SYSTEM 1: ONE-PIECE, TIGHT-FIT MOLDING INSTALLATION

Transcription

1 Installation Guide for Omega-Lite Aluminum Building Panels SYSTEM 1: ONE-PIECE, TIGHT-FIT MOLDING INSTALLATION Laminators has complete installation guidelines for a variety of applications. When installing our panels on Clip & CaulkTM, Rout and Return, or Two-Piece, Snap-Fit Molding installations call OMEGA77 to request the appropriate installation guide. Over 40 years of delivering quality products & innovative solutions Tech support: OMEGA77

2 BEFORE YOU START Substrate and Framing Prior to installation, the installer MUST verify that the framing and substrate are in compliance with all architects' specifications. Inspect BOTH primary and secondary wall framing to verify that all girts, angles, channels, studs and sheathing and other structural panel support members and anchorage have been installed within the following tolerances: 1/4" in any 20' length vertically or horizontally 1/2" in any building elevation Inspect sheathing to verify that sheathing joints are supported by framing and that installation is within flatness tolerances. These surfaces must be even, smooth, sound, clean and dry. If the substrate or framing is not within architectural specifications, the installer must submit a written report to the General Contractor listing conditions that are detrimental to the installation of panels. Do NOT proceed with installation until unsatisfactory conditions have been corrected. Summary of Installer Responsibility The Panel Installer assumes total responsibility for all components of the panel installation including, but not limited to attachment to sub-construction, panel-to-panel joints, joints between panels and dissimilar material, and the joint seal associated with panel system. Installation Supplies & Accessories See page 14 to be sure you are using materials that have been tested and approved by Laminators for use with Omega-Lite panels. Inventory all materials and accessories to ensure that all materials are available on-site. Call Tech Support if you need additional recommendations. Receiving and Storage Examination: Upon receipt of materials, perform a thorough examination to identify any damage that may have occurred during shipping. Storage: Panels are to be stored horizontally on pallets with a positive slope for drainage of water and should be covered with watertight and ventilated materials. Standing water will damage panel finish. No more than 1500 pounds should be stacked on one pallet. Depending on panel size, this should be fewer than 50 panels at 30 pounds per panel and less than 2-1/2' high. Do not stack other materials on or in contact with panels to prevent staining, denting, or other damage. Storage temperature must not exceed 120ºF (49ºC). Omega-Lite panels are manufactured with a slight concave bow to assist in bonding the center to studs and furring. Panels must be kept stacked and weighted to retain the bow during storage. Laminators warranty does not cover water damage caused by improper storage or installation. Inspect panels on delivery, then store them on skids 8" above the ground. Place a breathable cover over them and store them in a ventilated space under roof. Tech Support: If wet panels are discovered, uncrate them and dry them with towels to prevent wood rotting, paint attaining or aluminum corrosion. Panel Handling Use clean work gloves to avoid hand injury from any sharp edges and to prevent smudging of the prefinished surfaces. Although panels are shipped with protective masking on both sides, always lift one panel completely off the next to prevent scratches. Do not slide one panel across another. Protect panels from construction hazards. Good construction practice provides for panel protection and cleaning in the contract documents. Normally these are the general contractor s responsibility. Temporary protection may be required if welding, cutting, sandblasting, or other potentially damaging construction activities are scheduled nearby. Cutting the Panels Omega-Lite panels are designed to be cut to size on the job site. Even if the panels have been received cut to size, it may be necessary to do some minor trimming to account for areas of an elevation that may be out of square. To cut Omega-Lite panels, use a circular saw with a sharp, carbide-tipped blade (40-tooth minimum). Do not remove the protective masking from the panel face. After cutting, use a screwdriver or deburring tool (see page 7) to remove burrs or sharp edges from the panels. Carbide-tipped blade (40 tooth min.) recommended Safety tip: Wear safety glasses when cutting! Wear gloves when handling cut edges! Ventilation is Important The wood or exterior gypsum board of the substrate must be protected and ventilated. Trapped moisture can cause major damage in a short time. When mounting over exterior gypsum or masonry, use steel strapping or hat channels to separate panels from the structure for good air circulation. Flashing Laminators can supply flashing materials made from 0.32"(0.813 mm) aluminum sheet painted to match the adjacent panel system or surface. Use proper flashing technique when installing flashing with panels. Complete product specifications can be downloaded from our architectural web site or you can request them by fax at Laminators Incorporated. Omega-Lite Aluminum Faced Building Panels Installation Guide.

3 TABLE OF CONTENTS One-Piece, Tight-Fit Molding Laminators durable, One-Piece, Tight-Fit Extruded Molding System requires no prefabrication. Panel installation is easy and economical. Moldings can either be color-matched or a contrasting color. Before You Start Inside Front Cover Panel Maintenance 1 Preparing the Wall 2-5 Installation over Plywood Sheathing 2 Installation over Gypsum with or without Building Wrap 3 Installation over Hat Channels or Furring Strips 4 Mounting the Panels 5-7 Installing the Moldings 5 Installation Summary 7 End of Run Detail 7 Installation of Flex Panels over Plywood Sheathing 8-9 Tools and Accessories 10 Tools and Accessories Available from Laminators Code of Quality Inside Back Cover Omega-Lite Panel Maintenance Routine cleaning: Omega-Lite panels should be washed periodically to keep them bright. Plain water and a clean cloth are all you need to remove ordinary dirt buildup. A mild, non-abrasive household detergent with a clean-water rinse can be used for more stubborn stains. Solvents such as alcohols, mineral spirits, naphtha, turpentine, and xylene can be applied with a soft cloth. Never soak panels in solvents. For scratches and rub-marks: Omega-Lite touch-up paint and re-paint instructions are available from Laminators. For larger paint repairs, call Laminators for standard paints designed for aluminum surfaces available at paint stores. Keep harsh solvents away from finish: Panel finishes are resistant to most but not all solvents and chemicals. If in doubt, call Laminators for compatibility charts. You can safely use mineral spirits to remove uncured sealants and paints. Panels with Metallic Paint Finishes: The protective masking on the face of each panel should be left in place until work is complete on any given area of an installation. However, to help ensure good color uniformity, periodically remove the masking from half of a panel (peel masking upward from the bottom of the panel) to check for color, scratches and dents. On panels with metallic finishes, a good color match is much more difficult to achieve. In this case, two adjoining panels should be periodically checked by removing the masking from half of two panels as the installation progresses. The masking should then be taped back over the panel to protect it. Should any defects be found, stop work immediately and call Laminators for assistance. When installing panels with metallic finishes, it is very important that the directional arrows on the panel masking are oriented in the same direction. Color variation is a characteristic of Aluminum composite panels with metallic paint finishes. Laminators Incorporated DOES NOT warrant a color match for these panels. 1

4 PREPARING THE WALL Tech Support: Installation Over Plywood Sheathing A Sealant Panel adhesive Back leg of Vertical has been cut away to accept Horizontal Foam tape* Detail A Back leg of Vertical has been cut away to accept Horizontal 24" on center Molding intersections are pressed into silicone sealant Press molding intersections into silicone Sealant Plan View *Tape width is exaggerated for illustration purposes B Detail B 1/4" Ice & water shield 2 This installation process is the basis for mounting panels over a variety of substrates. You should read and understand this process before attempting to mount panels over other substrates such as plywood covered with building paper, exterior gypsum with or without building paper, etc. In all cases, the same elements must be present: 1) A structural surface, such as plywood, that will hold mechanical fasteners, such as screws. 2) A surface that can be bonded to with panel adhesive. If these two elements are not present, additional steps must be taken to provide them. Exterior grade gypsum, building wrap, or block walls are examples of substrates that will require additional preparation before panels can be mounted. These substrates are covered in this manual. The main drawing (upper left) depicts the layout for one panel at ground level. J-molding is shown: either J- or Drip Edge moldings can be used here. The detail drawings (Detail A & B) show close-up details from the main drawing. The instructions on page 5 explain this process and the purpose of each element shown in the above drawings. Note: To guard against water penetration, Laminators recommends that all these installation systems include a vapor permeable, water-tight moisture barrier (appropriate for the climate and wall construction) installed on the substrate behind the metal wall panels. Follow Installation Instructions as shown on page 5.

5 PREPARING THE WALL Installation Over Gypsum with or without Building Wrap A Sealant Panel adhesive 24" on center Molding intersections are pressed into silicone sealant Back leg of Vertical has been cut away to accept Horizontal Foam tape* 3" x 3" Steel squares Detail A Press molding intersections into silicone Sealant Back leg of Vertical has been cut away to accept Horizontal Plan View *Tape width is exaggerated for illustration purposes B Detail B 1/4" Ice & water shield When installing panels over exterior grade gypsum, with or without building wrap, remember that neither exterior grade gypsum nor building wrap are structural. For proper installation, 18 or 20 gauge steel squares must be used to create a surface that will accept panel adhesive. All steel squares must be attached with low-profile, pan head screws at all four corners. These screws must pass through the steel squares, the exterior grade gypsum, and attach to the stud wall. Moldings must be attached through the gypsum to the studs. The main drawing (upper left) depicts the layout for one panel at ground level. J-molding is shown: either J- or Drip Edge moldings can be used here. The detail drawings (Detail A & B) show close-up details from the main drawing. The instructions on page 5 explain this process and the purpose of each element shown in the above drawings. Follow Installation Instructions as shown on page 5. 3

6 PREPARING THE WALL Tech Support: Installation Over Hat Channels or Furring Strips A Gap for drainage Panel adhesive Hat channel Back leg of Vertical has been cut away to accept Horizontal Back leg of Vertical has been cut away to accept Horizontal Foam tape* Detail A 24" on center Molding intersections are pressed into silicone sealant Press molding intersections into silicone Sealant B Plan View *Tape width is exaggerated for illustration purposes Detail B Again, the drawing above depicts the layout for one panel at ground level. As with previous substrates, J-molding is shown at ground level. Either J-molding or Drip Edge moldings can be used here. Hat channels are used for installing panels over surfaces such as brick or masonry that, while structural, cannot directly accept the Tight-Fit Molding System. Hat channels can also be used to create additional depth behind the panels if required. Hat channels should be 3 inches wide across the face and a minimum of 1/2" in depth. The main drawing (upper left) depicts the layout for one panel at ground level. J-molding is shown: either J- or Drip Edge moldings can be used here. The detail drawings (Detail A & B) show close-up details from the main drawing. The instructions on page 5 explain this process and the purpose of each element shown in the above drawings. Follow Installation Instructions as shown on page 5. 4

7 MOUNTING THE PANELS Installing the Moldings Set up a clean worktable Using available materials (2 x 4s, sound plywood, OSB, etc.) construct a worktable at least 48" x 96" and at a comfortable working height. 1/8" minimum Step 1: Attach bottom molding to substrate Keeping the molding 1/4" above ground level, use galvanized drywall screws to attach the molding to the substrate; one screw per hat channel or furring strip on verticals; 16" to 24" OC on horizontals. Ice and water shield is recommended to prevent water from getting to the wall at ground level. This is shown in Detail B on page 2 and 3. See manufacturer s instructions for the proper use of ice and water shield. Step 2: Cut away intersecting molding The dotted line shown in the drawing indicates an area where two moldings will intersect. This area must be cut away so that after installation, moldings will sit on the same plane. An area approximately 4 square inches should be adequate for the entire intersection. Use tin snips to cut the area to be removed. Using sheet metal pliers (duck-bill vice grips), bend the material up and down until the piece snaps off. Piece cut away from the corner Drip edge Step 3: Attach vertical molding To prevent water intrusion where two moldings intersect, spread an eighth inch thickness of silicone on the wall and press the moldings into it. Examples of this are shown on page 4 in the main drawing, as well as in Details A & B. Moldings should be screwed down as close to intersections as possible to ensure that everything sits flat. Vertical molding Panel Step 4: Cut the first panel to size Measure and cut the first panel to size. Dry fit the panel to make sure it fits properly. 5

8 MOUNTING THE PANELS Tech Support: Masking Step 5: Remove panel masking Remove the masking from the back of the panel. Pull the masking back about 6" from all edges in the front of the panel but do NOT remove it completely. Step 6: Apply Gaska Foam Tape Apply Gaska Foam Tape to the substrate as instructed on pages 2 through 4. This will help to prevent panel suck in when the adhesive cures. Gaska foam tape Panel adhesive Sheathing Panel edge Step 7: Apply caulk to moldings Using a silicone caulk recommended by Laminators, run enough sealant into the moldings so that it will seal the edges when the panel is inserted. Use a 1/4" diameter (approx.) bead and be sure that there are no skips in the sealant. Fill the corner molding with caulk. Caulk molding for one panel at a time. Step 8: Apply panel adhesive Apply beads of Laminators approved panel adhesive (See list, page 10) to the furring strips, sheathing, steel squares or hat channels as appropriate, using generous 3" wide dabs staggered every 16" on center. The adhesive should go between the strips of Gaska tape. Step 9: Install first panel Slide the panel sideways into the pre-caulked outside corner or edge molding. If necessary, use wide blade putty knives to fit the panel into the vertical molding. Measure to be sure the panel is completely inserted into the molding. If necessary, nudge the panel into place using a 2 x 6 and tapping it with a hammer to prevent damage to the panel edge. 1/8" space created by shims Caulk Step 10: Install top molding If molding is required at the top of the first row of panels, insert two rubber shims into the molding for every four feet of molding. Fill the molding with caulk to seal the panels and attach it along the top edge of the panel. This provides space for panel expansion caused by weather changes or direct sunlight. 6

9 MOUNTING THE PANELS Step 11: Install next molding Take the next vertical molding piece, caulk it with silicone sealant, and fasten the back leg of the H or reveal molding using recommended fasteners (see page 5, step 3). Non-marking scraper Step 12: Continue panel installation Remove any squeeze out with a non-marking plastic scraper. Mineral spirits and a clean rag should be used to remove any residue that the scraper missed. C Place panel Continue installing panels until the job is completed. Cover the top of the panels with polyethylene to keep water out if a parapet or flashing detail is to be installed at a later date. Remove masking from the front of the panels. Failure to remove masking within 2 weeks of installation may result in surface imperfections. Note: Remember to remove any shims from under the bottom molding when installation is completed. Installation summary: B Attach outside corner A Attach drip edge D Place & attach H molding A. Attach drip edge moldings fastened every 12" with recommended fasteners. B. Attach outside corner molding making sure to notch the back of the corner molding to allow the drip-edge to lie flush against the wall. C. Install panel. Be sure masking has been removed from back of the panel. D. Place and attach H molding. Fastener Wall Caulk Silicone backer rod Wall 1-Piece H molding End of run detail For One-Piece, Tight-Fit moldings, fill an H molding with caulk. Attach it to the final edge, then install the final panel to complete the run. 7

10 INSTALLING FLEX PANELS Tech Support: Installation of Flex Panels over Plywood Sheathing 3" Stud wall 16"on center Two layers of 3/8" or one layer of 1/2" plywood sheathing Panel adhesive Foam tape or drip edge Do not use Omega-Flex panels for flat wall applications. Omega-Flex panels should only be used on a 17' radius or less. Omega-Lite panels should only be used on an 18' radius or larger. If your radius is less than 8', call Technical Support for special instructions. Use a recommended silicone sealant as a panel adhesive. Failure to do so will cause panel defects. If combining Omega-Lite and Omega-Flex panels on the same job, do not install the flex panels beyond the radius termination. Do not store panels in direct sunlight or in extreme cold temperatures. Store flat on a pallet. Omega-Flex panels should only be installed using molding supplied by Laminators Incorporated specifically for such use. Contact Laminators Incorporated for ordering and detailed installation Omega-Flex TM panels can only be installed with the One-Piece, Tight-Fit Molding System and should only be installed over plywood sheeting with or without building wrap. Additionally, they should only be used on a radius that measures 17 feet down to a minimum of 8 feet. In any case, you are advised to call Laminators to discuss your application, as every installation is different and every possibility cannot be covered in this guide. Installation is very similar to flat-panel installation except that glue spacing is reduced to 16 inches on center and no more than 3 inches from a molding. When installing over building wrap, simply use steel squares as described on page 3 of this Installation Guide. Silicone Sealant Omega-Flex Panel 2-Layers 3/8" Plywood Sheathing Reveal H Molding 8

11 INSTALLING FLEX PANELS Installation of Flex Panels over Plywood Sheathing Step 1: Install s will need to be relieved with a saw cut in order for them to curve along a tight radius. These saw cuts should be made on the back leg of the J and go no lower than the front leg of the J. The space between the cuts will be determined by the radius you are working with. Use a scrap piece for testing. J-moldings will need to be screwed down more frequently on a curve in order to conform smoothly to the radius. Tape Step 2: Saw Cut to Allow for Curve Once you have determined the frequency of your cuts, the process can be sped up by taping J-moldings to a length of wood and running it repeatedly over a table saw. Be sure that the blade is set to the correct height so that you do not damage the front leg of the J. To avoid injury, be sure to follow all applicable safety procedures when making these cuts. The saw operator should be fully trained in the use of his equipment and all guards, eye protection, and other prudent safety equipment should be used. for fascia for soffit Step 3: Fascia Soffit Transition Fascia/Soffit transitions will need to be formed with two s as shown here, as an outside corner will not conform to a curve. Notice that the fascia molding sits lower than the soffit molding to create a drip edge. This detail can be very difficult on a tight radius. Please call your factory rep before attempting. Silicone Sealant 9

12 TOOLS AND ACCESSORIES Tech Support: Hand Tools Aviation or tin snips for cutting extrusions or flashing metal Carpenter s circular saw (7-1/4" blade) with 40 teeth (min.) for cutting panels to size triple chip grind (for nonferrous metal or plastic) Deburring tool (or screwdriver) to remove burrs from cut panel edges Disc grinder or sander (4-5") to adjust sheathing, panel, and extruded moldings for a good fit. Fine, single-cut flat file for trueing metal edges of panels or moldings Hammer (with crutch tip) or a rubber mallet to adjust panels Jigsaw with sharp, 24-tooth, sheet metal cutting blade to make panel cuts Miter saw for cutting extruded aluminum moldings Sheet metal pliers (duck-bill vice grips) to trim moldings Screw gun to drive self-drilling, self-tapping screws for mounting panels and extruded moldings with #2 Phillips-head tips and 1/8" quick-change drill bits Screws (galvanized) #6 x 1-1/4" bugle-head drywall or #12 phillips-head pan-head screws for securing clips into sheathing #8 or #10 x 3/4" or longer, TEKS/3 screws to secure clips into steel studs #6 x 1/2" and #6 x 1" Phillips pan-head, TEKS/2 screws for mounting moldings to plywood or metal Caulking Tools Caulking gun (11oz. or 1-quart tube) for panel adhesive Caulking rope or backer rod; use 1/4" or 3/8" to suit job Clean rags (24), approximately 2' x 2' in size for caulk wiping and clean-up Masking tape (Scotch brand Safe Release Masking tape TM is recommended) 1" wide Mineral spirits to clean caulk from panels if necessary Plastic putty knife (1-1/2") for use with 1" masking tape to keep caulk off the panel faces, making the job easy to clean up Utility knife to cut and trim tape Contractor s Supplies Furring strips or studs as needed Gloves (clean) to handle panels Insulation, 3/4" foam to go between furring strips Peel-and-stick flex flashing ( Snow and Rain flashing ) for flashing building transitions and bottom edges of sheathing Safety goggles Rubber shims, for spacing if molding is used Wood shims, for spacing between ground and bottom molding Tape measure Panel Adhesives (Tested and Approved) Surebond ( ) SB-400; PS-800 Macco Adhesives ( ) LN-901 Liquid Nails Heavy-Duty for Construction and Remodeling Franklin International ( ) Titebond construction adhesive Silicone Sealants (Tested and Approved) GE Silicone ( ) Silpruf Silglaze II Dow Corning ( ) (20 year warranty available) 791 Silicone sealant 795 Silicone sealant 995 Silicone sealant Tremco ( ) Spectrem 1 Gaska Foam Tape Gaska Tape, Inc. ( ) V 710 3/16" x 1/4" x 2" Note: Trademarks are registered by the companies noted How Much Will I Need? For every 100 square feet of Omega-Lite panels you will need: 3 tubes silicone sealant 2 tubes panel adhesive 1 roll Gaska Foam Tape 10

13 TOOLS AND ACCESSORIES Available Direct from Laminators Inc. Call OMEGA77 to order. 1-Piece, Tight-Fit Moldings: H molding Part #4505 Reveal molding Part # Piece, Tight-Fit H Molding J molding Part #4515 Z used with J for fascia soffit Part # Piece, Tight-Fit Reveal Molding Inside corner (drip cap) Part #4525 Adjustable (bendable) outside corner Part # Piece, Snap-Fit Moldings: Faceplates are shown in grey and Receptors are shown in black. J molding Faceplate part #4315, Receptor part # Piece, Snap-Fit H Molding H molding Faceplate part #4305, Receptor part #43000 Reveal molding Faceplate part #4395, Receptor part #43900 Outside corner Faceplate part #4335, Receptor part # Piece, Snap-Fit Reveal Molding Inside corner (drip cap) Faceplate part #4325, Receptor part #

14 TOOLS AND ACCESSORIES Tech Support: Essential Supplies Available Direct from Laminators Inc. Fabrication Supplies: Clip & Caulk metal clips (box of 100) Color-matched sheet metal for flashing Color-matched, soffit vent, 3/4" diameter Color-matched caulk Dow Corning caulk 995 Silicone sealant Tremco Spectrum 1 silicone sealant Gaska foam tape V 710 3/16" x 2" Panel adhesive LN-901 Liquid Nails for heavy-duty construction and remodeling Router bit To V-groove panels for 90 bends. This bit is required for Rout and Return applications Repair Supplies: Touch up paint For spot repairs customized for your requirements. Dent repair kit Customized for your requirements with all the tools to fix the panel. Caulk repair kit Everything you need to repair failed joints including tools and instructions on how to maintain or repair caulk joints. Tips and tricks kit Everything you need for professional results with over 25 hard-to-find, timesaving tools for moldings, Rout & Return or Clip & Caulk installations. Laminators recommendations for sealants are developed from our field tests and compiled from years of feedback from our customers. Recommendations are based on product availability, durability and ease of application. We suggest that the sealants build up enough strength in an overnight cure so that bubbles do not form. Carefully review the caulk manufacturer s literature for skin formation, tack-free time and cure times before using. Remember, your environmental condition is the biggest factor in deciding which sealant is appropriate for your project. Caulk only one joint at a time so that the caulk does not skin over before it can be tooled. Only caulk 4' to 6' at a time for a smooth finish. It is important to only use sealants from our recommended list and to always test your sealant in the environmental conditions you are currently working in to find the one that works best. Consult with us if your caulk is not performing as expected. Liquid Nails Heavy-Duty for Construction & Remodeling Apply a generous amount of Liquid Nails to the sheathing to prevent panel adhesive from drawing the panel toward the building as it dries, Gaska foam tape should be placed out in the field of the panel where it will shim the adhesive to the proper thickness away from the furring or sheathing. There are several types of Liquid Nails. Each Liquid Nails adhesive is specially formulated to bond to various substrates and common building materials with different construction requirements. LN-901 Heavy-Duty for Construction & Remodeling is the only exterior version that will stick to wet and/or frozen lumber as well as metal panels. Liquid Nails is a registered trademark of Macco Adhesives 12

15 CODE OF QUALITY Can Anyone Install Omega-Lite Panels? Our installers work in several areas of construction trade specialities: Wall cladding Glass and glazing Sheet metal Roofing contractors Carpentry Metal fabricators What is a Factory Authorized Installer? Factory authorized installers have signed the Laminators Code of Quality. What is the Laminators Code of Quality? The Code of Quality represents an installers commitment to: Ensure that ALL tradesmen on a given project understand and strictly adhere to the contents of this guide. Maintain regular communication with the general contractor and architect to ensure that all pre-existing conditions as well as the finished job are consistent with the approved drawings. Have all shop drawings approved and signed by the architect and general contractor prior to beginning installation. Any mid-job plan modification MUST be approved and signed by the architect and the general contractor. Guarantee all workmanship for a period of not less than one year. Visit our web site for standard CAD details. Download the architectural details you need. Call tech support if you can t find what you re looking for, or for installation assistance. Support Materials Available from Laminators to help with your installation requirements: Call OMEGA77 or visit Laminators warranty is limited to the panel construction only and does not apply to panel fabrication, storage or installation Laminators Incorporated. Omega-Lite Aluminum Faced Building Panels Installation Guide.

16 WARNING! FAILURE TO FOLLOW THESE GUIDELINES WILL VOID YOUR WARRANTY! For technical and installation support, call OMEGA77 or visit Laminators Incorporated. All rights reserved Penn Street, Hatfield, PA A120 (11/07) Omega-Lite Aluminum Building Panels Installation Guide.