TYPICAL TECHNOLOGICAL CARD FOR INSTALLATION OF A VENTILATED FACADE WITH COMPOSITE PANELS COVERED

TK-23

Moscow 2006

The technological map was prepared in accordance with the requirements of the “Guidelines for the development of technological maps in construction”, prepared by the Central Research and Design-Experimental Institute of Organization, Mechanization and Technical Assistance to Construction (TsNIIOMTP), and based on the designs of ventilated facades of NP Stroy LLC.

A technological map has been developed for the installation of a ventilated facade using the example structural system FS-300. The technological map indicates the scope of its application, sets out the main provisions for the organization and technology of work when installing elements of a ventilated facade, provides requirements for the quality of work, safety precautions, labor protection and fire-fighting measures, determines the need for material and technical resources, calculates labor costs and Work schedule.

The technological map was developed by technical candidates. Sciences V.P. Volodin, Yu.L. Korytov.

1 GENERAL PART

Hinged ventilated facades are designed for insulation and cladding of external enclosing structures with aluminum composite panels during the construction of new, reconstruction and major renovation existing buildings and structures.

The main elements of the FS-300 facade system are:

Support frame;

Thermal insulation and wind-hydroprotection;

Cladding panels;

Framing the completion facade cladding.

A fragment and elements of the FS-300 facade system are shown in figures , - . An explanation for the drawings is given below:

1 - supporting bracket - main load-bearing element frame intended for fastening the load-bearing control bracket;

2 - support bracket - additional element frame intended for fastening the support adjusting bracket;

3 - load-bearing regulatory bracket - the main (together with the load-bearing bracket) load-bearing element of the frame, intended for the “fixed” installation of the vertical guide (load-bearing profile);

4 - support control bracket - an additional (together with the support bracket) frame element intended for movable installation of a vertical guide (supporting profile);

5 - vertical guide - a long profile designed for attaching the facing panel to the frame;

6 - sliding bracket - fastening element designed to fix the cladding panel;

7 - blind rivet - a fastening element intended for fastening the load-bearing profile to the load-bearing control brackets;

8 - set screw - a fastening element designed to fix the position of the sliding brackets;

9 - locking screw - a fastening element designed for additional fixation of the upper sliding brackets of the panels to the vertical guide profiles to avoid shifting cladding panels in the vertical plane;

Rice. 1.Fragment of the system facade FS-300

10 - locking bolt (complete with a nut and two washers) - a fastening element designed for installing the main and additional frame elements in the design position;

11 - thermal insulating gasket of the supporting bracket, intended for alignment work surface and eliminating “cold bridges”;

12 - thermal insulating gasket of the support bracket, designed to level the working surface and eliminate “cold bridges”;

13 - facing panels - aluminum composite panels assembled with fastening elements. They are installed using sliding brackets (6) in the “spacer” and are additionally fixed from horizontal shift with blind rivets (14) to the vertical guides (5).

Typical sheet sizes for the manufacture of cladding panels are 1250×4000 mm, 1500×4050 mm (ALuComp) and 1250×3200 mm (ALUCOBOND). In accordance with customer requirements, it is possible to vary the length and width of the panel, as well as the color of the facing layer;

15 - thermal insulation from mineral wool slabs for facade insulation;

16 - wind-hydroprotective material - a vapor-permeable membrane that protects thermal insulation from moisture and possible weathering of insulation fibers;

17 - disc dowel for attaching thermal insulation and membrane to the wall of a building or structure.

Façade cladding frames are structural elements intended for the design of a parapet, plinth, window, stained-glass and door connections, etc. These include: perforated profiles for free access of air from below (in the plinth) and from above, window and door frames, folded brackets, strips, corner plates, etc.

2 AREA OF APPLICATION OF THE TECHNOLOGICAL MAP

2.1 A standard technological map has been developed for the installation of the FS-300 system of suspended ventilated facades for cladding the walls of buildings and structures with aluminum composite panels.

2.2 The scope of work to be performed is taken to cover the facade of a public building with a height of 30 m and a width of 20 m.

2.3 The work covered by the technological map includes: installation and dismantling of facade lifts, installation of a ventilated facade system.

2.4 Work is performed in two shifts. There are 2 lines of installers working per shift, each on its own vertical grip, 2 people in each line. Two façade lifts are used.

2.5 When developing a standard technological map accepted:

the walls of the building are reinforced concrete monolithic, flat;

the façade of the building has 35 window openings, each measuring 1500×1500 mm;

panel size: P1-1000×900 mm; P2-1000×700 mm; P3-1000×750 mm; P4-500×750 mm; U1 (angular) - H-1000 mm, B - 350×350×200 mm;

thermal insulation - slabs of mineral wool on a synthetic binder with a thickness of 120 mm;

the air gap between the thermal insulation and the inner wall of the facade panel is 40 mm.

At development of PPR this standard technological map is tied to the specific conditions of the facility with clarification: specifications of elements load-bearing frame, cladding panels and framing of façade cladding; thermal insulation thickness; the size of the gap between the heat-insulating layer and the cladding; scope of work; labor cost calculations; volume of material and technical resources; work schedule.

3 ORGANIZATION AND TECHNOLOGY OF WORK EXECUTION

PREPARATORY WORK

3.1 Before you start installation work For the installation of a ventilated facade of the FS-300 system, the following preparatory work must be carried out:

Rice. 2. Construction site organization diagram

1 - construction site fencing; 2 - workshop; 3 - logistics warehouse; 4 - work zone; 5 - boundary of the zone dangerous for people when operating façade lifts; 6 - open storage area building structures and materials; 7 - lighting mast; 8 - facade lift

Inventory mobile buildings are installed at the construction site: an unheated material and technical warehouse for storing ventilated facade elements (composite sheets or ready-to-install panels, insulation, vapor-permeable film, structural elements of the load-bearing frame) and a workshop for the production of cladding panels and framing the completion of the façade cladding in construction conditions;

Inspect and assess the technical condition of façade lifts, mechanization equipment, tools, their completeness and readiness for work;

In accordance with the work project, facade lifts are installed on the building and put into operation in accordance with the Operation Manual (3851B.00.00.000 RE);

The location of beacon anchoring points for installation of load-bearing and support brackets is marked on the wall of the building.

3.2 The facing composite material is delivered to the construction site, as a rule, in the form of sheets cut to the design dimensions. In this case, cladding panels with fastenings are formed in a workshop at the construction site using hand tools, blind rivets and cassette assembly elements.

3.3 Store sheets from composite material on a construction site it is necessary on beams up to 10 cm thick laid on a level place, in increments of 0.5 m. If the installation of a ventilated facade is planned for a period of more than 1 month, the sheets should be arranged with slats. The height of the stack of sheets should not exceed 1 m.

Lifting operations with packaged sheets of composite material should be carried out using textile tape slings (TU 3150-010-16979227) or other slings that prevent injury to the sheets.

It is not allowed to store the facing composite material together with aggressive chemicals.

3.4 If cladding composite material arrives at the construction site in the form of finished cladding panels with fastening, they are stacked in pairs, with their front surfaces facing each other so that adjacent pairs touch with their rear sides. The packs are placed on wooden supports, with a slight slope from the vertical. The panels are laid in two rows in height.

3.5 Marking of installation points for load-bearing and support brackets on the building wall is carried out in accordance with the technical documentation for the project for the installation of a ventilated facade.

On initial stage determine the beacon lines for marking the facade - the lower horizontal line of the mounting points for the brackets and the two outermost vertical lines along the facade of the building.

The extreme points of the horizontal line are determined using a level and marked with indelible paint. At the two extreme points, using a laser level and tape measure, determine and mark with paint all intermediate points for installing the brackets.

Using plumb lines lowered from the parapet of the building, vertical lines are determined at the extreme points of the horizontal line.

Using façade lifts, mark the installation points of load-bearing and support brackets on the outermost vertical lines with indelible paint.

MAIN WORK

3.6 When organizing installation work, the area of ​​the building’s façade is divided into vertical sections, within which work is carried out by different sections of installers from the first or second façade lifts (Fig. ). The width of the vertical grip is equal to the length of the working deck of the facade lift cradle (4 m), and the length of the vertical grip is equal to the working height of the building. The first and second links of installers working on the 1st facade lift, alternating in shifts, carry out sequential installation work on the 1st, 3rd and 5th vertical grips. The third and fourth sections of installers working on the 2nd façade lift, alternating in shifts, carry out sequential installation work on the 2nd and 4th vertical grips. The direction of work is from the basement of the building up to the parapet.

3.7 For the installation of a ventilated facade, one team of workers from two installers determined a replaceable grip equal to 4 m 2 of the facade.

3.8 Installation of the ventilated facade begins from the base of the building on the 1st and 2nd vertical sections simultaneously. Within the vertical grip, installation is carried out in the following technological sequence:

Rice. 3. Scheme of dividing the facade into vertical sections

Legend:

Direction of work

Vertical grips for the 1st and 2nd sections of installers working on the first facade lift

Vertical grips for the 3rd and 4th sections of installers working on the second facade lift

Part of the building on which the installation of a ventilated façade has been completed

Cladding panels:

P1 - 1000×900 mm;

P2 - 1000×700 mm;

P3 - 1000×750 mm;

P4 - 500×750 mm;

U1 (angular): H=1000 mm, H = 350×350×200 mm

Marking installation points for load-bearing and support brackets on the building wall;

Attaching sliding brackets to guide profiles;

Installation of cladding elements of a ventilated facade to the outer corner of the building.

3.9 Installation of the frame of the façade cladding of the plinth is carried out without the use of a façade lift from the ground surface (with a plinth height of up to 1 m). The parapet flashing is installed from the roof of the building at the final stage of each vertical section.

3.10 The installation points of the load-bearing and support brackets on the vertical grip are marked using beacon points marked on the outermost horizontal and vertical lines (see), using a tape measure, a level and a dye cord.

When marking anchor points for installing load-bearing and support brackets for subsequent vertical gripping, the beacons are the attachment points of the load-bearing and support brackets of the previous vertical grip.

3.11 To attach load-bearing and support brackets to the wall, holes are drilled at marked points with a diameter and depth corresponding to anchor dowels that have passed strength tests for this type of wall fencing.

If a hole is drilled by mistake in the wrong place and a new one needs to be drilled, then the latter must be at least one depth away from the wrong one drilled hole. If it is impossible to perform this condition you can use the method of fastening the brackets shown in Fig. 4.

Cleaning the holes from drilling waste (dust) is done with compressed air.

Rice. 4. Mounting point for load-bearing (support) brackets if it is impossible to attach them to the wall at the design drilling points

The dowel is inserted into the prepared hole and tapped with a mounting hammer.

Thermal insulation pads are placed under the brackets to level the working surface and eliminate “cold bridges”.

The brackets are attached to the wall with screws using an electric drill with adjustable rotation speed and appropriate screwing attachments.

3.12 Thermal insulation and wind-hydroprotection device consists of the following operations:

Hanging on the wall through the slots for the brackets of the insulation boards;

Hanging wind-hydroprotective membrane panels with an overlap of 100 mm on heat-insulating slabs and temporarily securing them;

Drilling holes in the wall for disc dowels through the insulation and wind-hydroprotective membrane in full according to the project and installing the dowels.

The distance from the dowels to the edges of the heat-insulating board must be at least 50 mm.

Installation thermal insulation boards start with the bottom row, which are installed on a starting perforated profile or base and mounted from bottom to top.

The slabs are hung in a checkerboard pattern horizontally next to each other so that there are no through gaps between the slabs. The permissible size of an unfilled seam is 2 mm.

Additional thermal insulation boards must be securely fastened to the wall surface.

To install additional thermal insulation boards, they must be trimmed using hand tools. Breaking insulation boards is prohibited.

During installation, transportation and storage, thermal insulation boards must be protected from moisture, contamination and mechanical damage.

Before starting the installation of heat-insulating boards, the replacement grip on which work will be carried out must be protected from atmospheric moisture.

3.13 The adjusting load-bearing and support brackets are attached to the load-bearing and support brackets, respectively. The position of these brackets is adjusted in such a way as to ensure alignment with the vertical level of deviation of wall irregularities. The brackets are secured using bolts with special stainless steel washers.

3.14 Attaching vertical guide profiles to the adjusting brackets is carried out in the following sequence. The profiles are installed in the grooves of the regulating load-bearing and support brackets. Then the profiles are fixed with rivets to the supporting brackets. The profile is installed freely in the support control brackets, which ensures its free vertical movement to compensate for temperature deformations.

In places where two successive profiles join vertically, to compensate for temperature deformations, it is recommended to maintain a gap in the range from 8 to 10 mm.

3.15 When arranging an abutment to the base, the perforated cover plate is fastened using an angle to the vertical guide profiles using blind rivets (Fig. ).

3.16 Installation of facing panels begins from the bottom row and proceeds from bottom to top (Fig. ).

Sliding brackets (9) are installed on the vertical guide profiles (4). The upper sliding bracket is installed in the design position (fixed using setscrew 10), and the lower one in the intermediate position (9). The panel is placed on the upper sliding brackets and, by moving the lower sliding brackets, is installed “in the spacer”. The upper sliding brackets of the panel are additionally secured with self-tapping screws against vertical shift. Against horizontal shear, the panels are also additionally secured to the supporting profile with rivets (11).

3.17 When installing facing panels at the junction of vertical guides (bearing profiles) (Fig.), two conditions must be met: the upper facing panel must close the gap between the supporting profiles; The design gap between the lower and upper facing panels must be accurately maintained. To fulfill the second condition, it is recommended to use a template made of a square wooden block. The length of the bar is equal to the width of the facing panel, and the edges are equal to the design value of the gap between the lower and upper facing panels.

Rice. 5. Connection to the base

Rice. 6. Installation of the facing panel

Rice. 7. Installation of facing panels at the junction of supporting profiles

Rice. 8. Mounting point for cladding panels on the outer corner of the building

3.18 The connection of the ventilated facade to the outer corner of the building is carried out using a corner cladding panel (Fig. 8).

Corner cladding panels are manufactured by the manufacturer or on site to the dimensions specified in the façade design.

The corner cladding panel is attached to the supporting frame using the above methods, and to the side wall of the building using the corners shown in Fig. 8. A prerequisite is the installation of anchor dowels to secure the corner cladding panel at a distance of no closer than 100 mm from the corner of the building.

3.19 Within the removable area, installation of a ventilated facade that does not have junctions and window frames is carried out in the following technological sequence:

Marking anchoring points for installing load-bearing and support brackets on the building wall;

Drilling holes for installing anchor dowels;

Fastening load-bearing and support brackets to the wall using anchor dowels;

Thermal insulation and wind protection device;

Fastening to the supporting and support brackets of the adjusting brackets using locking bolts;

Attachment to adjusting brackets of guide profiles;

Installation work is carried out in accordance with the requirements specified in paragraphs. - and pp. and this technological map.

3.20 Within the removable area, installation of a ventilated facade with a window frame is carried out in the following technological sequence:

Marking anchor points for installing load-bearing and support brackets, as well as anchor points for fastening elements window frame on the wall of a building;

Fastening the window frame substructure elements to the wall ();

Attaching load-bearing and support brackets to the wall;

Thermal insulation and wind protection device;

Attachment to load-bearing and support brackets of control brackets;

Attachment to adjusting brackets of guide profiles;

Fastening the window frame to the guide profiles with additional fastening to the frame profile (Fig. , , );

Installation of facing panels.

3.21 Within the removable area, installation of a ventilated facade adjacent to the parapet is carried out in the following technological sequence:

Marking anchoring points for installing load-bearing and support brackets to the building wall, as well as anchoring points for attaching the parapet ebb to the parapet;

Drilling holes for installing anchor dowels;

Fastening load-bearing and support brackets to the wall using anchor dowels;

Thermal insulation and wind protection device;

Fastening to the supporting and support brackets of the adjusting brackets using locking bolts;

Attachment to adjusting brackets of guide profiles;

Installation of facing panels;

Attaching the parapet ebb to the parapet and to the guide profiles ().

3.22 During breaks in work on a replaceable grip, the insulated part of the facade that is not protected from atmospheric precipitation is covered with a protective polyethylene film or in another way to prevent the insulation from getting wet.

4 REQUIREMENTS FOR QUALITY AND ACCEPTANCE OF WORK

4.1 The quality of the ventilated facade is ensured by ongoing monitoring of technological processes of preparatory and installation work, as well as during acceptance of work. Based on the results of current monitoring of technological processes, inspection reports are drawn up hidden work.

4.2 In the process of preparing installation work, check:

Readiness of the working surface of the building facade, structural elements of the facade, mechanization equipment and tools for installation work;

Material: galvanized steel (sheet 5 > 0.55 mm) according to GOST 14918-80

Rice. 9. General form window frame

Rice. 10. Connection to the window opening (bottom)

Horizontal section

Rice. 11. Adjacent to the window opening (from the side)

*Depending on the density of the building envelope material.

Rice. 12. Connection to the window opening (top)

Vertical section

Rice. 13. Junction to the parapet

The quality of the supporting frame elements (dimensions, absence of dents, bends and other defects of brackets, profiles and other elements);

Quality of insulation (slab sizes, absence of tears, dents and other defects);

Quality of facing panels (size, absence of scratches, dents, bends, breaks and other defects).

4.3 During installation work, the following is checked for compliance with the design:

Accuracy of façade markings;

Diameter, depth and cleanliness of holes for dowels;

Accuracy and strength of fastening of load-bearing and support brackets;

Correctness and strength of fastening of insulation slabs to the wall;

The position of the adjusting brackets that compensate for wall unevenness;

Accuracy of installation of supporting profiles and, in particular, gaps at the places where they are joined;

Flatness facade panels and air gaps between them and the insulation boards;

The correctness of the framing of the completion of the ventilated facade.

4.4 When accepting work, the ventilated façade as a whole is inspected and especially carefully the frames of the corners, windows, plinth and parapet of the building. Defects discovered during inspection are eliminated before the facility is put into operation.

4.5 Acceptance of the assembled facade is documented in an act with an assessment of the quality of work. Quality is assessed by the degree of compliance of the parameters and characteristics of the installed façade with those specified in technical documentation to the project. Attached to this act are certificates of inspection of hidden work (according to).

4.6 Controlled parameters, methods of their measurement and evaluation are given in table. 1.

Table 1

Controlled parameters

5 MATERIAL AND TECHNICAL RESOURCES

5.1 The need for basic materials and products is given in Table 2.

table 2

5.2 The need for mechanisms, equipment, tools, inventory and fixtures is given in Table 3.

Table 3

The façade is one of the first building structures to be affected during a fire. This is especially true for ventilated facades, the air layer of which creates the effect of a chimney. Therefore, the fire resistance of facade systems and materials is one of the most important indicators.

Facades must have class fire danger K0 i.e. not fire hazardous.

How to determine the fire hazard class of facades?

Determination of the fire hazard class for ventilated facades is carried out only using fire tests of the integral structure, i.e. subsystem and facing material. The rules for conducting such tests are regulated according to the GOST 31251-2003 standard.

The presence of flammability group NG (non-flammable) or G1 (lowly flammable) in the façade cladding material does not guarantee class K0 for the entire façade system. The same applies to individual materials, from which the substructure, insulation and fasteners are made. Those. ideally, both substructure materials and facing material and the insulation system must be non-flammable.

Nevertheless, there are also individual cases when the system has class K0, but contains a limited amount of low-flammable materials, group G1, for example. Usually such exceptions are made when a non-standard requirement requires it. architectural solution or technical and economic feasibility.

What is the difference between fire hazard class and flammability group?

Fire hazard classes are divided into 4 categories:

• K0 - non-fire hazardous;
• K1 - low fire hazard;
• K2 - moderately fire-prone;
• K3 - fire hazard.

The flammability groups of materials are divided into the following:

• NG - completely non-flammable
• G1 - low flammable
• G2 - moderately flammable
• G3 - normally flammable
• G4 - non-flammable

The main difference between the fire hazard class and the flammability group is that the fire hazard class is assigned to the entire system as a whole, i.e. fasteners, insulation, subsystem and each of its elements, cladding. The flammability group is assigned to each structural element separately, including bolts, nuts, rivets, windproof membrane or thermal break.

Which façade systems have fire hazard class K0?

Today, almost 90% of facade systems on the market correspond to class K0, since this is one of the main requirements for obtaining a technical certificate. First of all, this applies to ventilated facades. Mainly comprehensive solutions systems including porcelain stoneware cladding, natural stone, ceramic panels, clinker, metal cassettes made of galvanized steel. Stainless or galvanized steel is used as a substructure material for K0 systems. Mineral wool as insulation.

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« Where there is uncertainty, imagine horror.”

Andrey Tomantsev. Soldiers of fortune

A problem when designing systems of suspended ventilated facades (like any other new system) is a very limited number of data and requirements in unified state standards (SNiP, SP, GOST, The federal law) and availability large number disparate documents developed for specific products.

These documents include a technical certificate + technical assessment, a book of technical solutions, design recommendations and some others, for example a fire certificate, a conclusion on corrosion resistance, seismic resistance tests.

According to the Decree of the Government of the Russian Federation of December 27, 1997 No. 1636, new materials, designs and technologies are subject to confirmation of suitability for use in construction. Suitability of new construction products confirmed by a technical certificate (TC) of the Ministry of Regional Development of Russia. The technical certificate for suspended facade systems reflects: the purpose and scope of application of the structures, a fundamental description, parameters, indicators and technical solutions structures, additional conditions for quality control of installation and conclusions about the suitability of products and the permitted scope of application.

Another document for the design and calculation of a ventilation façade is recommendations for the design of suspended façade systems with an air gap. The recommendations contain: basic provisions on the scope of application of systems and constructive solutions; methods of strength, heat engineering and heat and humidity calculations of a ventilated façade; provisions for installation and performance indicators. These documents are methodological and reference manual in the preparation of projects, developed by the Central Research and Design Institute of Residential and public buildings TsNIIEP of dwellings and approved by the instructions of the Moscow Architecture Committee. In form, the recommendations are more similar to regulatory documents such as SNiP for ventilated facades or GOST.

Strength and other calculations of a ventilated facade in accordance with the Recommendations can be performed using a program for calculating facade systems.

All of the listed documents (Albums of technical solutions, technical equipment, Recommendations and fire reports) can be downloaded by subscribing to the VKontakte blog page in the panel on the right.

Everyone understands the need to introduce a single normative document in relation to systems of suspended ventilated facades. The issue has been repeatedly discussed in publications and appeared in every round table dedicated to this topic. It is worth noting, however, that things do not stand still; in the new SP 50.13330.2012 “Thermal protection of buildings”, a method of thermophysical calculation of suspended facade systems with ventilated air gap. Let's hope that the higher comrades will soon get to a single document on ventilated facades.