aramax freespan installation guide

ARAMAX® Installation Guide

2 /// ARAMAX® Installation Guide ARAMAX® Installation Guide /// 3

INTRODUCTION

With its unique profile shape and long spanning structural capabilities, ARAMAX® provides unparalleled design opportunities. When coupled with high-tensile steel supplied by BlueScope or fully hardened Marine Grade Aluminium, ARAMAX® serves not only as a visually stunning solution but also as an excellent structural system offering long, clean, joint-free spans and significant reductions in conventional structural framing. It offers the ability to eliminate the cost and complexity of a building’s secondary structure, as well as low roof pitches, and in turn providing savings in overall building costs, material costs, fabrication and installation.

The system functionality is further enhanced by the design flexibility of the ARAMAX® profile shape to allow for varying cover widths anywhere in between 700mm to 900mm.

NOTE: This installation process / procedure provides an overview of some the main steps involved to install an ARAMAX® roof.

Each roof is different and careful consideration should be given to the project specific work method before commencing work on site. Fielders personnel are available to assist where required in this process.

This document does not replace a SWMS or risk assessment for the process. It is intended as a guide only to assist in the installation of this specialised product.

Profile Data (700mm – 900mm Cover)

ProfileThickness

(mm)Cover

Width (mm)Depth (mm )

Weight (Kg/m2)*

Weight (Kg/ Lm)*

700A100 1.00

700 357

13.786 9.650

700A120 1.20 16.477 11.534

700A120al 1.20 5.816 4.071

800A100 1.00

800 314

12.063 9.650

800A120 1.20 14.418 11.534

800A120al 1.20 5.089 4.071

900A100 1.00

900 247

10.722 9.650

900A120 1.20 12.816 11.534

900A120al 1.20 4.523 4.071

* Based on double sided COLORBOND® paint system. Other gauges available, subject to inquiry and MOQ.

800mm

900mm

MATERIAL SPECIFICATION

247mm

314mm

357mm

700mm


1. Prepare for job

Coil is ordered for the job. Note, most ARAMAX® coil has at least an 8 week lead time for delivery.

1.a At least 2 weeks prior to arrival at a site to roll ARAMAX® a site inspection will be performed by Fielders personnel. This will include but not be limited to:

• Entry / exit to site with trucks

• Location for machine and space requirements

• Safety of operators whilst onsite, toilets, induction, etc.

• Discussions about crane location and requirements

• Coil loading facilities and storage location

Documentation is then collated and prepared as required for the job. This could include a SWMS statement, maintenance records, insurance details, etc.

Transport is arranged for the machine, accessories and coil to site. Specific times for their arrival will be communicated to the installer prior to arrival.

1.b Fielders operators are booked to be on site, these may need to fly from interstate to perform this job. Travel and accommodation for the operators is arranged.

A project manager will typically accompany the machine and operators for the start of the job.

2. Set up machine and prepare for rolling

Upon arrival at site the Fielders operators will set up the ARAMAX® machine. This process requires a crane to be supplied by the installer to unload and install the accessories for the machine.

The ARAMAX® rollformer itself arrives on a semi trailer and has hydraulic legs which lift the machine clear of the truck trailer which is then driven out from under the machine. It then lowers itself onto the ground into position to run.

From arrival on site to set up ready to run typically takes 3-4 hours.

Coil will arrive on a separate truck from the supplier and be unloaded on site by the installer supplied crane.

3. Load Coil

The installer supplied crane is used to place the uncoiler mandrel into the coil and it is lifted onto the uncoiler frame.

The operators will then cut the corners from the start of the sheet and feed this into the mill.

The material is fed all the way through the machine and about 2-3m is cut from the leading edge. This is the outer wrap of the coil which typically has damage and is discarded.

4. Program job, run first sheet, QA checks

The installer is required to supply the sheet details including punching requirements to the operators. This is programmed into the machine control system ready for running.

Once the first sheet has been run QA checks are performed on the sheet checking components such as:

• Length of sheet

• Position of holes

• Corrugation depth and spacing

5. Roll sheet

Material handling stands are placed into position in front of the roll former where each rolled sheet exits the machine. The stands are placed approximately 10m apart.

When the sheet is being produced it is fed over the stands by the installer’s personnel.

Only Fielders trained operators are to operate the ARAMAX® machine.

When the end of the coil is reached (typically a coil has between 400-500m on it), the tail, which isn’t long enough for another sheet is cut into 3-4m pieces as scrap. This scrap is the responsibility of the installer to dispose of.

6. Pack up machine and leave site

Once the job has been completed the operators will pack up the machine utilising the installer supplied crane. The accessories and machine are loaded back onto a truck to head to the next job.

INSTALLATION PROCESS : SECTION 1 : RESPONSIBILITY OF FIELDERS PERSONNEL INSTALLATION PROCESS : SECTION 1 : RESPONSIBILITY OF FIELDERS PERSONNEL


3. Lift sheet onto roof – overslung roof

Soft slings are wrapped under the sheet and connected to the lifting equipment ready for lifting.

Fielders recommend for:

• Sheets less than 25m long, 2 slings are used

• Sheets 25m – 40m long, 3 slings are used

• Sheets greater than 40m, a spreader bar is used with slings at least every 6m

Slings are wrapped around the ARAMAX® sheet in a choke arrangement unless using a spreader bar where a basket lift is used.

To stop outer slings sliding towards the centre of the ARAMAX® sheet a hook over the end of the sheet and a rope back to the sling is used. Tag lines are added to assist in manoeuvring the sheet into position

The sheet is lifted onto the roof and lowered into the cleats. A small podgy bar is used to align the sheet punched holes with the cleat holes. Bolts are put through the holes and tightened only by hand to allow some movement whilst stitching occurs.

To complete the alignment and bolt installation 1 installer is required on the roof at each cleat point (wearing a harness) and one installer under the roof on an EWP.

Safety precautions

• Any personnel working from height should wear a harness connected to an appropriately installed safety line.

• ARAMAX® sheet edges are sharp, wear gloves when handling the sheet

• All lifting gear should be inspected prior to use by a competent person

• Lifting operations are to be performed by qualified operators.

1. Provide sheet details to Fielders operators

The installer is required to supply and sign off on the sheet length and punching details for the job to be run.

It is recommended to use a steel tape and clamp it on the first cleat at the point on the tape showing the overhang. The tape is then stretched along the other cleats and measurements taken at each hole position.

Fielders supply a form for the installer to record and sign off on the measurements for the sheets.

During production, measurements can be changed slightly to alter the hole positions. This could be to accommodate for steelwork that isn’t aligned accurately. The ARAMAX® operators will typically only roll 1 sheet in advance of the sheet being installed so that these changes can be made.

2. Assist to run machine, mark and prepare sheet

When the machine is running a minimum of 2 people (supplied by the installer) are required to feed the sheet over the run out trolleys.

A third person marks the location of roofing screws as the sheet exits the machine onto the stands using the supplied marking ruler and a black permanent marking pen. These marks are used during installation to line up the stitching tek screws along the sheet.

Some installers drill a 4mm hole at every mark to assist in locating and driving in the stitching tek screws when the sheet is installed on the roof.

Brackets for underslung roof could be attached to the sheet at this time. This can be done whilst the sheet is running out of the machine although this will require additional personnel on the ground.

Once the sheet is lifted (see next sections) the next sheet will start to be rolled.

Safety precautions


• Ensure there are enough personnel available on the ground to assist in running the sheets

BEFORE FIELDERS ROLLFORMER ARRIVES

Before the Fielders rollformer arrives on site it is the responsibility of the installer to ensure there is adequate space for the set up and amenities are provided for Fielders personnel.

INSTALLATION PROCESS : SECTION 2 : RESPONSIBILITY OF ARAMAX® INSTALLER INSTALLATION PROCESS : SECTION 2 : RESPONSIBILITY OF ARAMAX® INSTALLER

SHEETLENGTH

1650

0-17

000

TIL

T U

P D

OO

RS

TIL

T U

P D

OO

RS

A DIMENSIONMin:2600 Ideal:2900

B DIMENSIONMin:7600 Ideal:8200

AR

AM

AX

MO

BIL

E M

ILL

1220

0

2400

B

AA


6. Clamp and stitching the sheets together

Working from one end of the sheet to the other, the installer pulls the overlap of one sheet over the top of the underlap of the sheet beside it and places a clamp (C-clamp locking pliers) on the two. Clamps are placed about 1m apart. The installer continues along the sheet placing clamps. A second person progresses along behind the first installing screws every 500mm where the marks are. The clamps are then removed and passed to the clamping person. A minimum of 6 clamps is typically required for a roof.

Two teams installing the stitching screws can work at the same time, although they need to work from the middle of the sheet out. Stitching the sheet together from each end towards the middle will be more difficult due to the stresses in the sheet.

Some assistance may be required from below the roof to push sheets up and into position so the overlap sits on top of the underlap. This is due to the length of sheets and bending under the weight of the sheet.

NOTE: It is important that all metal filings (swarf) are removed from the roof at the end of each day with a blower to prevent rust marks.

Safety precautions

• Personnel should not stand in a sheet that has an unrestrained edge, the sheet can be very unstable. Stand a sheet back from the unrestrained one or next to the cleats

7. Tighten bolts

Once all stitching has been completed the bolts installed through the sheet and cleat may be tightened. This is performed with a rattle gun from above or below. The other side of the bolt will need to be restrained. The bolts should be tightened to a snug fit as per AS 1400-1998 Section 15.2.5.2.

4. Lift sheets up to roof – underslung roof

With the brackets in place for attaching to the roof, the sheet is lifted by winches on each beam up to the underside of the roof.

Specifics for this process are worked out on a project by project basis. Depending on roof design, winch design and length of sheet. Fielders can assist with information on how to perform this installation method.

Safety precautions

• Any personnel working from height should be wearing a harness connected to an appropriately installed safety line.


• All lifting gear should be inspected prior to use by a competent person

• Lifting operations are to be performed by qualified operators.

5. Producing sheets for installation later

If storage of the ARAMAX® sheets is required for installation later Fielders can supply designs for timber stacking frames. These allow the sheets to be stacked and restrained until they are required to be installed. A method of stacking the sheets is required to be built by the installer

A method of lifting the sheet from the run out trolleys into the storage racks is required whilst running. This is typically a crane with lifting equipment as specified in item 3.


NOTE: All dimensions are in mm, unless otherwise stated. This is for standard steel Aramax bolting system, Aluminium details and special arrangements consult with Fielders.


8. Attach edge restraint

Once all roof sheets have been installed, angle type edge restraints (as per drawing AFS12009) are installed at 500mm centres to support the edge of the outer sheets.

Clamp the 20mm SHS tube to the underside of the outer edge of the last sheet as per the drawing.

Fix one end of the edge restraint to the inner sheet lap/crest, removing and reinstalling the existing stitching screw as required. Then fix the other end of the angle through the outer edge of the sheet and into the tube under.

It is best to work in pairs (one fixing and one holding) to ensure that the outer sheet edge is installed straight and the edge restraints are installed square to the sheet edge.


9. Personnel requirements

The installer is required to supply at least 2 people to work with the Fielders ARAMAX® team on the ground. One person will help to guide the sheets over the trolleys as it is produced, the second will mark the 500mm intervals on the sheet for the stitching screw locations.

It is recommended for efficiency that at each cleat location there is a person on the roof and a person below the roof in an EWP during installation. Additionally there should be 2 installers on the roof to assist with the stitching of sheets.

For example to install a roof with 50m ARAMAX® sheets with 4 cleat locations the installation team should be at least 12 strong.

An additional floating person (possibly a supervisor) is beneficial to prepare screws and bolts and deliver to the installers and assist the crane crew in slinging the sheets.

Installer Responsibility Summary

PRIOR TO ONSITE COMMENCEMENT REQUIRED

Confirm order requirements for Coil procurement. Minimum of 8 weeks prior to commencement onsite.

Provide crane for:

• Rollformer set up

• Coil movement

Crane ready:

• At agreed arrival time for rollformer

• At agreed arrival time for coil unloading

ONSITE DURING ROLLFORMING REQUIRED

Provide minimum additional personnel to work on the ground with the Fielders personnel to assist unloading ARAMAX® Sheet from rollformer.

During rollforming number of personnel as per:

Sheet length < 40m ............................2

Sheet length >40m <60m ...................3

Sheet length >60m <90m ...................4

Sheet length >90m ..............................5

Provide crane and accessories for loading ARAMAX® sheets to roof.

As required for installation process

Ensure adequate space is available for the machine. Min of 16.5m x 7.650m area for rollformer plus 2m x sheet length for sheeting run out

Build sheet stacking frames if sheets are to be stored onsite

Timber Stacking frames as per Fielders design

Source bolts, stitching screws, edge restraints and any other accessories required to be installed. Note: HDPE washers can have a long lead time (4 weeks)

Accessories size and grade as per Fielders Specification

NOTE: The above diagram is a sample only, actualy sizes spacings and fixings to be verified by a Structural Engineer. All dimensions are in mm, unless otherwise stated.

fielders.com.au | 1800 182 255

PRODUCT DESCRIPTIONS All descriptions, specifications, illustrations, drawings, data, dimensions and weights contained in this publication, all technical literature and websites containing information from Fielders are approximations only. They are intended by Fielders to be a general description for information and identification purposes and do not create a sale by description. Fielders reserves the right at any time to: a) supply Goods with such minor modifications from its drawings and specifications as it sees fit; and b) alter specifications shown in its literature to reflect changes made after the date of such publication.

DISCLAIMER, WARRANTIES AND LIMITATION OF LIABILITY This publication is intended to be an aid for all trades and professionals involved with specifying and installing Fielders products and not to be a substitute for professional judgement. Terms and conditions of sale available at local Fielders sales offices or via the Fielders websites. Except to the extent to which liability may not lawfully be excluded or limited, BlueScope Steel Limited will not be under or incur any liability to you for any direct or indirect loss or damage (including, without limitation, consequential loss or damage such as loss of profit or anticipated profit, loss of use, damage to goodwill and loss due to delay) however caused (including, without limitation, breach of contract, negligence and/or breach of statute), which you may suffer or incur in connection with this publication.

COLORBOND® steel, ZINCALUME® steel, BlueScope, the BlueScope brand mark, ® product, product brand and colour names are registered trademarks and ™ product, product brand and colour names are trademarks of BlueScope Steel Limited.

The Fielders® range of products is exclusively made by or for BlueScope Steel Limited trading as Fielders.

© BlueScope Steel Limited December 2021 ABN 16 000 011 058. All rights reserved. FLD0077

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