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ZIP-RIB ® by Merchant & Evans, Inc. The Tides @ Seaboard Point The Point @ Moore’s Inlet Contractor – Erector MANUAL Merchant & Evans, Inc. 308 Connecticut Drive Burlington, New Jersey 08016 USA Phone 800.257.6215 609.387.3033 Fax 609.387.4838 http://www.ziprib.com Merchant & Evans, Inc. ZIP-RIB® TABLE OF CONTENTS ZIP-RIB SYSTEM – SECTION A Specification Data Sheet PS-1 MATERIAL HANDLING – SECTION B Unloading, Storage, Handling Procedure, Weights, Forklift Slings, Spreader Bars, Loading Roof Storage, Standard Package Modified Pack Miscellaneous Helicopter Information Guidelines for Damage Claims EQUIPMENT – SECTION C Zip-Rib Tools Zipper Tool Operations and Checkout Zipper Tool Parts, Button Punch and Pan End Tool Un-zipper Tools ERECTION SUGGESTIONS – SECTION D Erection Check-off, Planning, Layout Uneven Surfaces, Installing Panels Fixing for Thermal Movement, Installation Sequence Fastening to Wood Fastening to Steel, Concrete, Track Systems Track Anchorage CLIPS AND FASTENERS – SECTION E Zip-Rib System Components Typical Clip Usage Ridge and Hip Closure Details Knee Joint and Leg Clamps Anchor and Fastener Selection Guidelines FLASHING AND SEALANTS – SECTION F Flashing Details Hip Closure, Zip-Rib End Lap Roof to Fascia Transition Diagonal Flashing, Flashing Lap Joints Sealants Flashing Fabrication Engineering Newsletter on Sealants Design Guide ORDER PLANNING, DELIVERY – SECTION G Planning Loads WARRANTIES, PRODUCT LIMITATIONS – SECTION H Product Limitations – Items for Review Technical Reviews Structural, Finish and Leak Proof Warranties JOBSITE ROLL FORMING – SECTION I Scheduling: Advantages and Disadvantages Equipment Space Requirements ALTERNATE PRODUCTS – SECTION J Architectural vs. Structural Systems JOB TIPS – SECTION K Estimating and Purchasing Check-off Design and Detailing Check-off Planning and Erection Check-off Walkways Snow Area Precautions Snow Guards PROMOTION – SECTION L Zip-Rib Advantages Market Opportunities Literature MISCELLANEOUS – SECTION M PRICING, POLICY FORMS – SECTION N Accessory Price Sheet CURVED ZIP-RIB – SECTION O General Information, Factory and Jobsite Curved Curving Responsibilities Space Requirements, Advantages, Disadvantages Costs Diagrams Merchant & Evans, Inc. ZIP-RIB® B-1 UNLOADING, STORAGE & HANDLING CAUTION: READ BEFORE RECEIVING MATERIAL Inspect: Check for broken battens. Look for tie down damage between battens. Inspect for diesel smoke stain. Damage claim: See Contractor Manual, pg. B-7; accept delivery; note damage on the receipt; get photo documentation; get driver's signature (make sure name is legible); protect from further damage; file notification. Unloading and Hoisting Bundles: Limit space between lift points to 30 feet and overhangs to 15 feet; use slats under slings; avoid extending forks beyond bundle; protect bottom panels (see illustrations). Storage: Slope for drainage; cover all bundles; vent ends; avoid wet ground; on roofs, tie down against wind and brace on steep slopes. Maximum Bundle Net Weights: *Standard 36 piece bundles for aluminum and 36 piece bundles for steel. Table is for Zip Rib in lbs./lf GAUGE 12” Panels 16” Panels 0.040” 35 43 0.032” 28 35 22 73 89 24 58 71 *Smaller bundles available upon request at additional cost UNLOADING When using fork trucks: -Use fiber board or plywood on blades to protect the bottom of the panels. See figure A. -Never extend the fork blades beyond the width of any bundle as the tips may dig into adjoining bundles and damage panels. See figure A. -For panels over 34 feet, a spreader bar or strong-back should be used to spread the load. See fig. B. NOTES- 1. Always use slings, not cables or chains which will damage panels. 2. Place bundles on roof where load can be supported. 3. Avoid loading decking, purlins, or bar joists at mid-span. Locate bundles over primary structural supports near column lines. Consult with the architect about safe roof loads. Merchant & Evans, Inc. B-2 ZIP-RIB® When using cranes: -Space between lift points should not exceed 30 feet and overhangs should be limited to 15 feet. -A spreader bar should be used if the distance between outer pick points is greater than the length of the cable. See figure C. -Use spreader bar light enough so that the crane can lift the combined weight of the bundle and the spreader bar. Several slings can be supported by a single spreader bar as shown in figure D. -Place a spreader plank between sling and bottom of bundle to prevent damage at corners. If a choker is used, a spreader may also be required at the top of the bundle. See figure E. Merchant & Evans, Inc. B-3 ZIP-RIB ® PLACING BUNDLES ON THE ROOF Place bundles on the roof at a place where the load can be supported. Avoid setting on purlins or decking away from trusses or joists; locate over beams at column lines. Check with the architect regarding safe roof loads. Since long panels are difficult to turn end for end, it is important that bundles placed on the roof be set with the ribs oriented for the direction of installation. Normally, the big hook is laid over the small hook with the small hook pointing in the direction of installation. See section D for a discussion on optional lay- outs. With pre-installed hook clips, reverse lay-out can be accomplished with installation in the direction of the big hook. Normal Laying Direction Reversed Laying Direction; Possible only with pre-installed #2080 Sliding Hook Clips All panels in a shipment are in the same direction. Check the end of the bundle to determine which way you want the load to be placed on the roof. All bundles should be placed on the roof according to their intended direction of installation. Merchant & Evans, Inc. ZIP-RIB® B-4 STORAGE SUGGESTIONS Space the bundles on the roof so that they are close to the actual area of installation. If bundles are left overnight, tie them down to prevent wind damage. Plan ground storage carefully so panels can be removed in the sequence they are needed. Ideally, bundles should be unloaded directly onto the roof. If ground storage cannot be avoided, do not allow sharp bends or dips that can pond water. ADDITIONAL RECEIVING INFORMATION Packaging: While Zip Rib is normally delivered in standard bundles three stacks wide, 16" Zip Rib must be packed in alternating 3 wide and 2 wide bundles because of limitations in truck body widths. Short lengths may be mixed with longer ones except that a "staircase" bundle may not permit another bundle to be loaded on top of it. Painted panels are shipped with a polyethylene film on the big hook to prevent transit abrasion between painted surfaces. Accessories such as clips and closures are shipped in cardboard cartons. NOTES: Remember, one fork lift or crane with a spreader bar should be used for lengths to 35 feet. Multiple fork lifts or a crane with a spreader bar will be required for lengths over 35 feet and no more than 15 feet should overhang at the ends. Merchant & Evans, Inc. ZIP-RIB® B-5 MODIFIED DOMESTIC PACKAGING 72 PIECE BUNDLE - 24 PIECES PER SUB BUNDLE NOTE: This package can be done only upon special request at additional cost. USE OF HELICOPTERS In helicopter operations, quick disconnect cables and slings are used for lifting panels and are applied in a manner similar to crane operations. If bundles are long and relatively flat, slings may be attached so that the bundle is on edge when lifted. This minimizes pressure from the downdraft of the rotor and improves stability. Consult page B-6 in the CE manual for additional information. MANUAL ROOF LOADING Panels can be loaded to the roof by hand, however, it is best to handle the panels in pairs on edges for strength. One man per every 20 to 30 feet of length is usually sufficient. If panels must be curved to go around corners or to go up a steep slope, panels should be handled individually with the ribs to the outside of the curve. For long runs, dollies or hand carts can be designed for distributing bundles once they are on the roof. JOBSITE ROLLFORMING If panels are to be formed on site, these and other preparations must be made in advance (see CE manual section I for details): 1. Sufficient space for roll forming equipment and run-out tables. 2. A 5000 pound capacity fork lift for loading coils to the pay-off. 3. Covered storage of the coils on or near the jobsite with means for daily delivery if off site. 4. Sufficient storage for fabricated panels. The entire job must be run at once, which, is normally much faster than panel installation. Merchant & Evans, Inc. ZIP-RIB® B-6 HELICOPTER INFORMATION WHEN TO USE A HELICOPTER A helicopter can lift an object of awkward size and shape. It can lift that object across a wide area of difficult access. It can lift an object many, many stories into the air. These things can be done faster by helicopter than by any other way. A helicopter should be considered where there are schedule problems, expensive ground crews or standby crews, large quantities of material or minimum and accessibility problems. OPERATING CREWS A helicopter crew normally consists of three operating engineers: two signalmen and the pilot. One signalman is at the pickup sight and one at the delivery point. For safety and expediency, all three members of the helicopter crew are in constant radio contact. Once you have decided to use a helicopter, you are in partnership with the helicopter company as the rigger. This means that you will assume the cost of the ground and roofing crews. You will need a ground crew at the pickup site and a roofing crew at the delivery site. The responsibility of the site crews is to hook up the cables of the units and to guide the units into place at the delivery site. The number of personnel to be used at the pickup and delivery sites will depend upon the size and weight of the units to be lifted. This is decided by the helicopter company. The roof and ground crews are usually selected from the union which claims jurisdiction over the materials to be lifted. SAFETY PRECAUTIONS Before starting an operation, the pilot will brief the ground and roofing crews, go over safety precautions and explain how the job is to be done. Hard hats and goggles must be worn for protection from flying debris. Loose bundles may be moved by the down draft unless secured. No one can work under a helicopter except its crew. Therefore, a helicopter cannot set material on a factory that is in production unless workers are cleared from the flight pattern of the helicopter. On certain large construction projects with a large number of workers of various trades, the helicopter must fly early in the morning, late in the afternoon or on a weekend. SITE PREPARATION The construction site must be properly prepared. Loose materials on the roof and on the ground must be cleared from the area or weighted or tied down. Trash such as paper, plastic coverings and sheet metal would be blown about, if loose, and possibly cause damage to persons or property. All extension cords for power tools must be removed from the roof area. PERMITS In most large cities it is necessary to get permits for a helicopter airlift. The permits are usually obtained by the helicopter company. In some cases streets surrounding the area of operation must be blocked off by police. In smaller areas it is usually only necessary to advise the local authorities of the contemplated airlift. Merchant & Evans, Inc. ZIP-RIB® B-7 GUIDELINES FOR SALESMEN AND CUSTOMERS in matters relating to FREIGHT LOSS AND DAMAGE CLAIMS based on the general terms and conditions of a contract sale. A sales contract is much more than just an order for goods. It contains the binding agreements between the buyer and seller relating to the responsibilities of one to the other. When these responsibilities are faithfully performed the change of possession and title of goods and the payment of the invoice follow in natural course. Usually the general terms and conditions of this contract include five important terms which have a bearing on freight loss and damage problems. (1) The payment of transportation charges is fixed; (2) delivery and change of title are defined; (3) the seller warrants that the goods will be in merchantable condition as they pass the FOB point; (4) the buyer agrees to be responsible for conditions resulting from his default, which include all of the normal functions of receiving and recording; (5) the remedy for the injured party is usually described. This contract is between the buyer and the seller. Only in exceptional situations can a carrier be involved and then only with his consent. The sales contract is the authority for a shipper to negotiate a bill of lading contract with a carrier, which contract can be concluded only by the signature of the customer on the delivery receipt. This contract is binding, first on the shipper and the carrier, and when perfected by signature of consignee, between that consignee and the carrier. The carrier can transact claim settlement with either the shipper or the receiver and can lawfully require the claimant to prove title to the goods by furnishing a copy of the invoice and bill of lading. The carrier when settling claims may also require an inspection report and a delivery receipt. The responsibility for obtaining the documents is provided for in the term and conditions of the sales contract variously under warranty, default and remedy. To the end that these affairs may be handled efficiently, the following guidelines for specific actions are presented: A. DEFINITIONS 1. Carrier Claim A Carrier Claim is a demand for monetary reimbursement for damage to a product and is filed when, for reasons of negligence, a transportation company fails to deliver a shipment to a customer in the same condition as it was when it was shipped. 2. Carrier Claim-Concealed Damage Same as above, except that the damage is not visible at the time of delivery, and may not be discovered for an undetermined length of time. 3. Exception Report Delivery Receipt copy of the freight bill with notes of the damage signed by the truck driver and the consignee Merchant & Evans, Inc. ZIP-RIB® B-8 4. Inspection Report A formal report made by a trained damage inspector who may either be an employee of the carrier or one of many inspection bureaus. B. JOINT INVOLVEMENT AND RESPONSIBILITY ON CARRIER CLAIMS 1. Three parties have rights and responsibilities in all Carrier Claims a. Customer b. Carrier c. Shipper 2. Who is Protected a. The interests of ALL THREE are protected, PROVIDING that the injured party (parties) TAKES ACTION PROMPTLY AND AS DIRECTED. b. The TERMS AND CONDITIONS OF SALE further confirm this protection by indicating that (1) goods will be merchantable at the FOB point; (2) consignee is in default if he fails to take steps to protect all interests; (3) remedy requires timely notification in writing. 3. Carrier -Negotiating Obligation a. A Carrier is legally bound to negotiate claims ONLY with the PARTY HOLDING BENEFICIAL TITLE to the damaged goods. TITLE PASSES under terms of the Sales Contract. b. Usually when F.O.B. ORIGIN . . . . The CUSTOMER files the claim. When F.O.B. DESTINATION . . . . Seller files the claim. 4. When any one or more of the three parties deviates from the following responsibilities and instructions, full settlement among all parties may be delayed, and collection from the Carrier jeopardized. RESPONSIBILITIES WHEN A CARRIER CLAIM OCCURS A. THE CUSTOMER 1. MUST take exception by BRIEFLY DESCRIBING THE DAMAGE on the delivery receipt and SECURING THE DRIVER'S SIGNATURE as a witness, at the time of the original delivery. KEEP A COPY. Take photographs when possible. EXAMPLE: "1 crate broken" or "2 pallet short" or "1 coil wet". 2. MUST receive all shipments unless the goods are totally worthless. Any goods which have a scrap value cannot be classed as worthless. Refusal to accept goods invokes Section 4 of the Bill of Lading Contract and may be found to be a default in the Contract of Sale resulting in back charges to consignee. 3. MUST store and protect the damaged goods from further deterioration and assist in repair or salvage. All costs can be claimed. 4. MUST call the Carrier's local office and request an inspection. If inspection not made within five days, must inspect and record his findings. Merchant & Evans, Inc. ZIP-RIB® B-9 5. MUST contact the Seller IMMEDIATELY for claim action and ultimate disposition of the damaged goods. 6. If CONCEALED DAMAGE, not visible at time of delivery, is discovered later, the customer... a. Keeps all packaging and goods. Takes photos. b. MUST call Carrier for inspection within 15 days and confirm to him IN WRITING. c. Contact the Seller as per note 5 above. B. THE CARRIER 1. MUST acknowledge damage at time of original delivery by DRIVER SIGNING EXCEPTION on delivery receipt, and leaving a copy with the customer. 2. MUST promptly provide inspection services on demand from customer. 3. SHOULD assist with mitigation by transporting the goods back to origin, or nearest place of repair, or dispose of salvage when appropriate and as instructed by the claimant. C. THE SALESMAN 1. MUST accept COMPLETE RESPONSIBILITY for acquainting his customers, in his normal customer account coverage activity, of the customer's responsibilities when a Carrier Claim situation arises as outlined in Section "C" above. 2. MUST promptly investigate the complaint after it is reported to him by the customer, and arrive at the mutually agreed upon and verified amount of product in claim. 3. SHOULD refrain from expressing an opinion or committing for a settlement where there is any reasonable doubt that a bonafide claim exists. 4. MUST promptly advise pertinent details to the shipping facility traffic representative by wire or phone. 5. MUST prepare a full report for the shipping plant traffic manager and include copies of: a. Exception Report (Obtained from customer-See C-1 above) b. Inspection Report (Obtained from customer -See C-4 above) c. Contingency Cost Invoice (Obtained from customer - If applicable) d. Photographs (Obtained from customer - If available) Remarks should be sufficiently explanatory to enable traffic representative to proceed without delay. Merchant & Evans, Inc. ZIP-RIB® B-10 IMPORTANT: It will be the prerogative of the Shipping Facility Traffic Representative to RETURN to the Salesman for resubmitting any report which is incomplete or unsupported by the necessary documents to the extent that the Seller's recovery from the Carrier is jeopardized. 6. SHOULD undertake normal follow-up with Facility Traffic Representative on (a) salvage disposition instructions, (b) customer's compliance with same, and (c) proper credit to customer. D. THE SHIPPING FACILITY- TRAFFIC REPRESENTATIVE AFTER preliminary notification from the Salesman that a Carrier Claim is in process (See E- 4) AND receipt of the report and supporting documents (See E-5), the Shipping Facility Traffic Representative accepts complete responsibility for....... 1. Control of the claim investigation. 2. Accumulation and evaluation of all standard claim documents. 3. Recommendations which would mitigate loss, where this is possible. 4. Disposition of scrap or salvage. 5. Approval of and authorization to issue credit to the customer, if claim is valid. 6. Keeping the Salesman informed on status of claim and customer's credit. 7. Forward the freight Loss/Damage Claim. In some companies, claims are filed by shipping plants, in others claims may be filed by Corporate Traffic Department. Merchant & Evans, Inc. ZIP-RIB® C-1 ZIP RIB TOOLS GENERAL: Standard Zipper Tool operates on 110V for closing the hook rib over the bulb rib of panels. Standard Unzipper Tool is used for opening the seams of previously installed Zip-Rib panels. This tool may be used manually or pulled by the zipper tool when connected to it by means of a hitch. Crimping Tool is used where there is not enough clearance for the zipper tool, for holding panels temporarily prior to zipping or for closing the rib where the zipper cannot be started at the end. Pan End Tool is used to form a raised end at ridges, and walls, etc., to back up the foam filler in the Low Pitch Ridge Closure. Clearances of at least 3" beyond the end of the panel and 30" vertically are required for operation of the tool. Button Punch is used to fix panels against thermal movement by dimpling the sides of the rib into the clips without penetrating the panel. Replacement die sets are also available. ZIPPER TOOL OPERATION The zipper tool normally is started and fed onto the end of the panel in the closed position. It does not need to be opened and clamped on unless clearances at the panel end are restricted. When the zipper tool must be clamped on, it is desirable to first use the Hand Crimper to close the seam over about a 6" length. Forcing the machine closed over a rib will cause excess wear on the tie rods and gear teeth. The top handle must be removed to place the tool, which weighs 27 lbs. in the box, but OSHA requires the top handle in place whenever the tool is in operation. Always use a three-wire grounded electrical supply of 110 volts and maintain adequate voltage at the machine by properly sized service lines. (Machines wired for 220 volts are available on special order.) In extreme cases, a voltage control device may be required to keep the power up. If the machine slows down or stalls, it is a good indication of low voltage. This tool with standard rolls is engineered for all available gauges of Zip-Rib. Shafts are mounted in pre- lubricated ball bearings that need no maintenance unless the machine has been submerged or filled with dirt. External guide bearings and tie rods should be kept lubricated with light machine oil. MAIN CHECKOUT POINTS Electrical: Grounded plug with good wire insulation; cord end connections tight; drill motor brushes at least 5/16" long; off-on switch working. Rolls & Guides: Front and rear rolls in right position and right side up; guide bearing free turning and in alignment; extension bells tight and round. Closing:Meeting faces clean; handle closes firmly. Tighten any screws which are loose. Repair or replace items as necessary. Custom parts or major repairs may be obtained through your Zip-Rib supplier. Standard commercial items may be procured locally. Follow normal safety practice in checking to be sure that the machine is properly grounded and that the supply cord is not cut or frayed. When the brushes inside the drill motor measure less than 5/16" long they should be replaced. Short brushes can result in a burned armature. Merchant & Evans, Inc. ZIP-RIB® C-2 ZIPPER TOOL CHECKING FORMING ROLL POSITIONS If the forming rolls have been removed for any reason they should be checked to insure they are installed right side up and right size front to back. Rolls are marked (F) front and (R) for rear. With the machine closed, the opening of the rear rolls is slightly over 5/8" wide and the opening gap of the front rolls (next to the guide end) is slightly over 3/4" wide. The outside diameter of the edge of the rolls closest to the machine is larger than the other. There should be about 3/16" clearance between rolls at the edge away from the machine, if not, one or more of the rolls is upside down. NOTE: DISCONNECT POWER BEFORE CHECKING ROLLS Tie rods normally need no adjustment, but with wear of the closing cam the lock nut may need to be reset so the machine closes firmly. The meeting halves of the machine must be clean. If the cam handle does not close firmly, the machine may come open during use. This is particularly hazardous on steep roof or on walls. If the machine is loose, adjust tie rod nuts and lock nuts so that there is a small but noticeable resistance to closing the cam handle. Side guide rolls prevent the machine from tipping sideways. Machines equipped with 1-1/4" diameter plastic wheels are designed to ride in the flats of either 12" or 16" Zip-Rib. Machines equipped with 7/8" diameter steel bearings ride on the pencil ribs of 12" Zip-Rib and should not be used on 16" panels. CHECKING ALIGNMENT OF FRONT GUIDE BEARINGS The front guide bearing struts may become bent. If so, realign to a 5/8" diameter rod placed through the machine as shown below. To check alignment of top front guide bearing, hold the rod in the center and up against the top of both front and back forming rolls as shown in the "middle position" in the detail. The top front guide should be within 1/16" of the rod. If the bearing is touching the rod it should turn without resistance. Merchant & Evans, Inc. ZIP-RIB® C-3 To check alignment of the bottom front guides pull the rod down and to the side as shown in the "side position" of the detail. Again, the bearings should be within 1/16" of the rod or barely touching and free to turn. After checking one side move the rod to the other side to get the opposite guide. NOTE: DISCONNECT POWER BEFORE CHECKING TOOL PAN END TOOL STANDARD UNZIPPER TOOL OPERATION 1. Starting at the most convenient end of the panel, pry open the seam slightly with a screw driver or claw hammer. 2. Installer ZIPPER Tool over panel seam just slightly ahead of pried open end. Do not close the ZIPPER Tool at this point. Machined Aluminum Block should be bolted to rear of ZIPPER Tool. This part can remain on the tool during standard ZIPPING operations. 3. Insert Wheel Bracket into Machined Aluminum Block as illustrated. 4. Close the ZIPPER Tool at the point on the panel seam where the Tapered Wheel engages with the pried open seam. 5. Operate the ZIPPER Tool in the forward direction. As the tool moves forward, the tapered wheel will pry open the panel seam. 6. Depending on the location of the panel near transitions, flashings, etc., the last few feet of panel may require hand prying of the seam since the ZIPPER Tool may be obstructed from running off the end of the panel. 7. When working with mill finish materials and/or unzipping large areas of roof, application of light oil to the tapered wheel may reduce scuffing, scratching, and abrasions. 8. Vertical height adjustment of the Tapered Wheel is accomplished by moving the set- screw in the Wheel Bracket up or down which in turn changes the location of the Wheel Bracket in the Machined Aluminum Block. If panels are to be re-used, the seam should be opened just enough to allow disengagement of the big hook from the small hook of the panel. Too low of a setting will not open the seam sufficiently while too high of a setting will severely deform the big hook and make re-use difficult. Merchant & Evans, Inc. ZIP-RIB® C-4 Un-ZIPPER Tool Mounted to back of ZIPPER Tool Hand Crimping Tool Merchant & Evans, Inc. ZIP-RIB® D-1 ZIP-RIB CHECKOFF LIST, PLANNING AND INSTALLATION PRELIMINARY PLANNING *Check material delivery schedule: Anticipate rate of usage; insure adequate supply of basic parts and accessories. *Plan Storage: Provide abuse and weather protection, keep in mind proper alignment of Zip-Rib sides. *Handling Equipment: Provide for lifting gear, slings, panel protection. *Specs. & Details: Get approval on exceptions, file drawing & approved samples. Check field dimensions against plans and lengths on order. RECEIVING, STORAGE, HANDLING (REFER TO SECTION B) *Inspect: Check battens, look for tie down damage between battens, diesel smoke. *Damage Claim: See B-7; accept delivery; note damage on receipt; get driver's signature; protect from further damage; file notification. *Unloading and Hoisting Bundles: Limit overhangs to 15' and limit space between supports to 30'; use slats under slings; avoid extending fork beyond bundle, use stop block; protect bottom panels. *Handling: Pairs are stronger; if flexing is necessary, single panels may be curved with the ribs out to avoid kinks. *Storage: Slope for drainage; cover bare (unpainted) bundles; vent ends; avoid wet ground; on roofs, tie down against wind and brace against sliding on steep slopes. INSTALLATION *Layout: Establish straight side and crosswise benchmarks; check for true structure. *Verify Fasteners: Use proper size and length for strength requirements: proper head size for clip hole yet provide for clearance from Zip-Rib. *Train Crews: To allow for thermal movement; to avoid crimps in ribs; to avoid crews into ribs at clips; to avoid fasteners into end lap joints of flashing; and to avoid attaching gable flashing to Zip-Rib. Crew training is important even with experienced roofers since common practice are often not adequate for the installation of the Zip-Rib system. *Zip As You Go: Tie down last edge at night. Tie down all bundles and loose pieces. Merchant & Evans, Inc. ZIP-RIB® D-2 EQUIPMENT CHECK LIST Unloading or hoisting rig. Spreader bar or strong-back. Slings & spreader planks. Under panel protection. Long tape for layout. Transit or line level. Chalk-line, piano wire. Marking pen, crayon, soapstone. Ladders, roof-protection at top. Duck-boards, chicken ladders. Power Generator - gas. Electric extension cords. Three-way pigtails. Drill motors. Extra chuck keys. Drill bits - in proper sizes for anchors. Aircraft snips L/R. Circular saw/metal cutting blades. Screw guns/bits/drive sleeves. Rivet gun/rivets. Explosive fastener tool/loads. Caulking gun/tubes. Vise grip pliers. Zipper Tool. Skylight Rolls. Hand Crimp Tool. Pan End Tool. Unzipper Tool. Button Punch Tool. INSTALLATION LAYOUT Rectangular roofs should be checked for square and straightness. Gable ends may not be straight. A crooked gable will look bad on the finished job. If clips are badly out of line they may wear holes in the roof with thermal movement. Set a true line for the gable clips and flashing with string line or transit. If the gable trim will not easily cover the variation in the edge of the roof, the building may be straightened, clips shimmed, or a new detail developed with the architect. Wind loads are highest at the edge of the roof, be sure gable clips are securely anchored to solid material; do not attach gable clips to extension or overhangs unless engineered for uplift. Measure the roof lengthwise to confirm panel lengths, overhangs, coverage of flashing at eaves and at ridges, and verify clearance for thermal movement. For example, be sure that eave drip angles have room for the roof to shrink when it gets cold. If the structural eave and ridge are uneven, some adjustment of the flashing may be required to keep the eave line and ridge cap straight. Again, if the end conditions do not have sufficient tolerance, the building may need to be straightened. Measure crosswise to the panels to see how the panel width module works out. To get the proper gable end conditions, panels may be spread slightly - up to 1/4" over normal width. This must be a uniform spread - abrupt changes in spacing can cause side pressure on clips that will accelerate wear with thermal movement. Merchant & Evans, Inc. D-3 ZIP-RIB® UNEVEN SURFACES Inspect visually for dips or undulations in the plane of the roof and check problem areas with a Zip-Rib panel or with a taut wire. Longer fasteners may be required if clips are shimmed. Specific conditions to check carefully are where there are transitions in the structure under the roof. One example is where the roof runs from steel purlins to the top of a wall. This can be especially out of line if the purlins are long and sag or rise from either too little or too much camber. Another condition that can produce a sharp change of direction in the roof panel is where joists on the structural supports for purlins meet a column line or main structural member. This is especially true with wood framing under a plywood deck. When re-roofing over an existing deck, there may be large irregularities caused by settlement as well as smaller undulations in the applied roofing material. If an existing structure is extended, look for sharp changes of direction where the new work joins. During installation, low spots in an uneven roof will show up because the roof panel will have to be forced down on the clip. When excessive force is needed to bring a rib down to the level of the clip, thermal movement can cause the clip to wear through the rib and low purlins must be straightened or clips shimmed. When structures are not true, it is generally the general contractor's responsibility to correct the problem, but the difficulty must be reported as early as possible. Another problem is appearance. The installed roof panels will follow the contour of the structure and the strong linear pattern of the vertical ribs may emphasize the appearance of an irregular structure. There are no hard and fast rules for what is "acceptable appearance" on an architectural project and requirements can vary with the viewing position. When in doubt, get the architect's approval before proceeding with Zip-Rib installation over any undulating surface. From the standpoint of performance of the roof, Zip-Rib can tolerate variations crosswise to the panels but lengthwise the pressure required to make the panels conform to the surface must not restrict thermal movement or be enough to accelerate clip wear. The best way to verify this is to lay a 5 lb. weight (such as a hammer) on the panel next to the rib before installing the clip and to shim any gaps that remain. Merchant & Evans, Inc. ZIP-RIB® D-4 INSTALLING PANELS Make sure that crews are using fasteners of the required size and length for the strength into the structure. The head size must be large enough to hold the clip but small enough that it does not protrude above the base where it can wear a hole in the roofing. To avoid possible difficulties due to wind, installation of Zip-Rib panels should proceed in the direction of the prevailing winds unless specified otherwise on the shop drawings. When opening bundles, be careful that panels don't slide or get blown off the roof. Panels are best lifted in pairs for easier handling. Important specifications for clip type spacing and fasteners must be followed to assure the integrity of the finished installation. They have been determined carefully on the basis of anticipated thermal movement (both expansion and contraction), uplift loads, and overall building structure. FIXING - FOR THERMAL MOVEMENT Of particular importance is the correct placement of the clips "fixing" the panels against thermal movement. To keep panels from working off the roof, at least one row of clips must be "fixed" to the panels. Normally, panels are fixed at their midpoint to allow thermal movement in both directions. On steep roofs or long lengths it may be necessary to fix panels at two or more adjacent rows of lips to provide the required holding power. Fixed clips must be in a straight line to prevent panels from moving relative to each other. Where roof shape or large opening prevent such a straight line attachment at the middle, the panels must be fixed at some point away from their center. Hip roofs are fixed at the eave. Roofs with valleys are fixed at the ridge. Some flashing conditions require fixing at one end or the other. Design rules for locating the fixed point are found in the Design Guide section C-11. There are several ways to "fix" the rib to the clip. PINCH CLOSED Bolt and Nut: This is a more positive way to fix the ribs at a clip. It requires drilling or punching a hole through the stainless clip and the rib. To prevent 1/4" DIA. STAINLESS STEEL NUT & BOLT leakage, a neoprene faced washer needs to be W/ NEOPRENE WASHER ON EACH SIDE placed on both sides of the rib. Always use stainless steel nut bolt and washers to prevent rust. Never use pop rivets. PINCH BASE OF CLIP CLOSED TO PREVENT CLIP FROM SLIDING. Screw into Structure: This is the most positive way to secure a roof against movement because it is not # 2080 FIXED CLIP limited by the strength of the clip. To eliminate leaks, this method is usually employed where the fastener is FLASHING FASTEN TO CLOSURE. not exposed. When the roof is fixed at the ridge, screws may be installed behind the foam closure. In the case of a roof with end tapped panels, if the lap point is the fixed point, the same screws that close the lap may be used to fix the panels to the structure. FOAM & MEATAL CLOSURE. PAN In all cases, avoid depressing the roof at the fastener END by inserting a spacer equal to the clip base height, and always use fasteners with neoprene faced washers to avoid leaks. Never use nails to secure FASTEN THROUGH Zip-Rib. PANEL BEHIND CLOSURE, FOR FIX POINT (2 FASTENERS PER PANEL). UTILIZE A 3/8" SHIM BETWEEN PANEL & SUBSTRATE. FIX PT. BEHIND CLOSURE Merchant & Evans, Inc. ZIP-RIB® D-5 INSTALLATION SEQUENCE To install the first panel, start with gable clips. The hook rib must be zipped or hand crimped ahead of time to fit loosely enough for thermal movement. The gable clips also serve as attachment parts for gable caps of flashing. Flashing should not be fastened to the Zip-Rib panels because of thermal movement of the panels relative to the roof. If job conditions permit, it is usually more efficient to install clips before panels are set. But don't get too far ahead of the panel installation until you are sure the spacing is correct. Job sequence is as follows: 1. Set panels: Align with gable clip or previous panel. Check benchmarks every 10 or 20 feet. Apply rib sealant as specified. 2. Insert clips in rib and secure to structure. 3. Zip seams closed. 4. Fix panels at fix point. 5. Install flashing for penetrations as adjoining panels are installed. Avoid heavy traffic in any local area. Use duck-boards where necessary to protect panels. Avoid walking on panels before they are zipped. Take special care on painted panels since they are especially susceptible to abuse. Secure the edge of the last panel installed each evening. Do not leave panels unzipped overnight. As a minimum, panels should be hand crimped at each clip. Don't crimp the bulb over the clip, crimp the hook over the bulb. Zipping as the panels are installed distributes the walking loads on the roof and also simplifies securing the job overnight. As a minimum, edges should be clamped down and the hook rib of panels hand crimped over the bulb at the clips before they are left overnight. Do not crimp the bulb rib of the last panel over the clip since this will interfere with thermal movement. Merchant & Evans, Inc. ZIP-RIB® D-6 FASTENING ZIP-RIB ANCHOR CLIPS TO WOOD Nails should not be used for fastening clips since they do not provide pull-out resistance. Self-tapping sheet metal screws with type A points are preferred over wood screws since they are fully threaded and designed for application by power tools. Only self-drilling screws specifically designed for wood should be used, as self-drilling screws for metal do not have the same holding strength. When power screwdrivers are used, they must be properly matched to the fastener to prevent overdriving. This recommendation of the equipment manufacturer should always be followed. In addition an extension may be needed to enable the tool to get close enough to the standing rib of the panel. FASTENING ANCHOR CLIPS TO STEEL Screws in tapped holes or explosive driven drive pins in heavy structural steel exceed the requirements of most Zip-Rib clips. Care must be exercised, however, in the selection of fasteners for light gauge steel or steel decking. The fastener manufacturer should be able to demonstrate that its fasteners will provide an adequate factor of safety. Note that most manufacturers publish ultimate pullout values which must be reduced by at least half for safe design loads. Self drilling fasteners have tips designed for specific steel thicknesses and should be used only within the allowable ranges. Screws will not develop their rated strength if used in material thinner than for which they were designed. Steel decks designed for uniform loads must be checked for the concentrated or straight line load of the Zip- Rib anchors. FASTENING ANCHOR CLIPS TO CONCRETE Make sure the concrete will provide a good base for the clips and that anchors will not produce any spalling. Explosive or powder-actuated fasteners can be used for attaching clips to concrete, but in order to assure a true surface, it is better to use an intermediate steel member or track that can be shimmed. With lightweight insulating concrete and poured decks, fasteners must be attached to the structural support underneath, since this type of concrete does not have adequate strength for holding the fasteners. ANCHORING SUB-PURLINS TO IRREGULAR SURFACES Find the high point on the roof deck with string-line or transit. Then lay out the roof to clear this point. Shim the sub-purlin to this plane. Avoid high stacks of thin shims and avoid using plastic material which will creep and loosen with time. Steel shims are preferred since they will not creep and the stacks can be welded together to make them more rigid. Anchor bolts usually carry the load of several clips and must be connected securely to the structure. They must be rigid enough to resist the side pressure of thermal movement of the roof panels. If there is any question about the strength of anchor bolts, refer to the section of "Anchor and Fasten Guidelines" in the Zip- Rib Design Guide. Spacing for sub-purlin anchors are determined by the holding strength of the anchor and the bending strength of the sub-purlin. As a general rule, the end distance to the first anchor should not exceed one fourth the allowable spacing between anchors. If the end distance at a joint is more than a foot, the sections of sub- purlin should be spliced together. If sub-purlin spacing is not critical the ends may be lapped side by side. Merchant & Evans, Inc. ZIP-RIB® E-1 ZIP-RIB SYSTEM COMPONENTS CONCEALED ANCHOR CLIP SYSTEM WITHOUT PANEL PERFORATION In the Zip-Rib roofing & siding system, concealed anchor clips are available which meet nearly any condition of thermal movement, positive and negative loads and structure type. Zip-Rib sales representatives and technical personnel can assist you in clip selection to meet the requirements of your roof or side-wall project. Consult the Zip-Rib Design Guide for additional technical information on clips and substrates. Basic panel design is simple. Rugged, attractive 2-1/2" standing rib supplies high girder strength and puts closure high above runoff levels. Standing seam is roll-formed by zipper tool to locked position. #2080 Sliding Hook Clip #2002 Gable Clip #2006 Fixed-Point Clip #2050 Leg Clamp Foam Closures Metal Closures Merchant & Evans, Inc. ZIP-RIB® E-2 3 Piece Hip Closure Components Keyhole Closure Typical Ridge Closure Assembly with Pan End Bearing Plate on Rigid Insulation #2080 Clip on Bearing Plate Merchant & Evans, Inc. ZIP-RIB® E-3 ACCESSORY DESCRIPTIONS and APPLICATIONS PLYWOOD DECKING OR WOOD PURLINS #2080 Sliding Hook clips and #2002 Gable clips can be mounted to plywood, tongue and groove wood decking, or wood purlins and are spaced and anchored to comply with specified design loads. METAL PURLINS AND METAL DECKING -#2080 Sliding Hook Clips and #2002 Gable clips can be mounted to steel purlins. Use 1 to 3 screws per clip depending on uplift load conditions. Fasteners must penetrate flange a minimum of 1". -#2080 Sliding Hook clips and #2002 Gable clips can be mounted to purlins with draped blanket insulation. Utilize wood sleeper or high density rigid board insulation to compress insulation and act as a thermal block. -#2080 Sliding Hook clips and #2002 Gable clips can be installed on rigid board insulation (2 pound per cubic foot minimum density) and 22 GA min. metal decking provided a 22 GA, 6" square bearing plate is used between clip and insulation to spread load and keep edges of clip from cutting into insulation. GABLE CLIP #2002 Gable clips secure panel edges at ends of roof. These can also provide means of securing fascias, side-wall flashings, building expansion joint covers which are fastened to the lip of the clip to allow thermal movement of Zip-Rib panels. CLAMPS Standard #2050 leg clamps are available for securing accessories such as hand railings, catwalks, platforms and snow rails without penetrating the Zip-Rib panels. RIDGE CLOSURE PART NUMBERS 12" bare- #3071 12" painted- #3073 16" bare- #3074 16" painted- #3075 12” Rubber Inserts- #3070 16” Rubber Inserts- #3080 The ridge closure assembly consists of a flexible foam filler (Rubber Inserts) that resists air and water penetration and it is protected and supported by a formed metal channel which attaches to the top of each rib. The ridge cap covers the closure screws so there is no exposed penetration into the panel itself. Ridge cap screws should fasten into metal closures ONLY and NOT into panel ribs which may cause leakage into the building envelope. For additional protection, a pan end formed by the Zip-Rib Pan End Tool has the effect of raising the upper end of the panel pan approximately 1-1/2". In severe climates, two ridge closure assemblies are often recommended. The closure assembly may be further sealed by embedding the insert in wet sealant and applying a seal tape across the top of the channel. HIP CLOSURE SYSTEM Hip Closure Channel- #3093 Hip Closure Support- #3094 Hip Foam Closure- #3095 The parts shown are field cut to diagonal requirements from 10' lengths of channel and support strip, and 25' rolls of closure. Pan ending of diagonal cuts at hips is difficult hand work, and it is desirable to follow the same procedures outlined for ridge closures in extreme climates. For slopes below 2:12 or in extreme climate areas, two rows of closures are reasonable requirements. Refer to the Design Details for more specific performance notes. The hip cap is screwed to this closure assembly between ribs, and covers the closure - to - rib screws so there is no exposed penetration of the roof. Merchant & Evans, Inc. ZIP-RIB® E-4 KEYHOLE CLOSURE #3096 Keyhole Closures close off the vertical stem of the ZIP-RIB standing seam at eaves and valleys. These should be installed as panels are placed into position and the locations thereof are as illustrated in the ZIP-RIB Detail Plates which are available. KNEE JOINT TRIM Available in mill finish or standard Zip-Rib colors, this formed molding is used for various transition treatments such as gambrels, fascia-to-soffit, etc. See Detail Plates for typical applications of the #7090 Knee Joint Trim. LEG CLAMP (STAINLESS STEEL) #2050 Leg Clamps are utilized for the securing of hand railings, guy wires, catwalks, machinery platforms, snow guards, solar panels, etc. to completed installations without penetrating the Zip-Rib roofing. The attachment accessory may be wood or metal, but must not interfere with roof panel thermal movement. The maximum total dead load (roof and accessory) should not exceed 20 lbs. per clamp. See the ZIP-RIB Design Guide for additional information. K AC ST UE FL TO Merchant & Evans, Inc. ZIP-RIB® E-5 ANCHOR AND FASTENER SELECTION GUIDELINES ARCHITECT-ENGINEER RESPONSIBILITY The strength of the individual components of the Zip-Rib system has been determined by air pressure load testing. Zip-Rib design load recommendations for panels are based on minimum factors of safety as recommended by national associations for the material involved. The contractor should have the architect or engineer verify that the fasteners and the support structure to which the clips are capable of carrying the intended loads. Since there are many different materials and proprietary anchors (bolts, self drilling screws, masonry anchors) the fastener manufacturer is frequently the best source of safe values for the architect or engineer to use under specific job conditions. However, note that these sources usually provide average test values which must be reduced by appropriate factors of safety to arrive at design values. FASTENING TO WOOD NAILS Nails of any type are not recommended for use where direct pullout or withdrawal resistance is a design factor. SCREWS The safe holding strength for screws is a function of length, screw size and dry density of the wood. For attachment of Zip-Rib clips, self-tapping sheet metal screws (Type A point) are preferred over wood screws since they are fully threaded and are designed for economical placement with power screw drivers. Safe design values for standard threads are published by NFPA. Self drilling screws (other than those designed specifically for wood) are not acceptable. Screws especially designed for wood, as well as standard screws with Type A points are available from Fabricated Products Division of Townsend Co. (Fabco WSD) the Buildex Division of Illinois Tool Works (Tru Grip) or Construction Fasteners Inc. (Wood Grips or Type A point screws). NATIONAL FOREST PRODUCTS ASSOCIATION SPECIFICATION NFPA The "National Design Specification for Stress-Grade Lumber and Its Fastenings" of the National Forest Products Association provides allowable load values that are recognized by code agencies. For Coast Douglas Fir, Larch and Southern Pine with specific gravity of 0.51, the long-term holding power of #12 (.216") and #14 (.242") screws would be 160#/inch and 179#/inch respectively. A 1/3 increase is allowed for short duration loads, such as for wind, making these values 212 and 238. Plywood values published by the American Plywood Association are not as broadly recognized as the above. For Group I species CDX. average pullout values of tests indicate allowable pullout values should be 139#/in. for #12 and 156#/ion. for #14 screws to resist wind loads. In cases where fasteners pass through plywood decking into the structural framing, the plywood thickness should not be figured in the embedment to allow for screws installed through joints in the decking. Merchant & Evans, Inc. ZIP-RIB® E-6 POWER SCREW DRIVERS With the use of power screw drivers, the fastener and driver must be properly matched to prevent overdriving and stripping of threads. Be sure to follow the recommendations of the manufacturer in driving equipment used. FASTENING TO CONCRETE GENERAL One method of attachment to concrete is the use of explosive or powder actuated fasteners. The condition of the concrete must be such that it will make a good base for the Zip-Rib and accept the anchor without spalling. Lightweight insulating concrete, cement-fiber plants or poured decks do not have adequate strength for individual fasteners. The attachments for these roofs will have to be made to the structural support deck underneath. Consult the codes and fastener manufacturers for safe holding values and minimum embedments for anchors of this type. Because holes drilled under field conditions tend to be less precise than those drilled for laboratory tests, the codes may be significantly more conservative than most manufacturers' tables. Code values "with special inspection" may be double the allowable loads for these fasteners installed without special inspection, and the inspection cost may warrant the savings in fastener material and installation labor. Make certain that tracks do not span construction joints in a way that the track must resist building movement. FASTENING TO STEEL Screws in tapped holes or explosive driven drive pins in heavy structural steel exceed the requirements of most Zip-Rib clips. Care must be exercised, however, in the selection of fasteners for light gauge steel or steel decking. The fastener manufacturer should be able to demonstrate that its fasteners will provide an adequate factor of safety. Self-drilling fasteners of the same screw size can have markedly different strengths because of variations in the size of the starting hole they make. Some are small for thin sheet (lap joint fasteners); others are for heavier gauge. When joining heavy gauge track to thinner gauge deck, the screw must be sized for the deck gauge to develop its rate strength. Steel decks designed for uniform loads must be checked for the concentrated or straight line load for the Zip-Rib anchors. FLASHING FASTENERS Wherever possible, fasteners should not penetrate the Zip-Rib panel or flashing in such a way that leakage will pass on to the interior. Where screws must penetrate the building, a self-sealing type, such as with an integral sealing washer on the exposed surface, should be used. Tubular rivets, such as pop-rivets, will leak and should never be used in this manner unless they are sealed individually with a good grade of exterior sealant. Zip-Rib recommends that fasteners be no smaller than #14 screws or 3/16" diameter rivets for attaching flashing, drip angle, closures or trim members to Zip-Rib panels or to each other. Merchant & Evans, Inc. ZIP-RIB® F-1 FLASHING DETAILS SPECIAL CLOSURE ASSEMBLY FOR ZIP-RIB ROOF HIP The closure support may be continuous or cut into individual pieces long enough to span between ribs. Attach closure support to ribs and to channel at several places with pan head screws. END SPLICES UPPER PANEL. APPLY TWO ROWS OF SEALANT TAPE AS SHOWN UTILIZE 9 BULB TITE RIVETS AT LAP FOR 16" WIDE PANEL AS SHOWN BELOW & 6 RIVETS FOR 12" PANEL, ONE ON EACH SIDE OF LAP BTW. BEADS. 2"1 AP RL VE DO DE EN MM DAB OF SEALANT CO RE LOWER PANEL. PLAN NOTE: EVERY OTHER PANEL LAP IS TO BE STAGGERED 24" ZIP RIB - PANEL LAP STEP 1 - Close bulb rib of underlap panel for length of lap and install. Close Underlap Open Overlap (Step 1) (Step 3) STEP 2 - Apply two lines of sealant across the underlap panel. Apply a dab of sealant to the bulb at the end of the underlap panel, before setting down the upper panel. Be careful not to block capillary groove at male leg. STEP 3 - Open bulb rib of overlapping panel for length of lap and press panel into place. STEP 4 - Hand crimp hook and the bulb ribs of the overlap panel for tight nesting of the ribs. Put a dab of sealant below the end of the overlapping bulb rib. STEP 5 - Install fasteners above the bottom line of sealant in each flat. Use rivets as specified above. STEP 6 - Zip the assembled rib immediately. Merchant & Evans, Inc. ZIP-RIB® F-2 GAMBREL ROOF JOINT OR ROOF TO MANSARD, FASCIA OR SIDING- Good for all gauges KNEE JOINT TRIM UTILIZE BACK TO BACK SPLICE PLATES SO FINISH IS ON BOTH SIDES. = ROOF PITCH FILL VOID WITH SEALANT. COPE VERTICAL PANEL RIBS TO FIT INSIDE ROOF RIBS. FIELD CUT PANEL RIB DOWN THROUGH STIFFENING BEADS. SEAL AS REQUIRED. NOTE : STIFFENING BEADS IN MIDDLE OF PANEL WILL TAKE . THE BEND. (DO NOT CUT THEM) COPE DETAIL 4" MIN SECTION "A" A CUTTING DETAIL #7090 KNEE JOINT TRIM. 4" MIN. RIVET PANEL RIBS TOGETHER. 4" MIN. TYP. KNEE JOINT TRIM. JOINT ANGLE, RIVET TO ROOF PNL. A FIELD CUT PANEL RIB AND & VERT. PNL. @ 3" 0.C. ( MAX.). BEND PANEL TO SUIT FASCIA CONDTION. BACKER ROD & SEALANT IN STIFFENING INSTALL BACK TO BACK SPLICE PLATES AS EACH BEAD. ALSO SEAL BETWEEN PANELS PANEL IS INSTALLED. AND JOINT ANGLE. PLATES CAN NOT BE IN- STALLED AFTER PANELS ARE ZIPPED TOGETHER. SEALANT IN VERTICAL RIB. RIVETS OPITIONAL OUT OF F5 RIVETS REQUIRED IN SNOW AREAS. SNOW AREAS. 1/4" ONE PIECE ROOF TO FASCIA DETAIL KNEE JOINT DETAIL - TWO PIECE * THIS DETAIL WILL ONLY WORK IN 22 GA. STEEL Product : Application : Plate : Product : Application : Plate : ZIP-RIB KNEE JOINT ZR-15 ZIP-RIB KNEE JOINT ZR-16 DIAGONAL FLASHING RIDGE FLASHING. When there is unbalanced thermal movement on METAL & FOAM CLOSURE opposite sides of a diagonal flashing member, the SYSTEM. (Do not set in sealant if second row is used.) assembly must provide for longitudinal slippage as well as flexing crosswise to the roof. This condition occurs CONT. SLIP JOINT CLEAT. (Mandatory at diagonal cuts.) on diagonal cut gables or ridges where there is roofing on only one side of the joint. It may occur at valleys or #2080 SLIDING HOOK CLIP. hips where the slope length or pitch is not the same on both sides. In these cases an interlocking slip joint, ZIP RIB PANEL. such as shown below will keep the sections together yet allow both kinds of motion. SECOND ROW OF CLOSURES IS OPTIONAL WHERE PAN ENDING CAN NOT BE ACHIEVED, ON DIAGONAL CUTS. SET IN SEALANT. EXPOSE FASTEN FLASHING. Product : Application : Plate : SHED ROOF RIDGE / ZIP-RIB DIAGONAL RIDGE ZR-32 Merchant & Evans, Inc. ZIP-RIB® F-3 1. COVER PLATES FOR RIDGE & GUTTER ARE 6" WIDE FASTEN TO EACH SIDE OF JOINT. APPLY SEALANT 100% TO EACH END OF COVER PLATE. O/S CP 1/4" BUTT JT. 1a. COVER PLATES FOR FASCIA'S ECT... ARE 6" WIDE WITHOUT THE USE OF FASTENERS. APPLY SEALANT 100% TO EACH END OF COVER PLATE. I/S CP. 1/4" BUTT JT. 2. LAP JOINTS ARE 4" LONG MIN. AND 100% SEALED. DO NOT FASTEN LAPS TOGETHER. LAPS SHOULD BE SHINGLED IN DIRECTION OF FLOW. (NOT RECOMMENDED FOR HORIZONTAL RUNS.) 4" MIN. DIRECTION OF FLOW 3. FLASHING EXPANSION JOINTS ARE AT EVERY THIRD JOINT IN ALUMINUM & EVERY FIFTH JT. IN STEEL. FASTEN AND SEAL OUTSIDE COVER PLATE TO ONE SIDE OF JOINT. FASTEN & SEAL INSIDE COV. PL. TO OTHER SIDE OF JOINT. LEAVE 1/2" GAP AT JOINT BETWEEN FLASHINGS. OFFSET COV. PL. 1" FROM ONE ANOTHER SO THAT RIVETS DO NOT INTERFERE WITH EXPANSION & CONTRACTION. (SEE BELOW) 1/2" 1" O/S CP I/S CP Merchant & Evans Inc. Merchant & Evans, Inc. ZIP-RIB® F-4 SEALANTS The Zip-Rib roofing and siding system is designed and manufactured to give 20 plus years of service. DO NOT USE A 5-YEAR SEALANT WITH A 20-YEAR ROOF SYSTEM. For exposed conditions, use only good quality sealants that will cure to a rubber-like consistency. Do not use oil base or asphalt-type caulking or mastic. For concealed applications a non-hardening sealant may be used. In any case, the sealant must have good adhesion, retain its properties at temperature extreme, and resist deterioration from water heat and sunlight. A major factor in the successful application of sealants is surface preparation. Make certain that the surface is prepared in accordance with the manufacturer's recommendations. Sealant will function best if installed between parts when they are assembled rather than being forced into the completed joint. Except in heavy freeze areas where ice may spread joints apart, it is best to apply sealant away from the open face of joints so that the metal will shield the seal and protect it from direct exposure to water or sunlight. FLASHING BENDS Aluminum sheet must be fabricated with a large bend radius to avoid cracking the metal and/or the paint. When metal is formed to a zero “T” (“T” = metal thickness) bend, the metal and paint will usually fracture. To avoid metal and paint fractures a minimum inside bend of 3T is suggested. To get a larger bend radius on a sharp steel die it may be necessary to add a bent strip of the desired thickness to the nose of the male die. This can be held in place with masking tape. Merchant & Evans, Inc. ZIP-RIB® F-5 ENGINEERING NEWSLETTER IN-HOUSE SEALANT/CAULK TESTS In-house tests were performed on randomly chosen sealants and caulks recommended by manufacturers for the metal roofing and siding industry. The sealants tested are from one of four categories: 1. Gun Grade Butyl Sealants 2. Silicone Sealants 3. One Part Polyurethane Sealants 4. Butyl Tapes All were observed over a three (3) day period. Gun Grade Butyl Sealants and Butyl Tapes are primarily used for little or no joint movement. The sealant should remain soft and tacky after 48 hours. They are normally used as a gasket type seal held in compression. Silicone and One Part Polyurethane Sealants are primarily used where there are dynamically moving joints. Both can be exposed to the elements and should remain “rubber-like”. Silicone Sealants should be non-acetic acid cured. Three beads of each sealant were applied to a 3” x 4” piece of metal. Characteristics such as skinning over, tackiness, becoming “rubber-like”, curing, and texture were observed. Also, one bead of each sealant was applied between two pieces of metal. Adhesion and bonding characteristics were observed. For the Butyl Tapes, a 2 ½” piece was applied between two pieces of metal. Adhesion and bonding characteristics were also observed. The proceeding is the manufacturers brief description and application of each product tested, followed by my observation after testing. For product limitations and complete technical information, refer to the manufacturer or Merchant & Evans Engineering Department. Butyl Tapes MB – 10A Sealant Tape/ Gulf Seal Specialties, Inc. Description: Butyl Rubber Based Extruded Sealant on Silicone Release Paper. Application: Applied between two flat surfaces (normally held in compression). EG: Lap joints and a variety of construction joints. Observation: After three (3) days, Tape held a relatively strong bond. It exhibited little tackiness. TC-95 Modified Isobutylene Tripolymer Tape/ Chemseco Description: High Performance Permanently Elastic Modified Butyl Tape on Silicone Release Backing Paper. Application: Ideally for standing seam roof systems and endlaps. Applied between two flat surfaces where superior tensile strength, extensibility, weathering, and good adhesion are required. Observation: After three days, Tape held a very strong bond. Tape also remained very tacky. Gun Grade Butyl Sealants PSI – 301 Butyl Rubber Caulk/ Polymeric Systems, Inc. Description: A One Part Gun Grade Butyl Rubber Caulking Compound. Application: For little or no joint movement for sealing panel perimeters, copings and flashings. Durable and long lasting. Observation: After three days, sealant was still tacky to touch. Seal was fairly easy to pull apart and remained soft. Merchant & Evans, Inc. ZIP-RIB® F-6 SM-532/ Chemseco Description: A High Solid, Non-Skinning, Non-Drying, Modified Polyisobutylene Caulk. Application: Ideal for sealing batten cleats of standing seam roofs and wall panel joints. Can withstand joint movement. Observation: After three days, sealant was very tacky to touch. Seal was fairly easy to pull apart and remained soft. Chemcaulk 300/ Chem Caulk Description: A One Part Polymeric Butyl Rubber Caulk. Application: For non-moving joints when long life, minimum maintenance, and weathering characteristics are desirable. Observation: After three days, sealant skinned over and was not tacky to touch, however, the inside stayed tacky. Seal was fairly easy to pull apart and remained soft. Silicone Sealants PSI 631 RTV/ Polymeric Systems, Inc. (non-acetic acid cured) Description: A Non-Corrosive One Part, Neutral Cure, Moisture Curing Sealant. Cures to a tough flexible rubber and has excellent adhesion to metals. Application: Ideal for all building components of non-porous material. Observation: After three days, sealant became “rubber-like”. Seal was difficult to pull apart. Inside of seal did not completely cure. Silglaze -N- Sealant SCS 2500/ General Electric (non-acetic acid cured) Description: A General Purpose Sealant with a 50% Dynamic Movement Capability. Application: Good adhesion to a wide variety of substrates such as Kynar 500 resin based paints, glass, copper, mill anodized finish aluminum, galvanized steel, etc. Observations: After three days, sealant became “rubber-like” and flexible. Of the three tested, this sealant was the most difficult to pull part and the most cured. MB-45A Polymer Seam Sealer/ Gulf Seal Description: A Medium Viscosity, High Performance, Elastomeric Sealant. Exhibits “rubber-like” characteristics. Application: For sealing joints on roofs or side walls on materials such as galvanized steel, aluminum and gutters. Observation: After three days, sealant exhibited a soft “rubber-like” texture. Outside skinned over. Inside was not very tacky. Seal did not completely cure. One Part Polyurethane Sealants PSI – 901/ Polymeric Systems, Inc. Description: A Non-Sagging, Low Modulus Sealant – ideal for dynamically moving joints. Has extraordinary adhesion and cohesion characteristics. Application: Ideal for sealing expansion joints and perimeter caulking. Observation: After three days, sealant became “rubber-like” and not completely cured. Seal was very difficult to pull apart. Sikaflex 201/ Chemseco Description: A General Purpose Industrial Sealant with excellent adhesion to painted materials, aluminized steel, Galvalume, etc. Non-corrosive. Application: Ideal for standing seam endlaps, roof curbs, jacks, gutters, eaves, valleys, skylights, windows and doors. Observation: After three days, sealant remained soft but skinned over. This sealant was the most difficult to pull apart. Merchant & Evans, Inc. ZIP-RIB® F-7 Chemcaulk 900 / Chemcaulk Description: A One Part Gun Grade Sealant which cures by reaction with humidity in air to a rubbery highly Elastomeric Sealant. Application: Ideal for moving exterior joints and most common building materials. Observation: After three days, sealant exhibited a hard “rubber-like” texture. Seal was very difficult to pull part and not completely cured. A typical application properties chart is available upon request. For future inquires, Merchant & Evans would like to recommend the following sealants, caulks, and tapes from each category: 1. Gun Grade Butyl Sealant - SM-532/ Chemseco 2. Silicone Sealant - Silglaze -N- Sealant, SCS 2500/ GE 3. One Part Polyurethane Sealant - Sikaflex 201/ Chemseco 4. Butyl Tapes - TC-95/ Chemseco In closing, before choosing a sealant, refer to the manufacturer’s complete technical information on each product. Also, it is recommended that the sealant be field tested in its environment to determine its effectiveness. Merchant & Evans, Inc. ZIP-RIB® G-1 ESTIMATING TRUCK LOADS Standard available trucks have a 40 ft. long by 8 ft. wide bed and can carry eight standard bundles for a total of 288 pieces 12” ZIP-RIB or 240 pieces 16” ZIP-RIB up to 40 ft. long. 12” ZIP-RIB is packed in 3-wide bundles and 2 bundles wide per truck. 16” ZIP-RIB is packed in alternating 3-wide and 2-wide bundles and is packed 2 bundles wide like 12” ZIP-RIB. Most trucks available for Zip-Rib cannot overhang in the front, but some states allow overhanging loads. Contact Merchant & Evans for permissible overhangs in various states. Panels longer than this will require a stretch trailer which can be extended up to 85 ft. and with the maximum overhangs accommodate lengths up to 100 ft. Note: Multiple lengths (i.e., bundles of 30 ft. panels) cannot be shipped end-to-end on a stretch trailer. Lengths over 45 ft. require special trucking, and permits may not be available in all states. Before quoting a price on any project involving lengths over 45 ft., consult the nearest Zip- Rib plant for an indication of possible shipping problems. When quantities of specific sizes do not make a full 36 piece bundle, shorter lengths can be packed on top of longer lengths, however, “stair-cased” bundles are extremely inefficient since stacking is limited. When less than 4 bundles are required in a shipment, the size of the bundle may be increased or decreased slightly to make the load more efficient. Some partial bundles may be feasible on full loads, depending upon height limits of the route. In planning to lay short panels over longer ones, several short panels may be laid end-to-end in each layer to fill out the lengths. As a general rule, to avoid packaging extras, there should be at least six pieces of any given size. In loading the truck the shorter bundles must be on top. Each space, except the uppermost layer, must contain a nested pair of panels. Remember to allow for accessories. Heavy flashing sheet cannot be placed on top of the Zip-Rib without danger of crushing the panels. Merchant & Evans, Inc. ZIP-RIB® H-1 Product Limitations CERTAIN PROJECTS HAVE BEEN IDENTIFIED AS HAVING THE KIND OF RISK FOR ZIP-RIB THAT REQUIRES A TECHNICAL REVIEW OF SPECIFICATIONS AND ARCHITECTURAL PLANS PRIOR TO QUOTING OR SUPPLYING MATERIALS FOR THAT PARTICULAR END USE. SHOP DETAILS ON THESE MUST BE REVIEWED PRIOR TO SHIPMENT OF MATERIAL. IT IS THE RESPONSIBILITY OF THE CONTRACTOR OR DESIGNER TO MAKE MERCHANT & EVANS AWARE OF ANY SPECIAL PROJECT CIRCUMSTANCES THAT MAY REQUIRE A REVIEW BY THE MANUFACTURER. THESE USES ARE AS FOLLOWS: CURVED SURFACES - WARPED SURFACES Any applications involving Zip-Rib on surfaces that are curved relative to the length of the panel must be reviewed. (Surfaces curved relative to the width of the panel pose no special problems.) Thermal movement is critical and load capacity is modified by the bending of the panel. Warped roof surfaces (with twisted panels) must be reviewed to verify that the dimensions are within the panel limitations. LONG LENGTHS Lengths in excess of 85 feet are difficult to ship and handle. Thermal movement and temperature stress are major considerations in these long lengths. Numerous jobs have been successfully installed in lengths to 100 feet and some others up to 290 feet, but contractors should have the benefit of the past experience with these longer lengths. Long lengths includes spliced (end lapped) sheets that make the total run over 85'. SPLICED PANELS AND END LAPS Experience with field made, close fitting, splice end laps has been successful in 24 GA steel and .032" aluminum Zip-Rib when the proposed staggered-joint is used with suitable sealant and fasteners. Only offset (separated) end laps should be considered in .040" and 22 GA steel. Some variations are feasible to suit project conditions, but a job review to resolve the position of the laps, the fixed point and lap details is essential. TAPERED PANELS AND CONICAL SURFACES Within certain limits, Zip-Rib has the capability of manufacturing tapered panels for conical surfaces. A job review is necessary to verify that the project conditions can be met. JOBS OVER 400 SQUARES Jobs of this size can pose significant losses if problems develop, so a job review of specifications and details is required to make certain that the Contractor-Erectors are alerted to potential problem areas. JOBS OUTSIDE THE CONTINENTAL UNITED STATES Any job outside the continental limits of the United States except Alaska and Hawaii. This policy is necessary because of the cost and difficulty of servicing these areas. Specific terms and conditions apply to orders coming from foreign countries, and a Zip-Rib training session is required for all erectors. Merchant & Evans, Inc. ZIP-RIB® H-2 TECHNICAL REVIEWS In order to protect Zip-Rib and our customers from unnecessary risk, certain Zip-Rib projects require a technical review prior to quoting. While we prefer plans and specifications, the information can be given by telephone. If we are successful bidders, we will require technical review of shop drawings prior to shipment of material. These projects are those involving: Over 400 squares Lengths over 85 ft. Spliced or end-lapped panels. Curved or tapered panels Export from US (except Alaska and Hawaii) INFORMATION REQUIRED FOR REVIEW INCLUDES: Roof plan: lengths, hips, valleys, penetrations, knee joints. Section details: slopes, perimeter conditions. Supports: materials, spacings, insulation( specific type). Specifications: uplift and down load, codes, performance standards, warranty, scope of work. Special conditions: snow, snow-guards, harsh environment, fumes, delivery dates. MAIL INFORMATION TO: (U.S. Mail Service) Merchant & Evans, Inc. PO Box 1680 Burlington, NJ 08016 Attn: Dan McAuliffe, Engineering Manager (Other Carrier) Merchant & Evans, Inc. 308 Connecticut Drive Burlington, NJ 08016 Attn: Dan McAuliffe, Engineering Manager Phone (609)-387-3033 Phone (800)-257-6215 Fax (609)-387-4838 Merchant & Evans, Inc. H-3 LIMITED ROOFING WARRANTY PROJECT: ___________________________ OWNER: _______________________________ This Limited Warranty is issued by Merchant & Evans, Inc., 308 Connecticut Drive, Burlington, New Jersey 08016, herein after referred to as "The Company" and “The Installing Contractor” designated herein and runs to The Building Owner, herein after referred to as “The Customer”. The Terms and Conditions of this Limited Warranty shall constitute the entire agreement and understanding between The Company, The Installing Contractor and The Customer with respect to the Warranted Roofing System on the Project specified above, only. I. PERFORMANCE STANDARDS: The Company solely warrants that the Warranted Roofing System as herein defined will, under normal atmospheric conditions and ordinary wear and tear by the elements as herein defined, perform as follows: The Warranted Finish will not blister, peel, chip, check or crack, lose adhesion, chalk in excess of eight or fade in excess of five for a period of _____________ years. Cracks or checks are defined as breaks in the coating as distinguished from microchecking at the radii, which shall be considered normal and acceptable. Failure due to mechanical damage of the coating after manufacturing is outside this Warranty. Additionally, the panel system will not fail to remain weather-tight for a period of _______________ years or structurally fail [up to a design wind speed of __ miles per hour] for a period of ________________ years from defective materials, manufacturing workmanship, perforation of the base metal, or system design. The Installing Contractor solely Warrants for the designated periods stated above, that the Warranted Roofing System as herein defined will be installed in a workmanlike manner and in accord with The Company’s published installation guidelines and/or specific instructions for the project. II. FAILURE TO COMPLY: If the Warranted Finish and/or Warranted Roofing System fails to perform in accordance with the PERFORMANCE STANDARDS noted above, The Company's and the Installing Contractor’s liability under this Warranty will be limited to refinishing or replacing or repairing that portion of panels having a defective Warranted Finish and/or defective Warranted Roofing System. Refinishing and/or repairing shall be performed using standard field practices and materials (not necessarily the Warranted Finish) selected by The Company and/or The Installing Contractor. Refinishing and/or replacing and/or repairing shall be done only on areas deemed non-performing and not necessarily on performing areas. The Company and/or The Installing Contractor will, in all instances, at its own discretion, determine whether refinishing and/or replacing and/or repairing is required in order to fulfill the original performance guarantee without extension of the duration thereof. Claims or defects must be made by the Customer in writing to The Company and The Installing Contractor within thirty (30) days after initial discovery of the defect. Notwithstanding anything to the contrary stated in this Warranty, Liability, corporate or otherwise, in examining, replacing, repairing, and refinishing the non-performing warranted finish or warranted roofing system shall be limited to costs not to exceed the purchase price from The Company of the original product. III. EXCLUSION AND MODIFICATION OF WARRANTIES: There are no Warranties which extend beyond the description on the face hereof and except as provided herein. THIS LIMITED WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY OR MERCHANTABILITY OR THAT THE GOODS ARE FIT FOR, OR CAN BE FOR A PARTICULAR PURPOSE BY THE CUSTOMER. THE COMPANY AND THE INSTALLING CONTRACTOR DISCLAIMS AND THE CUSTOMER WAIVES ALL REMEDIES NOT PROVIDED HEREIN INCLUDING ANY LIABILITY OF THE COMPANY AND THE INSTALLING CONTRACTOR IN TORT, STRICT OR OTHERWISE, FOR DAMAGES OR INJURIES TO PERSONS OR PROPERTY OR FOR LOSS OF USE, OR REVENUE OR PROFIT, WHETHER DIRECT, INCIDENTAL OR CONSEQUENTIAL INCLUDING MOLD CLAIMS, RESULTING FROM ANY DEFECT IN DESIGN, MATERIAL WORKMANSHIP OR MANUFACTURE, WHETHER OR NOT CAUSED BY NEGLIGENCE ON THE PART OF THE COMPANY AND THE INSTALLING CONTRACTOR, ORAL STATEMENTS MADE BY THE COMPANY'S AND THE INSTALLING CONTRACTOR’S REPRESENTATIVES ABOUT THE PRODUCT AND WRITTEN DESCRIPTIONS OF THE PRODUCT APPEARING ELSEWHERE THAN ON THE FACE HEREOF ARE NOT WARRANTIES AND SHALL NOT BE RELIED UPON BY THE CUSTOMER. Purchase Orders and Contracts of the Customer, acknowledgements by The Company and The Installing Contractor, product literature, promotional material or advertising shall in no way affect, alter, or modify any of the Terms or Conditions of this Warranty. The Terms and Conditions of the Warranty shall constitute the entire agreement, understanding and responsibilities by and between The Company, The Installing Contractor and The Customer with respect to the Warranted Finish and/or Warranted Roofing System on the PROJECT specified above. None of the Terms and Conditions of the Warranty may be modified by any party unless done so in writing. If any of the Terms, Conditions, Limitations of this Warranty are violated by the Customer then the Terms, Conditions and Provisions are absolutely void and of no legal effect. If any party ceases to exist, other surviving parties are not bound to obligations of the non-surviving party. This Warranty is subject to the Conditions and exclusions printed in Schedule A, and incorporated as a part of this Warranty. SCHEDULE A I. DEFINITIONS: As used in this Warranty, the following words shall be ascribed the respective meanings as herein set forth: A. “CUSTOMER”- The Person, Firm or Corporation to whom this Warranty runs, or, building “Owner”. B. “NORMAL ATMOSPHERIC CONDITIONS” AND “ORDINARY WEAR AND TEAR BY THE ELEMENTS”- This term shall exclude corrosive or aggressive atmospheres, including but not limited to those atmospheric conditions set forth in Paragraph II hereof. C. “WARRANTED FINISH”- When applicable, these are approved colors of the exterior finish noted herein when applied to coil coated panels manufactured by The Company and installed by The Installing Contractor that are exposed to normal atmospheric conditions. D. “REPLACEMENT”- Replacement includes repairing or replacing non-performing products supplied by The Company and/or non-performing installation provided by The Installing Contractor but does not include the cost of other materials and labor required for removal and/or re-installation of other materials not supplied by The Company or The Installing Contractor. E. “WARRANTED ROOFING SYSTEM”- The standing seam metal roof system (SSMRS) manufactured by The Company and installed by The Installing Contractor. H-4 F. “MECHANICAL DAMAGE”- Refers to any physical damage such as scratches and abrasions to the Warranted Finish after the Warranted Roofing System is manufactured by The Company. II. WARRANTY LIMITATION This Warranty shall apply only to the Warranted Finish and/or the Warranted Roofing System as herein defined which has been exposed to normal atmospheric conditions, and shall not apply where any failure of the Warranted Finish and/or the Warranted Roofing System is the result of fire, vandalism, radiation, harmful fumes, dissimilar metals, foreign substances in the atmosphere inside or outside, including corrosive aggressive atmospheres such as those contaminated with chemical fumes or salt spray, mishandling or non-compliance with The Company’s published product information, falling objects, acts of God including: hurricanes, tornadoes, floods, damage from wind-storm, etc., or deliberate damage from riots, civil commotions, acts of war, or mechanical or any other physical damage to the Warranted Finish and/or the Warranted Roofing System. In addition, this warranty shall not apply to any failure of, or damage to, the Warranted Finish and/or Warranted Roofing System as the result of moisture entrapment or other contamination, or to a defect in design such as ice-damming, improper drainage, failure of guttering, etc. which is detrimental to the Warranted Finish and/or Warranted Roofing System prior to or after its use by the Customer; nor to damage to the Warranted Finish and/or Warranted Roofing System as the result of edge corrosion or failure of the metal substrate from aggressive atmospheres, storage, fabrication, shipping, or processing by the installing contractor; nor to any damage to the Warranted Finish and/or Warranted Roofing System resulting from circumstances where it is subjected to continuously generated abrasive forces or continual or periodic submersion in water; nor does this warranty apply to any air dry touch up paint systems and/or non coil coated finishes. III. TERRITORIAL RESTRICTIONS Subject to WARRANTY LIMITATIONS as herein above set forth, this Warranty shall extend to the Warranted Finish and Warranted Roofing System which is installed as an exterior building component anywhere in the Continental United States, but excluding the States of Hawaii and Alaska. IV. DISCONTINUANCE OF WARRANTIES The Company reserves the right to discontinue issuance of Warranties. Discontinuance of future warranties will not affect the Terms and Conditions of this written Warranty since it shall remain in effect for the full WARRANTY PERIOD, unless the WARRANTY PERIOD is reduced or discontinued by mutual agreement of all parties. If the Company shall determine to liquidate, dissolve or sell its building products business, The Company may give notice to you and if no written notice of complaint is received by The Company within four (4) months after the date of such notice, this Warranty shall terminate and expire and The Company shall not have any further liability hereunder. V. USE OF TRADE MARKS AND ADVERTISING The Company trade names, product names, names of the Warranted Finish and Warranted Roofing System described herein or the Terms and Conditions of the Warranty shall not be used by the Customer in any of its advertising, promotional material, technical reports, or any other published communications without the prior written permission of The Company. VI. ASSIGNMENT This Warranty is extended to the Customer as the original purchaser. It is non-transferable and non-assignable. No rights against The Company or The Installing Contractor shall be created by any transfer or assignment nor shall any rights against The Company or The Installing Contractor survive any transfer or assignment. VII. CLAIMS In the event of alleged failure of the Warranted Finish and/or Warranted Roofing System, written notice containing particulars sufficient to identify the Customer and PROJECT and also reasonably obtainable information with respect to the time, place and circumstances thereof shall be given by or on behalf of the Customer to The Company and The Installing Contractor WITHIN THIRTY (30) DAYS of the detection of such failure. The Company and The Installing Contractor reserves the right to examine and investigate each complaint and to jointly determine with the Customer (or any party authorized by the Customer) the exact cause of any failure. If the failure of the Warranted Finish and/or Warranted Roofing System is not the result of any act or omission on the part of The Company and/or The Installing Contractor then The Company and The Installing Contractor shall have no further obligation on the CLAIM and all examination and investigative costs such as traveling expenses, laboratory analyses, and professional services will be paid for entirely by the Customer. The Customer shall further provide any information and personnel having knowledge of, or information pertaining to, the CLAIM of an alleged failure of the Warranted Finish and/or Warranted Roofing System in question. The Company and The Installing Contractor will not participate in any CLAIMS or pay any CLAIMS until the full contract price for all work performed and materials furnished is received by The Company and The Installing Contractor. ________________________________________________________________________________ By: _______________________________ Daniel T. McAuliffe, Engineering Manager Print Name: Merchant & Evans, Inc. Installing Contractor’s Firm: Date: Date: Print Name: Owner’s Representative: Date: _____________________________ ________________________________________________________________________________ NOTE: Must be signed by all parties with one copy returned to The Company for its records. Merchant & Evans, Inc. ZIP-RIB® I-1 JOB SITE ROLL FORMING SCHEDULING Since there is only one portable roll former, several factors must be considered to insure its availability at the time your job will be ready. These are: (1) other jobs scheduled for the equipment, (2) your job site location, (3) production schedules at the coil fab mills to assure that adequate metal will be available, (4) weather. Merchant & Evans needs to know tentative schedules 8 weeks prior to rolling. Schedule must then be confirmed 4 weeks prior to rolling. Keep in mind that changes made by the customer may cause a complete re-scheduling depending on confirmed commitments we have with other customers. Contact your project manager well in advance so that these things can be coordinated to have the machine and the metal arrive at the job site when the roof is ready. MAJOR ADVANTAGES 1. No transit damage or transit delays. 2. Lengths beyond allowable transportation limits are possible. 3. Savings in material handling at the job site are possible. Plans can be made to hoist all the panels at one time rather than separately for each truck load as it arrives. 4. On large projects, there is the possibility of a significant reduction in freight costs. MAJOR DISADVANTAGES 1. Timing is critical to get the roll former and the metal at the job site at the proper time. 2. Weather may be a determining factor. Heavy winds, rain or snow make job site roll forming difficult or, in some cases, impractical. Extended exterior exposure of the metal or panels can lead to water stains. 3. In some areas, unions will not permit production at the job site with non-union personnel. Get this point cleared well in advance, in writing, prior to shipment of the roll forming equipment. 4. When the roll former and metal arrive at the job site, the entire job must be run continuously and placed in storage. 5. A large storage area is required to accommodate the finished panels. The storage area must be dry and graded to prevent ponding water. All metal must be covered and ventilated to prevent water stain. COSTS There are so many variables on each job that it is impossible to provide a rule of thumb on costs. They must be figured on a job-by-job basis. Contact your Zip-Rib representative at the earliest possible time with information on job location, size and timing requirements so that an accurate cost study can be made. Merchant & Evans, Inc. ZIP-RIB® I-2 JOB SITE RESPONSIBILITIES ZIP-RIB Manufacturer 1. Insure that sufficient metal arrives at the job site on time with freight paid. 2. Insure that arrival of the roll forming equipment at the proper time with freight paid. 3. Maintain production schedules and product quality. 4. Provide (1) mechanic to feed coil and operate roll former only. 5. Provide wood battens, nails, steel banding strap and strap tensioning equipment for standard Zip-Rib packaging. Extra cost may be involved for non-standard size bundles. 6. All scrap metal will be removed by the manufacturer. CONTRACTOR ERECTOR 1. Provide written confirmation of the union's approval to allow job site roll forming at the proposed site at least 60 days prior to roll forming. Contact the general contractor for the project to determine what union would be involved. 2. Arrange for a 5,000 pound capacity fork lift and operator for the duration of the roll forming for daily movement of coils from their storage place to the roll forming equipment. The lift must be suitable to the terrain at the job site, e.g. sand, rocky, uneven. Charges for the lift will be paid by the contractor- erector. 3. Make available weather tight storage for the rolls of coil in the vicinity of the job site or make arrangements with a local warehouse to deliver the daily coil requirements to the roll forming equipment. Any charges here will be paid by the contractor-erector. 4. Provide a complete bill of materials prior to start of production. The need for running the order in a particular sequence must be approved prior to the time that the roll former arrives at the job. Roll former production cannot be restricted once it has started. The entire job must be run at one time. Normally, the job will be rolled faster than it can be installed. Objective is to run 12 hrs/day 7 days/wk. 5. Provide laborers to handle panels once cut-to-length. Figure one man per 20' length plus one. 6. Provide the proper work area for the roll-forming equipment. (a) There must be a solid foundation for the roll former as it weighs 16,000 lbs. A solid foundation is also required to maintain the alignment of the roll former and maneuverability of the truck and trailer. (b) There must be adequate storage space to accommodate the finished panels for the entire job. Any costs incurred to accomplish (a) and (b) above will be paid by the contractor. Any moves of roll former after the one original set-up will be done by equipment furnished by the contractor and cost $500 per move. Merchant & Evans, Inc. ZIP-RIB® I-3 JOB SITE ROLLFORMING - EQUIPMENT REQUIREMENTS Equipment space provides for coil storage, coil reel, roll former, cutoff saw, and for access with fork truck for changing coils. This should be a clean, hard surface such as blacktop (minimum 20 ft. x 40 ft.). Note: all equipment is pre-set and mounted on a 40' closed trailer. Run-out tables space allows for panels to be nested and banded prior to assembly in bundles. This can start 5 ft. or 15 ft. from the edge of the equipment area. Storage area size is determined by pieces required. It should have a surface suitable for moving light loads on small wheeled carts. The maximum height stack (which nets out to 24 pieces per foot of ground space) is based upon long lengths which must be manually placed by the roll forming crew. Short length bundles which can be picked up by the forklift can be stacked higher. In this case figure 40 pieces per foot of ground space. If the size of the project requires a storage area width greater than 75 ft., the contractor will have to arrange for moving bundles to another area or provide for storage on the opposite side of the run out tables. Bundles produced at the job site are usually smaller than the standard pack. They are 36 piece bundles for 12” panels and 24 piece bundles for 16” panels. A- Equipment Storage Space B- Equipment, Truck, and Trailer Space C- Coil Loading Area D- Run-Out Tables E- Panel Storage Area ***- Determined by the amount of panels to be stored. Figure 24 pieces to a 37” wide bundle. Bundles can be stacked 2 high. A 25’ 15’ B 30’ D 15’ 68’ C E 40’ 10’ *** Panel Length Plus Seven Feet Merchant & Evans, Inc. ZIP-RIB® J-1 ARCHITECTURAL SYSTEMS - 3:12 MINIMUM PITCH - REQUIRES SOLID DECK AND UNDERLAYMENT - PANEL LENGTHS LESS THAN 45'-0" - SEAM HEIGHTS BETWEEN 1" AND 2" - LIGHT GAGE CLIPS SPACED LESS THAN 24" O.C. - NO WEATHERTIGHT WARRANTIES AVAILABLE - PERFORMANCE TESTING LIMITED - NOT USUALLY ENGINEERED TO MEET CODES, THUS NOT FOR PROJECTS WITH HIGH WIND LOADS STRUCTURAL SYSTEMS - 1/4:12 MINIMUM PITCH - PANEL LENGTHS GREATER THAN 45'-0" - SEAM HEIGHTS GREATER THAN 2" - HEAVIER GAGE CLIPS SPACED MORE THAN 24" O.C. - SPANNING CAPABILITIES - WEATHERTIGHT - MECHANICALLY SEAMED (MOST SYSTEMS) - FULLY ENGINEERED AND TESTED - CAN BE USED IN ARCHITECTURAL APPLICATIONS Merchant & Evans, Inc. SEALANT K-1 ZIP-RIB® -Polyethylene Rod & diameter. -Polyethylene Rod 3/8 diameter. -Caulking (Tubes/Tape) ZIP RIB CHECK OFF LIST – ESTIMATING & PURCHASING SPECIAL TOOLS -Zipper Tool ZIP-RIB -Pan End -Button Punch -Gauge (.040-.032, 24ga-22ga) -Width (12"-16") -Hand Crimp -Unzipper -Finish (Side) Extra Packing? -Lengths (Extra Pieces in longest) -Non-standard Tolerance on Length HOISTING -Bundle Size Limits -Unloading Equipment (Forklift/Crane) -Special Packaging -Freight Costs (No. of loads) -Hoisting Slings (Bottom Pads) -Spreader Bar of Strong Back -Structural Certification or UL Label -Bracing for Sloped Storage on Roof FASTENERS LABOR COST VARIABLES FOR: -Clip Screws -"Top Seal" for Flashing (Stainless) #14 -Siding (Vertical Travel) -Roofing -Pan Head for Closure -Soffits (Awkward handling-scaffold) -Pop Rivets (3/16" aluminum or stainless steel) -Explosive Fasteners -Height -Steepness (Safety gear or ladders) -Concrete Anchors -Size (learning curve) Cuts -Fab-Loks or Bulb-Tites (for end splice) -Access - Panel Storage Location FLASHING -Material (Finish) ZIP RIB CHECK OFF LIST- -Eave Closure (for frieze board) DESIGN & DETAILING -Drip Angle -Fascia STRUCTURAL ADEQUACY -Gutter -Gable or Rake Trim Zip-Rib span: positive load, negative load, walking loads. -Side wall Clip strength in Zip-Rib for negative load. -Headwall -Ridge Cap Fastener head size for clip for uplift (head clearance with Zip-Rib) -Ridge Closures (12" or 16") Fastener into support material for uplift. -Hip Cap -Hip Closures (Foam, Channel, Backer) Possible ice load on steep roof. Snow Guards -Pipe Jacks Adequate distance of clips from panel end. -Formed Skylight or Hatch opening. -Valley -Knee Joint Trim THERMAL MOVEMENT PROVISIONS Specify fixed anchor line for minimum movement or -Touch-up Paint minimum flashing problems. Is the ridge and eave free to flex or slide? Adequate ANCHORS end clearance? Make sure gable edge is free to slip between -Gable Clips flashing and roof. -Bulb Clips -Barb Clips Remember, box ends of gutters, gables, ridge caps, etc. are not free to flex. -Hook Clips (Use #2080 for 16" & Steel) Is gutter length free to move relative to roof and -Straps -Clamps structure? Merchant & Evans, Inc. K-2 ZIP-RIB Provide for two way movement at all diagonal Storage: slope for drainage; cover bare (unpainted) conditions. bundles; vent ends; avoid wet ground; on roofs, tie Provide independent anchorage at both sides of down against wind and brace on steep slopes. expansion joint. Are flashing joints free to slip? (Sealant ok in short INSTALLATION lengths 10-12 ft.) Handling: pairs stronger; if flexing is necessary, Omit sealants on sliding connections. bend ribs out to avoid kinks. Make certain that skylight and roof penetrations are Layout: establish straight side and crosswise fixed to roof, to structure or both at fixed line only. benchmarks; check for true structure. Give notice to owner regarding roof penetrations by Verify fasteners: proper size and length for others. strength; proper head size for clip hole and clearance. Train Crews: allow thermal movement; avoid MISCELLANEOUS crimps in ribs; avoid screws into ribs at clips; avoid fasteners into lap joints of flashing. Consider break up of wide flats on flashing or use Zip-as-you-go. Tie down last edge at night. Tie heavy gauge material to keep lines straight. down all open bundles. Check fastener spacings. Detail open hems on exposed edges for stiffness EQUIPMENT LIST CHECK and water block. Include drip angle for a straight eave line and uplift Unloading or Hoisting rig strength. Slings and Battens for hoist Check side wall and gable details for Zip-Rib width Spreader Bar module. Consider optimum laying direction. Hoisting Frame Show minimum 1/8" radius bend to avoid cracking at Rope Falls corners. Rope Is there adequate slope to drains for gutters? Tape 100' or 50' Request supplemental alignment for concrete Transit or Long Level anchorage where possible. Chalk line, Piano Wire Concealed sealant. Marking Pen, Crayon, Soapstone Vapor barrier on the warm side of insulation. Scaffold, Planking Ladders PRIMARY PLANNING Duck boards, Chicken Ladder Generator-Gas - Check material delivery schedule; anticipate rate Electric Extension Cords of usage; insure adequate supply. Three -Way Pigtails - Plan storage: abuse and weather protection, Drill Motors alignment of Zip-Rib sides. Drill Bits-Sizes - Equipment: unloading, slings, blocking, power Aircraft Snips L/R distribution required. Screw Guns/Bits - Specs, & Details: approval on exceptions, file Hammer drawings & approved samples. Vise Grips - Check field dimensions against order quantity C. Clamps and lengths. Rivet Gun Zipper Tool DELIVERY, STORAGE, HANDLING Skylight Rolls Hand Crimp Tool Inspect: check battens, look for tie downs between Pan End Tool battens, diesel smoke. Scrap Fold Tool Damage claim: see manual, p. B-7; accept delivery; Unzipper Tool note damage on receipt; get driver's signature; Caulking Gun/Tubes protect from further damage; file notification. Button Punch Unloading and Hoisting Bundles: limit overhangs Drill Chuck Keys to 15' and space between supports to 30': use slats Skil Saw/Blades under slings; avoid extending fork beyond bundle - Ramset Tool/Loads use stop block: protect bottom panels. Merchant & Evans, Inc. ZIP-RIB® K-3 WALKWAYS Where continued foot traffic on the roof indicates the need for a permanent walkway, the use of clamps (part #2050) permits installation without penetrating panels. The design may be in wood or metal but must not impair the thermal movement of the Zip-Rib. The weight of the walkway must be distributed sufficiently to prevent excessive wear of the Zip-Rib by the support structure. The total dead load (roof and walkway) should not exceed 20 pounds per clip. See accessory illustrations for examples of walkways with #2050 Leg Clamp. SNOW AREA PRECAUTIONS SNOW DEPTHS Snow depths higher than the rib can force water through the roof. On heated buildings the snow will melt first on the bottom of the snow next to the roofing. If it is not free to run off as fast as it melts, it will back up several inches deep. To assure against leakage in these cases, the seams should be caulked before the panels are zipped. When the entire length is sealed, the sealant should fill the capillary groove to prevent freezing water from prying open the seam. ICE DAMS Ice dams result when water from melting snow freezes on a cold overhang, eave or gutter. This problem can be prevented by proper design that eliminates the heat loss through the roof, such as with a ventilated attic or by heating the roof all the way to the eave. See the ZIP-RIB Design Guide for specific illustrations in snow areas. If ice dams cannot be prevented, the standing ribs at the eave and all flashing in the affected area must be caulked well enough to endure standing water. Thoroughly caulk any seam, standing rib or pencil rib where standing water could intrude. It is recommended that all critical areas be sealed with a waterproof membrane if an area poses the risk of an ice dam (see photo). SNOW SLIDES Snow slides can be dangerous to gutters, or other structures or roofs below an eave, or to people below. Slabs of ice slide easily off of even low pitched metal roofs. Snow guards placed only at the eaves can be subjected to considerable impact from material higher on the roof and must be engineered to resist all implied forces. IMPORTANT CONSIDERATION Roof panels must be secured to the buildings structure well enough to resist the force of any retained ice and snow. Since most Zip-Rib clips are designed to slide, the "fixed point" for thermal movement is the only point at which Zip-Rib is secured to the building. Therefore, this fixed point must be strong enough to resist the force exerted by the snow and ice. Merchant & Evans, Inc. ZIP-RIB® L-1 ADVANTAGES OF ZIP RIB *Over thirty five years experience with thousands of successful installations all over the world. The system has proved that it has a reasonable tolerance for normal construction variations. *Zip-Rib is installed in the United States by experienced and capable Contractor-Erectors authorized by Zip-Rib manufacturers. Training for overseas projects is available on a job-by-job basis. *Load span tables are based upon physical load tests which simulate actual service conditions. An appropriate factor of safety is included in the load span tables. All panel tests are supervised and certified by reputable independent testing companies. Copies of test procedures and results are available upon request. *National sales coverage is provided by over 30 professional manufacturers' representatives trained in proper use and application of Zip-Rib. *Zip-Rib roofing and siding is an engineered system that includes the attachment clips, accessories and tools needed for a properly installed product. Custom designed components are available from the manufacturers or the erectors to satisfy unique requirements. *Zip-Rib panels are furnished in long lengths--usually in ridge to eave lengths--thus eliminating the problem of end laps. The panels are attached to the roof structure by hidden anchor clips. Therefore, there is no penetration of the roofing panels by the anchoring fasteners. *Zip-Rib is supplied as a standard product in steel or aluminum. Panels may be fabricated in copper, lead coated copper, zinc, or stainless steel as required. *Zip-Rib is available with structural, finish and weathertight warranties upon request when specific conditions are satisfied. MARKET OPPORTUNITIES NEW CONSTRUCTION *Schools - Districts like the life-cycle cost opportunity. *Multi-Family Housing and Shopping Centers - Add sales appeal to draw customers. *Coverage for Water Supply or Sewage Treatment Facilities - Aluminum's natural corrosion resistance plus the capability of removing panels for inspection gives Zip-Rib an edge in controlling noxious fumes. Long lengths and corrosion resistance are favored for reservoir covers. *Industrial - Commercial Buildings - Life-cycle benefits. *Port Authority Buildings - Corrosion resistance and long lengths Aluminum Zip-Rib has performed well in severe marine and industrial atmospheres at Los Angeles, Long Beach, San Francisco and New York port authorities. *U.S. Government and Military Construction - Life -cycle value for long term projects. CONTACTS FOR NEW CONSTRUCTION *Architects and engineers are the primary targets. *Design - Build Construction Companies. *Military- Regional Offices of The Corps of Engineers, Naval Facilities Engineering and National Guard Units. REROOFING CONSTRUCTION *Military Buildings. *Municipal, State, County and Port Authority Buildings. *Industrial-Commercial Buildings. Most roofs are built-up. Inadequate slope requires additional framing. Buildings in this classification with inadequate insulation offer the best opportunity. Insulation can be added between the new sleepers. Building owners with leaking metal roofs are most often looking for a real solution - not just the lowest bid. The quick solution that Zip-Rib offers when installed over the existing deck may permit a negotiated rather than a bid job. CONTACTS FOR REROOFING JOB LEADS *At Port Authorities - Chief Engineer *Commercial and Industrial Building - Maintenance Dept. and Plant Engineers. Visual inspection from the street or air makes it easy to spot old roofs needing replacement. Look for the patchwork colors indicating successive repairs. *Contact the local representative of re-roofing specialists such as roof consultants. *Military -Individual Bases and Regional Offices. M-1 ZIP-RIB GUIDE SPECIFICATIONS Guidelines to Specifiers Before printing, delete these first three pages of comments as well as all notes and options in square brackets [ ] that do not apply to your project. The values in empty brackets [ ] need to be filled in to suit the specific project. To facilitate editing large blocks, we suggest using Set Block (Alt F4) with the cursor under the first bracket ( [ ) of the text to be eliminated. Use Search (F2) for the second bracket ( ] Esc) and then delete the block with the (Del Entr y ). Comments on specific sections are: 1.0.A. A recent trend in construction contract bidding is to require General Contractors to name subcontractors and material suppliers with the bid forms. This greatly reduces bid shopping and virtually eliminates an architect or owner from being forced into use of non-complying subcontractors and suppliers because time does not permit as construction schedules tighten and erection is supposed to proceed. In addition, it is strongly recommended that an additional bid form be added to the contract documents which ensures that all performance criteria of the specification have been met with the product being proposed. A sample is made a part of this guide specification. The form is to be signed and sealed by a Registered Professional Engineer attesting that all criteria are in compliance. This ensures the level of quality established by the specification is met and creates an awareness that performance criteria will be enforced. 1.04 A. Zip-Rib policy is to routinely review shop drawings for projects over a certain size as well as those that contain conditions with known potential problems. This review is made to determine if details are consistent with good sheet metal practice and those that have given good service in similar situations. Architects may request a review and comments prior to submittal. In making such a review, Zip-Rib assumes no responsibility for completeness of details, for unique applications or for magnitudes of loads or for design conditions other than those explicitly stated in the project plans and specifications. The review implies no warranty other than the express warranty that applies to products manufactured by Merchant & Evans, Inc. 2.02 A. Zip-Rib may be fabricated in materials or alloys other than those indicated, but strength tests need to be included as part of the project or the capacity will need to be determined on other information acceptable to the project engineer. 2.02 C. Coil coated 70% Kynar or Hylar 5000 based fluorocarbon (20 year warranty) is the standard available finish for Zip-Rib and flashings. Where additional abrasion resistance is desired, a heavier finish is also available. Other finishes may be available for specific project requirements, this specification contains the performance requirements for the basic finish. **Caution, projects located in coastal environments with a steel substrate will contain a “salt spray exclusion” that effectively voids the paint finish warranty. Aluminum should be considered as the substrate material.** 2.02 D. Calculations and pull tests do not accurately produce properties of light gauge sheet under air pressure and are not always conservative. Aluminum Association l982 "Specifications for Aluminum Struc- tures" requires air pressure testing for some building sheathing profiles including those with interlocking clips. The AISI "Light Gauge Cold-Formed Steel Design Manual" suggests testing to confirm bending strength whenever flat width to thickness ratios exceed 500 and requires tests for attachments other than bolts or welds. ASTM E-330 test method for curtain walls covers the basic principles of a proper air-pressure test, but some sections require emphasis or revision to eliminate constraints that can seriously overstate the capacity of sheet metal panels. ASTM E 1592 is also a performance test. 2.02 D.2. Underwriters uplift classification may be included as a requirement where desirable for reduction of insurance rates but are not recommended as the sole reference for structural integrity. Published safe design loads for panels with UL 90 ratings range as low as 29 psf by several manufacturers. 2.03 A. The #2080 clip normally comes with a galvanized base. In severe environments, an all stainless steel version is available for use with aluminum panels. 2.03 B. In some climates, condensation on anchor fasteners could lead to rusting and premature failure, es- pecially when driven through wood to an interior space. NAIMA and NRCA recommend the use of corrosion resistant fasteners whenever used to fasten through insulation to a metal deck. Lumber treated with water soluble salts may lead to corrosion unless stainless is used. M-2 2.03 E. This section is a minimum for sealants, and the architect is urged to develop a more detailed speci- fication section 7900 for the requirements of the project. 2.03 F. Traditional sheet metal practice calls for underlayment between metal roof coverings and wood decks with perforated asphalt sheets covered by dry rosin paper to avoid sticking. Materials are now available which will not stick to metal roofing but will prevent water from leaking down into the structure yet allow water vapor to be vented to the outside. Zip-Rib panels do not always require underlayment for weather tightness, but when installed over solid decking, this is suggested as inexpensive insurance against minor leakage at difficult flashing conditions. (See also 3.01 E). When metal roofing is installed over insulation in cold climates, a good continuous vapor retarder is recommended on the warm side of the insulation. The mechanical engineer may be consulted for specific recommendations for a specific project. Refer to ASTM E-241 for comments on good practice for control of moisture damage in buildings. Underlayment on top of insulation should be vapor permeable but water repellant. 3.01 B. Zip-Rib provides contractors with information on acceptable limits of surface deviation for roof perfor- mance in terms of limiting the force required to engage a panel with a clip, but only the architect can determine acceptable visual limits for surface irregularity. 3.01 E. The Zip-Rib seam without sealant survives dynamic wind and water tests without leakage up to 70 mph. In extreme climate areas and where deep snow or ice dams can force water through unsealed metal joints, a seam sealant is recommended. Underlayment may also be specified, but total reliance on a membrane in cold climates is not recommended because of the possibility of ice dams and freeze-thaw damage. 3.02 A. Interpretation of codes or wind speeds into design pressures should not be left to the roof contractors or to independent engineers hired by them. Project engineers or architects should develop wind and/or snow pressures for the roof covering at the same time the basic structure is designed. With the more complex variations of pressure in different areas called for by current codes, it may be easier to show pressure zones on the roof plan rather than in a table. 3.02 C. In snow areas, roof panels must be secured against sliding from the structure due to the weight of retained snow. If snow guards are involved, the project engineer should indicate the weight of snow to be retained on the roof for design of the strength of the attachment of the individual snow guards to the panels as well as the anchorage of each panel to the structure. Merchant & Evans, Inc. ZIP-RIB® O-1 ZIP-RIB CURVING GENERAL INFORMATION A full understanding of what to expect when handling and installing curved panels is critical to the success of a project. Therefore, this section should be reviewed by both field and office personnel. Aluminum ZIP-RIB panels can be curved to a standard radius as tight as 20'-0". Tighter radii are possible, however, subject to inquiry. Both factory and field curving options are available. When feasible, it is recommended that all panels be factory curved. Only Merchant & Evans personnel will be permitted to operate the curving machine. The curving machine will be shipped in an enclosed 8'-0" x 10'-0" x 10'-0" container. The machine must remain in the container during the entire curving operation. All panels will be curved on the ground. Approximate weight of curving machine and container is 6,500 lbs. The machine curves the panels at a speed of 60 ft per minute. Depending on the material type, strippable film may be applied prior to curving and must be removed upon exposure to direct sunlight. Verify with M&E prior to shipment. FACTORY CURVED PANELS Panels can be shipped pre-curved to the site by Merchant and Evans with usual limitations. Maximum panel length depends on radius. Contact M&E for feasibility review. Lengths and rises exceeding a standard truck load can be reviewed on a job to job basis. All panels curved at the factory will be bundled and transported to the site as an arch type bundle made from 2X lumber OR packaged on their side. Size of bundle will depend on radius, panel length, panel weight, etc. Contact Merchant & Evans prior to shipment to discuss exactly how panels will arrive. Accessible site storage is required as would be for straight lengths. See drawing showing a typical bundle of curved panels. JOB SITE CURVED PANELS Panels will be shipped in straight lengths and curved on-sight. Panels may also be job site roll formed and curved on site if necessary (See Job Site Roll Forming Section for more information). Adequate site space must be provided during the entire curving operation. This will depend on panel length and radius and must be reviewed with Merchant & Evans prior to shipment. Once curved, panels are typically nested together and hoisted to the roof with slings and a spreader bar. Size of nested panels will depend on radius, panel length, panel weight, etc. Curving operation will depend on existing job site constraints. Contact Merchant & Evans prior to shipment to discuss curving operation procedures specific to your project. Panel Seam Sealant Factory Curved Panels- Until further notice, factory curved panels will be shipped from M&E WITHOUT seam sealant. If the project requires, seam sealant must be provided and applied in the field by the installer. This is normally done during the installation process. Gun grade butyl seam sealant or butyl sealant tapes must be used. Contact M&E for pricing and/or suppliers. Refer to M&E shop drawings and/or standard details for additional information. Jobsite Curved Panels- If the project requires, the installer must apply seam sealant during the curving operation. M&E will provide the necessary equipment and materials for the installer to apply the seam sealant. Merchant & Evans, Inc. ZIP-RIB® O-2 CURVING RESPONSIBILITIES MERCHANT & EVANS, INC. WILL: Factory Curved 1. Insure that the curved panels will arrive at the job site on time. Freight to transport curved panels is additional. 2. Provide curved panels bundled on a 2X wood arched bundle. Shipment will be on a flat bed trailer. Job Site Curved 1. Insure that the curving machine arrives at the job site on time with freight paid. Freight to transport straight panels is additional. 2. Maintain production schedule and product quality. 3. Provide (1) mechanic to operate curving machine. 4. Provide equipment and materials for the contractors to field apply seam sealant during the curving operation. CONTRACTOR ERECTOR MUST: 1. If job site curved, provide written confirmation of the union's approval to allow job site curving at the proposed site at least 60 days prior to curving. Contact the general contractor for the project to determine what union would be involved. 2. Arrange for a 7,000 lb. capacity fork lift and operator. The lift must be suitable to the terrain at the job site, i.e.: sand, rocky, uneven. Charges for the lift will be paid by the contractor-erector. 3. Make available weather tight storage for the non-curved and curved panels on the sight. 4. Provide a complete bill of materials prior to start of production. Curving production cannot be restricted once it has started. The entire job must be run at one time. Normally, the job will be curved faster than it can be installed. Objective is to run 12 hrs/day 7 days/wk. 5. Provide laborers to handle panels entering and exiting curving machine. Figure one man per 20' length plus one. 6. Provide one (1) laborer to apply seam sealant during the curving operation in the field. This laborer is in addition to laborers needed to handle the panels. See Item 5 above. 7. Provide the proper work area for the curving equipment. (a) There must be a solid foundation for the curving machine as it weighs with container approximately 6,500 lbs. (b) There must be adequate storage space to accommodate the finished panels for the entire job. Any costs incurred to accomplish (a) and (b) above will be paid by the contractor. Any moves of the curving equipment after the one original set-up will be done by equipment furnished by the contractor and cost $500 per move. 8. Verify that all components and materials are shipped and/or produced on site. Merchant & Evans, Inc. ZIP-RIB® O-3 JOB SITE CURVING - SPACE REQUIREMENTS Curving space requirements include areas for 1) panel entry and exit of the curving machine, 2) panel storage area prior to entry of the curving machine (straight panels), 3) panel storage area upon exit of the curving machine (curved panels), and 4) an 18'-0" x 8'-0" area for the curving machine. Note: the curving machine should be located on a clean hard surface such as blacktop. See diagram. Storage area size is determined by pieces required. It should have a surface suitable for moving light loads. MAJOR ADVANTAGES - JOB SITE CURVING 1. No transit damage or transit delays. 2. Lengths beyond allowable transportation limits are possible. 3. Savings in material handling at the job site are possible. Plans can be made to hoist all the panels at one time rather than separately for each truckload as it arrives. See Section B for hoisting methods. 4. On large projects, there is the possibility of a significant reduction in freight costs. MAJOR DISADVANTAGES - JOB SITE CURVING 1. Timing is critical to get the curving machine at the job site at the proper time. 2. Weather may be a determining factor. Heavy winds, rain or snow make job site curving difficult or, in some cases, impractical. Extended exterior exposure of the metal or panels can lead to water stains. 3. In some areas, unions will not permit production at the job site with non-union personnel. Get this point cleared well in advance, in writing, prior to shipment of the curving machine and equipment. 4. When the curving machine arrives at the job site, the entire job must be run continuously and placed in storage. 5. A large storage area is required to accommodate the finished panels. The storage area must be dry and graded to prevent ponding water. Bare metal must be covered to prevent water stain. COSTS There are many variables on each job that it is impossible to provide a rule of thumb on costs. They must be figured on a job-by-job basis. Contact your Zip-Rib representative at the earliest possible time with information on job location, size, and timing requirements so that an accurate cost study can be made.
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