to advanced planning so as to avoid lost time in repetitive handling or in searching for specific items. 5. When as many parts as can be safely raised in a single lift are bolted together in subassemblies on the ground where assembly work is faster and safer, thereby, requiring fewer lifts and fewer connections to be made in the air. 6. When erection of the steel framework starts at one end and continues bay by bay to the other end of Introduction to Metal Buildings 93 Lesson 8 Self Test Lesson Eight: Self-Test 1. Which one of the following is the Builders usually offer the owner design service by his/her staff architects an/or engineers? A. Bid General Contractor B. Bid Subcontractor C. Design Build General Contractor D. Design Build Subcontractor E. None of the Above 2. Which of the following is not a pre-construction site consideration? A. Laying the Foundation B. Building Codes C. Previous use of Land D. Building Site Restrictions E. Utility Connections 3. To which load is a foundation extremely subjected? A. Snow B. Collateral C. Vertical D. Transverse E. None of the Above 4. During the Pre-Installation stage it is necessary to develop a comprehensive safety awareness program in advance to familiarize the work force with the unique conditions of the site, and the building materials, along with the appropriate "Safe Work" practice that will be utilized during erection. A. True B. False 5. What are the two essential requirements of quality concrete? A. Cement and Sand B. Coarse Aggregate and Water C. Strength and Durability D. Placement and Curing 6. Which of the following is not a common location of building parts during unloading, layout, and storage of material? A. Purlins and Girts near the sidewalls B. Central location of Hardware Packages C. Endwalls are laid out at each end of the slab D. Accessories are unloaded in the center of the slab E. None of the Above 7. What are 3 criteria that handling and storing panels should meet? A. Handle carefully B. Stored elevated off the ground. C. One end of the panels be elevated higher than the other end to promote drainage. D. B and C E. A and B F. All of the Above 8. Safety issues should be discussed and initiated in advance of any work procedures. A. True B. False 94 Introduction to Metal Buildings Glossary Glossary: Terminology Commonly Used in the Metal Building Industry Basic Terms and Descriptions Accessory: A building product which supplements a basic solid panel building such as a door, window, light transmitting panel, roof vent, etc. Agricultural Building: A structure designed and constructed to house farm implements, hay, grain, poultry, live- stock or other agricultural products. Such structures should not include: spaces meant for habitation or to be occupied, spaces in which agricultural products are processed, treated, or the possibility of being as a place of occupancy by the general public. Aluminum Coated Steel: Steel coated with aluminum for corrosion resistance. Anchor Bolts: Bolts used to anchor members to a foundation or other support. Anchor Bolt Plan: A plan view drawing showing the diameter, location and projection of all anchor bolts for the components of the Metal Building System and may show column reactions (magnitude and direction). The maximum base plate dimensions may also be shown. Approval Drawings: A set of drawings that may include framing plans, elevations and sections through the building for approval of the builder. ASD: Allowable Stress Design. Assembly: A group of mutually dependent and compatible components or subassemblies of components. Astragal: a closure between the two leaves of a double swing or double slide door. Automatic Crane: A crane which when activated operates through a preset series of cycles. Auxiliary Crane Girder: A girder arranged parallel to the main girder for supporting the platform, motor base, operator's cab, control panels, etc., to reduce the torsional forces that such a load would otherwise impose on the main crane girder. Axial Force: A force tending to elongate or shorten a member Bar Joist: A name commonly used for Open Web Steel Joists Base Angle: An angle secured to a wall or foundation used to attach the bottom of the wall paneling. Base Plate: A plate attached to the bottom of a column, which rests on a foundation or other support, usually secured by anchor bolts. Base Tube: See "Cast in Place Base" Bay: The space between the main frames measured normal to the frame Beam: A member, usually horizontal, that is subjected to bending loads. Three types are simple, continuous, and cantilever. Beam and Column: A Structural system consisting of a series of rafter beams supported by columns. Often used as the end fame of a building. Bearing End Frame: See "Beam and Column" Introduction to Metal Buildings 95 Glossary Bearing Plate: A steel plate that is set on the top of a masonry support on which a beam or purlin can rest Bent: See "Main Frame". Bill of Materials: A list that enumerates by part number or description each piece of material or assembly to be shipped. Also called tally sheet or shipping list. Bird Screen: Wire mesh used to prevent birds from entering the building through ventilators and louvers. Blind Rivet: A small headed pin with expandable shank for joining light gauge metal. Typically it is used to attach flashing, gutters, etc. Box Girder: Girders, trucks or other members of rectangular cross section enclosed on four sides. Bracing: Rods, angles or cables used in the plane of the roof and walls to transfer loads, such as wind, seismic and crane thrusts to the foundation Bracket: A structural support projecting from a structural member. Examples are canopy brackets, lean-to brackets, and crane runway brackets, Bridge (Crane): That part of an overhead crane consisting of girders, trucks, end ties, walkway and drive mechanism that carries the trolley and travels in a direction parallel to the runway Bridge Crane: A load lifting system consisting of a hoist, which moves laterally on a beam, girder or bridge which in turn moves longitudinally on a runway made of beams and rails Bridging: Bracing or systems of bracing used between structural members British Thermal Unit (BTU): The amount of heat required to raise the temperature of one pound of water by 1 degree Fahrenheit. Builder: A party who, as a routine part of his/her business, buys Metal Building Systems from a manufacturer for the purpose of resale. Building: A structure forming an open, partially enclosed, or enclosed space constructed by a planned process of combining materials, components, and subsystems to meet specific conditions of use. Building Aisle: A space defined by the length of the building and the space between building columns. Building Code: Regulations established by a recognized agency describing design loads, procedures and construction details for structures usually applying to a designated political jurisdiction (city, county, state, etc.). Built-Up Roofing: A roof covering made up of alternating layers of tar and materials made of asphalt. Built-Up Section: A structural member, usually an "I" shaped section, made from individual flat plates welded together. Bumper: An energy-absorbing device for reducing impact when a moving crane or trolley reaches the end of its permitted travel, or when two moving cranes or trolleys come into contact. Butt Plate: The end plate of a structural member usually used to rest against a like plate of another member in forming a connection. Sometimes called a splice plate or bolted end plate. Bypass Girt: A wall framing system where the girts are mounted on the outside of the columns. "C" Section: A member in the shape of a block "C" formed from steel sheet, that may be used either singularly or back to back. Cab-Operated Crane: A crane controlled by an operator in a cab supported on the bridge or trolley. Camber: Curvature of a flexural member in the plane of its web before loading. Canopy: A projecting roof system that is supported and restrained at one end only. Cantilever Beam: A beam supported only at one end with the other end free to move. 96 Introduction to Metal Buildings Glossary Capillary Action: That action which causes movement of liquids when in contact with two adjacent surfaces such as panel sidelaps. Cap Plate: A plate located at the top of a column or end of a beam for capping the exposed end of the member. Capacity (Crane): The maximum load (usually stated in tons) that a crane is designed to support. Cast In Place Base: A continuous member imbedded in the edge of the foundation to which the wall panels are attached. Caulk: To seal and make weather-tight joints, seams, or voids by filling with a waterproofing compound or material. Chalking: When the paint finish on panels has a white powder film due to over exposure. Channel, Hot Rolled: A member formed while in a semi-molten state at the steel mill to shape having standard dimensions and properties. Cladding: The exterior metal roof and wall paneling of a Metal Building System. See also "Covering." Clip: A plate or angle used to fasten two or more members together. Closure Strip: A strip, formed to the contour of ribbed panels and used to close openings created by ribbed panels joining other components, either made of resilient material or metal. CMU: Concrete Masonry Unit. Generally, used to construct masonry walls Cold Forming: The process of using press brakes or rolling mills to shape steel into desired cross sections at room temperature. Collateral Loads: The weight of additional permanent materials required by the contract, other than the Building System, such as sprinklers, mechanical and electrical systems, partitions and ceilings. Column: A main member used in a vertical position on a building to transfer loads from main roof beams, trusses, or rafters to the foundations. Component: A part used in a Metal Building System. See also "Components and Cladding". Components and Cladding: Members which include girts, joists, purlins, studs, wall and roof panels, fasteners, end wall columns and endwall rafters of bearing end frames, roof overhang beams, canopy beams, and masonry walls that do not act as shear walls. Concealed Clip: A hold down clip used with a wall or roof panel system to connect the panel to the supporting structure without exposing the fasteners on the exterior surface. Connection: The means of attachment of one structural member to another. Continuity: The terminology given to a structural system denoting the transfer of loads and stresses from member to member allowing the members to act as a single unit. Continuous Beam: A beam having three or more supports. Covering: The exterior metal roof and wall paneling of a Metal Building System. Crane: A machine designed to move material by means of a hoist. Crane Aisle: That portion of a building aisle in which a crane operates, defined by the crane span and the uninterrupted length of crane runway. Crane Girder: The principal horizontal beams of the crane bridge that supports the trolley and is supported by the end tracks. Crane Rail: A track supporting and guiding the wheels of a top-running bridge crane or trolley system. Introduction to Metal Buildings 97 Glossary Crane Runway Beam: The member that supports a crane rail and is supported by columns or rafters depending on the type of crane system. On underhung bridge cranes, the runway beam also acts as the crane rail. Crane Span: The horizontal distance center-to-center of runway beams. Crane Stop: A device to limit travel of a trolley or crane bridge. This device normally is attached to a fixed structure and normally does not have energy-absorbing ability. Crane Support Column: A separate column that supports the runway beam of a top-running crane. Curb: A raised edge on a concrete floor slab or in the roof for accessories. Curtain Wall: Perimeter wall panels that carry only their own weight and wind load. Damper: A baffle used to open or close the throat of ventilators. They can be operated manually or by motors. Dead Loads: The dead load of a building is the weight of all permanent construction, such as floor, roof, framing, and covering members. Design Professional: Any Architect or Engineer. Diagonal Bracing: See "Bracing". Diaphragm Action: The resistance to racking generally offered by the covering system, fasteners, and secondary framing. Distortion of the overall roof, floor, or wall shape. Door Guide: An angle or channel used to stabilize or keep plumb a sliding or rolling door during its operation. Downspout: A conduit used to carry water from the gutter of a building. Drift (Sidesway): Transverse displacement at the top of a vertical element due to lateral loads. Drift should not be confused with Deflection. Drift (Snow): The snow accumulation at a height discontinuity. Drift Pin: A tapered pin used during erection to align holes in steel members to be connected by bolting. Eave: The line along the sidewall formed by the intersection of the planes of the roof and wall. Eave Canopy: A projecting roof system on the sidewall whose overhanging edge is supported at the building. Eave Gutter: See "Gutter". Eave Height: The vertical dimension from finished floor to the top of the eave strut. Eave Strut: A structural member located at the eave of a building that supports roof and wall paneling. Edge Strip: The surface area of a building at the edges of the roof and corners of the walls where the wind loads on components and cladding are greater than at other areas of the building. Effective Wind Area: The area used to determine the wind coefficient. The effective wind area may be greater than or equal to the tributary area. Elastic Design: A design concept utilizing the a property of materials allowing for non-permanent shape distortion under a specified range of loading. Electric Operated Crane: A crane in which the bridge, hoist or trolley is operated by electric power. Electric Overhead Traveling Crane: An electrically-operated machine for lifting, lowering and transporting loads, consisting of a movable bridge carrying a fixed or movable hoisting mechanism and traveling on an overhead runway structure. End Approach: The minimum horizontal distance, parallel to the runway, between the outer-most extremities of the crane and the centerline of the hook. 98 Introduction to Metal Buildings Glossary End Bay: The bays adjacent to the endwalls of a building. Usually the distance from the endwall to the first interior main frame measured normal to the endwall. End Frame: A frame located at the endwall of a building that supports the loads from a portion of the end bay. End Post: See "Endwall Column". End Stop: A device attached to a crane runway or rail to provide a safety stop at the end of a runway. End Truck: The unit consisting of truck frame, wheels, bearings, axles, etc., which supports the bridge girders. Endwall: An exterior wall that is parallel to the interior main frames of the building. Endwall Column: A vertical member located at the endwall of a building that supports the girts. In post and beam endwall frames, endwall columns also support the rafter. Endwall Overhang: See "Purlin Extension". End Zone: The surface area of a building along the roof at the endwall and at the corners of walls. (see Edge Strip) Engineer/Architect of Record: The engineer or architect who is responsible for the overall design of the building project. The manufacturer's engineer is not the Engineer of Record. Installation: The on-site assembling of fabricated Metal Building System components to form a completed structure. Erection Bracing: Materials used by erectors to stabilize the building system during erection, also typically referred to as temporary bracing. Erection Drawings: Roof and wall erection (framing) drawings that identify individual components and accessories furnished by the manufacturer in sufficient detail to permit proper Erection of the Metal Building System. Erector: A party who assembles or erects a Metal Building System. Expansion Joint: A break or space in construction to allow for thermal expansion and contraction of the materials used in the structure. Exterior Framed: A wall framing system where the girts are mounted on the outside of the columns. Fabrication: The manufacturing process performed in a plant to convert raw material into finished Metal Building System components. The main operations are cold forming, cutting, punching, welding, cleaning and painting. Facade: An architectural treatment, partially covering a wall, usually concealing the eave and/or the rake of the building. Fading: Refers to the paint finish on panels becoming less vibrant of color. Fascia: A decorative trim or panel projecting from the face of a wall. Field: The job site, building site, or general marketing area. Filler Strip: See "Closure Strip". Film Laminated Coil: Coil metal that has a corrosion resistant film laminated to it prior to the forming operation. Fixed Clip: A standing seam roof system hold down clip that does not allow the roof panel to move independently of the roof substructure. Fixed Base: A column base that is designed to resist rotation as well as transverse or vertical movement. Flange: The projecting edge of a structural member ( e.g. the top and bottom horizontal projections of an I beam). Flange Brace: A member used to provide lateral support to the flange of a structural member. Flashing: The metal used to "trim" or cover the juncture of two planes of material. Introduction to Metal Buildings 99 Glossary Floating Clip: A standing seam roof system hold down clip that allows the roof panel to transversely move independently of the roof substructure. Also known as a "Sliding Clip" or "Slip Clip". Floor Live Load: Those loads induced on the floor system by the use and occupancy of the building. Flush Girts: A wall framing system where the outside flange of the girts and the columns are flush. Footing: A pad or mat, usually of concrete, located under a column, wall or other structural member, that is used to distribute the loads from that member into the supporting soil. Foundation: The substructure, which supports a building or other structure. Framed Opening: Framing members and flashing which surround an opening. Framing Plans: See "Erection Drawings". Gable: The triangular portion of the endwall from the level of the eave to the ridge of the roof. Gable Overhang: See "Purlin Extension". Gable Roof: A roof consisting of two sloping roof planes that form a ridge and form a gable at each end. Galvanized: Steel coated with zinc for corrosion resistance. Gantry Crane: A crane similar to an overhead crane except that the bridge for carrying the trolley or trolleys is rigidly supported on one or more legs running on fixed rails or other run-way. Girder: A main horizontal or near horizontal structural member that supports vertical loads. It may consist of several pieces. Girt: A horizontal structural member that is attached to sidewall or endwall columns and supports paneling. Glaze: The process of installing glass in windows and doors. Glazing: Glass panes or paneling used in windows and doors. Grade: The term used when referring to the ground elevation around a building. Grade Beam: A concrete beam around the perimeter of a building. Ground Snow Load: The probable weight of snow on the ground for a specified recurrence interval exclusive of drifts or sliding snow. Grout: A mixture of cement, sand and water used to fill cracks and cavities. Sometimes used under base plates or leveling plates to obtain uniform bearing surfaces. Gusset Plate: A steel plate used to reinforce or connect structural elements. Gutter: A light gauge metal member at an eave, valley or parapet designed to carry water from the roof to downspouts or drains. "H" Section: A steel member with a cross section in the shape of an "H". Hair Pin: "V" shaped reinforcing steel used to transfer anchor bolt shear to the concrete floor mass. Hand-Geared (Crane): A crane in which the bridge, hoist, or trolley is operated by the manual use of chain and gear without electric power. Haunch: The deepened portion of a column or rafter designed to accommodate the higher bending moments at such points. (Usually occurs at the intersection of the column and the rafter.) Header: The horizontal framing member located at the top of a framed opening. High Strength Bolts: Any bolt made from steel having a tensile strength in excess of 100,000 pounds per square inch. 100 Introduction to Metal Buildings Glossary High Strength Steel: Structural steel having a yield stress in excess of 36,000 pounds per square inch. Hinged Base: See "Pinned Base". Hip: The line formed at the intersection of two adjacent sloping planes of a roof. Hip Roof: A roof that is formed by sloping planes from all four sides. Hoist: A mechanical lifting device usually attached to a trolley that travels along a bridge, monorail, or jib crane. May be chain or electric operated. Horizontal Guide Rollers: Wheels mounted near the ends of end trucks, which roll on the side of the rail to restrict lateral movement of the crane. Hot-Rolled Shapes: Steel sections (angles, channels, "S" shapes, "W" shapes, etc.) which are formed by rolling mills while the steel is in a semi-molten state. "I"-Beam: See "S" shape. Ice Dam: A buildup of ice which forms a dam at the eave, contributing to an excessive build-up of snow on the roof. Impact Load: A dynamic load resulting from the motion of machinery, elevators, craneways, vehicles, and other similar moving forces. See "Auxiliary Loads". Impact Wrench: A power tool used to tighten nuts or bolts. Importance Factor: A factor that accounts for the degree of hazard to human life and damage to property. Insulation: Any material used in building construction to reduce heat transfer. Internal Pressure: Pressure inside a building. Jack Beam: A beam used to support another beam, rafter or truss and eliminate a column support. Jack Truss: A truss used to support another beam, rafter, or truss and eliminate a column support. Jamb: The vertical framing members located at the sides of an opening. Jib Crane: A cantilevered or suspended beam with hoist and trolley. This lifting device may pick up loads in all or part of a circle around the column to which it is attached. Jig: A device used to hold pieces of material in a certain position during fabrication. Joist: A light beam for supporting a floor or roof. Kick-Out (Elbow) (Turn-Out): An extension attached to the bottom of a downspout to direct water away from a wall. Kip: A unit of measure equal to 1,000 pounds. Knee: The connecting area of a column and rafter of a structural frame such as a rigid frame. Knee Brace: A diagonal member at a column and rafter intersection designed to resist transverse loads. Lean-to: A structure having only one slope and depending upon another structure for partial support. Length: The dimension of the building measured perpendicular to the main framing from outside to outside of endwall girts. Leveling Plate: A steel plate used on top of a foundation or other support on which a structural column can rest. Lift (Crane): Maximum safe vertical distance through which the hook, magnet, or bucket can move. Lifting Devices (Crane): Buckets, magnets, grabs and other supplemental devices, the weight of which is to be considered part of the rated load, used for ease in handling certain types of loads. Introduction to Metal Buildings 101 Glossary Light Transmitting Panel: Panel used to admit light. Liner Panel: A metal panel attached to the inside flange of the girts or inside of a wall panel. Live Load: Loads that are produced (1) during maintenance by workers, equipment, and materials, and (2) during the life of the structure by movable objects and do not include wind, snow, seismic, or dead loads. Also see "Roof or Floor Live Load". Load Indicating Washers: A washer with dimples, which flatten when the high strength bolt is tightened. The bolt tension can then be determined by the use of feeler gauges to determine the gap between the washer and the bolt head. Longitudinal: The direction parallel to the ridge or sidewall. Longitudinal (Crane): Direction parallel to the crane runway beams. Louver: An opening provided with fixed or movable slanted fins to allow flow of air. Low Rise Building: A description of a class of buildings usually less than 60' eave height. Commonly, they are single story, but do not exceed 4 stories. LRFD: Load and Resistance Factor Design. Main Frame: An assemblage of rafters and columns that support the secondary framing members and transfer loads directly to the foundation. Main Wind Force Resisting System: A structural assembly that provides for the overall stability of the building and receives wind loads from more than one surface. Examples include shear walls, diaphragms, rigid frames, and space structures. Manufacturer: A party who designs and fabricates a Metal Building System. Manufacturer's Engineer: An engineer employed by a manufacturer who is in responsible charge of the structural design of a Metal Building System fabricated by the manufacturer. The manufacturer's engineer is not the Engineer of Record. Masonry: Anything constructed of materials such as bricks, concrete blocks, ceramic blocks, and concrete. Mastic: See "Sealant". Mean Roof Height: Average height of roof above ground. Metal Building System: A complete integrated set of mutually dependent components and assemblies that form a building including primary and secondary framing, covering and accessories, and are manufactured to permit inspection on site prior to assembly or erection. Mezzanine: An intermediate level between floor and ceiling occupying a partial area of the floor space. Mill Duty Crane: Cranes with service classification E and F as defined by CMAA. Moment: The tendency of a force to cause rotation about a point or axis. Moment Connection: A connection designed to transfer moment as well as axial and shear forces between connecting members. Moment of Inertia: A physical property of a member, which helps define strength and deflection characteristics. Monolithic Construction: A method of placing concrete grade beam and floor slab together to form the building foundation without forming and placing each separately. Monolithic Pour: The placing of concrete in a monolithic construction. Monorail Crane: A crane that travels on a single runway beam, usually an "S" or "W" beam. Multi-Gable Building: Buildings consisting of more than one gable across the width of the building. 102 Introduction to Metal Buildings Glossary Multi-Span Building: Buildings consisting of more than one span across the width of the building. Multiple gable buildings and single gable buildings with interior columns are examples. Multiple Girder Crane: A crane, which has two or more girders for supporting the lifted load. Oil Canning: A waviness that may occur in flat areas of light gauge formed metal products. Structural integrity is not normally affected by this inherent characteristic; therefore oil canning is only an aesthetic issue. Oil canning is not a cause for rejection of the material. Open Web Steel Joists: Lightweight truss. Order Documents: The documents normally required by the Manufacturer in the ordinary course of entering and processing an order. Outrigger: See "Auxiliary Crane Girder". Overhanging Beam: A simply supported beam that extends beyond its support. Overhead Doors: See "Sectional Overhead Doors". Panels: See "Cladding". Panel Notch: A notch or block out formed along the outside edge of the floor slab to provide support for the wall panels and serve as a closure along their bottom edge. Pan Panel: A standing seam panel, which has vertical sides and has no space between the panels at the side laps. Parapet: That portion of the vertical wall of a building that extends above the roofline. Parts and Portions: See "Components and Cladding". Peak: The uppermost point of a gable. Peak Sign: A sign attached to the peak of the building at the endwall showing the building manufacturer. Pendant-Operated Crane: Crane operated from a pendant control unit suspended from the crane. Personnel Doors: doors used by personnel for access and exit from a building. Pick Point: The belted part of panel bundles where the bundle is to be lifted. Piece Mark: A number given to each separate part of the building for erection identification. Also called mark number and part number. Pier: A concrete structure designed to transfer vertical load from the base of a column to the footing. Pig Spout: A sheet metal section designed to direct the flow of water out through the face of the gutter rather than through a downspout. Pilaster: A reinforced or enlarged portion of a masonry wall to provide support for roof loads or lateral loads on the wall. Pinned Base: A column base that is designed to resist transverse and vertical movement, but not rotation. Pin Connection: A connection designed to transfer axial and shear forces between connecting members, but not moments. Pitch: See "Roof Slope". Plastic Design: A design concept based on multiplying the actual loads by a suitable load factor, and using the yield stress as the maximum stress in any member, and taking into consideration moment redistribution. Plastic Panels: See "Light Transmitting Panels". Introduction to Metal Buildings 103 Glossary Ponding: 1) The gathering of water at low or irregular areas on a roof. 2) Progressive accumulation of water from deflection due to rain loads. Pop Rivet: See "Blind Rivet". Porosity: The measurement of openings in buildings, which allow air to enter during a windstorm. Portal Frame: A rigid frame so designed that it offers rigidity and stability in its plane. It is generally used to resist longitudinal loads where other bracing methods are not permitted. Post: See "Column". Post and Beam: A structural system consisting of a series of rafter beams supported by columns. Often used as the end frame of a building. Post-tensioning: A method of pre-stressing reinforced concrete in which tendons are tensioned after the concrete has reached a specific strength. Power Actuated Fastener: A device for fastening items by the utilization of a patented device that uses an explo- sive charge or compressed air to embed the pin in concrete or steel. Pre-tensioning: A method of pre-stressing reinforced concrete in which the tendons are tensioned before the concrete has been placed. Pre-Painted Coil: Coil of metal, which has received a paint coating. Press Brake: A machine used in cold-forming metal sheets or strips into desired sections. Pre-stressed Concrete: Concrete in which internal stresses of such magnitude and distribution are introduced that the tensile stresses resulting from the service loads are counteracted to a desired degree; in reinforced concrete the pre-stress is commonly introduced by tensioning the tendons. Primary Framing: See "Main Frame". Prismatic Beam: A beam with a uniform cross section. Public Assembly: A building or space where 300 or more persons may congregate in one area. Purlin: A horizontal structural member that supports roof covering and carries loads to the primary framing members. Purlin Extension: The projection of the roof beyond the plane of the endwall. Rafter: The main beam supporting the roof system. Rail (Crane): See "Crane Rail". Rails (Door): The horizontal stiffening members of framed and paneled doors. Rake: The intersection of the plane of the roof and the plane of the endwall. Rake Angle: Angle fastened to purlins at rake for attachment of endwall panels. Rake Trim: A flashing designed to close the opening between the roof and endwall panels. Rated Capacity (Crane): The maximum load (usually in tons), which a crane is designed to support safely. Reactions: The resisting forces at the column bases provided by foundations that hold a structure in equilibrium under a given loading condition. Reinforcing Steel: The steel placed in concrete as required to carry the tension, compression and shear stresses. Remote-Operated Crane: A crane controlled by an operator not in a pulpit or in the cab attached to the crane by any method other than pendant or rope control. 104 Introduction to Metal Buildings Glossary Retrofit: The placing of new metal roof or wall systems over deteriorated roofs or walls. Rib: The longitudinal raised profile of a panel that provides much of the panel's bending strength. Ribbed Panel: A panel, which has ribs with sloping sides and forms a trapezoidal shaped void at the side lap. Ridge: The horizontal line formed by opposing sloping sides of a roof running parallel with the building length. Ridge Cap: A transition of the roofing materials along the ridge of a roof; sometimes called ridge roll or ridge flashing. Rigid Connection: See "Moment Connection". Rigid Frame: A structural frame consisting of members joined together with moment connections so as to render the frame stable with respect to the design loads, without the need for bracing in its plane. Rolling Doors: Doors that are supported at the bottom on wheels that run on a track. Roll-Up Door: A door that opens by traveling vertically and is gathered into a roll suspended some distance above the floor. Roof Covering: The exposed exterior roof surface consisting of metal panels. Roof Live Load: Loads that are produced (1) during maintenance by workers, equipment, and materials, and (2) during the life of the structure by movable objects which do not include wind, snow, seismic or dead loads. Roof Overhang: A roof extension beyond the endwall or sidewall of a building. Roof Slope: The tangent of the angle that a roof surface makes with the horizontal, usually expressed in units of vertical rise to 12 units of horizontal run. Roof Snow Load: The load induced by the weight of snow on the roof of the structure. Runway Beam: See "Crane Runway Beam". Runway Bracket: A bracket extending out form the column of a building frame, which supports the runway beam for top-running cranes. Runway Conductors: The main conductors mounted on or parallel to the runway, which supplies electric current to the crane. "S" Shape: A hot rolled beam with narrow tapered flanges. Sag Member: A tension member such as rods, straps or angles used to limit the deflection of a girt or purlin in the direction of its weak axis. Sandwich Panel: A panel used as covering consisting of an insulating core material with inner and outer metal skins. Screw Down Roof System: A screw down roof system is one in which the roof panels are attached directly to the roof substructure with fasteners that penetrate through the roof sheets and into the substructure. Scupper: An opening in a gutter or parapet system, which prevents ponding. Sealant: Any material that is used to seal cracks, joints or laps. Secondary Framing: Members that carry loads from the building surface to the main framing. For example - purlins and girts. Seaming Machine: A mechanical device that is used to close and seal the side seams of standing seam roof panels. Sectional Overhead Doors: Doors constructed in horizontally hinged sections. They are equipped with springs, tracks, counter balancers, and other hardware, which roll the sections into an overhead position clear of the opening. Introduction to Metal Buildings 105 Glossary Seismic Load: The lateral load acting in any direction on a structural system due the action of an earthquake. Self-Drilling Screw: A fastener that combines the function of drilling and tapping. Self-Tapping Screw: A fastener that taps its own threads in a predrilled hole. Seller: A party who sells a Metal Building System with or without its erection or other fieldwork. Shear: The force tending to make two contacting parts slide upon each other in opposite directions parallel to their plane of contact. Shear Diaphragm: See "Diaphragm Action". Shim: A piece of steel used to level base plates or align columns or beams. Shipping List: See "Bill of Materials". Shop Primer Paint: The initial coat of primer paint applied in the shop. A temporary coating designed to protect the steel during shipping and erection until the building exterior and interior finish coverings have been installed. This coating may or may not serve as a proper prime coat for other finishing paints. Shot Pin: See "Power Actuated Fastener". Side Lap Fastener: A fastener used to connect panels together above their length. Sidesway: See "Drift (Sidesway)". Sidewall: An exterior wall, which is perpendicular to the frames of a building system. Sidewall Overhang: See "Eave Canopy". Sill: The bottom horizontal framing member of a wall opening such as a window or louver. Simple Connection: See "Pin Connection". Simple Span: A term used in structural design to describe a beam support condition at two points which offers no resistance to rotation at the supports. Single Slope: A sloping roof in one plane. The slope is from one sidewall to the opposite sidewall. Siphon Break: A small groove to arrest the capillary action of two adjacent surfaces. (Anti- Capillary Groove). Sister Column: See "Crane Support Column". Slide Door: A single or double leaf door, which opens horizontally by means of sliding on an overhead trolley. Sliding Clip: A standing seam roof system hold down clip, which allows the roof panel to thermally expanded independently of the roof substructure. Slope: See "Roof Slope". Snow Drift: See "Drift (Snow)". Snow Load: See "Roof Snow Load". Snug Tight: The tightness of a bolt in a connection that exists when all plies in a joint are in firm contact. Soffit: A material, which covers the underside of an overhang. Soil Bearing Pressure: The load per unit area a structure will exert through its foundation on the soil. Soldier Column: An intermediate column used to support secondary structural members; not part of a main frame or beam and column system. Spacer Strut (Crane): A type of assembly used to keep the end trucks of adjacent cranes on the same runway beams a minimum specified distance apart. 106 Introduction to Metal Buildings Glossary Span: The distance between two supports. Specification (Metal Building System): A statement of a set of Metal Building System requirements describing the loading conditions, design practices, materials and finishes. Splice: A connection in a structural member. Spreader Bar: Elongated bar with attached hooks and/or chains used from a crane to lift long sections of panels, or structural members such as rafters. Spud Wrench: A tool used by erectors to line up holes and to make up bolted connections; a wrench with a tapered handle. Square: The term used for an area of 100 square feet. Stainless Steel: An alloy of steel, which contains a high percentage of chromium to increase corrosion resistance. Also may contain nickel or copper. Standing Seam: Side joints of roof panels that are arranged in a vertical position above the roofline. Standing Seam Roof System: A roof system in which the side laps between the roof panels are arranged in a vertical position above the roofline. The roof panel system is secured to the roof substructure by means of concealed hold down clips attached with screws to the substructure, except that through fasteners may be used at limited locations such as at ends of panels and at roof penetrations. Stiffener: A member used to strengthen a plate against lateral or local buckling. Stiffener Lip: A short extension of material at an angle to the flange of cold formed structural members, which adds strength to the member. Stiles: The vertical side members of framed and paneled doors. Stitch Screw: A fastener connecting panels together at the sidelap. Straight Tread Wheels: Crane wheels with flat-machined treads and double flanges, which limit the lateral movement of the crane. Strain: The deformation per unit length measured in the direction of the stress caused by forces acting on a member. Not the same as deflection. Stress: A measure of the load on a structural member in terms of force per unit area. Strut: A member fitted into a framework, which resists axial compressive forces. Stud: A vertical wall member to which exterior or interior covering or collateral material may be attached. May be either load bearing or non-load bearing. Suspension System: The system (rigid or flexible) used to suspend the runway beams of underhung or monorail cranes from the rafter of the building frames. Sweep: The amount of deviation of straightness of a structural section measured perpendicular to the web of the member. Tapered Members: A built up plate member consisting of flanges welded to a variable depth web. Tapered Tread Wheels: End truck wheels with treads which are tapered; the large diameter being toward the center of the span. Tensile Strength: The longitudinal pulling stress a material can bear without tearing apart. Tension Forces: Forces acting on a member tending to elongate it. Thermal Block: A spacer of low thermal conductance material that is installed between the purlin and roof insulation, to prevent energy loss. Introduction to Metal Buildings 107 Glossary Thermal Conductance, (C-Factor): The time rate of heat flow through unit area of a body induced by unit temperature difference between the body surfaces. Units are BTU / (Hour x ft 2 x degree F) [Imperial system] or Watts / (m 2 x degree C) [SI system]. See "Thermal Resistance". Thermal Conductivity, (K-Factor): The time rate of heat flow through unit thickness of a flat slab of a homoge- nous material in the perpendicular direction to the slab surfaces induced by unit temperature gradient. Units for K are (BTU x in) / (hour x ft 2 x degree F) or BTU/ (hour x ft x degree F) [Imperial System] and Watts / (m x degree C) [SI System]. See "Thermal Resistivity". Thermal Resistance (R-Value): Under steady conditions, the mean temperature difference between two defined surfaces of material or construction that induces unit heat flow through unit area. Note: Thermal resistance and thermal conductance are reciprocals. To obtain the U-Factor, overall thermal transmittance. R-Value for materials and/or combinations of materials must first be evaluated. U-Factor is then the reciprocal of the sum of these individual R-Values. Thermal Resistivity: Under steady conditions, the temperature difference between parallel surfaces of a slab (large enough so there is no lateral heat flow) of unit thickness that induces unit heat flow through unit area. Note: Thermal resistivity and thermal conductivity are reciprocals. Thermal resistivity is the R-Value of a material of unit thickness. Thermal Transmittance (U-Factor): The time rate of heat flow per unit is under steady conditions from the fluid on the warm side of a barrier to the fluid on the cold side, per unit temperature difference between the two fluids. To obtain, first evaluate the R-Value and then compute its reciprocal. Through-Fastened Roof System: A roof system in which the roof panels are attached directly to the roof substructure with fasteners, that penetrate through the roof sheets and into the substructure. Through Ties: Reinforcing steel, usually in the concrete, extending from one column pier to the other column pier, tying the two columns of a rigid frame together to resist thrust. Thrust: The transverse component of a reaction usually at the column base. Tie: A structural member that is loaded in tension. Ton: 2,000 pounds. Track: A metal way for wheeled components; specifically, one or more lines of ways, with fastenings, ties, etc., for a crane way, monorail or slide door. Translucent Panels: See "Light Transmitting Panels". Transverse: The direction parallel to the main frames. Tributary Area: The area directly supported by the structural member between contiguous supports. Trim: The light gauge metal used in the finish of a building, especially around openings and at intersections of surfaces. Sometimes referred to as flashing. Trolley (Crane): The unit carrying the hoisting mechanism. Trolley Frame (Crane): The basic structure of the trolley on which are mounted the hoisting and traversing mechanisms. Truss: A structure made up of three or more members, with each member designed to carry a tension or compression force. The entire structure in turn acts as a beam. Turnout: See "Kick-Out". Turn-of-the-Nut Method: A method for pre-tensioning high strength bolts. The nut is tightened an additional amount from the Snug Tight position, corresponding to a few blows of an impact wrench or the full effort of a man using an ordinary spud wrench. The amount of rotation required depends on the bolt diameter and length. 108 Introduction to Metal Buildings Glossary Twist Off Bolts: Bolts with a segment, which shears off at a predetermined torque during bolt tightening. These bolts utilized a specially designed wrench for proper installation. Uplift: Wind load on a building, which causes a load in the upward direction. Valley Gutter: A heavy gauge gutter used for multi-gabled buildings or between buildings. Vapor Barrier: Material used to retard the flow of vapor or moisture to prevent condensation from forming on a surface. Ventilator: A roof mounted accessory, which allows the air to pass through. "W" Shape: A hot rolled I-shaped member with parallel flanges generally wider than "S" shapes. Wainscot: Wall material, used in the lower portion of a wall that is different from the material in the rest of the wall. Walk Door: See "Personnel Door". Wall Covering: The exterior wall surface consisting of panels. Web: That portion of a structural member between the flanges. Web Stiffener: See "Stiffener". Wheel Base: Distance from center-to center of the outermost crane wheels. Wheel Load: The vertical forces without impact produced on a crane ok wheel bearing on a runway rail or suspended from a runway beam. Maximum wheel load occurs with the crane loaded at rated capacity and the trolley positioned to provide maximum vertical force at one set of wheels. Width: The dimension of the building measured parallel to the main framing from outside to outside of sidewall girts. Wind Bent: See "Portal Frame". Wind Column: A vertical member designed to withstand transverse wind loads, usually in the endwall. X-Bracing: Bracing system with members arranged diagonally in both directions to form an "X". See "Bracing". "Z" Section: A member cold formed from steel sheet in the approximate shape of a "Z". Zinc-Aluminum Coated: Steel coated with an alloy of zinc and aluminum to provide corrosion resistance. Introduction to Metal Buildings 109 Answers to Lesson Self Tests Answers to the Self-Tests Lesson One 1. C 7. B 2. A 8. D 3. B 9. C 4. A 10. D 5. E 11. A 6. A 12. A Lesson Two 1. B 7. D 13. A 2. E 8. B 3. D 9. A 4. B 10. E 5. C 11. B 6. A 12. B Lesson Three 1. D 7. A 13. C 2. B 8. C 3. E 9. B 4. B 10. E 5. D 11. A 6. A 12. B Lesson Four 1. D 7. B 2. C 8. D 3. A 9. C 4. C 10. A 5. A 11. A 6. D 12. E Lesson Five 1. A 7. D 2. B 8. A 3. D 9. A 4. B 10. D 5. B 11. E 6. C 12. B 110 Introduction to Metal Buildings Answers to Lesson Self Tests Lesson Six 1. E 5. D 2. D 6. D 3. E 7. A 4. A 8 B Lesson Seven 1. A 6. A 11. B 2. D 7. B 3. A 8. D 4. C 9. B 5. A 10. B Lesson Eight 1. C 5. C 2. A 6. D 3. D 7. F 4. A 8. A Introduction to Metal Buildings 111 MESCO BUILDING SOLUTIONS P.O. Box 93629 Southlake, TX 76092 800-556-3726

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