site installation guide - smd ltd...1 no nelweld 6000 machine part no. 0618 or similar 2 no stud...

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1 of 56SMD.SITE.210.V3Operations Department

SMDStructural Floor and Roof Solutions

Site Installation GuideSMD.SDC.210.V3

Author - Richard Brokenshire

Review Date - May 2017

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Site Installation GuideContents

03 Introduction 04 Pre-Site Preparations

General04 PPE – What we are required to wear & why05 Vehicles and Equipment08 SMD Drawings – Symbols and Keys09 Familiarise Yourself With Your Project10 Toolbox Talks & Inductions

Netting11 Training and Competence11 Before you Start

Netting – On-Site Operations11 Installation Procedure12 Access12 Minimum Spacings

Netting – Post Installation12 On site checks / Record Keeping

Damaged Nets12 Damaged Nets Report14 Netting – Good and Bad Practice14 Technical References

DeckingDecking On-Site Operations15 Access to Level15 Understanding Pack Labels15 What do Spray Lines on the Decking Indicate?15 Painted Beam Top Flanges15 Using Setting Out Point16 Installation Process17 Marking up Beam Flange Widths on Decking Sheets18 Ribs Running Through from Bay to Bay18 Cutting of Sheets19 Plasma Cutting19 Cutting Out Ribs Over Beams (TR+)20 Notching21 Flashing Details and Examples21 End Caps22 Edge Trim24 Cantilevered Decking (stitch on trim)

24 Edge Trim Direct to Steel Edge Beam25 Edge Trim to Blockwork or Masonary26 Engineered Trim Positions26 Faceted Trim to Form Curve27 Restraint Straps28 Foaming Up – Good and Bad Practice29 Waste Removal31 Surplus Materials31 On-Site Checks Before Leaving33 Technical References33 Drawing Feedback

Shear Stud Welding Shear Studding – On-Site Operations34 Installation Procedure, Setting up Your Equipment34 Setting up the ‘Nelweld 6000’35 Gun Settings36 Preparing Your Area of Work36 Lifting Studs to Level36 Pre-Start Test

Shear Studding – Installation Procedure39 Shear Stud Spacings41 Testing of Shear Studs42 Ferrule Breaking, Picking & Disposal42 Failed Studs42 On-Site Checks Before Leaving43 Foaming Up Gaps43 Stud Count44 Stud Welding – Good and Bad Practices

Site Administration45 Communication45 Accidents46 Time Sheets47 Mark-up Wages Drawings48 Confirmation of Instruction48 Site Record Sheet49 Handovers

Responsibilities and Expectations52 SMD Site Foremen53 The Golden Rules

Quick Reference Guide54 Fixings

Page Section

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IntroductionThis guide has been written to give specific practical guidance to SMD employees on matters relating to the installation of safety nets, metal decking, edge trims & thru deck welded shear connectors. It includes descriptions of the basic methods & principles to be adopted and may prove useful as a reference when planning works involving metal decking.

The aim of this guide is to improve our standards of Quality, Health & Safety and above all, consistency. It also aims to reinforce ‘The SMD Approach’:

Quality – Service – Safety – SustainabilityThrough high levels of repeat business our Company remains a market leader in our field regardless of market trends & commercial pressure. Our aim through continuous improvement is to set the highest standard for Quality – Service – Safety – Sustainability in our sector and this guide provides a benchmark against which we should measure our performance.

We must always strive to Deliver a High Quality and Comprehensive Service with Honesty and Integrity for the Benefit of our Customers, Employees and Suppliers.

Through communication and working together we can achieve our goal.

Richard BrokenshireOperations Manager

IntroductionSite Installation Guide

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Pre-Site PreperationNetting, Decking, Edge trim and Stud Welding

GeneralPPE – What we are required to wear and why

Company policy states that all operatives are to wear the appropriate PPE at all times, paying particular attention to specific site rules. Operatives should consult with their foremen / Construction Manager if required PPE is not clear within the contract specific RAMS.

If any PPE is worn, damaged or not suitable for purpose, you must see your line manager who will arrange for it to be replaced. New PPE will be issued on a ‘new for old’ basis, with new PPE only issued when the old is returned. DO NOT enter any site with sub-standard PPE.

In addition to your PPE, the company will also supply you with branded clothing to be worn on site. These clothes must be worn at all times. Remember you are a representative of the company and your appearance is a reflection on SMD Ltd.

These will be issued in summer and winter packs and will include appropriate type and quality depending on job role.

Below is the list of PPE that will be supplied for you to wear on site as required. Please ensure you only use PPE supplied or recommended by SMD:• Hard Hat, Chin Strap & Lanyard.• Ear Defenders (Not Stud Welders)• Protective Footwear• Protective Eye Wear (Goggles & Safety Glasses)• Gloves• Harness (Netting Operatives)• Hi-Vis Vest• Hi-Vis Waterproof Jackets (During Wet Weather)

Company Issued Branded Clothing:• Polo Shirts / Round Neck T-Shirts• Sweaters / Hooded Tops (2 No per year)• Work Trousers (2 No pairs per year)These will be issued in summer and winter packs and will include appropriate type and quality depending on job role.

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Make sure you have all the equipment that you require and that it is in good safe working condition. The standard contents of a vehicle should be:

Airbag Vans8 No 8x8 Airbags Part No. N/A14 No 8x6 Airbags Part No. N/A8 No 8x4 Airbags Part No. N/A4 No 8x2 Airbags Part No. N/A4 No 6x4 Airbags Part No. N/A2 No 6x2 Airbags Part No. N/A1 No Tool Box Part No. N/A3 No Pipes and Stoppers Part No. N/A2 No Stihl BG56 Part No. 0651 Petrol Blowers 2 No Electric Blower Part No. 08071 No 110v SDS Part No. 0664 Hammer Drill 6 No SDS Drill Bits Part No. 0686

1 No Cargo Net Part No. 0804

Net / Decking Vans2 No Petrol Disc Cutter Part No. TBCPetrol Disc Cutter Spanner Part No. 07541 No 2.7kVA 110v Part No. 0646 Petrol Generator 2 No Hilti DX460 C/W Part No. 0658 MX72 Magazine3 No Hilti DX460 Nail Part No. 0178 Gun Pistons 2 No Hilti DX460 Nail Part No. 0179 Gun Piston Buffer 1 No Hilti Single End for Hilti DX460 Tool Part No. 08031 No Hilti DX76 Part No. 0644 C/W MX76 Magazine2 No Hilti DX76 Nail Part No. 0183 Gun Pistons 1 No Hilti DX76 Nail Gun Part No. 0188 Piston Buffer 1 No Hilti DX76 Single End Part No. 0802

2 No 110v Hilti Tek. Gun, Part No. 0648 c/w Magnetic Driver End 3 No Magnetic Driver Ends Part No. TBC1 No First Aid Kit Part No. N/A (Supplied Free Issue with Vehicles) 5 No 20m Cables 110v Part No. TBC1 No 110v Splitter Part No. 0729 Junction Box 2 No Foam Guns Part No. TBC1 No Petrol Can / Jerry Can Part No. TBC1 No Powder Fire Extinguisher Part No. 03032 No Tape Measures Part No. 07891 No Hilti Gun Cleaning Kit Part No. 02812 No Trim Tether Part No. 08052 No Tool Tether Part No. 07101 No 2.5m Triple Extending Ladder Part No. 07941 No Net Pole Part No. 03043 No 6 x 100mm SDS Masonry Drill Bits Part No. 06864 No 20m Branded Ratchet Straps for area segregation Part No. TBC5 No A3 Warning Work in Part No. TBC Progress Signs

Shear Stud Wagons2 No Powder Fire Part No. 0303 Extinguishers 1 No Small Toolbox Part No. 0809Petrol Disc Cutter Spanner Part No. 0754Large Flat Head Screwdriver Part No. 0745Medium Flat Head Part No. 0746 Screw Driver 4mm Allen Key Part No. 07475mm Allan Key Part No. 0748Stanley Knife Part No. 0749250mm Adjustable Spanner Part No. 0750

Vehicle & EquipmentHow to Manage Tools & Equipment

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Self-Grip Pliers Part No. 0751Crimping Pliers Part No. 0752Small Electrical Screw Driver Part No. 07531 No Stud Testing Bar Part No. 02991 No 6m Fire Blanket Part No. 0743 (White Monarflex) 1 No Standard bucket for transporting ferrules Part No. 07622 No Strong Buckets for the transportation of shear studs Part No. 07612 No Petrol air blowers Part No. 06516 No 6 X 20m welding cables Part No. 03341 No Nelweld 6000 machine Part No. 0618 or similar 2 No Stud Welding Guns Part No. 05941 No 6m Earth Cable Part No. 8101 No 10m Earth Cable Part No. 811 Extension 1 No Petrol Disc Cutter Part No. 0274/06491 No Single Barrel Lifting Stillage Part No. 04261 No 5 Litre Petrol Can Part No. 08121 No Foam Gun Part No. 0287

2 No Tool Tethers Part No. 07101 No 20m Lifting Rope Part No. N/A1 No First Aid Kits1 No 15l Spill Kit (Yellow Bag) Part No. 04144 No 20m Segregation Ratchet Straps, inc. Ratchets Part No. 08065 No Warning Work in Progress Signs Part No. 08083 No 19mm Chuck Body’s Part No. 06896 No 19mm Chuck Skirts Part No. 06905 No 19mm Ferrule Grips Part No. 06912 No Ferrule Grip Extensions Part No. 06922 No Tufnol Isolator Part No. 0219 (Culy Wirley) 2 No Main Cable End – Male Part No. 02092 No Main Cable End – Female Part No. 02082 No Control Cable End – Male Part No. 02112 No Control Cable End – Female Part No. 0210

Vehicle & EquipmentHow to Manage Tools & Equipment

Your vehicle / equipment will be subject to random inspections during the year. Any missing or damaged equipment that has not been explained and reported, maybe expected to be replaced.Lost or stolen equipment due to negligence will be the responsibility of the foreman. A contribution may be requested for the replacement of these items.

IMPORTANT NOTE: Please take pride in your equipment, it is your equipment and you are responsible for it. Please do not swap equipment with other gangs without a good reason and always ensure stores / logistics know about it.

Daily vehicle inspections and vehicle defect reporting are the responsibility of the gang foreman. (Vehicle inspection sheets MUST be submitted with your weekly paperwork).

When tools are left for repair, please attach a note / label clearly indicating the fault.

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Make sure you have all the correct level of consumables on-board your vehicle at all times. These levels should be assed and replenished on weekly basis, all requests are to be made via the stores following the correct procedure. (If you are not sure on the procedure, please communicate with the stores):

Airbags Vans Consumable stock Levels SMD Item ID6 No Spare Values Part No. N/A10 No Jubilee Clips (What Size) Part No. N/A1000 No Hilti Impact Anchor HPS-1 Part No. 03251000 No Hilti Pins with Soft Washers X-SW 30 C37 Part No. 01631000 No Hilti Green Cartridges Part No. 0627

Net / Decking Vans Consumable stock Levels6000 No Hilti DX460 Magazine Nails Part No. 06202000 No Hilti DX460 Single Nails Part No. 06218000 No Hilti DX460 Yellow Shots Part No. 06602000 No Hilti DX76 ENP-19 Magazine Nails Part No. 0623200 No Hilti DX76 ENP-19 Single Nails Part No. 07932200 No Hilti DX Cartridge 6.8 / 18 M10 Large Red Shots Part No. 062430 No 300mm Cutting Discs Part No. 068212 No Cans of Expandable Foam Part No. 06801 No Foam Gun Cleaner Can Part No. 0781500 No Hilti Hammer Hit Concrete Fixings Part No. 0325500 No Hilti Mexican Hat Concrete Fixings Part No. 0163500 No Hilti DX460 Green Shots Part No. 06277000 No Tek Screw – 4.8 x 20mm (Deck Only) Part No. 016010 No Husqvarna 2-Stroke Oil Shots Part No. 0731500 No Hilti S-MD03Z 5.5 x 25mm Tek Screws (Roofing) Part No. 0162

Shear Stud Vehicles Consumable stock Levels7000 19mm x 95mm Shear Studs Part No. 04301800 No 19mm x 120mm Shear Studs Part No. 04319000 No Ceramic Thru Deck Ferrules Part No. 04584 No Husqvarna 2-Stroke oil shots Part No. 07316 No Cans of Expandable Foam Part No. 06801 No Foam Gun Cleaner Can Part No. 07812 Rolls of Bunting tape Part No. 0191

Your vehicle stock levels will be subject to random inspections during the year.Lost or stolen consumables due to negligence will be the responsibility of the foreman. A contribution may be requested for the replacement of these items.

IMPORTANT NOTE: It is very important to maintain the correct levels of consumables in your vehicle to ensure you can deliver the day to day requirements of your job role, along with having the flexibility to sort issues and manage problems.

Vehicle Consumable Stock LevelsHow to Manage Tools & Equipment

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Before you start on siteSMD Drawings – Symbols & Keys

Familiarise yourself with the ProjectPre-Start Check List1. Once parked safely (off site if necessary), put on appropriate PPE and let the client know you have arrived.2. Check requirement for inductions, hot works permits, security passes, working hours, quiet times etc and action as required.3. Check with SMD office that the drawings you have been supplied are the most recent revisions.4. Make checks on initial work area ensuring that there are no flammable materials below, no vertical obstructions that will protrude into the net ‘fall zone’, no other trades and that nets & handrails are complete with no obvious gaps.5. Check all beams to be studded have unpainted top flanges, if there is paint evident, please discuss this with the project Construction Manager in the first instance for advice.6. Be aware of the proximity of your initial work areas to fragile materials, site hoardings etc where your work may impact on others. If you have any concerns please speak with your Construction Manager.7. Erect suitable and sufficient segregation / signage to ensure other trades are aware of you working in that area and the possible dangers. This should be achieved by erecting ratchet straps to columns and installing warning signage at each entry point.

Read and understand project documentationBefore you start on any new project it is very important to spend a few minutes familising yourself with the job you have in front of you. Each and every project is different and will have different requirements, a bit of time now can save time in the long run! Ensure you have copies of the following and that you understand them before you start work:

• Method Statement.• Risk Assessment and COSHH.• Review the drawings, (check correct revision as noted above with drawing office / contracts co-ordinator before each Phase / area is started.

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H-CH-BH-A

H-2

H-3

3000

6000

9000

290

700 2300

3000

Trim BundleH8/T1

Flashing BundleH8/F1

3000 3000

Mark which represents theoff site cutting sheetEdge trim reference -

Refer to trim legend

TPTP

TEKLA Deck packreference mark

TEKLA Trim/Flashingpack reference marks

TEKLA Deck sheetlength notation

Shear stud mark

SMD.DOD.179b.V1

SMD TEKLA drawing layout extract(Inc' precut details)

Floor / Phase NoPack No

Floor / Phase NoTrim Pack No

Deck pack reference symbol

Trim pack reference symbol

Stud reference blockNo. of studs Pitch / c/c's of studs

'P' indicates studs in pairs

Abbreviated terms found on SMD drawings:-EOB = Edge of beamCOB = Centre of beamecc = Eccentric (distance from grid or other)

(This will indicate beam or SOP, not slab)SOP = Setting out pointTOS = Top of steelSSL = Structural slab levelTP = Temporary Propping

Floor / Phase NoFlashing Pack No

Deck Label and Pre-cut sheet Symbols

Sheet Length / Level Mark / Sheet number

SO

P

Setting out point

TP

TP

TP

TP

TP

Setting out point

Propping at mid-span location

Propping notefor clairty

TRIMBUNDLE

1/T1

FLASHINGBUNDLE

1/F1

1

A B C D

2

SMD.DOD.179.V3

Typical SMD AutoCAD drawing layout

100

100

COB

300

NS

B

B

TP TP

EOB

TP

TP

A

K

100

B CA

Floor / Phase NoPack No

Pack weight

Floor / Phase NoTrim Pack No

Deck pack reference symbol Trim pack reference symbol

Z3 Z3 Z3

F1

Deck reference blockNo. of deck sheets Sheet length

Stud reference blockNo. of studs Pitch / c/c's of studs

Chain dotted line labelled TP indicatesextent of temporary propping required

Propped slab edge

Dimension from C beamto slab edge

Edge trim reference - Refer to trim legend

Cantilevered deck to formlarge slab edge

Flashing reference - Refer to trim legend

Hatching indicates pack loadingout location

Diagonal line with 'DeckReference Block' indicates thearea/coverage of deck assigned

Stud reference

B

'P' indicates studs in pairs'R' Remainder studs to bedistributed starting at beam ends

L

Abbreviated terms found on SMD drawings:-EOB = Edge of beamCOB = Centre of beamecc = Eccentric (distance from grid or other)

(This will indicate beam or SOP, not slab)SOP = Setting out pointTOS = Top of steelSSL = Structural slab levelTP = Temporary Propping

Floor / Phase NoFlashing Pack NoSMD Site managers Ref

1200

3000

3000 3000 3915

TP

Up

0.40t

1/01

50

??

Dimension query

Beam ecc mm25

452

427GL-Slab

Beam away fromgrid mark Setting out point

Up

0.40t

1/01

50

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SMD.TBT.286.V4

Name Signature Name Signature Name Signature

www.smdltd.co.ukSMDLimited Unit C The Outlook Ling Road Tower Park Poole Dorset BH12 4PY Tel: +44 (0) 1202 718 898 Email:[email protected]

Job No:Project:

structural floor and roof solutionsDe l i v e r i ng Exce l l ence Sa fe l y and Sus ta i nab l y

Talk By:Client / Main Contractor: Date: Signature:

Slips, Trips and Falls contribute to 28% of reported major injuries on construction sites.

Toolbox Talk 01 | Good Housekeeping

Untidy materials can cause trips or fall on someone

Clear up yourself, don’t rely on

others

Be aware of cable runs and consider

access routes

Take care with stored

material stocks

Secure stored materials or scrap

at height

Place waste in skips or store

securely

Good Housekeeping

SMD.TBT.286.V4

Name Signature Name Signature Name Signature

www.smdltd.co.ukSMDLimited Unit C The Outlook Ling Road Tower Park Poole Dorset BH12 4PY Tel: +44 (0) 1202 718 898 Email:[email protected]

Job No:Project:

structural floor and roof solutionsDe l i v e r i ng Exce l l ence Sa fe l y and Sus ta i nab l y

Talk By:Client / Main Contractor: Date: Signature:

Gloves at levels explained: Cut 5 – Extreme hazard – Plate glass, cutting with knives.Cut 4 – High hazard – Handling metal or glass.Cut 3 – Moderate hazard – Metal product handling and Bricks.Cut 2 – Low hazard – General construction, automotive.Cut 1 – Nuisance cuts – paper.

Toolbox Talk 02 | Prevention of Hand Injuries

Understand the RAMS and the

requirement to use gloves

Hand Injuries

Understand site rules – Are gloves

mandatory?

Deck, trim, banding and flashing WILL CUT!

Gloves may not prevent trapping injurys,

i.e under sheets or against columns

Injury prevention is common sense! If

in doubt wear suitable gloves

Studwelding sparks WILL BURN!

Toolbox Talks & InductionsToolbox talks will be given to all operatives on a regular basis (Minimum of one per working week), by the Site Foreman / Construction Managers. They will be relevant to a particular issue or condition found on the site at that time.

IMPORTANT NOTE: Copies of all Toolbox talks undertaken are to be submitted to the office weekly with time sheets, if the site requires a copy for their records they will need to make a photocopy.

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NettingSite Installation Guide

Training and CompetenceEach netting gang MUST contain at least one person who holds a full FASET net rigger card.Any operative needing to use a MEWP for the installation of netting must hold a current IPAF ticket. If you do not hold the correct cards, do not use the MEWP.

Before you StartBody harnesses and lanyards are to be worn at all times. A daily inspection of the harnesses and lanyards should be carried out on site prior to works commencing by each operative. Weekly checks on all plant being utilised are to be carried out by a competent person and recorded on the appropriate form.

IMPORTANT NOTE: All MEWPS used by SMD operatives / contractors MUST be fitted with anti-entrapment and a sky siren as standard. If you are supplied or asked to use a MEWP that does not confirm to this, please contact your Construction Manager.

Familiarise yourself with your project – Pre start check listEnsure that you have familiarised yourself with the SMD drawings and that you have taken the correct number and size of nets and fixing’s required for the areas to be netted.

Netting – On Site OperationsInstallation Principles• There are 3 principle methods; Net claw, Grippas and tie ropes. The exact system and method used to attach the nets will be set out in the method statement.• Ideally safety nets should not sag more than 10% of the span, between two supporting structures.• The sag is measured from the tie off point at the centre of the net to mid span. With a 6m span, the sag should be about 600mm. • The safety net is designed to deform or stretch when someone falls into it. Therefore it is imperative that there is sufficient clearance below the safety net to allow for the deflection under load. This will depend on the free fall height and the span of the net. • A rule of thumb clearance distance is 3m.

Installation ProcedureBefore starting to erect nets on site it’s very important to ensure the nets are in date. All nets leaving the stores should be in date but nets must be double checked before being rigged.• Installation sequence should follow the principles as set out in the FASET training manual. If you do not have a copy, please request one.• Every project is different and sufficient time should be taken to asses and plan the works.• In general terms a net is fixed starting out from a corner and fixed progressively working away from the start point securing at 2m centres.• When the bay is fully netted and tensioned the adjacent bay can be started.• For progression over long runs, the nets can either be butted end-to-end and sewn or overlapped. When overlapping a minimum of 2 metres must be overlapped.

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AccessThere are four methods of access currently recommended by FASET for rigging and de-rigging safety nets, these should be considered in the following order:

1. Rig / de-rig Safety Nets remotely (remote attachment devices), i.e. Net Claw, use up to a height of 3.5m2. Rig / de-rig using powered access (MEWPs).3. Rig / de-rig using ladders (recommended maximum height 4.5m).4. Industrial climbing access techniques (rope access).

FASET do not recommend the use of scaffold towers or hop-ups for the rigging and de-rigging of safety nets under normal rigging conditions. Please consult with the SMD Construction Manager before using any of these systems.

Refer to the specific project method statement for the method identified as the most appropriate for the project.

Minimum SpacingsThe general practice for the erection of the safety net is to start in each corner first, then work down each side of the net, tying at a maximum of 2.0m intervals, ensuring that no gaps are >100mm.For progression over long runs, the nets can either be butted end-to-end and sewn or overlapped. When overlapping a minimum of 2 metres must be overlapped.

Netting – Post InstallationOn Site Checks / Record Keeping All nets must be checked for compliance with the minimum tie spacings and permissible gaps. All areas are to be checked for any loose fixings that may have fallen on the floor (nets claws etc.)Upon completion of netting, a handover certificate must be completed and handed over to the client / Principal contractor by the netting foreman.

Damaged NetsDamaged Nets ReportAny nets that are damaged on site, either by SMD Operatives / Contractors or other site personnel, need to be reported to the Construction Manager and a Damaged Net Report needs to be completed. The area of damage must be identified using red and white tape and taken out of Service. The net must be returned to Marchington as soon as possible for repair. The net must be marked as damaged with a copy of the damage report.

IMPORTANT NOTE: Nets are not to be removed from any area until decking sheets are 100% fixed to the steelwork.

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Sample: Below shows a sample of a correctly completed damaged net report. The crosses indicated the rough locations of the damaged sections of the net.

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Netting – Good and Bad Practice: Bad Practice – (Unacceptable) Good Practice

Harness Inspection Just use any harness you can find

Carry out weekly inspections on all harnesses, plus a visual inspection before every use

MEWPS Delivery Sign for a MEWP with no anti-entrapment

Send the MEWP away and contact the Construction Manager of the lack of required safety features

MEWP Inspection Just get in the MEWP and start work

Undertake a full inspection of the MEWP prior to use and then once every 7 days. Keep a record of all inspections carried out

Working form a Ladder Just get on with the job Ensure that you have completed and have position of a relevant Ladder permit. Always ensure that the ladder is footed

Net fixings Only fix where it is easy to install

Net fixing must be at secured at every 2 meter centres

Netting Gaps exceeding 100mm

Leave as there it isn’t too much over 100mm

Ensure that NO gaps exceed 100mm install additional fixings to reduce the gap size

Netting test dates Continue using a net once it’s safe and tested life has expired

Ensure that all nets in use are within their test date. Nets that are out of date should be removed from service and returned to Marchington

Damaged nets Return to Marchington with all the other nets

Complete and get signed a net damage report. Indicate on the net the areas that have been damaged with red and white tape

Technical ReferenceAll nets are manufactured to BS EN 1263 part 1 and erected in accordance with BS EN 1263 part 2.

FASET guide (Copy available in the Site Foreman’s Manual, additional copies are available on request.)

IMPORTANT NOTE: All ladders must be class 1 or EN131. No domestic ladders are permitted for use on site.

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DeckingInstallation Guide

IMPORTANT NOTE: Before starting any works you need to set up appropriate segregation and fix exclusion / warning signs at all access points. These need to remain in place for the whole duration of the works until the area is handed over to the client.

Decking – On-Site OperationsAccess to LevelAccess to level will be via either a permanent stair (must be handrailed), temporary / HAKI stair or ladders. Access to the decked area should ideally be directly adjacent to the first decking pack to be fixed. If no access has been provided or you are unhappy with the type / location of the access provided do not commence work until you have contacted SMD Construction Manager and adequate access has been installed.

Understanding Pack LabelsDecking bundles are identified on SMD’s layout drawings and will have a unique identification tag (right). The packs are also marked with a spray line down one side to indicate how they should be loaded onto the steel frame. The spray line should face towards setting out point indicated on SMD drawing.

What do Spray lines on the Decking Indicate?The colour of the spray line on each pack indicates the gauge of the decking material. Check that the pack is the correct gauge as per the SMD drawing, and that they are facing the direction indicated by the pack reference on the SMD drawing. If the decking packs have been unloaded incorrectly please contact the SMD Construction Manager.

Green 0.9mm Gauge Blue 1.0mm Gauge Red 1.2mm Gauge

Painted Beam Top FlangesBeam flanges that are to receive shear studs must be left un-painted and free from excessive dirt or rust. When you begin laying out decking, should you notice any beams that are to receive shear studs are painted, contact the SMD Construction Manager immediately. All paint needs to be removed to enable the shear studs to be welded. If this is not done then the studs may not achieve the required weld strength. (DO NOT install decking onto a painted beam that is to receive shear studs). Refer to SMD Best Practice Data sheet 13 for further guidance / information on weld contamination, if required.

Using Setting Out PointsIt is important that the decking sheets are set out from the setting-out point indicated on SMD drawings. If the decking is not set out in this manner, you will experience issues where the bay terminates and the sheets may not finish as expected. This could result in the flashing provided not being adequate to finish off the bay / floor. It could also have an effect on the decking lining through between bays. If the drawings do not indicate a clear setting out point, contact the drawing office for clarification.

Safety Notice: Eye protection is replaceable, your eyes are NOT!

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DeckingDecking Installation Process

If People are working in your areas, please politely ask them to leave until your works are complete. If they will not do so please contact the Construction Manager responsible for the project.

Before starting work in any area please ensure adequate segregation barriers and warning work in progress signs are erected in line with the project method statement.

No areas of decking are to be left unfixed at the end of any working day. If a sheet has been laid it MUST be fixed in line with the current fixing specification.

Please remember all areas that we are working on must have an exclusion zone and warning signs in place before we start.

Nets are not to be removed from under decked areas until the decking above has been 100% fixed, this includes both the sheet fixing and side stitching.

Once you have accessed the area to be decked, you need to evaluate which pack to use first, ensuring that each end of the decking pack is situated evenly on the beams, i.e. no trapped end or insufficient bearing.

• The first pack should ideally be located next to the access. If not, the operative must safely straddle the beams to gain access to the pack.

• Once you reach the pack, the metal bands should be broken with either snips or using a hammer & twisting the band until it breaks. Ensure that the strapping is not allowed to fall into the safety netting below. Bands must be collected and placed in a skip.

• Once the bands have been removed, the first sheet can be slid into position (taking care as not to pull the sheet off the beams) to create a working platform.

• Repeat this process until all the sheets are laid out or the starting point has been reached. (Care should be taken when walking on loose sheets as they can be easily displaced). Some projects with limited or restricted bearing will have to be fixed as they are laid (i.e. single span decking onto angles). SMD Construction Manager will advise where required.

• All tools and edge trim MUST be tethered when working within 3m of the perimeter of any building.

• Once the starting point has been reached (as indicated on the drawing), the first sheet is ready to be fixed in place. This may need cutting / notching.

• If the sheet needs cutting / notching, it should be carefully marked out and then cut using a petrol driven saw / plasma cutter, in line with the contract method statement.

• Once you have cut the sheet, it can then be fixed in place using the Hilti cartridge tool or self-tapping screws, ensuring to check the sheet is square to the beam. The fixing type to be used will be indicated on the SMD project drawings and general notes.

Loading out materials on framework and packs positioning on beams

Stacked decking packs

NEVER double stack decking packs

If decking packs are double stacked, each sheet from the top pack will have to be double handled, sheet by sheet onto an adjacent area. This will involve unnecessary manual handling and expose the decking gangs to the risk of falling into nets below

•

•

¸

¸

¸

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FD.01.V3 - Sheet 1 of 1April 2010

Metal Cladding & Roofing Manufacturers Association

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Plan - Position of packs overlapping

Evelavtion - Position of packs not overlapping

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standard industry safety guidelines

FD.01Material loading out and positioning guidelines for Principal / Sub-Contractors

Fig.1

Decking packs should be loaded out as shown on deck General Arrangement (GA) layouts.

Paint stripe on the side of each pack must always point towards the setting out point shown on decking layout drawings.

If for any reason the decking packs cannot be loaded out as detailed on the deck drawings, the deck contractor representative MUST be informed and alternative plan agreed in writing before packs are placed.

Edge trim bundles to be loaded out as detailed on drawings.

NEVER overlap ends of decking packs, If packs overlap, the adjacent bay cannot be decked until the obstructing pack has been moved (sheet by sheet) involving unnecessary manual handling (See Fig.1).

Barrels of studs must be lifted to level and area using mechanical lifting devices (Crane/Forklift) to suit stud welding programme.

Failure to follow this will involve unnecessary manual handling and increase the risk of injury to decking operatives. This could also result in enforcement action from the HSE.

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Packs on site Positioning Example

Loading out materials on framework and packs positioning on beams

Stacked decking packs

NEVER double stack decking packs

If decking packs are double stacked, each sheet from the top pack will have to be double handled, sheet by sheet onto an adjacent area. This will involve unnecessary manual handling and expose the decking gangs to the risk of falling into nets below

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FD.01.V3 - Sheet 1 of 1April 2010

Metal Cladding & Roofing Manufacturers Association

Paint Stripe

Plan - Position of packs overlapping

Evelavtion - Position of packs not overlapping

¸

standard industry safety guidelines

FD.01Material loading out and positioning guidelines for Principal / Sub-Contractors

Fig.1

Decking packs should be loaded out as shown on deck General Arrangement (GA) layouts.

Paint stripe on the side of each pack must always point towards the setting out point shown on decking layout drawings.

If for any reason the decking packs cannot be loaded out as detailed on the deck drawings, the deck contractor representative MUST be informed and alternative plan agreed in writing before packs are placed.

Edge trim bundles to be loaded out as detailed on drawings.

NEVER overlap ends of decking packs, If packs overlap, the adjacent bay cannot be decked until the obstructing pack has been moved (sheet by sheet) involving unnecessary manual handling (See Fig.1).

Barrels of studs must be lifted to level and area using mechanical lifting devices (Crane/Forklift) to suit stud welding programme.

Failure to follow this will involve unnecessary manual handling and increase the risk of injury to decking operatives. This could also result in enforcement action from the HSE.

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• Then lap the remaining sheets, fixing at one end of each sheet. Marking up beam flanges with a marker pen as you go to allow stud welding to be undertaken correctly.

• Sheets should be cumulatively measured during fixing to ensure the specified cover width for the profile is achieved, i.e. 10 sheets should cover a width of 10 x cover width = 6000mm for R51 or TR80+ and 10000mm for TR60+.

• Before fixing the last sheet or cutting / notching another sheet, you must ensure that all the sheets in the bay are square. This can be done using the steelwork or first sheet fixed as a reference point.

• Once the sheets are square, the last sheet can be fixed or where required, sheets cut / notched. The sheets can then be fixed to the steelwork at the remaining un-fixed end of the sheets. Decking sheets must be 100% fixed down to the steel frame before safety nets are removed.

• If a single span pack is detailed, it will be delivered to site with a bottom sheet oversized to allow for a greater bearing for the pack when loading out. This sheet is to be cut to suit and used, once the rest of the pack has been laid out.

• Once all the decking is in place, the side laps should be stitched together with self-tapping screws at maximum 1.0m centres using a TEK drill, starting at the mid-span position (see right).

Plan – Position of packs overlapping Elevation – Position of packs not overlapping Fig.1 Paint stripe on the side of each pack must always point towards the setting out point shown on decking layout drawings. If for any reason the decking packs cannot be loaded out as detailed on the deck drawings, the deck contractor representative MUST be informed and alternative plan agreed in writing before packs are placed. Edge trim bundles to be loaded out as detailed on drawings. NEVER overlap ends of decking packs, If packs overlap, the adjacent bay cannot be decked until the obstructing pack has been moved (sheet by sheet) involving unnecessary manual handling (See Fig.1). Barrels of studs must be lifted to level and area using mechanical lifting devices (Crane / Forklift) to suit stud welding programme. Failure to follow this will involve unnecessary manual handling and increase the risk of injury to decking operatives. This could also result in enforcement action from the HSE.

Marking up Beam Flange Widths on Decking SheetsWhilst laying out and installing the decking, ensure that the beam edges are clearly marked onto the decking sheets using marker pen provided (as shown below). This indicates the beam top flange position and width to the stud welder, to ensure the shear studs can be positioned as required. It also eliminates the need for the stud welders to ‘bang’ the decking to locate beams, which can lead to site issues where the decking is provided as a finished soffit. Please ensure you mark the beam positions at 300mm intervals.

This example reflects the fixing spacing for floor decking only.

Good Example of Beam marking on Deck Sheets

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Ribs Running Through from Bay to BayOnce the first bay has been fixed, the adjacent bays can then be fixed by sliding the sheets into position and lapping together (ensure all ribs and troughs are in line with adjacent bays / areas). This may involve opening / closing sheet joints by kicking in / out adjacent sheet.

Cutting of SheetsWhen cutting / notching decking sheets or edge trim, ensure that the item being cut is not rested directly on other decking sheets or trim, as this can result in damage to the decking sheets or edge trim below.

Where a project requires a large amount of cutting, an area should be set up where the sheets can be cut safely without damaging any other materials. Sheets to be cut in isolated areas should be raised off the surface below, to prevent damage by way of cut marks and / or scorch marks on the decking or trim below.

Do not cut sheets near the perimeter of the building where possible, where unavoidable, always cut the sheets with spark plume facing into the building. Care must be taken so that decking sheets are not cut in a manor where sparks may damage the safety netting below.

Safety Notice: If a sheet feels heavy, it is! Always adopt good manual handling techniques!

Poor Sheet CuttingGood Example of Sheet Cutting

Poor Sheet AlignmentGood Example of Sheet Alignment

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DeckingPlasma Cutting

Plasma Cutters are sometimes required on contracts that are located in busy built up areas that are sensitive to noise pollution and disk cutting is restricted or not permitted. You will be made aware before your arrival on site if the contract has a requirement for the use of Plasma Cutters.

ONLY operate plasma cutters if you have been trained to use them!

DO’s and DON’T’s:• DO NOT use plasma cutters in the rain or on wet surfaces.• DO NOT let electrode / cutting head burn down too far as this will cause damage to the torch. (approx. £250 to replace)• Change heads regularly.• Check machine for general maintenance and always bleed air daily.• Check oil on a daily basis.

Cutting Out Ribs Over Beams (TR+ profiles)Where the decking ribs fall over parallel beams to be stud welded, the rib must be cut away and flashing used to enable studs to be fixed (see typical detail below).

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DeckingNotching – Examples of Good and Poor Notching

Gaps deemed too big to foam / tape (i.e. inside columns) should be patched using offcuts of deck or trim. When patching areas, take your time to ensure a professional finish. See good and bad examples below.

With a bit of time and effort the decking and edge trim can be cut into the steel frame leaving a neat and tidy job (see example 1.0 above) and avoiding the need for excessive patching! If any jobs are left below standard (such as bad examples 3.0-6.0 above), you will be required to return to site in your own time and at your own expense to rectify the work.

1.0 – Good Example – Column Infill 2.0 – Good Example – Notching around base connection

3.0 – Bad Example – Column Infill 4.0 – Bad Example – Column Infill

5.0 – Bad Example – Column Infill 6.0 – Bad Example – End Capping

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Flashing Details and ExamplesIn situations where the decking sheet needs to be trimmed along its length to suit different cover and bay widths, flashing may be required to close the gap between the sheet rib / trough and the edge of the beam.

End CapsEnd caps are used at the ends of sheets at edges or changes in deck span direction, to minimise grout loss. We only use end caps on the TR+ profiles, with R51 the small gap at the end of the ribs can be adequately sealed with either tape or expandable foam. End caps are fixed to the top of the ribs with a single TEK screw. Please note end caps will typically be delivered to site in bundles of 50, taped into the edge trim packs. Please note end caps are universal for both decking profiles, one way up for TR60+ and the other way for TR80+.

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Edge TrimGalvanised edge trim is provided where required around perimeter and void edges. This edge trim acts as permanent formwork only to support the wet weight of concrete during construction.

Typically edge trim is supplied to site in lengths of 3.0m where it is then cut to suit on site. Edge trims are available in four gauges; 1.0mm, 1.2mm, 1.6mm and 2.0mm. The material gauge is determined by the depth of the concrete slab and the extent of the slab overhang (see table, right)

Edge trim can be either fixed to the end of the decking with TEK screws or to the main supporting structure using similar fixings as that used to secure the decking (see details on page 18).

Safety Notice: If in doubt, Ask! It’s not worth the risk.

Overall Slab

Depth

Edge Trim

Dimension from toe of Beam

1mm Gauge 1.2mm Gauge 1.6mm Gauge 2.0mm Gauge

130mm 70mm 125mm 160mm 200mm

150mm 50mm 115mm 150mm 185mm

175mm 25mm 110mm 145mm 175mm

200mm NA 100mm 135mm 165mm

250mm NA Propping Req’d Propping Req’d Propping Req’d

Guide for Maximum Unpropped Slab Edges

Edge Trim InstallationBefore fixing trim in place, a trim tether must be attached through one of the pre-drilled holes in the end of the trim, with the other end of the tether fixed to the handrail. This prevents the trim falling in the event that you lose grip on the trim, a trim tether must be used at all times. The trim is then fixed using a cartridge tool applied direct to the steelwork or by self-tapping screws in the case of ‘stitch on’ trim.

Sequence of work for installing edge trims is as follows:1. Check drawing, assess trim types required and locate relevant trim types within correct trim

bundle for phase or floor etc.2. Load out trim around perimeter of floor and adjacent to voids, ready for installation.3. Using SMD drawing and beam size assess the trim position relative to edge of beam. Mark CL

of beam on top flange and measure slab edge, then determine the dimension from slab edge to toe of beam.

4. Starting from column location or corner, attach trim tether to hole in trim and to handrail (or similar anchor point), sit trim on beam and measure required offset using tape.

5. Fix one end of trim into position using shot-fired fixing and check offset dimension.6. Fix other end of trim into position using shot-fired fixing and check offset dimension.7. Install intermediate shot-fired fixings at 750mm centres and remove trim tether.8. Repeat for all edge trims.9. Install restraint straps onto trim lip at 750mm centres (or 500mm for slab depths >200mm)

using TEK screw and either fix using TEK screw onto adjacent decking (preferred) or shot-fired fixing onto adjacent top flange dependant on site detail. Maintain a minimum 45 degree angle on straps where possible.

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Poor Example of Edge Trim InstallationGood Example of Edge Trim Installation

When stitching on trim the cantilever decking must be cut back to an accurate line using the dimension on SMD drawings to allow the trim to be fitted in place and secured with TEK screws from above. The general principles above apply, with shot-fired fixings replaced with TEK screws. The cutting back of cantilevered deck must be done within the building frame on a safe platform, not outside the building line!

The sheet that is due to be cut should be offered up in to position, measured and marked to denote the line of the required cut. This sheet should then be removed back on to a safe working platform within the building and cut along the marked line. The sheet can then be fitted in to position and appropriately fixed.

Standard edge trim is supplied in 3m lengths with holes pre-drilled to allow trim tethers to be fixed to the trim. Trim tethers are to be used on ALL contracts.

The edge trims must be fixed at the dimensions indicated on SMD drawings, ensure all dimensions are as accurate as possible as the acceptable tolerance in our contract is +/- 10mm. This requirement can be reduced on certain projects, ALWAYS check with the Construction Manager before starting.

The edge trim should be cut / notched around columns, handrails etc. as required. As noted in the decking section, care should be taken when notching edge trim to ensure a professional finish (refer page 16).

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Cantilever Decking (stitch on trim)Decking can be detailed to cantilever up to 450mm from toe of beam as indicated below, unless greater distance agreed with SMD Technical Department, where this is the case it will be indicated on the SMD layout drawings.

Wherever practical sheets should be fixed so that the ends line through without the need for further trimming in-situ. Trim will be ‘stitch on’ fixed with TEK screws at both ends and at 750mm centres along its length.

A trim tether must be used at all times and this may be a two man operation!

IMPORTANT NOTE: Overhangs >450mm will require temporary propping in place prior to installation of decking, unless agreed otherwise with SMD Technical Department.

Edge Trim Direct to Steel Edge BeamTrims fixed direct to steel beams must have a minimum bearing of 50mm and be secured at maximum 750mm centres using shot-fired fixings (unless noted otherwise on SMD drawings). Ensure that ends of trim closely butt together and straps are installed to restrain the trim.

Where 750mm centres are not be achievable the trim should be fixed in every other trough.

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IMPORTANT NOTE: Safety Handrails by others must be installed such that access can be gained safely to enable installation of the edge trim. If it is not possible to install the edge trim safely due to the type or location of the handrail, contact the SMD Construction Manager before proceeding.

Safety Notice: Slips, trips and falls account for 28% of all reported major injuries on construction sites! Make sure you work in a tidy manor.

Edge Trim to Blockwork or MasonryTrims fixed to blockwork or masonry must have a minimum bearing of 70mm and be secured at maximum 750mm centres using Hilti X-SW 30 ‘Mexican Hats’ shot-fired fixing’s or hammer screw type fixing’s (unless noted otherwise on SMD drawings). Ensure that ends of trim closely butt together and straps are installed to restrain the trim.

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Engineered Trim PositionsWhere a tighter tolerance on the trim position is required, edge trims may need to be installed to engineered gridlines instead of from centre line of beam. The specific procedure on site will depend on the engineer providing the marked positions physically on the deck / beams. For example; some engineers will mark the actual grid line on the decking once laid which makes the trim fixing procedure very simple as it can simply be fixed relative to this line. However, other engineers may provide dimensions at column locations indicating the difference between the theoretical column location and the actual location to allow the true slab edge position to be interpolated. The SMD Construction Manager on any contracts involving engineered trim installation to grids will explain the system to be adopted on site.

Faceted Trim to Form CurveWhere a curved edge is required, the trim must be slotted to enable the trim to be bent to form a faceted edge with the required radius (See below).

Faceted edge trim should be faceted to suit the site conditions. In some instances you will be required to facet the trim around an existing element of the structure with a defined offset. Here you must ensure you facet the trim adequately to follow the form of the structure. Alternatively, there may be a curved piece of steel frame below as a guide and in some situations there will be a series of co-ordinate or off-set dimensions indicated on the SMD Drawing (below).23GUIDANCE

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Restraint StrapsRestraint straps are to be fixed at 750mm centres generally, with frequency increased to 500mm centres where the slab depth is greater than 200mm.

Restraint straps are typically supplied as 25mm wide strips in standard 3.0m lengths or pre-cut to 300/500mm to suit project specific requirements. If supplied in 3.0m length these will need to be cut on site to suit the slab depth / overhang.

Good Example of Faceted Edge TrimGood Example of Faceted Edge Trim

Bad Example of Restraint StrapsGood Example of Restraint Straps

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Once the trim has been fixed, restraint straps need to be fixed from the lip at the top of the edge trim back to the metal decking. In some instances two rows of straps will be required if an upstand or deep slab is required.

Maximum height for edge trim with a single row of straps is 300mm, any sizes greater than this will have the required strapping detail indicated on SMD drawing. If no specific detail is shown refer to SMD Technical Department. Double row of restraint straps for upstand detail:

Foaming Up – Good and Bad PracticeThe pre-cut end caps supplied are to be used to seal the ends of the TR60+ and TR80+ profiles. When installing R51 profile the ends should be sealed using tape or expanding foam. (Please note, when installing structural roofing profiles foaming up / sealing is not necessary, requirements for sealant or mastic tape will be referenced on the SMD drawings).

All gaps in excess of 3mm must be sealed using expanding foam (see examples of good and bad practice below).

Good Example Bad Example

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Waste RemovalOn site waste management can be an issue with our clients and we need to make sure we are helping towards the management of these waste materials. Managed correctly this can also have a positive result for the business.

For further guidance please refer to the project specific method statement. See SMD Best Practice Sheet – DATA/07 – Disposal of Waste

Safety Notice: If you have a near miss, report it immediately. If you don’t, someone else might not be so lucky.

Good Example Bad Example

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Temporary ProppingWhen should it be installed?

Temporary propping may be required during construction to support the wet weight of the concrete and any construction imposed loads. When temporary propping is required to a span, SMD decking layout drawings will indicate the areas where temporary propping is required with a chain-dotted line and the notation TP.

In some instances the temporary props will need to be in place PRIOR to the decking being laid out and fixed. If this is a requirement, the Construction Manager will try to ensure that the props are in place prior to your arrival on site, but ALWAYS check. As a guide, the temporary props should be in place prior to fixing if the spans are greater than 4.0m for R51 or 5.0m for TR60+ and TR80+. Additional consideration will need to be given to the method of fall arrest used in this situation.

Always ensure that you check all SMD drawings you are going to be working on, that no temporary propping is required before starting. If you see any spans that you are not comfortable with, please call SMD office or Construction Manager to discuss, before proceeding. Installation of a sheet outside the above criteria could lead to a collapse and serious injury! If ever in doubt please ASK.If temporary propping is required, it will be indicated on the SMD Drawings and noted ‘TP’ as shown (below).

Temporary propping should look similar to that shown (below). If you are concerned with the standard or form of propping, contact the SMD Construction Manager.

IMPORTANT NOTE: Along with checking to ensure temporary propping is in place it’s important to highlight any locations around columns that require additional support prior to the decking being installed. If additional support is required, this must be communicated to the Construction Manager as soon as possible.

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Surplus MaterialsDeckingWhen the decking operations have been completed on site, ensure any useable decking sheets (2.0m sheets as a minimum) with straight ends, not raking cut ends, are stacked together in a central location. Contact the SMD Construction Manager to advise them how much surplus material is left on site. They will then make the necessary arrangements for this to be collected, where commercially viable.

Edge TrimAny excess edge trim should be stored on site at a central location. Once the project has been decked, trimmed and we are sure that no additional materials are required, contact the SMD Construction Manager to advise quantity of surplus trim / flashing. They will then make the necessary arrangements for these materials to be collected either by the studders when they are on site or the flat bed depending how much surplus material is to be collected.

Managing surplus materials, both decking and edge trim, back to our depot at Marchington allows us to build up a surplus material stock. These materials can be then called off and delivered or collected to manage minor problems or errors on site and help reduce the costs associated to any problem / error both for SMD and our clients.

On-Site Checks Before LeavingBefore leaving site at the end of your shift, the following checks should be made.

Site Checks• Is the decking and edge trim set out in accordance with SMD Drawings?• Are decking ribs in line throughout the building?• Has all of the scrap been removed and where necessary, adequately secured?• Are all gaps > than 3mm adequately sealed?• Have all fixings been installed at the correct centres and locations?• Are edge trim restraint straps at the correct centres and edge trim is rigid?• Has any loose materials or scrap been secured to the deck with strapping?• Has all hot works been finished in accordance with site permit procedures?• Ensure good housekeeping by removing all spent shots, material off cuts, failed studs

& empty foam cans.• Ensure any incomplete areas are adequately barriered off with the correct signage in place.

DO NOT expect following gangs to rectify any areas or items that you have left uncompleted!

If any areas are left uncompleted, you will be expected to return to site to rectify the situation, in your time and at you own expense!

It is recommended that you finish work 20 minutes before end of working hours to ensure you have adequate time to check your work.

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Decking – Good and Bad Practice: Bad Practice – (Unacceptable) Good Practice

Painted top flanges Carry on and deck the area Prior to rigging nets check the top flange. If painted stop, inform the Construction Manager and do not rig nets until you have been instructed to proceed

Access Just get on to the level by any means. Even our own ladders

Do not gain access to the working area unless it is from approved safe method that has been installed by others

Marking beams Do not mark the location of any of the beams

Clearly mark the beam locations on every sheet

Decking alignment It doesn’t matter if the ribs line up at the lap joints

All of the ribs must line up at the lap joints

Cutting sheets Proceed with cutting of sheets without hot works permit as there is no one site

Always sign up to a hot works permit before carrying out any cutting works ensure that the cool down period stipulated is adhered to and the permit signed off at the ends of each shift

Ribs over beams Just deck over the beam leaving the rib in place

Cut out the rib and install suitable V or Z flashing

Foaming up Gaps left in excess of 3mm All gaps in excess of 3mm should be sealed up with expanding foam

Trim Always install trim to the edge of beam

Always install trim to the dimension stipulated on the drawing from the centre line of the steel

Start off point Start off from where every you want Always start off from the point stipulated on the drawing

Strapping Install strapping at trim but joints only

Install strapping at 750mm centres or 500mm if the trim is higher than 200mm

Drawing query Carry on as to how you think it should be installed

Stop check with the drawing office. If in doubt ask

Strapping Scrap & loose sheets to the deck

There is no need just leave them loose

All loose materials must be strapped and secured to the decking at the end of every shift

Missing or Incorrectly installed Steel Beam

Carry on and Deck the area Contact SMD Construction Manager and seek further advice

Plant, Materials or Other Obstacles below work area (Within 2m)

Carry on and Deck the area Liaise with client representative and make arrangement for the obstacles to be moved

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Technical ReferencesThere are numerous references that cover the design and installation of metal decking and shear studs. The most commonly used and referenced documents are:

BCSA PublicationsBCSA Code of Practice for Metal Decking and Studwelding – Publication No 37/04National Structural Steelwork Specification for Building Construction 5th Edition (NSSS)

Concrete Society Good Concrete Guide 5: Composite concrete slabs on steel decking.

The Steel Construction InstitutePublication P300 – Composite Slabs and Beams using steel decking: Best practice for design and construction.

Some of the more critical aspects from these publications are covered in the SMD Technical Manual, you will have been provided a copy of this manual on joining the company. Any queries relating to its content should be directed to SMD Technical Department. (Please note, copies of all of the above documentation are available on request from Head Office).

Drawing FeedbackForemen are required to provide both good and bad feedback on drawings, by way of marking up returned drawings sent in with time sheets. This may include suggestions of more suitable deck / flashing / trim details in certain circumstances or just general feedback on any aspect related to the decking and / or studding works. It is also useful to have feedback where a particular detail works well, as this enables the drawing office to gain continuous practical knowledge to consider alongside the theoretical detailing process. In some instances, particularly on more standard and straight forward projects, the comment may just simply be decking / studs installed without any detailing issues.

This feedback will enable us to continuously develop our library of preferred details from both a commercial and practical perspective.

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IMPORTANT NOTE: The procedures outlined in this section ensure compliance with BS EN 14555 : 2014 and MUST be followed.

Installation Procedure, Setting up your EquipmentIt is very important that the welding set and guns are adjusted for the type of welding (thru’ deck or straight to steel) and type / grade of steel on the project, in accordance with the Welding Procedure Specifications and SMD Training provided.

Thru’ deck stud weldingWhere the shear stud is welded to the steel beam through the decking sheet. This is the application most common on site (see below). Note: All site stud welding to beams perpendicular to the deck span should be thru’ deck welded, unless noted otherwise on SMD drawings or agreed with SMD Technical Department.

Straight to steel stud weldingWhere the shear stud is welded directly to the steel beam. Straight to steel welding is normally carried out in a fabrication work shop. Note: This operation requires a different type of ferrule.

Setting up the ‘Nelweld 6000’ Before any settings can be made to the welding set, it has to be connected to the power supply and switched on. The connection of the machine to the power supply must only be carried out by a trained and competent person.

Once the welding set is connected to the power source, switch the machine on. When the machine is first switched on it will run through a sequence of self-tests. These will show up on the LED screens on the machine front display cards. When these tests have completed, the existing settings will show up on the screens.

There are four screens on each welding set, two for each line. Line one is on the right hand side of the set as you look at it and line two on the left. The top screen on each side is for the welding amperage (power) and the bottom one for the welding time for each weld.

For thru’ deck stud welding the amperage may have to be adjusted quite frequently due to the thickness and / or grade of the steel you are welding to or the distance between the welding set and the area in which you are welding. If you are only using a small amount of cable, typically less power

Shear Stud WeldingOn-Site Operations

Shear stud thru' deck welded to steel beam (ferrule not yet removed)

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is required than if you are using the maximum amount of cable. Thru’ deck welding amperage settings would normally range from 1350 amps up to 2000 amps. The only shear studs that are normally used for thru’ deck stud welding are 19mm in diameter. Unless noted otherwise on SMD drawings.

Thru’ deck welding time settings normally range from 1.35 to 2.0 seconds. Again, this is dependent on the thickness and grade of the steel along with how much weld cable being used.

For straight to steel welding, settings for both amperage and weld time varies more than thru’ deck welding due to the amount of various studs and grades of steel used. For the settings required on these contracts, speak to your line manager.

Gun SettingsWhen you are setting the welding gun up you should ALWAYS have it disconnected from the cables.

Lift SettingsLift setting is approx. 4mm for straight to steel welding and approx. 4-6mm for thru’ deck stud welding. This is adjusted by the large threaded section at the top of the gun (marked 1 above). Before you attempt to make any adjustment, you will need to free a small locking screw in the side of the adjuster. The easiest way to adjust the gun to the measure of lift that you require, is by winding the lift adjuster in flush with the top of the lift adjustment housing. Then for every full 360 degrees you turn the adjuster out it will provide 1mm of lift.

Protrusion and burn off settingsProtrusion and burn off settings are set by the legs of the gun that hold the ferrule grip in position. To make adjustments to these settings, loosen the two small grub screws on the side of the gun (half way down, one on each side – marked 2 above). This allows the legs to slide up and down inside the housing. Whilst setting this you will need to have two studs and one ferrule to hand. The setting is determined by how much the stud is protruding through the bottom of the ferrule when both the stud and ferrule are in position in the chuck and ferrule grip respectively. For thru’ deck stud welding you should have the depth of a stud head protruding out of the bottom of the ferrule (approx. 10mm). This is where you use the second stud, by offering the stud head up to the underside of the ferrule to measure the setting. For stud welding straight to steel, this amount should be halved to give a protrusion of approx. 5mm.

Plunge settingsPlunge settings should not have to be adjusted on site, this is governed by the tightness of the plastic cap that goes over the end of the damper on the underside of the main body of the gun. If you have problems with the plunge you should speak to SMD Operations Manager.

Safety Notice: If you think we could do something better, say! SMD will always listen to any innovative new ideas to improve our industry.

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Lift setting adjustmentGrub screws for protrusion settingFerrule gripChuck

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All parts of the gun should be fixed into place as straight and secure as possible before commencing welding.

All operatives should receive suitable training before making any adjustments or carrying out any repairs to any of the equipment. No repairs should be carried out unless instructed by SMD Operations Manager.

Preparing Your Area of WorkOnce the equipment tests have been completed, you should then check the area to be stud welded. This includes the areas below and alongside for flammable materials, plant, anything that could get damaged and other trades.

When the area is clear to work on, exclusion strapping and appropriate signage must be erected around the area to segregate it and ensure other trades do not enter the area, or area below, whilst welding is in progress.

Inclement Weather – Should I Stud or Should I go?Please note that studs should not be welded in wet weather. Moisture vastly affects the quality of the weld and failure rates will increase. If the decking is wet, a small part of the area should be blown off and allowed to dry whilst carrying out further checks and starting up the welding plant.

IMPORTANT NOTE: All standing water and moisture should be blown away and left to dry before welding commences. If you are unsure, discuss with your Construction Manager.

Lifting Studs to LevelThe lifting of the studs to level is the responsibility of the client, the sequencing of the lifts must be managed on site between the SMD foreman and the Clients site staff. Any other heavy welding equipment that can be mechanically lifted to level to prevent any unnecessary manual handling, should then be considered.

All other remaining equipment, such as tools and ferrules can then be carried up safely to the working area or level.

IMPORTANT NOTE: All studs and heavy equipment MUST be loaded over a supporting member! We should insist in the client lifting the studs to level.

Pre-Start TestIf the welding set is powered by a generator, the generator should be started and allowed to run for approximately ten minutes before it is put under load for mechanical reasons.

You should then check whether the decker’s have marked out all beams that require stud welding. If not, the welding operatives should carefully bang the decking either side of the beam flange to define where the edges of each beam are located. Sometimes this is not acceptable due to the decking providing the finished soffit on the underside of the floor. Where banging out is necessary, this should be checked with SMD Construction Manager to avoid problems when the area is being handed over.

Welding Procedure Qualification Tests (WPQR) must be undertaken on ALL stud welding worksThe ‘WPQR’ is the set-up test that MUST be carried prior to starting works. The settings used must be within the parameters indicated below in SMD Through deck Welding Procedure Specification (WPS).

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Through Deck stud welding WPS qualified settings

At the start of each stud welding shift, following any change in settings or after the welding equipment has been moved, a minimum of 10 No test studs shall be welded. These studs will be bent to 30°.

If one of the studs fails, two additional studs are to be welded and tested, if these further studs fail, the settings and conditions MUST be assessed to determine corrective action required, if necessary contact Construction Manager for advice. Once corrective action has been undertaken the WPQR test must be repeated.

IMPORTANT: The WPQR welding set settings (Amps, Time, Lift and Plunge) and results must be recorded on the drawing, as drawing example Drg 01. on page 42.

Why?The ‘WPQR Test’ is not optional as this ensures the welding equipment settings and conditions are qualified to achieve the required weld quality. The documentation records are essential to provide quality assurance records to the client.

Shear Stud QualityIf the shear studs turn up and seem of a poor quality do not use them. Report it to the Construction Manager and Stores.

Maximum of 4 No cables to be used at any one time as a standard practice. This may be exceeded in some circumstances but must be discussed with the Construction Manager.

There are many reasons for a weld to fail, the following points should all be checked before any adjustments are made to the welding set or gun.

• Check the area and ferrules are dry and have not been contaminated by anything such as diesel. If the ferrules are wet you would tell just by touch. If they have got any other fluid soaked into them you would smell it when welding, it would also discolour the ferrule and the weld.

All equipment and ferrules should be stored in a dry place whilst not being used.

WET FERRULES SHOULD NEVER BE USED

• Check there is nothing on the steelwork, such as paint or diesel. Again, the best way of checking this is by the smell when welding the stud. If it is mud or heavy dust you will tell, as when welding the stud it will blow away the weld from around the stud, leaving no fillet.

• Check for any water under the deck. It is possible for deck to be laid on top of wet steel and wet weather continues so steel does not dry out. Or where a lot of rain has fallen it can soak through the butt ends of the deck onto the steel and not have adequate time to dry out.

Welding Current (Amps)

Welding Time (S)

Protrusion (mm) Lift (mm) Remarks

1500-150 / +500

1.5-0.15 / +0.5

6-10mm 4.0 – 6.0mm None

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• There may be small gaps between the deck and the steelwork (referred to as ‘deck lift’). This can be caused by many reasons such as deformed deck or steelwork, decking not being fixed correctly or a steel beam fixed slightly higher than the adjacent beam. We can overcome this problem by knocking down the deck in the problem areas where the stud and ferrule are to sit, this should only be required in isolated areas.

• If the problem is not caused by any of the above, the problem may be with the settings on the welding set or gun. If it is not the gun, then you should try changing power and / or time settings. However issues such as these should be identified in the WPQR pre-start checks.

Safety Notice: 59% of construction related fatalities are caused from falling from height. Ensure that you have received the correct training for the role that you are being asked to undertake!

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Installation ProcedureShear Stud SpacingThere are many different setting out patterns for the studs and the ones you are required to use on each contract are normally on the drawings. Please see below details that set out the required spacing information.

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IMPORTANT: The above shaded note is a change from previous practice and must be followed wherever possible!

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Testing of Shear Studs – Ring, Bend and Visual TestsProduction Surveillance Testing – Test as you go!When carrying out stud welding you should not leave the testing of the studs to the end of each shift. You should weld up to 200 No. studs and then keep dropping back to remove the ferrules and visually check the welds and ring / bend test as you go. This will avoid having a large quantity of studs with poor or unacceptable welds.

Should visual inspection reveal studs not having a full 360° weld fillet and fail a ring test, studs will be bent by placing a steel tube over the stud and bending approximately 15° (1 in 4) from vertical towards the nearest end of the beam. If the weld does not fracture, the stud should be considered acceptable and left bent. Studs that fail this test must be replaced

If all the studs pass the visual inspection and ring test, the greater of 2 No. studs per beam or 5% should be bend tested; if a failure is found then the 3 No. studs welded on either side of the failed stud should also be bend tested If one of these further six studs fails, contact the Construction Manager for advice.

If any failures occurs, the decking environment, studs and equipment should be checked and reset, replacement studs welded and tests repeated to ensure acceptable quality. Typically operatives that are experienced on the welding gun will tell by the sound and feel of each weld if they are welding correctly.

Studding Hand overs:The Stud welding foreman must complete a Stud Welding Handover Form, as shown over the page. This must be accompanied with a marked up drawing showing the position of the Qualification test of 10 studs bent to 30° marked WPQR. This must include any failures and re tests that are undertaken. The WPQR welding set settings (Amps, Time, Lift and Plunge) and results must be recorded on the drawing, as shown below. All studs that have been bent to 15° must also be highlighted as either a pass (P) or fail (F).

Drg 01

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Decking / Studding Handover Sheet

Structural Metal Decks Ltd Unit C The Outlook Ling Road Tower Park Poole Dorset BH12 4PY UK Tel: +44 (0) 1202 718898 Fax: +44 (0) 1202 714980 Email: [email protected]

Signed for SMD: Print Name: Position: Signed for Client: Print Name: Position:

Legend: White - Client Pink - SMD Supervisor Yellow - SMD Offi ce

Contract:

Final Handover Qty: Trim Waste: Desk Waste:

Client:Job No: Date:Handover No:

AREA HANDED OVER: (Refer to level / grid reference / etc.)

We have together / independently inspected the above area and confirm that it has been completed in accordance with Structural Metal Decks Ltd Drawing No.:

Decking / Edge Trim: Yes No N/A Comments:

Are props in position as noted on SMD’s drawings?

Is deck / trim set out in accordance with SMD’s drawings?

Are ribs in line throughout the length of the building?

Are bearings equalised at butt joints and greater than 50mm on all steelwork and 75mm on concrete / masonry?

Has all scrap been removed to skip or area in central position?

Are edge trim restraints straps and pins at correct centres and trim rigid?

Is there adequate support around columns?

Is side stitching at correct centres?

Are all gaps > 3mm sealed?

Studwelding: Yes No N/A Comments:

Have ferrules been broken away for visual inspection?

Have minimum of 2 or 5% (whichever is the greater) studs been 15 degree bend tested on all beams?

Are studs on all beams as drawing?

Are studs spacings and edge distances correct?

Are studs staggered at butt joints?

Are all Shear Studs located in the favourable side of the trough? (TR60 / TR80 ONLY)

DISCLAIMER – On signing this form you are confi rming works have been completed as described above, to an appropriate standard. With the exception of latent defects, any remedial works required once handover accepted, may result in additional costs being incurred.

SMD 33673 (03/14)

Ferrule Breaking, Picking and DisposalFerrules should be completely broken away from the base of the stud to allow a full visual inspection. For some contracts you will be required to remove the ferrules. The SMD Construction Manager will instruct you when this is a project requirement.

Failed StudsOnce the phase or contract is complete, all failed shear studs should be collected up, accounted for on your time sheet and returned to nearest Logistics Centre for re-cycling. All failed studs must be returned and accounted for. Any other waste such as empty barrels, ferrule boxes etc. should be removed from the welded area and placed into the correct skips provided on site, and in accordance with waste management procedure on page 30.

On-Site Checks Before LeavingIt is very important that you take responsibility for your work. Before leaving site, the area should be checked to make sure all studs have been fixed in accordance with SMD drawings and no beams that require studs have been completely missed. If SMD drawing does not show either a stud specification or the letters NS to indicate ‘No Studs’, check with the drawing office contact noted on the drawing – DO NOT assume that this means ‘No Studs’!

Before leaving site at the end of your shift, the following checks should be made. It is recommended that you finish work 20 minutes before leaving to ensure you have adequate time to check your work.

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• Have all ferrules been broken away for visual inspection & collected if necessary?• Have all of the studs been installed in accordance with SMD Drawings?• Are the studs staggered at all butt joints?• Are stud spacings and edge distances correct?• Have pre-production tests, surveillance tests been carried out and recorded on drawings

as required?• Have all failed studs been collected up to be returned to the nearest Logistics Centre?• Have the lids been secured of part barrels of shear studs to ensure they are secure and

moisture will not contaminate the materials?• Have the ceramic ferrules been left in a safe dry place?• Ensure all hot works are completed in accordance with site permit procedures.

IMPORTANT NOTE: DO NOT expect following gangs to rectify any areas or items that you have left uncompleted. If any areas are left uncompleted you will be expected to return to site to rectify the situation, in your time and at you own expense!

Safety Notice: Don’t just walk by, if you see anything that concerns you with regards to Health & Safety – Report it!

Foaming Up GapsOccasionally, when carrying out the stud welding process, areas that have been foamed up previously by the decking gangs to reduce grout loss may get damaged. If this happens, DO NOT just leave it, the foaming will need to be replaced to ensure excessive grout loss does not occur during concreting.

Stud CountAt the end of each shift make a note of how many studs you have fixed, the number of failures, stud type and the Studs charge number on the barrel sticker. This information must be added to your weekly time sheet. Recording of this information is a critical requirement of BS EN 14555 : 2014 to ensure traceability of studs used on specific contracts.

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Stud Welding – Good and Bad Practices

Bad Practice – (Unacceptable) Good Practice

Testing of Studs Ignore testing and see what the site engineer picks you up on.

Bend test studs on each & every beam, bending using a bar towards the nearest beam end. Replace failed studs and test studs either side. Ring test any studs not displaying a full weld fillet.

Flammable Materials Not your responsibility – you’ve got a hot work permit!

Check area below works prior to commencing. Satisfy yourself that all flammable materials have been removed. If in doubt ask!

Failed Studs Leave on deck as additional reinforcement

Collect & remove from decked area. Return to Marchington for stock reconciliation.

Painted Beams From fumes & weld quality you can tell beams are painted. Crack on regardless – you are on a price.

From fumes & weld quality you can tell beams are painted. Stop, investigate and inform Construction Manager. Deck may need to be lifted & paint removed

Wet / Cold Weather Crack on but don’t test studs because they might fail.

Undertake test studs, adjust set up as required, if appropriate proceed with caution but increase testing regime accordingly.

Other Trades Ignore them if in your area – they’ll get fed up of being burnt

Stop, advise Construction Manager / Client and communicate issues back to office if necessary.

Removal of Waste Pile it high – get away quick or leave it scattered across deck so as to be less conspicuous.

Read & understand method statement, action as directed, if physically cannot be removed contact Construction Manager to discuss and note on the handover sheet.

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Site AdministrationSite Installation Guide

CommunicationGood communication is essential in all parts of the site installation process. Operatives, Foremen, Construction Managers, Logistics Manager and Operations Manager all have their part to play in the communication that ensures effective, efficient completion of any process and continual improvement of the Company.

Key communication stages are:1. SMD Construction Manager agrees programme and sequence with client, together with any

special requirements for the contract (e.g. HVB’s or concrete fixings required) and communicates to Logistics Manager.

2. Logistics Manager communicates general information (e.g. drawings, RAMS etc.) together with full site address, contact details and any special requirements to operatives.

3. Foremen communicate with client upon arrival at site and report any issues to Construction Manager / Logistics Manager / Drawing Office as works proceed. Simple actions, such as a phone call to the Construction Manager mid-morning to advise that anticipated completion that day is looking unlikely, allows time for alternative arrangements to be made without a last minute panic! Similarly, if you are going to be late in the morning, the simple courtesy of letting someone know will greatly reduce the impact.

4. Foreman must contact the Construction Manager at the end of each shift as a minimum to inform them of the progress throughout the shift.

COMMUNICATION – DON’T LET IT BREAKDOWN!

AccidentsAnnually the Construction Industry accounts for approximately 27% of all fatalities at work. Along with this the Construction Industry accounts for 35% of all reported injuries involving falls from height annually.

WE WORK IN CONSTRUCTION AND WE WORK AT HEIGHT – WE ARE AT RISK!

Accidents cost in many ways:• Physical Pain • Disability either permanent or temporary• Loss of Life• Emotional Costs• Financial Costs

It is important that ALL accidents and near misses are being reported, so that we can investigate the cause fully, record details of individuals involved and any materials damaged. The most important aspect of any incident is to learn from it so a recurrence can be avoided.

In the event that you are involved in any accident, immediate first aid attention for any injured persons is the initial priority. This should be sought via the first aiders on site, or the emergency services if necessary. As soon as possible, the incident should be reported to SMD Construction Manager or, if unavailable, to SMD Logistics Manager or Operations Manager. If required, SMD will make an entry in the site Accident Book and if required, report to the HSE. It’s important that near misses are reported. If it happens again somebody else may not be so lucky.

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Time SheetsThe foreman in all site operatives’ gangs (deckers, netters and stud welders) are required to complete weekly time sheets. The information stored on the time sheets is critical for the job costing information that is compiled at Head Office. Some examples of time sheets that have been filled in correctly are shown below.

All sections must be completed, with maximum information supplied. Moving forward, incomplete time sheets will not be able to be processed through the wages system, as full data is required to process payment of wages.

Example of Decker / Netter Time Sheet

IMPORTANT NOTE:

• Please ensure information is input daily.• If claiming an day rate, please ensure actual fixed quantities are also included.• Please ensure you log all failed studs (these must be returned to Marchington).• All consumables must be accounted for on a daily basis.• All mileage should be logged, however small!

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Mark-up Wages Drawings All weekly time sheets must be submitted / backed up with marked up drawings showing the work completed that week. The marked up drawing must be clear and show an accurate reflection of the work completed that week.

If an area has not been 100% completed in the period, the following information needs to be clearly highlighted on the drawings:

Nets Rigged / Nets De-rigged / Deck Fixed / Edge Trim Fixed / Shear Studs Fixed.

IMPORTANT NOTE: If for whatever reason a part drawing is being marked up, the mark-up MUST contain the number of the drawing that the extract is from.

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Confirmation of InstructionReceiving instructions for work outside the confirmed scope is extremely important. Instructions must detail the changes that have been requested by the client. All instructions MUST be conveyed to the Construction Manager and the drawing office.

Failure to manage this situation correctly can lead to SMD not being paid for any additional work or in the worst case scenario being requested to return to site to change altered work back!

Any changes that have time / cost implications should not be undertaken without the Construction Manager receiving instruction from the client.

If you are in doubt of the Implications of any actions that a client asks you to perform consult with your Construction Manager.

If you are unable to make contact with the Construction Manager, please contact the Operations Manager neither of the options are available please contact the SMD QS available on the Head Office number (01202 718898).

Site Record SheetThe site foremen are required to manage the signature of site record sheets. These sheets record any issues on site that result in SMD operatives either standing or in worst case having an aborted day.

When an issue arises the foreman is to contact the Construction Manager and ensure that he fully understands the reasons why this has occurred. The Construction Manager will contact his counterpart and the SMD QS to ensure that everyone is aware of the situation.

The foreman must accurately fill out the Site Record Sheet paperwork.

PLEASE ENSURE YOU HAVE A STOCK OF THESE IN YOUR VEHICLE

When a resolution has been found, obtain the signature of an authorised person on site (advised by the Construction Manager).

The sheets are to be included within your wages paperwork and must be returned to the Head Office in a timely manner. The white copy is for the client and the pink copy is SMD’s.

The failure to get sheets signed may result in SMD not receiving payment. If the client refuses to sign the paperwork, please make a note of this and also advise the Construction Manager.

If you are unable to make contact with the Construction Manager, please contact the Operations Manager, if neither of the options are available please contact the SMD QS available on the Head Office number (01202 718898).

Handovers The completion and signing of area handover sheets are the responsibility of SMD’s site foremen. Handover sheet must be completed and signed for all area and trades on the projects. Once completed, the handover sheet MUST be signed by our client on site. Failure to get handover sheets signed may have implications when we are agreeing the financial aspects of our works.

There will be situations from time to time when people refuse to sign sheets. You must NEVER get into arguments with our clients, if they refuse to sign, just get straight on the phone and let either the SMD Construction Manager (or Operations Manager) know.

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NEVER be rude to our clients, you are a representative of the company and must present yourself in a professional manner at all times! Please speak to people how you expect to be spoken to.

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Sample Site Record SheetsEdge Protection Missing

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Sample Site Record SheetsPacks Unloaded Incorrectly

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Responsibilities and ExpectationsNetting, Decking, Edge Trim and Stud Welding

SMD Site ForemanPromotion to the position of Foreman comes with additional responsibilities, tasks and expectations that should not be taken lightly. Your success in these additional responsibilities will be critical to maintain or progress from this position.

A number of these duties will be client facing and therefore, you should act in a professional manner at all times!

The additional responsibilities involved include, but are not limited to the following:• Read, understand and convey all safety documentation (Method Statement / Risk Assessment)

to all second men and comply with contents, along with any specific site rules.• Obtain hot works permit daily and undertake pre start checks as required before netting,

decking and studding.• Ring SMD Office to check current revision of drawing before fixing a new area.• Check all tools, consumables and equipment (including vehicle) for defects and general

maintenance – WEEKLY.• Submit fully completed time sheets and expenses (including second men) by Monday of

following week. Must ALWAYS include marked up drawings, quantities fixed, consumables used and mileage, even if on day rate. If not fully complete, time sheets cannot be processed and wages not paid! Must be posted in prepaid envelopes provided – WEEKLY.

• Obtain Site Record Sheet / Confirmation of instruction sheets when required – MUST check with SMD Construction Manager first.

• Check all areas fixed for compliance with drawings – DAILY.• Ensure all scrap, spent shots, failed studs, foam canisters and stud barrels are removed from

the deck and disposed of correctly – WEEKLY.• All fixings must be accounted for and stock control procedure adhered to.• Fuelling of the company Vehicles should be at garages that accept the company Fuel cards.

Mileage MUST be recorded when Purchasing Fuel.• Complete and issue handover sheets on all projects and phases.• Ensure that all SMD operatives have the correct PPE and SMD clothing prior to

commencement.• Foremen must communicate with SMD’s Construction Manager at the end of each shift to

update them on progress and issues.• Completion of daily vehicle inspections.• Offer training and guidance to all members of your site team in partnership with SMD’s

Training Manager.• Ensure the safety and welfare of team members at all time whilst on site.

If upon promotion, or at any time in this role you are unsure of the correct course of action, do not hesitate to contact either SMD Construction Manager or Operations Manager.

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The Golden RulesNetting, Decking, Edge Trim and Stud Welding

1. Safety First.

2. Ensure correct PPE is worn all times – It is your responsibility to look after and use correctly.

3. Read, understand and read again the method statement, risk and COSHH assessment.

4. If there is a problem, or you are in doubt about anything, speak to your Construction Manager.

5. Before erecting nets, always check the net tags to ensure the net is in date.

6. Neverdropnetsuntilthedeckedareaaboveis100%fixedtothesteel.

7. Beforelayinganydeckingensuretheworkareahasbeensegregatedoffand correct warning signs erected – Do not let people into the work area until it has been fully handed over.

8. Any items left on the decking overnight must be suitably strapped down to the deck.

9. All decked areas are to be 100% to the steel frame before leaving the work area each night.

10. Always set the decking out as indicated on the SMD drawings.

11. Never do anything other than set out on the SMD drawing without speak toyourconstructionmanager/Drawingoffice.

12. Remember to mark the beams for following trades.

13. IfabeamhasnostudsitneedsENP2fixings.

14. Ensure all holes / gaps are neatly foamed, especially recheck after stud welding operations

15. Always tidy up and remove site waste as agreed.

16. Follow and record the correct welding procedures, ensuring pre-test are carried out.

17. Once works have been completed they must be handed over and the correct paperwork completed.

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Quick Reference GuideNetting, Decking, Edge trim and Stud Welding

Fixings – Deck and Trim

Fixings – Roof Decking and Flashing

1

Decking Edge Trim

(mm) Fixings Spacings (mm) Fixings Spacings (mm)

Min

' bea

ring,

Dec

k +

Trim

At

sup

por

ts /

Stu

ds

req

'd*

At

sup

por

ts /

NS

req

'd*

Sid

e la

ps

End

Cap

s

End

sup

port

Int'

supp

ort

Sid

e la

ps

Sta

rtin

g m

id s

pan

End

Cap

Fix

ing

(1 p

er ri

b)

At

sup

por

ts*

Can

tilev

ered

trim

Str

aps

Fixi

ngs

at s

upp

orts

<19

9 S

lab

Fixi

ngs

at s

upp

orts

20

0-30

0 S

lab

***

Can

tilev

ered

trim

Str

ap S

pac

ings

<20

0mm

hig

h tr

im

Str

ap S

pac

ings

>20

0mm

hig

h tr

im

Steelwork

R51 50 DAK ENP2 TEK NA 300 600 1m Foam DAK TEK TEK 750 500 150 750 500

TR60+ 50 DAK ENP2 TEK TEK 333 666 1m TEK DAK TEK TEK 750 500 333 750 500


Blockwork

R51 70 NA X-SW TEK NA 300 600 1m Foam X-SW** TEK TEK 750 500 150 750 500

TR60+ 70 NA X-SW TEK TEK 333 666 1m TEK X-SW** TEK TEK 750 500 333 750 500


* Unless stated otherwise in Project Specification ** Hammer screws to be used for Concrete or Masonry due to brittleness

*** For slabs deeper than 300mm, the requirement will be detailed on SMD project drawings


Fixings - Floor Decking and Trim

Decking Flashing

(mm) Fixings Spacings (mm) Spacings (mm)

Min

' bea

ring,

Dec

k +

Trim

At

sup

por

ts

Sid

e la

ps

End

sup

port

Int'

supp

ort

Sid

e la

ps

Sta

rtin

g m

id s

pan

Fixi

ngs

at s

upp

orts

<19

9 S

lab

Fixi

ngs

at s

upp

orts

20

0-30

0 S

lab

***

Steelwork

SR30 75 Refer Drgs

NA UNO 200 400 NA

UNO 450 450

SR60 75 Refer Drgs 450 333 333 450 450 450

All the above Roof deck specification may differ to that stated on specific contracts. Refer to individual drawings for details for each contract.

Fixings - Roof Decking and Flashing

1

Decking Edge Trim

(mm) Fixings Spacings (mm) Fixings Spacings (mm)

Min

' bea

ring,

Dec

k +

Trim

At

sup

por

ts /

Stu

ds

req

'd*

At

sup

por

ts /

NS

req

'd*

Sid

e la

ps

End

Cap

s

End

sup

port

Int'

supp

ort

Sid

e la

ps

Sta

rtin

g m

id s

pan

End

Cap

Fix

ing

(1 p

er ri

b)

At

sup

por

ts*

Can

tilev

ered

trim

Str

aps

Fixi

ngs

at s

upp

orts

<19

9 S

lab

Fixi

ngs

at s

upp

orts

20

0-30

0 S

lab

***

Can

tilev

ered

trim

Str

ap S

pac

ings

<20

0mm

hig

h tr

im

Str

ap S

pac

ings

>20

0mm

hig

h tr

im

Steelwork

R51 50 DAK ENP2 TEK NA 300 600 1m Foam DAK TEK TEK 750 500 150 750 500



Blockwork

R51 70 NA X-SW TEK NA 300 600 1m Foam X-SW** TEK TEK 750 500 150 750 500



* Unless stated otherwise in Project Specification ** Hammer screws to be used for Concrete or Masonry due to brittleness

*** For slabs deeper than 300mm, the requirement will be detailed on SMD project drawings


Fixings - Floor Decking and Trim

Decking Flashing

(mm) Fixings Spacings (mm) Spacings (mm)

Min

' bea

ring,

Dec

k +

Trim

At

sup

por

ts

Sid

e la

ps

End

sup

port

Int'

supp

ort

Sid

e la

ps

Sta

rtin

g m

id s

pan

Fixi

ngs

at s

upp

orts

<19

9 S

lab

Fixi

ngs

at s

upp

orts

20

0-30

0 S

lab

***

Steelwork

SR30 75 Refer Drgs

NA UNO 200 400 NA

UNO 450 450

SR60 75 Refer Drgs 450 333 333 450 450 450

All the above Roof deck specification may differ to that stated on specific contracts. Refer to individual drawings for details for each contract.

Fixings - Roof Decking and Flashing

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Full List of Data Sheets Available:SMD have developed a suite of Best Practice sheets for clients, directly employed operatives and sub contracted labour.

These have been designed to set out the best practices to be followed when working on netting, decking, stud welding and concerting works.

Please see below a reference guide of all currently available best practice sheets. Downloadable versions are available from our website www.smdltd.co.uk.

If there are any other Best Practice Sheets you feel would be beneficial please put in a request in to contracts @smdltd.co.uk and we will do our best to develop the sheet.

• SMD Best Practice Data Sheet – Perimeter Edge Protection DATA/01• SMD Best Practice Data Sheet – Void Protection DATA/02• SMD Best Practice Data Sheet – Manual Handling DATA/03• SMD Best Practice Data Sheet – Lifting Shear Studs to Level DATA/04• SMD Best Practice Data Sheet – Power Supply for Stud Welding Operations DATA/05• SMD Best Practice Data Sheet – Fixings for Metal Decking & Edge Trim DATA/06• SMD Best Practice Data Sheet – Disposal of Waste DATA/07• SMD Best Practice Data Sheet – Loading Guidelines & Restrictions DATA/08• SMD Best Practice Data Sheet – Edge Trim DATA/09• SMD Best Practice Data Sheet – Deflections Explained DATA/10• SMD Best Practice Data Sheet – Shear Studs DATA/11• SMD Best Practice Data Sheet – Crane Voids DATA/12• SMD Best Practice Data Sheet – Stud Welding to Painted Beams DATA/13• SMD Best Practice Data Sheet – Concrete Slab Surface Regularity DATA/14• SMD Best Practice Data Sheet – Concrete Weather Review DATA/15• SMD Best Practice Data Sheet – Removal of Broken Ferrules DATA/16• SMD Best Practice Data Sheet – Scorching to Underside of Top Flanges DATA/17• SMD Best Practice Data Sheet – Grout Loss DATA/18• SMD Best Practice Data Sheet – Ground Conditions DATA/19• SMD Best Practice Data Sheet – Safety Harnesses with Safety Nets DATA/20

Please call to request a digital copy.

Contact us for further support or any site issue you would like to discuss.For all your site requirements, please contact our Head Office at [email protected] or call on 01202 718898 where our Contracts Team will be happy to advise.

Safety Notice: Don’t just walk by, if you see anything that concerns you with regards to Health & Safety – Report it!

UK Tel: +44 (0) 1202 718898 UK Email: [email protected]

UK Head OfficeThe Outlook Ling Road Tower Park Poole Dorset BH12 4PY UK

UK Midlands Logistics Centre Units 1+2 Nunn Brook Rise County Estate Huthwaite Nottinghamshire NG17 2PD

UK Scottish Logistics Centre 12 Palacecraig Street Coatbridge North Lanarkshire ML5 4RY

International Offices United Arab Emirates – Dubai Email: [email protected] – Mumbai Email: [email protected]

© SMD is a trading name of Structural Metal Decks Limited. Copyright 2016. Liable to change without notice.

SMDStructural Floor and Roof Solutions

www.smdltd.co.uk

site installation guide - smd ltd...1 no nelweld 6000 machine part no. 0618 or similar 2 no stud...

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