Series 10 installation guide v 01

v.01 ©Firestone Metal Products Company, LLC, 2010

p. 800-426-7737

DESIGN & INSTALLATION GUIDE SERIES 10 HONEYCOMB WALL PANEL SYSTEM

This document is to be used as a guide in the installation of Firestone Metal Products wall panel

systems. The contractor /erector should refer to Firestone Metal Products installation shop drawings for all details and notes specific to the project.

________________________________________________________________

FOR THE MOST CURRENT TECHNICAL INFORMATION, VISIT OUR WEB SITE:

www.UNACLAD.com

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Series 10 – HONEYCOMB PANEL SYSTEM

1-800-426-7737 WWW.UNACLAD.COM

TABLE OF CONTENTS

1.1 General ...................................................................................................... 3

1.2 Job Site Considerations ................................................................................. 3

1.3 Personal Safety ........................................................................................... 4

1.4 Quality Assurance ........................................................................................ 5

1.5 Field Dimensions ....................................................................................... 6-9

1.6 Wall Substrate Preparation .......................................................................... 10

1.7 Project Start Up ......................................................................................... 11

1.8 Material Handling ................................................................................... 11-13

1.9 Tools ........................................................................................................ 14

1.10 Items Included ......................................................................................... 15

1.11 Items Not Included .................................................................................... 15

1.12 System Installation Guidelines .................................................................... 15

1.13 Installation Procedure Guide ................................................................... 16-18

1.14 Joint Sealing ............................................................................................. 19

1.15 Touch-up Paint ......................................................................................... 19

1.16 Panel Cleaning .......................................................................................... 20

1.17 System Details.......................................................................................... 20

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1.1 GENERAL INFORMATION

This section of Firestone’s Design & Installation Manual provides information and instructions for all the steps required to supply a quality finished product. These steps will include everything from proper field dimensions through the finished product installation. Reference to the Shop Drawings, Technical Information Sheets (T.I.S.), and other sections of the Firestone’s Technical Specifications may be necessary to ensure that the finished wall panel system is installed in compliance with Firestone Metal Products requirements. The main purpose of this manual is to create a better understanding of how to properly field dimension, design and install the Firestone Metal Products wall panel systems. There are literally hundreds, if not thousands, of different details and not all of them can be addressed in this technical manual. However, with a basic understanding of the panel systems and shop drawings, you will be able to accommodate almost any situation. This manual does not attempt to make judgments of whether or not an existing wall product should be left in place or torn off. Nor does this manual make structural judgments for weight considerations. Use this manual as a guide in understanding the Firestone Series 10 Metal Products wall panel system and its application. For the most current information about Firestone Metal Products, Panel Systems, Details and Technical Information Sheets, please visit our web site: WWW.UNACLAD.COM

1.2 JOB SITE CONSIDERATIONS (CAUTIONS AND WARNINGS)

A. Keep all adhesives, sealants and cleaning materials away from ALL ignition sources (i.e. flame, spark, fire, etc.). Do not smoke while using these materials.

B. Consult Container Labels, Material Safety Data Sheets and Technical Information Sheets for specific safety instructions for all products used on the project.

C. Care must be used when installing fasteners to avoid possible conduits and other piping under the wall sheathing.

D. Do not allow other non-compatible metals to interact with the metal in the Metal Wall Panel System.

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1.3 PERSONAL SAFETY

Safety is a top priority for Firestone. Walking around any job site can be dangerous. To ensure safety always use an OSHA approved hardhat and a method of fall protection that meets regulations of the local regulatory agency responsible for your building. Serious injury or death can result if the proper safety equipment is not provided and utilized. Monetary fines can result from any failure to comply with fall or head protection. It is your responsibility as an owner or employer to make sure that your personnel are properly trained regarding OSHA, state and local safety procedures and that safety equipment is in proper working order. The installer is solely responsible for following local building, electrical and plumbing codes. The contractor shall bear full responsibility for personal safety. Remember during wall panel installations to take the following precautions:

A. Use hardhat, fall protection and additional safety equipment. B. Never walk on a panel. C. Never walk or stand on any skylight, fiberglass type panel or any other component

not specifically designed to support man weight. D. Rope off your open work area or assign a person to guard these locations during

the installation of the panels. E. Never install wall panels over a wet surface. F. Wear appropriate gloves when handling any metal that could have sharp edges G. Proper eye protection is recommended H. Handling of wall panels in windy conditions is unsafe and should be avoided.

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1.4 QUALITY ASSURANCE

Contractor must supply effective quality control over all stages of design, fabrication and erection activities including sealant adhesions at panels to all building substrates. Contractor shall bear full responsibility for quality control. Product and work may be required to meet the following standards and references:

A. LEED (Leadership in Energy & Environment Design) B. AAMA (American Architectural Manufacturers Association) C. USBC (U.S. Green Building Council) D. ASTM (American Society for testing and Materials) E. ICBO (International Conference of Building Officials) F. BOCA (Building Officials and Code Administrators International, Inc.) G. SBCCI (Southern Building Code Congress International) H. ASHRAE (The American Society of Heating, Refrigerating and Air-Conditioning

Engineers) I. IECC (International Energy Consulting Corporation) J. ALUMINUM ASSOCIATION K. BCCO (Miami-Dade County’s Building Code Compliance Office ) L. IBC (International Building Code) M. Federal, State and local codes not listed.

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1.5 FIELD DIMENSIONS

Take accurate field measurements to verify wall dimensions prior to fabrication. Field dimensions should be taken as needed per architect’s directive and/or Firestone Metal Products shop drawings. The accuracy of dimensions taken in the field will affect the size of the panels provided for the building as well as possibly affecting the lead-time for product. Dimensions should accurately indicate where you are measuring, building angles, revisions to details, etc. Refer to the following examples on pages 7, 8 and 9 for basic information on how to take field dimensions.

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A. OVERALL DIMENSIONS: Take overall horizontal field dimensions of structure at job site. Label the dimensions you are taking and where taken to (i.e. plywood, dens glass, steel stud, and concrete opening). If building is out of square, please take diagonal dimensions. We will take into account how far the panel is off of structure and add this into our Submittal Drawings. Make sure Plan and Elevation Over-all dimensions coordinate with each other. After entering dimensions onto drawings, make sure they add up to each other and coordinate with overall dimensions. Make sure all numbers are neat and legible.

Please contact the project manager prior to field measure of a radius or segmented wall, for further direction.

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B. GLAZE AND DOOR FRAME DIMENSIONS: Take window, door frame and overall vertical structural field dimensions at the job site

(only if panel applies). Label the dimensions you are taking and where taken to (i.e. plywood, dens glass, steel stud, finished floor, top of wood blocking at coping, window/door frame, window/door rough opening, window center of mullion to center of mullion, window day light opening, etc.).

If windows/door frames are not installed yet, provide window/door rough opening dimensions.

If panel joints are aligning with window mullions please provide center to center dimension of mullions. Provide window frame mullion width sizes (i.e. 2", 2 1/4", or 2 1/2"). Check that centerline-to-centerline dimensions add up to overall window frame dimension. After entering dimensions onto drawings, make sure they add up to each other and coordinate with overall dimensions. Make sure all numbers are neat and legible. If building and/or windows are out of square, please take diagonal dimensions. We will take into account how far the panel is off of structure and add this into our submittal drawings. Make sure soffit and elevation overall dimensions coordinate with each other.

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C. COLUMN COVER DIMENSIONS:

Take column cover field dimensions to structure at job site. Rough opening dimensions work best for column covers (i.e. from finished floor to soffit or ceiling). Label the dimensions you are taking and where taken to (take in account for floor material not installed). We will adjust column height by adding joints top and bottom. If there are intermediate horizontal joints in column covers coordinate & align joints as needed with horizontal window mullions, stone joints, brick joints, etc. Provide column diameters required. After entering dimensions onto drawings, make sure they add up to each other and coordinate with overall dimensions. Make sure all numbers are neat and legible.

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1.6 WALL SUBSTRATE PREPARATION

A. Preparatory Requirements 1. The substrate must be no more than ¼” in 10’ out of plane in any direction. 2. The building must be squared, acceptable to standard practices. 3. Verify that any required subgirt framing members are installed as detailed and that

they are straight and shimmed plumb. B. Correct Substrate Defects

1. Defects that need to be corrected before work can commence should be brought to the attention of the General Contractor or owner in writing and addressed by them.

2. Complete removal of any and all existing wall panel system components is required.

3. Do not attach panels to improperly framed building components. C. Remove Moisture

Water, snow, frost and/or ice, present in more than trace amounts must be removed from the work surface(s) prior to installing Firestone Metal Products wall panels.

D. Prepare Surface Acceptable substrates to which the Firestone Metal Products wall panel system is installed must be properly prepared prior to wall panel or underlayment installation. The surface must be relatively even (no more than ¼” in 10’ out of plane in any direction), clean, dry, smooth, free of sharp edges, fins, loose or foreign materials, oil, grease and other materials that may damage the metal wall system.

E. Install Underlayment Install an acceptable wall panel system underlayment as specified by the project designer. Follow all installation directions provided by the underlayment manufacturer as needed to provide a weather resistant barrier behind the panel system. The use of a weather resistant barrier within the wall cavity is mandatory.

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1.7 PROJECT START UP These details are designed to illustrate the most common situations encountered on a project. For the occasional situation that is not covered here, please contact your regional manager for further assistance.

A. Designate an area for jobsite storage and equipment access. B. Determine scaffolding and staging requirement. C. Check grade conditions for panel base and establish elevation points. D. Check the structural steel and alignment of all supporting members. The face of all

supporting members should be flat and free of all obstructions. E. Review Firestone Metal Products shop drawings, details and individual panel drawings

for specific project conditions. F. Review Firestone Metal Products individual panel release information; number of

crates, location of material on building per release and packing list(s). 1.8 MATERIAL HANDLING

A. The installer shall inspect the condition of the panels during unloading to detect damaged materials. Any damage shall be immediately reported to the driver and noted on the Bill of Lading. All damaged materials must be confirmed to Firestone Metal Products within 24 hours of receipt of materials. Any and all concealed damage must be noted within five days of receipt of materials.

B. The installer shall unload panels with care to prevent damage. Panels of short lengths may be unloaded with a forklift if the forks are spaced a minimum of five feet apart and are adequate strength to safely support the load and with an adequate bearing surface. Longer crates and pallets should be unloaded with a lifting beam and with spreader bars between frames. Only use nylon slings. Never transport open crates (ref. page 13).

C. Panels shall be stored on level ground as close as possible to the area they are to be installed. Use bearing boards under crates. Do not stack wall panel crates during storage.

D. Protect material with a tarpaulin or polyethylene shroud. Provide an air space between bundles and ventilation between stacked panels (ref. page 13).

E. To keep panels from falling over when opening crates, support the vertical members of the perimeter frames with blocking or braces before removing the top frame.

F. The installer shall keep an inventory of all materials delivered to the site. G. Panels shall be stored, moved and carried keeping the panel face in a vertical position.

Panels longer than seven (7) feet should be carried by more that two (2) men (ref. page 13). The panels should be lifted out of the crates one at a time. Do not slide one panel on another, this can scratch the finish.

H. If the panels are coated with a strippable coating, they should not be stored where they will be exposed to direct sunlight, as this will cause the strippable coating to bake on to the face of the panels.

I. Depending on your material type, panels are supplied with one or more of the number identification types listed below (Ref. page 12 for photos):

1. Scribed numbers in the back of the panels 2. Numbers stenciled on back of panels 3. Bar coded stick-on labels

J. Packing lists included with each shipment list contents of crates (ref. page 12).

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Caution Improper unloading and handling of bundles and crates may cause bodily injury or material damage. Firestone Metal Products is not responsible for bodily injuries or material damages during unloading and storage.

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1.9 TOOLS The following are examples of some tools that will facilitate an easy and accurate installation:

The items above may be system exclusive to the Series 10 and do not represent Firestone’s entire panel system. Parts will vary per system.

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1.10 INCLUDED ITEMS Items that are included for panel installation are: A. Sized fabricated panels

1.11 NOT INCLUDED ITEMS

Unless noted otherwise, items that are not included are: A. Anchor clip shims B. Anchor clip fasteners C. Substrate weather/water barriers D. Perimeter flashings and metal trim shapes E. Joint sealants/adhesives

1.12 SYSTEM INSTALLATION GUIDELINES

The following guidelines are for installing Firestone Metal Wall Panel Systems. It is your responsibility as an owner or employer to make sure that proper training of your personnel is adequate for safety procedures and that safety equipment is in proper working order. Remember during wall panel installations to take the following precautions:

A. Review all FSMP shop drawings and details before starting installation of panels. B. Determine fastener applications, sizes and spacing prior to start of installation. Unless

pre-engineered, a licensed structural engineer should confirm all metal wall panel and accessory fastener sizes and spacing.

C. When engaging panels, use even pressure to draw panels together. Do not hammer a panel into place. Localized forces may cause damage to the panel.

D. Panels should be shimmed as required to maintain a flush exterior surface. E. When erecting panels, use spacers to temporarily maintain a gap at the joints. Spacers

may be removed after panel is firmly attached to the building. F. All burrs and chips from field cutting of panels must be removed. Panels must be cleaned

after field cutting. G. Remove any strippable masking immediately before or after installation of panel. Do not

allow panel to sit on the face of the building with the strippable masking exposed to the sunlight.

H. Install an acceptable wall panel system sealant/adhesive as specified by the project designer.

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1.13 INSTALLATION PROCEDURE GUIDE

Prior to actual panel installation inspect the substrate for any defects in the weather barrier. The weather barrier is a vital component of any building façade system. If the weather barrier is compromised in any way contact the General Contactor immediately. All flashings must be in place prior to application of panels. Flashings also are the responsibility of the General Contractor and as such the General Contractor should be contacted with any deficiencies. After inspection and approval of the weather barrier and flashings proceed to step installation step A.

Note: Firestone Series 10 is a non-sequential panel installation system. A. Position, shim and fasten the first panel to substrate with appropriate fasteners. B. Continue in any direction until all panels are installed.

(Make sure the panels are set plumb and square)

C. Although Series 10 panels are provided with a ½” mounting flange it may be necessary to use spacer blocks to maintain proper joint dimensions. Do not rely on spacer blocks solely as panel dimension may vary slightly, measure joint spacing and check to make sure the panels are plumb and square.

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D. Fastening is normally through the horizontal joints with an appropriate fastener and spacing. The top panel flange will be provided with a small hole to place a temporary holding fastener. The bottom flange of the panel will be provided with a matching notch, to facilitate easier ship lap installation of panels. Refer to project specific shop drawings for fastener size and spacing. Panels are only to be fastened on the two opposing sides through the ½” mounting flange. (Make sure the panels are plumb and square)

E. Continue applying panels until all panels are set.

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F. Clean, apply proper backer rod and seal all joints with accredited sealant. (Refer to Joint Sealing section 1.14 of this manual for proper joint cleaning methods)

G. Tool all joints with a non-marring tool. Clean off any excess sealant with a clean cloth rag.

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1.14 JOINT SEALING When sealing panel perimeter joints use the following procedures as a guideline:

A. Remove all loose dust, debris and/or foreign materials. B. Clean all surfaces that will be in contact with sealants/adhesives with the “isopropyl

alcohol two-cloth" cleaning method. (Inspect all surfaces prior to applying sealants.) C. Apply, and tool if required, an accredited joint sealant/adhesive only after a final

inspection of all surfaces to be sealed or adhered. Consult Architectural Specifications for recommended sealant type and follow all written manufacturer sealant installation guides.

1.15 TOUCH-UP PAINT

A. Air dry touch-up paint is inferior to factory baked finishes and the use of it is therefore discouraged.

B. Touch-up paint is made up of two components the first being the actual paint that has been applied to the aluminum. The second is an air-dry additive that has been made available to us by the paint manufacturer. Each paint type has its own additive that changes the paint from an oven-cured product to an air-dry. This product is to be used in small amounts and is recommended to only be used over minor scratches and blemishes. Touch-up is not to take the place of the factory-applied product as its sole purpose is to cover small scratches and it should not be applied over mill material. The touch-up paint does not have same adhesion, durability, chalking and fading characteristics as the factory applied coating.

C. If your panel system has been painted with a baked-on fluoropolymer finish it will resist color fade and chalking for an exceptionally long period of time. The touch-up paint provided by Firestone Metal Products is an air-dry acrylic enamel which will exhibit chalking and fading characteristics at a much faster rate than that of your building. Therefore, it is recommended that touch-up paint be used as sparingly as possible, as any touch-up will become faded in contrast with the original building color after a few years.

D. Regardless of the type of paint used on your original finish, please follow touch-up directions carefully for proper adhesion and final aesthetics in the coming years. This especially applies to the recommendation to use an artist's brush to apply the paint. Spray application is not recommended for touch-up paint.

E. On any large-scale or touch-up application, we strongly suggest that a material inspection is made so that the situation can be reviewed and determination made regarding the best suitable paint or repair procedure. Surface preparation, application, and finish should be properly executed for a long lasting finish. A minor mistake in any segment of repair will cause major problems over time.

F. It is preferred that minor scratches, which have not exposed the bare metal, be left untouched. Our standard primer will weather better than the touch-up paint.

G. If it is necessary to touch-up a scratch, only the scratch itself should be painted and not the entire immediate area. An artist’s brush or toothpick should be used to apply paint to the scratch.

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1.16 PANEL CLEANING Panels require cleaning on a regular basis depending on the location of the building and amount of dirt and pollution in the area. It is recommended that the panels be cleaned at the same time the windows are cleaned. A. Do not mechanically abrade any panel finish when trying to clean its surface. B. Do not use wire brushes, steel wool, sandpaper, rubbing compound, cleaning compound,

abrasives or other similar cleaning tools. C. Always test cleaning materials and procedures on a small inconspicuous area prior to use

on a large scale. D. For paint finished panels a 5% solution (one part detergent to 20 parts water) of

commonly used commercial and industrial detergent, such as Tide, will not have any deleterious effect on a painted surface.

E. Use cloth, sponges, or a soft bristle brush for application. F. Cleaning should be done on the shaded side of the building or, ideally, on a mild cloudy

day. G. Follow the cleaning immediately with an adequate rinse of clean water and drying. (Always

test cleaning materials and procedures on a small inconspicuous area prior to use on a large scale.)

H. Consult AAMA 610.1 Cleaning recommendations for detailed cleaning instructions. 1.17 SYSTEM DETAILS

Firestone has a multitude of panels systems. Be sure you refer to appropriate detail package sets for the corresponding system. These detail sets are designed to illustrate the most common situations encountered on a project. Most situations are covered in the detail sets, however occasionally there are some that may not be. If the details sets do not cover a particular situation contact the project manager for further assistance. The information in this Installation Guide is meant to guide a qualified and experienced wall panel installer in the accurate installation of Firestone metal wall panels. Firestone is not responsible for the misuse of the information in this Guide or the improper installation of wall panels.

©Firestone Metal Products Company, LLC, 2010

Documents

Series 10 installation guide v 01