Method of Statement: Roof & Wall Cladding

1. Purpose

 This method statement demonstrates how the Roof and Wall Cladding panels will be
install/erected in accordance with existing Standards.
 All safety precautions will be taken in accordance with PTI ISO certification guidelines and
standards.

2. Reference

 Drawings : Steel Erection Drawings from PEB/Hot Rolled Contractor

 Cladding Drawings : Main Contractor/Consultant
 Specification : As per contract scope of Work.

3. Equipment

 Level machines
 Man-lift
 Hand tools
 Electrical power source
 Electrical drill and bits
 Screw gun and screw gun socket drivers
 Scaffoldings
 Ladders
 Lifting machine- vacuum for wall panels (only in case of Hidden Fix panels by others)
 Cranes
 Boom loader

In order to have a proper functional panel system, the most important thing is to have an experienced
installation team. The functionality of the panel system purely depends upon the method of installation. PTI
standard roof and wall panel installation methodology is described below in detail.
 4. Procedure

4.1. Preliminary Checks: Applicable for Roof and Wall Panels

Prior to starting any erection works for wall and roof cladding, the structure should be inspected by
main contractor and a written confirmation must be received from main contractor that all building
component have been erected according to steel contractor's erection drawings and the building is
plumped and leveled.

 Ensure all permissions and consents are obtained.

 Ensure approval status of erection method statement is approved.
 Ensure all materials submittal in relation to this activity is at approved status
 Ensure all related drawings are stamped and approved.
 Ensure latest approved drawings are issued to the site team.
 Ensure work will be carried out in accordance with the program.

Checking shall be conducted by main contractor/consultant for the alignment of purlins and for purlin
spacing. This is applicable for both roof and wall purlins.

4.2. Preparation

4.2.1. Preparation - General

Lifting of roof panels on top of the roof shall be planned before starting the work and all necessary
personnel shall be made aware of the erection sequence and planning. Before lifting is started the
adjacent area shall be cleared and prepared to bring in the crane.

4.2.2. Materials Layout

After the roof panels are unloaded by suitable crane, it should be placed in and around the building
site near the place where it will be used, it should be stored on suitable timber sleepers, at designated
lay down area – free from water, inspected for damage on arrival at site. Each item to be checked
carefully against packing list to ensure that the correct parts and quantity have been received. Erection
crews and machines must have access to the portion of the building, which is undererection.
 4.2.3. Preparation of Crane & Boom Loader

The crane setting area shall be free for boom swing. The setting area shall be graded and
compacted if necessary. 20 ton to 50-ton crane will be used for shifting the panels to the roof with the
help of loading beam.
The crane will be at site until the last roof panel is installed for the full duration, for faster transfer
of panels to roof, the crane shall be shifted at different locations around the building.
The Boom loader stays active at site for the full duration of project; boom loader will be used to
shift the panels and various materials from one place to another.
Ideally 12 to 16m boom length boom loader will be used at site for the said purpose.
The boom loader and Crane will be parked inside the facility when not in use.

4.3. Installation of Roof Panels

4.3.1. Lifting the Roof Panels on Top of the Roof

 Lifting of roof panels to the rafters/purlins shall be done using an elevating platform.
 Roof panels are quality merchandise and should be handled with care.
 Two numbers crane belts to be used and rubber pads should be used to give more
protection to the roof panel edges.
 Roof panels should not be placed in the middle of the bay, always keep the panels on
top of frame or close to frame.
 Use ropes to tighten the roof panels to roof structure.

4.3.2. Panel Installations at Roof

 Clean the purlin of any obstructions which can resist the installation of panels
 Temporarily fix one run of panels to walk on, adjust the line of the panel for square
nets.
 In case of aluminum faced panels, install purlin tape to prevent direct contact of purlin
and roof panels
 Install foam enclosure flashing and gutters as per drawings.
 Start the panel installation with the eaves (or bottom) corner panel, with the projecting
side and end laps to the outside of the building. Install fasteners and apply sealant as
specified in drawings.

 Place the second panel upslope or above, so that it overlaps the first, adjusting its
position carefully before contacting the sealant. Repeat up to the ridge or eaves/gable.
 Start the second tier from the eaves (or bottom), side lapping the first panel, sealing
and fixing, as specified. Repeat the procedure for the complete roof.

 While installation of roof panels the side laps shall be treated with butyl tape and the
overlaps shall be treated with sealant or butyl tape.
 Ensure that the panel ribs are kept in a straight line from eave to ridge. Use a chalk
line to mark the purlin location and maintain a straight line of screw to avoid miss-
drilling and possible leakage
 Fixing shall be through the crown with suitable screws with washers. At the overlaps
and side laps saddle washers should be used.
 Three rows of sealant to be applied to overlaps and one row to side laps.
 Locate exact location of soaker panel, smoke vents, extract fans and install according
to specifications.
 Apply flashing to the top of the eave gutters side as shown on the drawing.
 Stitch-riveting must be applied to side laps upon completing the job.
 Ensure cleaning up the roof panels after each day's work.
 Crawling board shall be used to avoid damage to cladding profile.
 After installation of panels and flashing is completed, the protective covering on the
panels can be removed.
4.4. Installation of Wall Panels

4.4.1. Lifting the Wall Panels

 All the wall panels at site must be stacked only in two layers; no stack should be
higher than 2 layers.
 Wall panel lifting mechanism is a very precise activity and shall be carried out under
vigilance of the PTI site engineer.

 The vacuum lifting device/crane shall be placed very next to the wall which has to
receive the wall panels.
 Before commencement of the works, the purlins stability and alignment shall be
checked, the wall panels shall only be installed if the purlins are stable to receive panels.
 The vacuum device shall lift one panel at a time and transfer it from the ground to the
designated location on facade.

4.4.2. Panel Installation on Wall

 To ensure that the horizontal alignment of panels is maintained, the drip flashing shall
be installed beforehand.
 Works shall commence as per the drawings from the exterior corner or the gable end
of the building, after ensuring that the purlins are treated with tape.
 After the panels are placed on the designated location, they shall be screwed to the
purlins.
 All wall installation shall commence from bottom and then move to top.
 The crown and valley of the cladding shall be as per approved drawings.
 Each wall panel shall be screwed at all purlin intervals and the screws shall penetrate
the purlins and the panels to ensure strong support condition.
 Extra-long panels must be installed in two phases.
 In regular case the expansion joint panels shall stop 50mm away from either sides and
then filled with a flexible insulation layer before receiving flashing above.
 After the panels are secured to the purlins and the façade is ready, installation of
flashings can commence.
  All the end laps for external sheet shall be fixed with sealant tape to avoid leakage. (In
case of two layers of panels on façade)

4.5. Installation of Flashings

 The gutter flashing and the foam enclosure flashing shall be installed at the
commencement of roofing works.
 The drip flashing shall be installed before commencement of wall cladding works
 The cap flashing over wall shall be installed after the façade is ready
 The expansion joint flashing for the walls shall he installed after the joint is treated with a
flexible insulation layer.
 All other corner flashings shall be installed after the completion of façade works.

5. Safety

Prior to commencement of the works, the following safety requirements shall be fulfilled:

 All personnel shall wear safety gear and all site safety rules and regulation will be adhered to.
 Tool box meeting shall be conducted prior to any erection works.
 Movable scaffolding shall have locks in the wheels.
 All scaffolding shall be tagged and ladders shall be properly tied with intermediate landing.
 Landing platforms shall be hand railed.
 All lifting equipment shall be certified by third party approved.
 Lifting tackle shall be stamped with identification number and safe working loads.
 Erection works shall be stopped upon extreme weather conditions.
 All the surrounding areas shall be barricaded to prevent any unauthorized entry.
 Worksite supervisor shall be present at site full time.
 Scaffolding or man lift shall be used for working in heights.
 Crane/basket shall be used for removing the sling and nobody shall walk on beams on high
level.
 Slings will be used by all personnel working at night.
 Site wide heat stress guidelines will be followed, and will be no work under black flag
conditions.
5.1. Personal Protective Equipment’s

All employees should wear the following protective equipment’s while working.

Purpose Description

Protective clothing 100% cotton such as boiler suits,

Body Protection
aprons

Head Protection Safety hard helmets to protect from head injury

Purpose Description

Goggles and safety spectacles, against grinding

Eye Protection materials, sparks, welding spatters and chippings
while grinding, chipping and welding

Hand Protection Gloves to be worn all times

Foot Protection Safety steel toe cap boots

Ear plugs or ear defenders (muffs) while working at

Hearing Protection
high nose level areas

Full body safety harness with double lanyard while

Fall Protection
working at elevations (greater than 1.5m height)

Provision of fire extinguishers, hoses and fire blankets

Fire Protection as necessary. Appropriate measures should be taken
Client / Main Contractor's Scope to avoid the risk of fire and to immediately control the
outbreak of fire.

Upon hearing the alarm, all employees shall: stop

work and immediately shut down equipment. Check
General Evacuation Plan
for the wind direction and proceed in an orderly
manner by traveling crosswind.
5.2. Scaffolding & Ladders

 Scaffoldings shall rest on steel base plates and where the footings is soft or uneven,
provide timber plank
 The height of a mobile scaffolding shall not exceed three times the minimum base
width, unless the whole unit will be securely, guyed
 Don’t move mobile scaffold when materials and/or men are on it
 Where the work place is deemed unsafe and the use of scaffolding is impractical and
unsafe, then the use of man lift basket shall be considered
 Ladder shall be free from defects, and of adequate strength and length for the job
stepping off point
 Ladders shall be securely fixed at all times evenly supported on hard ground
 Ladders shall be set at an angle of 75 degrees to the horizontal ground or a ratio of 4:1
of its length

5.3. Safe Crane Operation & Lifting

 Cranes, A-frames, aside booms and other lifting devices such as, pulleys, chain pulley
blocks and power host shall be maintained in perfect working conditions. All wire ropes
and wire rope slings should be inspected and see that all strands are intact if there is
any wear and tear in the strands should be replaced.
 When crane is idle and not being used, the hook and block shall either be fully raised or
resting on the ground and parking brake shall be engaged.
 In all lifting activities, the crane outrigger shall be fully extended and the out rigger base
pad shall rest on compacted (solid) ground.
 Do not use the crane boom to drag a load side wise, or to ‘fish’ a load outside its safe
radius.

 Do not leave on unattended crane with a suspended load or with the engine running.
 Operated by competent persons
 5.3.1. Periodical Checklist of Cranes

A periodical inspection of the crane moving components are to be done and certified by
authorized and qualified inspection agency and must meet the requirements

 Hydraulic system – power pack – condition of oil seals and supply and return hoses.
 All breaks.
 Proper lubrication of moving shafts / pulleys.
 Wire rope (steel) all strands are to be intact.
 Check over load limit switch and hoisting limit switch. A regular check on these wire
ropes, slings and clamps is very essential to prevent snapping of ropes and fatal injury.
 Damaged or worn-out hooks, rings, eye bolts, shackles, chains, wire or fiber ropes and
slings shall be removed from the site.
 Slings should be protected by using ‘softeners’ to prevent damage when lifting sharp
edge objects.

5.4. Use of Drill Machine

 Good conditioned tools to be used

 Bit to be fastened properly
 Switch to be in proper working condition
 Proper electrical sockets to be used for connection.
 Proper PPE to be used particularly hand gloves, goggles etc.
 Tool box talks to be given before use
 Only 110 V supply to be used for electrical tools

5.5. Precautionary Measures

5.5.1. Workers Fall Protection (When working at 1.5meters or greater)

The following general principles to be applied to protect the worker from falls:

 Worker shall wear and use personal protective equipment which shall consist of the
following:
o Full body harness
o Anchor points
 o Shock absorber
o Lanyard
o Lifeline (horizontal or vertical)

 Where ever scaffolding will not be the most practicable or safest way to reach a location,
man lift.

The general principle for fall protection system is that a worker shall be connected at all times
to the system when undertaking steel erection where no other fall protection system has been
provided. This means that worker will be equipped with a double lanyard system, to allow security
at all time while moving from one system to another

 Anchorage Points: This component of the fall protection system will vary depending on
the situation – anchorage points can be fashioned on site. They may consist of rated eye
bolts, drilled holes, welded or bolted steel plates and beam clamps.
 Vertical Lifeline: A vertical life line must be positively secured to an appropriate
anchoring point as described previously. It may consist of a single line, secured to a
column or over hanged beam to which the worker attaches a lanyard
  Horizontal Lifeline: A horizontal lifeline may be fixed to columns or beams; it may consist
of single or double line (12mm diameter steel rope). Three workers could be secured to
the same horizontal line.

 Erection Procedure for Lifelines

o Columns
Prior to a worker climbing a column, it shall be adequately secured and life line
should be provided. The vertical lifeline shall be in place prior to the erection of the
column so that the worker does not need to climb a ladder or use other means to
secure the system.
o Beams
The installation of horizontal lifeline could not be done prior to erection. Thismeans
utilizing a man lift or the worker being secured to column lifeline system, as

o long as the travel distance away from the column do not allow for large swing
radius, should a fall occur.

6. MAINTENANCE

6.1. Maintenance Schedules

PTI sandwich panels are composite prefabricated panels, consisting of two layers of metal facers and
PIR insulation core between the facers, continuously laminated on a fully automatic production line.
 Sandwich panels are passive construction elements, i.e. there are no active moving parts and therefore,
are almost maintenance-free. Simple visual inspections and basic maintenance will ensure initial qualities for
the lifetime of the panel.
6.1.1. Inspections

Regularly at least once every year, panel surfaces and joints should be checked for accumulation of
dirt, sand, mud, entrapped water or debris. In case of any such occurrence, these should be removed at
once. And the surface that has remained under this dirt should be wiped clean with soapy water and soft
cloth.

A table of visual inspections is given below:

Item Inspection Criteria & Action

Check for accumulation of dirt and debris, remove and cleanas

instructed.
Panel Surface Check for dents or damages due to impacts. In case of any such
damage, check for scratches or bigger gashes/tears on the
surface. Inform the supplier with supporting photos.

Check for accumulation of dirt and debris. Remove and clear as

instructed.
Panel Joints If any sealant has been applied during initial installation, check
if sealant continuity is damaged. Re-apply supplier approved
sealant.

Inspect randomly some fasteners, both on panels and flashings,

Fasteners for tightness and corrosion. Replace with supplier approved
fastener as required.

Check for dirt and clean as instructed.

Check for minor scratches and use touch-up paint
(contact supplier for approved paint and methodology).
Panel Coating
Check for major scratches or tears on the panel surface.
Additional layer of metal cover may be needed, inform
the supplier.
 6.1.2. Washing the Panels

Panel surfaces can be washed with plain water and with soapy water for more persistent dirt. If the dirt is
not removed even with soapy water, then contact the supplier for further instructions on cleaning the
panel surface. Based on your product specifications, a proper detergent will be recommended.

When detergents are used for cleaning, the surfaces should be rinsed well afterwards with clean water to
avoid any residue of the detergent which could be detrimental to the coating in the long term.

Use of a pressure washer is not recommended. Pressurized water can get into the joints as well as any
minor scratches on the surface and cause corrosion. Abrasive cleaning tool or material should not be used.

Best Regards