SFS | Steel Framing System

Installation Manual | v4.0 November 2011

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Preamble
This document has been compiled to give installation trade contractors guidance on how the Kingspan Profiles
& Sections Steel Framing System (SFS) is installed and what services Kingspan offer for this product. This
document does not form a specification and responsibility for the quality of any SFS installation rests wholly with
the contractor and not with Kingspan Profiles & Sections. This document should be read alongside the following
other Kingspan Profiles & Sections publications:

SFS Designer‟s Risk Assessment

Identified risks associated with general installation of Infill and Oversail SFS
(for project specific guidance, please consult the Kingspan design service)
http://www.kingspanprofiles.com/Media-Centre/Literature.aspx

Product Brochure
Product overview & system applications
http://www.kingspanprofiles.com/Media-Centre/Literature.aspx

Technical Manual
Guide to technical application of both Infill & Oversail SFS framing
http://www.kingspanprofiles.com/Media-Centre/Literature.aspx

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British Board of Agrément (BBA) Certificate
Product summary and guidance on specification, installation, maintenance and durability
http://www.kingspanprofiles.com/Media-Centre/Literature.aspx

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Design Service Guide PR
Detailed and Basic Design Services, an overview of the services offered by Kingspan Profiles & Sections
http://www.kingspanprofiles.com/Media-Centre/Literature.aspx
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In addition to the guidance contained in these documents, Kingspan Profiles & Sections offer an installer
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training course. The course gives the attendee a better understanding of SFS, its applications, benefits and
installation principles - helping to increase productivity, reduce costs and minimise SFS related health and
safety issues. Kingspan also offer a site inspection and report service. Further information can be found on the
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Kingspan Profiles & Sections web site – www.kingspanprofiles.com.

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Contents
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1 SYSTEM OVERVIEW ........................................................................................................................... 5

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2 CDM REGULATIONS ........................................................................................................................... 6

2.1 Obligations of the Installer ....................................................................................................... 6
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2.2 Site Visits ................................................................................................................................. 6

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2.3 Remedial Works Arising from the Site Report ......................................................................... 6

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2.4 Competency of the Installer and Training ................................................................................ 6

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2.5 Notification of CDM Risk to the Installer .................................................................................. 6

2.6 Notification of CDM Risk to the Designer ................................................................................ 7
3 Tolerance ............................................................................................................................................. 8
3.1 Manufacturing Tolerance ......................................................................................................... 8
3.2 Primary Frame Tolerance ........................................................................................................ 8
3.2.1 Beam and slab level variation...................................................................................... 8
3.2.2 Beam and slab line variation ....................................................................................... 8
3.3 Installation Tolerance ............................................................................................................... 8
3.3.1 Structural requirements ............................................................................................... 8
3.3.2 Additional requirements ............................................................................................... 8
4 DESIGN INFORMATION ...................................................................................................................... 9
4.1 Drawing Submissions .............................................................................................................. 9
4.2 Reading Design Drawings ..................................................................................................... 10
5 MATERIAL ORDERING ..................................................................................................................... 14
5.1 Price Lists & Order Requirements ......................................................................................... 14
5.2 Call Offs ................................................................................................................................. 14
5.3 Scope of Supply ..................................................................................................................... 14
5.4 Building Regulation Requirements......................................................................................... 15

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5.5 Pre-Order Checks .................................................................................................................. 15

6 TOOLS & FIXINGS ............................................................................................................................. 16
6.1 Hand Tools & Accessories ..................................................................................................... 16
6.2 Measuring & Setting Out Tools .............................................................................................. 16
6.3 Cutting Tools .......................................................................................................................... 16
6.4 Fixing Tools ............................................................................................................................ 17
7 HEALTH & SAFETY ........................................................................................................................... 18
7.1 Edge Protection...................................................................................................................... 18
7.2 PPE ........................................................................................................................................ 18
7.3 Manual Handling .................................................................................................................... 18
7.4 Method Statements ................................................................................................................ 18
7.5 Risk Assessments .................................................................................................................. 19
7.6 Access Equipment ................................................................................................................. 19
8 MATERIAL INSPECTION & OFFLOADING ...................................................................................... 22
8.1 Method of Delivery ................................................................................................................. 22
8.2 Safe Handling......................................................................................................................... 22
8.3 Safe Storage .......................................................................................................................... 22
8.4 Component Identification & Marks ......................................................................................... 22
8.5 Damaged Material .................................................................................................................. 22

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9 INFILL SFS ......................................................................................................................................... 23

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9.1 Site Preparation ..................................................................................................................... 23
9.2 Basic Installation Principles ................................................................................................... 23

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9.3 Detailed Installation – Worked Example ................................................................................ 26
10 OVERSAIL SFS .................................................................................................................................. 35
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10.1 Site Preparation ..................................................................................................................... 35
10.2 Basic Installation Principles ................................................................................................... 35
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11 CLEATS, BRACKETS & ANCILLARIES ........................................................................................... 38
11.1 Jamb Cleats ........................................................................................................................... 38
11.2 Lintel & Cill Cleats .................................................................................................................. 38
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11.3 Flat Strap ................................................................................................................................ 38

11.4 „Z‟ Bars ................................................................................................................................... 38
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11.5 Face Fix Angles ..................................................................................................................... 39

12 INTERFACING ELEMENTS ............................................................................................................... 40
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12.1 External Sheathing Board ...................................................................................................... 40

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12.2 Masonry ................................................................................................................................. 42

12.3 Render ................................................................................................................................... 43
12.4 Rainscreen ............................................................................................................................. 43
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13 QUALITY CONTROL.......................................................................................................................... 45
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13.1 Area Sign Off.......................................................................................................................... 45

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13.2 Remedial Works ..................................................................................................................... 46

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13.3 Kingspan Profiles & Sections Site Support ............................................................................ 46

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14 COSHH & TECHNICAL DATASHEETS ............................................................................................ 47

14.1 General Specification Notes .................................................................................................. 47
14.2 COSHH Datasheet ................................................................................................................. 48
14.3 Cutting Tools .......................................................................................................................... 50
14.4 Drilling Tools .......................................................................................................................... 50
14.5 Fixing Tools ............................................................................................................................ 51
15 KINGSPAN PROFILES & SECTIONS SUPPORT SERVICES ......................................................... 52
15.1 Material Ordering & Production Enquiries ............................................................................. 52
15.2 Technical Enquiries ................................................................................................................ 52
15.3 Sales & Commercial Enquiries .............................................................................................. 52
15.4 Site Support ........................................................................................................................... 52

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External References
This document should be read in conjunction with the following publications:

Publications
 BS5950 Structural Use of Steelwork in Building - Part 5; Code of Practice for Design of Cold Formed Thin
Gauge Sections
 BS6399 Series; Loading for Buildings
 BS-EN-1990 Series; Basis for structural design
 BS-EN-1991 Series; Actions on structures
 BS-EN-1993 Series; Design of steel structures
 National Structural Steelwork Specification (NSSS) Fifth Edition, The British Constructional Steelwork
Association (BCSA)
 SCI Guide P125; Building design using cold formed steel sections: Worked examples to BS 5950: Part 5:
1987
 SCI Guide P301; Building design using cold formed steel sections: Light steel framing in residential
construction
 SCI Guide P262; Building design using cold formed steel sections: Durability of Light Steel Framing in
Residential Building
 BS 7364:1990 Specification for galvanized steel studs and channels for stud and sheet partitions and linings

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using screw fixed gypsum wallboards

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 BS8000 Series; Workmanship on building site; Codes of practice
 BS EN 10326; Continuously hot-dip coated strip and sheet of structural steels. Technical delivery conditions

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 BS EN 10162; Cold rolled steel sections – Technical delivery conditions – Dimensions and coss-sectional
tolerances
 Building Regulations; Approved Documents
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Industry/Regulatory Bodies
Steel Construction Institute (SCI)
http://www.steel-sci.org/
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Federation of Plastering & Drywall Contractors (FPDC)

http://www.fpdc.org/
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British Construction Steelwork Association (BCSA)

http://www.steelconstruction.org/
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Building Research Establishment (BRE)

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http://www.bre.co.uk/
British Board of Argrément (BBA)
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www.bbacerts.co.uk
The National House Building Council (NHBC)
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http://www.nhbc.co.uk/
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Communities & Local Government – Building Regulations

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http://www.communities.gov.uk/planningandbuilding/
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Unauthorised Distribution & Liability

Copyright
All text and drawing information contained within this document remains the sole property of Kingspan Profiles &
Sections Ltd. Copying and unauthorised distribution of this document is strictly prohibited. This document must
be read as a whole and must not have any of its content added to, removed or modified.

Liabilities
This document does serve not as a specification without prior written consultation with a Kingspan Profiles &
Sections engineer. Details and information provided do not constitute an extension of any warranty or
acceptance of liability by Kingspan Profiles & Sections unless used under the specific terms of the Kingspan
Profiles & Sections Detailed Design Service. Kingspan Profiles & Sections will not be held liable for any
consequential losses incurred by any party through the use of this document. Customers of Kingspan Profiles &
Sections accept that the information provided in this document is supplied for general guidance purposes only.

Unauthorised Distribution
This document is provided in good faith to Kingspan customers to assist in the design of the SFS product. It
should not be distributed to third parties without the prior written consent of Kingspan Profiles & Sections.

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1 SYSTEM OVERVIEW
The Kingframe Steel Framing System (SFS) is a component supply structural stud façade system commonly
used in two main methods: Infill and Oversail. The system consists of C shaped studs and U shaped tracks
designed on a project specific basis to form the inner leaf of an external façade.

Both systems are constructed on-site and must be designed and installed to relevant codes and standards.
Liability for the quality and accuracy of the installation rests with the installation contractor and not Kingspan
Profiles & Sections.

SFS has been extensively used in construction projects covering residential flats, apartments, healthcare and
educational developments, commercial developments, public buildings and industrial properties.

Sections are supplied to site as individual components and fully assembled in-situ. This is an advantage where
site access/craneage is restricted. Components can be supplied in final required lengths or standard lengths cut
to suit on site. By cutting to length on site, construction tolerances in structures can be fully accommodated.

Infill Systems are typically supported at the slab edge between hot-rolled steel or concrete. This

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allows insulation and external finishes to be installed outside the main structural frame if the correct

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tolerance scheme is adopted. The system is suitable for both low and high-rise construction. A
deflection allowance is required at each floor level.

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Oversail Systems are fitted outside the line of the structural frame using support cleats at each floor
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level with connections designed to allow slab deflection. It is particularly suited to situations where
cladding materials are sensitive to differing movement of the mainframe. Adequate base support
must be provided to accommodate vertical loading.
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Both systems achieve early weather protection of the building allowing other internal fitting trades to work inside
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the structure and removing external cladding from the critical path. Furthermore, these systems also provide
lateral support to most cladding materials including masonry, profiled metal sheets, proprietary panels, insulated
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render systems, terracotta and timber rain screen systems. It should be noted that SFS is not intended to
provide vertical support for masonry facades.
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It is also possible to design Kingspan SFS sections to form the primary load bearing structural framing for low
rise buildings. This is beyond the scope of this manual but information is available on request from Kingspan
Profiles.
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2 CDM REGULATIONS
The Construction (Design and Management) Regulations of 2007 have redefined the responsibilities and
guidance for system suppliers and designers on all construction projects in the UK. Wherever possible,
Kingspan Profiles & Sections will take measures to design out any risk to the installer during construction of the
SFS. Kingspan Profiles & Sections will identify potential CDM risks to the CDM coordinator within the project
team. It is the responsibility of the Installer to provide the contact details of this individual to Kingspan Profiles &
Sections. If this is not forthcoming, Kingspan Profiles & Sections will notify the project design team.

Kingspan Profiles & Sections has compiled this document to inform Main Contractors and Installers of the
system as to its correct use and method of installation. By receiving this document, the reader it obliged to
ensure that all personnel undertaking design, specification, procurement, installation and checking of Kingspan
Profiles & Sections SFS structures have read and understood its contents.

2.1 Obligations of the Installer

The design and specification given by Kingspan Profiles & Sections is a structural minimum and must be
observed at all times. It is the responsibility of the Installer to check and approve each area of SFS prior to any

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boarding or cladding treatments being applied.

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2.2 Site Visits

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Kingspan Profiles & Sections can visit sites where our system is being installed to check that the installation is
being carried out in accordance with our specification. These visits do not form a warranty or approval of the
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installation. A formal report will be written by the Inspector and issued to the installation company, as part of this
chargeable service. To arrange an inspection, please contact (contact details are available at the end of this
document).
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2.3 Remedial Works Arising from the Site Report

If the Kingspan Profiles & Sections Inspector has made recommendations to the installation company, it is the
responsibility of the installation company to ensure the recommendations are carried out in a full and efficient
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manner. In the event that the Inspector returns to find no remedial works have been undertaken, Kingspan
Profiles & Sections will raise the matter with either the Main Contractor or the client to ensure the works are
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carried out. In the event of a continual failure to undertake remedial works, Kingspan Profiles & Sections will
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remove all drawings and any associated insurances from the project.
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2.4 Competency of the Installer and Training

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The competency of the Installer remains in whole the responsibility of the installation company. If Kingspan
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Profiles & Sections has any reason to question the competency of installers, this will be raised with the
installation company in the first instance. If the competency of installers remains in doubt, Kingspan Profiles &
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Sections will raise concerns with either the Main Contractor or the client. Kingspan Profiles and Sections now
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offer an Installer Training program to instruct installers in the correct and safe installation of SFS systems. The
course can also be tailored to main contractors and site supervisors.

2.5 Notification of CDM Risk to the Installer

Kingspan take both a product specific and project specific approach to installation risks on SFS. At the product
level, all standard risks of installation are included in our product risk assessment which is available on our web
site – www.kingspanprofiles.com. This should be read and understood by the Installer and the design team prior
to commencing any works on site. The risks identified should be compiled into the project risk register by the
CDM coordinator as appropriate.

At a project specific level, when Kingspan Profiles & Sections recognises a risk to health and safety that cannot
be avoided through design, the hazard is identified on the drawings using the following symbol:

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CDM: HAZARD IDENTIFICATION - NAME

HAZARD
MITIGATION

A description of the hazard is also included together with any suggested measures which the Installer or Design
Team can take to mitigate the risk.

2.6 Notification of CDM Risk to the Designer

If an Installer identifies a potential CDM risk, it is their responsibility to notify Kingspan Profiles & Sections. Once
communicated, the designer will reassess the area in question and propose an alternative solution if possible. If
an alternative solution is not available, the Installer is responsible for communicating the risk to the named
individual within the project team.

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3 Tolerance
It is important to consider tolerance schemes for SFS on a project specific basis. Some aspects of the system
tolerance are generic but the architect or client may have special requirements which will need to be agreed
with the installation contractor.

The following gives summary guidance on the different tolerance schemes which affect the design and
installation of SFS.

3.1 Manufacturing Tolerance

Kingspan SFS components are rolled in accordance with BS EN 10162:2003.

3.2 Primary Frame Tolerance

When placing orders for studs and brackets, it is important to realise that the primary frame will not be set out,
cast or installed exactly as detailed in the design. There will be variation in line and level on all beams, slabs
and columns which will impact on the requirements for the SFS. Installers should pay particular attention to the
following:

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3.2.1 Beam and slab level variation
Kingspan design drawings will show the nominal distance between structural elements as given by the relevant

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designer‟s drawings but these MUST be checked on site for an accurate material schedule to be produced. See
section 5.2 for further guidance on calling off and ordering from either site measures or design dimensions.
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3.2.2 Beam and slab line variation
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Again, Kingspan design drawings will show the nominal setting out of the slab or beam edge. Variation in this
line can cause issues for SFS:
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1. Infill SFS requires 2/3 bearing onto the primary structural frame. If variation in the line of the frame
reduces this bearing, additional ancillary components may be required to correct it and the installer
should be aware that they may incur additional costs for these. Please contact Kingspan design for a
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solution if this occurs on site.

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2. Oversail SFS brackets will be designed to accommodate some tolerance in the line of the edge which
they will be fixed to (typically +/- 15mm). Any variation outside of the allowed tolerance may cause the
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bracket to extend outside the face of the SFS and foul the boarding. Alternatively, it may leave the
bracket too short. It is the responsibility of the installation contractor to advise what tolerance is required
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on brackets. In the absence of specific information, Kingspan will assume +/- 15mm to be sufficient.
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3.3 Installation Tolerance

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3.3.1 Structural requirements

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In order to satisfy structural requirements, the SFS must be installed in accordance with the guidance provided
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in the National Structural Steelwork Specification available from the British Construction Steelwork Association .
Specific requirements which should be followed for SFS installation are:
Maximum deviation in position at column (stud) base (i.e. track setting out)
o 10mm in either axis
Maximum deviation of single storey columns from plumb
o Height / 600 or 5mm – whichever is the greater to a maximum of 25mm in either axis
Maximum deviation of multiple storey columns from plumb (oversail applications)
o Individual storey height / 600 or 5mm – whichever is the greater to a maximum of 50mm in
either axis over the total height

3.3.2 Additional requirements

The project design team may have more onerous requirements than those presented in 3.3.1 in order to
achieve the required finish. Kingspan recommend that the installation contractor agrees a specific tolerance
scheme with the design team prior to undertaking the works.

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BCSA web site – http://www.steelconstruction.org/bcsa.html

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4 DESIGN INFORMATION
Design information is submitted to the Architect and the client for approval prior to construction. The drawings
serve a number of different purposes; approval by the Architect, estimating by the client QS, installation by the
Site Team and co-ordination with other sub contract designers (window suppliers, M&E services, principal
structural designers etc).

All drawn information submitted is a structural MINIMUM and must not be deviated from without prior
written consultation between the client and Kingspan Profiles & Sections.

4.1 Drawing Submissions

You will receive the following sets of information when you undertake detailed design with Kingspan Profiles &
Sections:

Elevation Drawings
These drawings provide plan, elevation and section information for a given area of a building structure. Each
component is individually drawn to allow for accurate setting out of the framework, though the „general‟ studs

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depicted are indicative only. The installer may choose to alter the setting out of this indicative grid to suit the
internal or external finishes, whilst maintaining the stated maximum spacing of studs at all times.

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Figure 1 - Typical Elevation Drawing

Detail Drawings
These drawings provide enlarged construction details of specific connections or constructions on the project.
Details are referenced on the elevation drawings to show where each is relevant. If fixing information is not
provided in the legend of the elevations, it can be found in the relevant detail drawing.

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Fabrication Drawings
Where Kingspan Profiles & Sections have agreed to undertake the design of specialist bracketry (especially
evident in oversail applications) a fabrication drawing for the bracket(s) specified will be provided. The brackets
can be by Kingspan supply but also hold enough information for a third party steel fabricator to supply if desired.

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Figure 2 - Typical Fabrication Drawing

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4.2 Reading Design Drawings

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Setting Out from Gridlines

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The section detail on the elevation drawing gives the setting out from gridline to either inside or outside face of
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the SFS. This information may also be shown on plan details if the line of the SFS varies between areas.
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Setting Out Structural Openings

Structural openings are set out from a given gridline to the inside face of the opening. The width of the structural
opening is given in either the plan or elevation detail with the head and cill heights given as datum levels on the
elevation detail. Dimensions are given from notional slab/steel level to the underside of heads and cills but these
must be carefully checked against the datum levels in case of any irregularities in the primary structure.

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Curved walls are shown in plan for setting out. Dimensions from parallel and perpendicular grids are given on
the drawings as an X, Y co-ordinate to allow accurate setting out. In some cases, a radius from a central point
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will be given if plywood templates are used to set the curve.

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Bracket Positions
In oversail applications, specific locations, heights and orientation of brackets is given on the elevation
drawings. This allows accurate setting out of the support bracketry prior to installation of the SFS. Brackets are
shown as symbols and the bracket type referenced in the legend of the drawing.

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RESTRAINT

COMBINATION

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DEAD-LOAD

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Cleats
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Where additional stiffening cleats are required to either jambs or cills/lintels, they are denoted by a symbol. The
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standard symbols are as below:

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Description Symbol Kingspan Profiles & Sections Standard Detail2

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Heavy Duty Cleat C.13 & C.14

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Lintel/Cill Cleat C.02, C.05, C.06, C.07 & C.08

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Fixing specifications for cleats are either given in the legend or the standard detail.
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Opening Construction Specifications

Product codes for sections are given in the legend of the drawing. Special constructions (nested jambs, cills and
lintels) are shown as symbols or annotated directly on the elevation drawing. The list of standard symbols is
given below:

Description Symbol Specification

Nested Jamb (base track) Stud boxed with base track

Nested Jamb (head track) Stud boxed with head track

Double Nested Jamb Two studs boxed with a single track

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Please refer to the Kingspan Profiles & Sections SFS Technical Manual for details

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Triple Nested Jamb Two studs boxed with two tracks

Nested Lintel/Cill Stud boxed with track (second track used to begin stud
wall above or below)

Double Nested Lintel/Cill Two studs boxed with two tracks (second track used to
begin stud wall above or below)

All these constructions are shown on elevation drawings as standard constructions with a standard description
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and reference.

Fixing Specifications
The general fixing specification is given in the legend. Special fixing conditions are described in the legend or in

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the specific details provided for the job. Under no circumstances can the specified fixing be deviated from
without prior written consultation with Kingspan Profiles & Sections engineers.

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Please refer to the Kingspan Profiles & Sections SFS Technical Manual for details

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5 MATERIAL ORDERING
5.1 Price Lists & Order Requirements
Your Area Sales Manager (ASM) will be able to provide a current price list. This list covers the standard
supplied items for SFS. Below is a checklist of what is required by Kingspan Profiles & Sections when placing
an order with us;

Requirement Description/Reference
Product References As price list
Quantity As required by Installer call off
Length In millimetres
Project Name Name
Delivery Address/Gate Postcode & Access Requirements
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Delivery Schedule/Time Time Slot/Packing Sequence
Order Number Your official order number
Transport Cost The agreed transport cost
Transport Method HIAB, Flat Bed or Curtain Sider

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5.2 Call Offs
It is the responsibility of the Installer to call off the required material from Kingspan Profiles & Sections drawings.

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Kingspan Profiles & Sections do not provide a call off or material estimating service. There are two methods of
call off; cut to length and over length. PR
Cut To Length
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Kingspan Profiles & Sections can roll and cut „C‟ section studs to your requirements with a minimum individual
length of 600mm. The advantage of this is the reduced amount of waste and cost while minimising the need for
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cutting on site. Accuracy of cut lengths is not assured when ordering from Kingspan Profiles & Sections
drawings due to construction tolerances in the primary structure. This is particularly important in infill
applications. The Installer is advised to survey the areas of installation prior to placing a cut to length order. For
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oversail applications, this is the best method of procurement as construction tolerances do not affect the façade
finished height or position as the tolerances are taken out in the supporting bracketry.
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Over Length
Ordering material over length reduces the risk of wasted material due to construction tolerances but introduces
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an inevitable amount of waste. It also requires cutting on site to the accurate length required. An example over
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length order for „C‟ sections would take the overall height of a particular area and add 100-200mm. „U‟ sections
must be ordered in stock lengths of 3.0 and 4.0m and cut in situ to suit a given area. Special lengths of „U‟
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sections are available in instances where lintel, cill and jamb constructions require lengths greater than 4.0m.
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These items require special ordering.

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5.3 Scope of Supply

Kingspan Profiles & Sections limits their scope of material supply to the items on the price list. An overview of
what is and is not supplied is given below:

Kingspan Profiles & Sections Supply Supply by Installer

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„C‟ Sections Special Bracketry
„U‟ Sections Fixings
Standard Cleats Hot Rolled Steel
Heavy Duty Cleats Any other component
„Z‟ Bars
Flat Strap

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The provision of sequenced packing and the advance booking of delivery slots may attract additional charges – please contact Kingspan
Profiles & Sections if in doubt
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The Installer may wish Kingspan Profiles & Sections to price and supply these items. Please ask your ASM or contact the Material
Ordering & Production Department for more details

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5.4 Building Regulation Requirements

The Installer should refer to the Main Contractor and the Architect to ensure that the requirements under
Building Regulations for air tightness, thermal bridging and acoustic protection are met before construction
begins. The most common requirements that may be required are listed below:

Thermal Bridging
The adequate insulation of „nested‟ SFS constructions; this involves the filling of boxed or nested sections of
SFS with a mineral wool insulator to prevent possible heat loss at the junction with structural openings. Installer
to gain confirmation from the main contractor if insulation is required within closed sections.

Air Tightness
The Installer may be required to apply sealant between the SFS and interfacing elements such as the primary
structure. This may be a secondary defence as the board linings provide the majority of air tightness.

Acoustic Protection
To reduce the risk of flanking sound transmission between units, the Installer may be required to provide an
acoustic mat between the track elements and the primary structure. The Installer will also be required to

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observe robust detailing when installing façades with party wall abutments.

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Fire Protection
The protection of the primary structure from fire may have an effect on the design of the SFS. The cloaking of

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primary steel beams with performance boards will affect the design of the fixings to the beam. Additionally, any
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intumescent paint finish applied to steelwork requires room to expand in the event of a fire which may also affect
the design of the SFS. The Installer is advised to clarify any special fire protection treatments and consult any
implications with Kingspan Profiles & Sections.
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5.5 Pre-Order Checks

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To minimise waste and cost, the Installer is advised that the following checks should be made prior to placing an
order with Kingspan Profiles & Sections;
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1 Check drawings are all at Construction status

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2 Check if there are any CDM notifications raised by Kingspan Profiles & Sections and discuss mitigation
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with the main contractor and design team

3 Survey the areas of the primary structure the order is intended for to ensure;
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a. The main structure is not out of tolerance

b. The given dimensions on Kingspan Profiles & Sections drawings are correct or the Installer should
O

take out any discrepancies pre-order after discussing with Kingspan

C

c. There is adequate access to the area

N

d. There are no scaffolding ties or similar that ‘foul’ the area of work
Check production lead time with Kingspan Profiles & Sections
U

4
5 Check supply lead times for brackets, cleats and fixings
6 Check delivery schedule requirements with the main contractor
7 Check transport method is appropriate to the site
8 Check the equipment required to offload the deliveries is available on site
9 Check that there is an adequate area to store the goods prior to use (refer to Section 8.3)

The Installer is advised that the accuracy of any order is undertaken at the sole risk of the Installer and not of
Kingspan Profiles & Sections. If Kingspan Profiles & Sections does offer guidance on material lengths and
quantities, this does not constitute an acceptance of liability in any form.

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 SFS Installation Manual

6 TOOLS & FIXINGS

6.1 Hand Tools & Accessories
The Installer may find a requirement for other or additional hand tools than the list given below. However, this
list is a guide to new Installers of the system of what basic tools may be required;
Steel Hand Clamps
Hammers, Lump Hammer, Claw Hammer
Screwdrivers (various)
Hacksaw, Stanley Knife,
Spanners, Ratchets, Socket Set
Drill Fixing Attachments, Hex Head Bit Holders, 5/16 SDS Bit Holders
Drill Bits For Steel And Masonry (Various Sizes), PH2, PH3 Bits Etc
Cutting Discs
Cone Cutter
Holesaws (Various Sizes According To Service Penetrations, Up To 22mm)
Lifting Straps (Various Weight Ratings And Lengths)

D
Spray Paint, Markers, Carpenters Pencils.

TE
110v Transformer
Splitter Box

IN
Extension Leads

6.2 Measuring & Setting Out Tools

PR
All items used in measuring should be calibrated to the relevant British Standard, cleaned and checked on a
IF

regular basis and audited at predetermined intervals. The following may be of use:
Laser level and staff
ED

Magnetic tape measure (various lengths)

String lines
Spirit Levels, various sizes
LL
O

6.3 Cutting Tools

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Grinders
Two types of hand grinders will be used, primarily to notch or adapt steelwork but also to clean up sharp edges
of cut material. Care must be taken to ensure that guards and handles are properly fitted and that there are
N

plenty of blades available on the cutting disc, operatives must use the specified PPE according to the
O

manufacturers specification. As an example, see the product specification sheets for grinders in Section 14.
C
N

Metal Cutting Saws

For cutting stud and track in any quantity it is advisable to use a Metal Cutting (Chop) Saw. These come in two
U

types.

Type A – Metal Cutting Discs

These are metal cutting saws that can be table or bench mounted – they have an integral vice and use a 14”
metal cutting disc, similar to a hand grinder. Care must be taken when cutting to ensure a clean cut, when
cutting through the open edges of channels and studs it may be necessary to double up the materials to prevent
the steel springing as the blade cuts the edges. This type of saw will leave a burr on the cut edge of the steel
and may remove the galvanised surface of the edge, this may leave the steel exposed to corrosion. The cut
edges will need recoating with a galvanised spray or a galvanised paint. As an example see the product
specification sheets for a Metal Cut-off Saw in Section 14.

Type B – Carbide/Titanium Blade Saws

As above, metal cutting saws table or bench mounted, the difference is in the blade. The carbide tips act to fold
the galvanised coating back over the cut edge of the steel, thus removing the need to recoat the edges. This
type of saw will also keep a cleaner cut than the traditional cutting disc blades. Cost of blades is more expensive
than the disc cutting saws, but the blades can be reground and reused.

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 SFS Installation Manual

6.4 Fixing Tools

SDS Drill
Designed for drilling into concrete and masonry the SDS drill will be fitted with the specified SDS bit and will drill
down to a specific depth that can be set using a depth gauge attached to the drill, before the specified fixing is
driven into the hole. As an example see the product specification sheet for an SDS Drill in Section 14.

Impact Screwdriver

TEK Gun
Single Fix Systems
110v corded or Cordless Type
For screw fixing applications a SDS screwdriver may be used, adapted from plasterboard screwdrivers, when
fitted with the correct end bit it will fix hex head, wafer and pan head types of fixings to and through steel and
will also drive some concrete fixing types. As an example see the product specification sheet for a metal
construction screwdriver in Section 14.

Note that impact drivers should NOT be used for fixing tek screws into hot rolled beams. TEK guns are
preferable for all framing connections.

D
TE
Powder Actuated Fasteners (Shot Firing)
Shot firing involves the use of a powder-actuated tool. It involves the loading of strips of shots and nails into the
tool before firing into the structural steelwork. Structural steelwork is generally between 8mm and 20mm thick

IN
and requires great effort to fix a specific SDS type fixing, often leading to pre-drilling of the steel. These
PR
operations are costly in terms of time taken and health and safety (vibration white finger). Shot firing is quicker
though, under obligatory structural calculation, it will be necessary to increase the amount of fixings used. The
specification, location and quantity of shot fired fixings must under all circumstances be checked with Kingspan
IF

Profiles & Sections engineers.

ED

Before any powder actuated system is used, operatives will need specific operator training in the safe system of
work using these tools and the safe disposal of the used strips of shots, as these shots are classified as
explosive materials. The Installer should carry out his own site specific risk assessment before using a shot
LL

firing tool. As an example see the product specification sheet for a powder-actuated tool in Section 14.
O

Power Drills / Mag Drills

TR

110V Power Drill

A commonly used item for pre-drilling into steel, either light gauge or structural steel, has a 110v connection
N

back to the power source supplied by 110v leads. A 110v power drill can also be used for drilling through
O

brackets and cleats. As an example see the product specification sheet for a High Speed Drill in Section 14.
C

Sidewinder Drill
N

Used when there are fixings or holes required in tight locations, can be cordless or 110V. Often the heads can
U

rotate and lock at odd angles to get over tricky details. As an example see the product specification sheet for an
Angle Drill in Section 14.

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 SFS Installation Manual

7 HEALTH & SAFETY

This section should be read in conjunction with the SFS Design Risk Assessment available on the Kingspan
Profiles & Sections web site.

7.1 Edge Protection

Under no circumstances shall persons be exposed to working at height without suitable control measures in
place. Also see section 7.6 for access equipment. When there is no scaffold present at the edge of the slab the
main contractor will have installed some form of edge protection. A common method of protecting the exposed
edges of a building is to fix a fencing frame to the structure; attached to posts fixed into the structural slab, to the
face of the structure or fixed to the soffit of the floor below. As works progress these will be stripped out. The
external wall will provide a satisfactory barrier to falls from the building once completed. However, this may lead
to areas above or below the works having an exposed edge, other forms of barrier will be needed, such as
standalone Heras fencing. At the exposed edge operatives will need to be harnessed to the structure to prevent
the possibility of falls. The method of edge protection will depend on the type of access equipment used:
Temporary or permanent barriers
Scaffolding

D
Netting
Harness / Lanyard – only when the options above are not possible

TE
IN
7.2 PPE
When attending any construction site, everyone must abide by the mandatory PPE requirements that are set by
PR
the main contractor or developer. As a minimum the following should be used by operatives when handling SFS
and installation of light gauge steel walling:
Hard hat/ Safety helmet
IF

Safety Boots
Hi-Vis Vest
ED

Gloves
Safety Glasses/Goggles
LL

Ear Defenders
O

As part of the on site induction there should be provided:

TR

Details Of Safe Access/Egress

Location Of Nearest First Aid Point
N

Identity Of Appointed First Aider

O

Route To Nearest A&E Department

Fire Rules And Assembly Point
C

PPE Requirements
N
U

7.3 Manual Handling

For any given site a specific plan and risk assessment should be developed by the Installer that will evaluate the
risks attached with handling SFS sections and equipment. Seek guidance from the HSE on reducing the risk of
manual handling injuries and further specialist training. Some general guidelines in management of manual
handling:
Workers should receive training in kinetic lifting
Plan material use and adopt good practice when stacking materials
Use mechanical lifting equipment where practicable
Use team lifting for awkward and heavy loads
Good housekeeping standards should be maintained in all work areas
All spillages or general rubbish should be cleared in a timely fashion

7.4 Method Statements

The method statement is the Installer‟s interpretation of how the installation is actually going to happen. Usually
a simple, brief document it demonstrates competence to the main contractor and is a guide to the individual
operatives, who should all read, sign and date to signify their understanding and acceptance of the document. It

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 SFS Installation Manual

should also form part of a checklist/handover document that the main contractor can use to check that the
installation has been carried out correctly.

The method statement will contain many of the elements that will be found in the Infill SFS, Section 8 and
Oversail SFS, Section 9 of this document.

7.5 Risk Assessments

The following is a list of risk assessments, from which any that are relevant to the project should be carried out
before the installation of the SFS system. It is not an exhaustive list and the site should be examined for any
specific risks not mentioned within this list. Any actions to reduce risk that are identified should be carried out
and documented before site works commence.
Use Of Abrasive Wheels
Crane Operations
Deliveries And Collections Of Plant, Equipment Or Materials To Site
Use Of Electrically Operated Power Tools
Use Of A Gin Wheel
Using General Hand Tools
Manual Handling

D
Use Of MEWP‟s

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Summer Working
Winter Working

IN
Working At Height
Employing A Foreign Operative On Site With A Lack Of Knowledge Of The English Language
PR
Use Of Stepladders
Use Of An Alloy Tower
IF

Refurbishing An Occupied Building

Maintenance And Repair Of Plant
ED

Using A Waste Chute

Use Of A Trestle Scaffold
LL

Use Of Vibrating Plant Or Equipment

O

Used in conjunction with Method Statement, all operatives involved on site should read and understand the
information within these documents. The site operatives should then sign and date their acceptance of these
TR

documents. The risk assessment system should be backed up with a series of health and safety toolbox talks
about a specific site related issue or a general health and safety concern.
N
O

7.6 Access Equipment

C

The following is a list of types of access to the working edge of the building with a brief description of issues that
N

need to be considered before installation of SFS.

U

Scaffold
A series of steel poles and planks that have been designed under calculation that provide scaffold lifts that can
be worked off. Generally set with 2m working heights along the outside of the elevations, nearly always used on
tall structures. Used when the footprint of site allows.

The cost of scaffold is expensive, prolongation and delay can cause massive overspend on scaffold; it requires
careful planning and coordination with other trades. Progressive build and strip method; there are problems with
tying into the building through the external wall that can prevent completion of works at the first visit. When set
up correctly scaffold provides good access to the outside of the wall and good storage of materials, however
other trades may also use scaffold which can create obstacles to progress of SFS installation.

Dependant on finishes and external wall build up, there is a potential for unsafe working conditions due to gaps
between scaffold edge and the wall, individuals often pull back boards making work areas unsafe - requires
careful coordination with scaffolders. Scaffold can provide excellent defence against damage to the wall, can be
sheeted and canopied to provide a barrier to wind, rain and general poor weather conditions.

Risks to be considered when working off a scaffold include:

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 SFS Installation Manual

Men falling from height through excessive gaps between the working platform and the structure
Materials or tools falling through excessive gaps between the working platform and the structure
People on the ground being struck by materials or men
Men or materials falling while being carried up or down the access ladders to the various working
platforms
Scaffold collapse due to excessive loads or incorrect erection

Scissor Lift
Scissor lifts are moving platforms that have a bed on which to work. They are often extendable platforms that
can reach out to 60‟ plus, diesel fuelled. It is considered a cheaper alternative to scaffold, the decision to use is
often a financial one which can lead to contractors specifying the use where it is inappropriate or dangerous
(ground conditions).

Operators working from scissor lifts need to be qualified. Untrained operators will cause accidents and damage.
Ground conditions are crucial – often where landscaping is required the contractor does not want to pay to put
down hard standing materials. Combined with poor weather this can cause the ground to turn muddy with
forklifts and scissor lifts churning up the ground, getting stuck and causing delay.

D
Scissor lifts are generally slow to manoeuvre and slow to lift and drop. Any deviations in the ground will prevent
the lift going up and are limited in extent of height that can be achieved. Diesel powered and with batteries there

TE
are often difficulties with fuelling up, flat batteries and flat tyres causing delays on site.

IN
With scissor lifts there are often delays getting to the point of work in comparison with scaffold. Scissor lifts do
not provide any protection to the workface or the workers. Risks to be considered when working from scissor
PR
lifts include:
Men falling out of the working platform while at height through overstretching out of the basket/platform
IF

when at height
The scissor lift coming into contact with existing services or the structure
ED

People being trapped in the moving parts of the scissor lift while it is being raised or lowered
People being hurt or property damage by the scissor lift overturning due to unstable ground
LL

Material or tools falling from the platform while aloft and hitting people or property at ground level
The scissor lift striking or being struck by other vehicles manoeuvring at ground level
O

The scissor lift malfunctioning while at height

TR

Cherry Picker
A cherry picker is a small man basket on an extendable arm that is fixed to a movable base (diesel powered), it
N

is not suitable for general SFS installation but can be used for small remedial works or the installation of oversail
O

brackets to a slab face. Operatives will need specific training (IPAF registration) and will be required to wear
C

harnesses. Risks involved are generally the same as working from a scissor lift.
N

Mast Climber
U

A mast climber is generally elevation sized with bed of up to 20m in width, they are generally pushed and fixed
into place through the external wall. It has limited mobility and is fairly slow to lift and lower. It doesn‟t provide
any protection to the workers or working edge. Risks involved are generally the same as working from a scissor
lift.

Mobile Towers
When working off the slab that has a structural soffit at storey level it will be necessary to work off some form of
equipment to get to the top of the steelwork. There are three types of equipment used:
Hop-up – an individual platform that provides a base of up to 1 metre. There are safety rails integral
within the hop-up, however more than one may be required when handling long lengths of steel
Mobile Tower – a clip together scaffolding tower that can provide a base level that is adjusted to the
height required. A mobile tower will have a larger sizes platform, however this can lead to accidents as
tools and materials are stored on the platform. Must be erected and signed off by a competent person
that holds a PASMA certificate.
Stepladders – not allowed on many sites as there is an increased risk of accidents

Risks involved when working from these types of equipment include:

Men / Materials Falling From Height

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 SFS Installation Manual

Collapse Of The Equipment

Overturning
Misuse

Site specific as part of Method Statement including elements of the following:

Crane - Suitable Design For Lifting Operations As Part Of Lifting Plan.
MEWP‟s (Scissor Lifts)
Telehandler Forklift
Genie Boom Lift (Cherry Picker)
Mobile Scaffold Towers
Hop-Up Personal Towers
Trolley Jack

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IN
PR
IF
ED
LL
O
TR
N
O
C
N
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 SFS Installation Manual

8 MATERIAL INSPECTION & OFFLOADING

8.1 Method of Delivery
Steel will be delivered to site in packs or bundles that have steel banding to hold the steel in place during transit.
They will be placed on bearers and generally delivered on open-sided flat bed vehicles. The bearers will assist
in passing through chains or slings for lifting with a crane or to provide access for the forks of a telehandler.
However there may be requirements for curtain sided vehicles or self-offloading (HIAB) vehicles. It is entirely the
Installer’s responsibility to communicate the site specific offloading method to Kingspan, along with any
deviation from the above for consideration, evaluation and agreement.

8.2 Safe Handling

For any given site, a specific manual handling plan and risk assessment should be developed by the Installer
that will evaluate the risks attached with handling SFS sections and equipment. Specifically, care must be taken
when snipping the bands from a pack of steel as the material is likely to spring apart as the band is removed.
SFS stud and track will always have sharp edges, so gloves must be worn and care taken when moving product
around.

D
The steel lengths will be supplied as ordered in lengths up to 10m, any longer by prior arrangement only. This

TE
can lead to instability in handling with an uneven centre of gravity and difficulty in handling through restricted
spaces. An assessment should be made before any material is ordered to determine the optimum size that can

IN
be safely handled. Smaller sections can be spliced together on site, preventing unsafe handling conditions.
PR
8.3 Safe Storage
Steel sections can be stacked either flat or on edge and should be supported along their length and width.
IF

All sections should be stored in clean, dry conditions, protected from inclement weather
No sections should be stored next to or in contact with dry cement, lime, plaster, mortar or salt.
ED

Full bundles of sections should not be stacked more than two high with each bundle adequately
separated by timber batons of equal sizes placed at regular intervals along the length of the pack
LL

Avoid unnecessary movement of packs. Each time the material is moved from one place to another, the
risk of damaged sections is increased
O
TR

8.4 Component Identification & Marks

Each individual section will have an inkjet reference printed on it that will state:
N

The type of material, product code – e.g. U104055120, 104mm wide track (web), 55mm high (leg),
O

1.2mm gauge
C

The length – e.g. 3000mm

N

Each pack will have a label attached detailing the quantity of parts and the same information as above.
U

8.5 Damaged Material

In cases of damaged material that has been delivered to site, notification must be sent to Kingspan Profiles &
Sections within 24hours of receipt. If material has been damaged during movement or loading into position, an
evaluation of the extent may lead to the sections being cut down to be used as smaller infill pieces around
openings. If the material is unusable then it should be removed to the waste steel skip that should be provided
by others.

The disposal of steel or other associated waste/scrap must be carried out by an authorized and qualified
disposal agent and in any case at a site suitable for the re-cycling of the steel section.

In cases of damage to installed material, Kingspan Profiles & Sections should be contacted immediately to
provide advice on remedial, repair or replacement works.

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 SFS Installation Manual

9 INFILL SFS
9.1 Site Preparation
Structural Level Checks
Before commencing installation, Kingspan Profiles & Sections drawings should be checked for approved status,
if the drawings are not at A status (passed off by the project Architects) then the Installer takes a risk of remedial
works or changes after the steelwork has been installed. The working area should be checked to ensure that
there is clear access to the workface, that the structure is as drawn and that there are no major deviations from
the drawn dimensions of the structural bays. The quality and integrity of the substrate should be checked and
the alignment of the structural elements assessed to ensure that the SFS can be put in with the requisite
bearing on the substrate. Checks to ensure that there is nothing to impede fitting the SFS should be carried out.
If there are any issues with the above, the main contractor should be notified before commencing installation.

Gridline Set Out

The Main Contractor‟s site engineer will be responsible for providing gridlines across the slab that will directly
relate to the Kingspan Profiles & Sections elevation drawings. These grids will be sprayed on marks at regular
intervals that can be connected using string lines and spray paint. The grids will not necessarily be on the drawn

D
position but may be off-set by a nominated dimension (usually 1 metre). This is done to avoid obstacles or to

TE
avoid being masked as the steel is placed on the external edge. The position of the SFS can then be identified
as it sits to the edge of the structure, using measurements from the centre of a structural opening (dimensioned

IN
to the edge of the jamb) within the bay to align to grid.
PR
The Installer will set-out the rear or the front of the SFS according to the drawing on the floor slab and will create
a chalk line along the edge. Using a laser, the Installer will then transfer the line onto the structural soffit. This
will provide position for base and head track.
IF

9.2 Basic Installation Principles6

ED

Head and Base Tracks

Tracks are supplied in 3 or 4m lengths. As specified by Kingspan Profiles & Sections structural engineers,
LL

normally the base track will be of a specified width with a 55mm equal leg and 1.2mm gauge (thick), and the
head track will be the same width with a 67mm equal leg and 2.0mm gauge. The head track has this length of
O

leg to accommodate deflection and is more substantial to cope with the increased structural loads at this point.
TR

It is advisable to set up a cutting area and identify it as a Hearing Protection Zone. Proper setup of a work bench
N

to site the metal cutting equipment and to support the individual sections will help to avoid accidents and manual
O

handling risks. The base and head tracks can be cut using the metal cutting equipment to the required bay
width. Checks may be needed to ensure that track is not fitted across the base of a doorway section, unless
C

shown on the Kingspan Profiles & Sections drawings; the contractor should be able to confirm this.
N
U

The base track should be aligned to the lines provided and then fixed to the substrate using the specified fixings
at the required centres. Care should be taken to ensure that the track does not move out of place as the initial
fixings are drilled through the steel. In some cases the steel may need to be predrilled with a High Speed Steel
drill before fixing. The head track can be fitted using the same methodology. However the alignment of the two
tracks should be checked using a length of stud cut to size and a spirit level. This will ensure that the tracks are
in line and the wall will not lean out of plumb. Final fixing should only occur after these checks, or time and cost
will be incurred if either track has to be moved.
Ensure that there are the specified fixings in proximity to track ends and split points, generally this will require
double the amount of fixings at these points, and within 100mm of the track edges. Check that there is plenty of
bearing on the substrate at both base and head, there will be a specific dimension for each situation on site, as
a general rule of thumb SFS can overhang the edge of the structure by up to 1/3rd of its width.

6
Details for all practices mentioned in this section are available in the Kingspan Profiles & Sections Technical Manual

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Key to Figure;

D1
Total depth of external wall build up
D2
Setting out line from grid to internal finishes
Dd1
Depth of finish to interface with SFS
Dd2
Depth of SFS system
Dd3
Depth of internal finishes
eD1
Distance from structural element to outside face of SFS
eD2
Minimum required edge distance to fixing (as specified by the
fixing manufacturer)
dF
Max. anticipated live load deflection experienced at the mid span
between vertical columns

D
TE
IN
PR
IF
ED

General Stud Installation – Please refer to Kingspan Profiles and Sections’ Technical Manual for all
Installation Standard Details.
LL

Initial stud position should be measured from grid using a tape measure and should be determined from the
centre of a structural opening. If there are no openings within the bay then the Kingspan Profiles & Sections
O

elevation drawing may specify the position of the first stud and provide stud centres across the rest of the bay.
TR

The bay height should be checked and the studs cut to size with allowance for deflection and the head track
web, e.g. 2400mm measured height with a 25mm specified deflection gap and 2mm head track = studs at
2373mm. In many cases where the structure has been built closely to tolerance and drawing the stud height will
N

be repetitive and the studs can be brought in made to length.

O
C

The studs should be placed (twisted) into position and fixed with the specified fixings through the base track – in
N

the centre of the track and the web of the stud (minimum distance from any edge 15mm). (Ensure that jamb
studs are oriented with the web of the studs providing the sides of the structural opening). There may be
U

occasions when it is not practical to reach one or other face of the wall. The fixings must be installed before any
boards or finishes cover the studs.

Simplest method of stud installation is to set out the studs at the edge of the structural opening, then measure
off the required centres of the rest of the studs within the bay (generally 600mm), or use a block cut to size as a
template. However, attention should be paid to the installation of the internal drylining – they may require the
studs to be set out from specific grids from one end of an elevation to the other. Check that each stud is vertical
and plumb using a minimum 6‟ spirit level and that each stud is not twisted prior to final fixing.

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Deflection Conditions
Kingspan Profiles & Sections Technical will default to Type 1 deflection method in all instances where a fixing
can be practically made on both sides of the SFS wall. If the Installer has a preference for a different method,
his preference must be communicated to Kingspan Profiles & Sections before design works commence.

Type 1 – Deflection Head Bracket (DHB) (Detail A14)

Fixings are driven through the head track to fix into the DHB, holding it in position horizontally. Both
sides must be fixed. The stud is then slotted into the DHB and gripped by the edge folds – no fixings
should attach the stud to the head track as this will compromise the deflection zone and cause
deflection failure.

Type 2 – Block and Bracing (Detail A15)

There may be areas of the build that it is impractical to fix the stud to both flanges of the head track.
Quite often this can be found where something is obstructing the inside of the track, preventing access.
Below the obstruction, the studs will receive flat strap fixed on either side with a noggin section tightly
fitted and fixed between every third stud.

Type 3 – Head Track Blocking (Detail A16)

An Installer may choose a third method of creating an allowance for deflection with agreement from

D
Kingspan Profiles & Sections engineer, by placing blocking sections of stud within the top track, tightly

TE
fitting between studs. This will prevent the studs from racking or twisting and allow the track to move
freely over the studs.

IN
Type 4 – Slotted Stud (Detail A21) PR
As a value engineering exercise, Kingspan have removed the need for the DHB bracket by slotting the
tops of the studs to allow for live load deflection of the primary structure. Refer to the detail for more
information but, fixings are driven through the head track to pass through the slots in the stud, holding it
IF

in position horizontally. Both sides must be fixed – no fixings should attach the stud to the head track
as this will compromise the deflection zone and cause deflection failure.
ED

Setting out Structural Openings

LL

The jamb studs either side of an opening will have been set to provide the width of the structural opening and a
bearing surface as a fixing point. The contractor‟s engineer is responsible for putting datum lines on the
O

structural columns. These marks will have an offset to the structural slab, usually 1metre from structural slab
TR

level (SSL). A simple calculation can be made to work out the position of the window cill from the datum mark.
The position of the cill height can be marked on the column before transferring the mark across the studs to the
relevant structural opening using a laser. On occasion the datum mark will be given offset to finished floor level,
N

(FFL). Care must be taken to take into account the possibility of screed sitting on the structural slab. The
O

dimensions of the screed must be made known and the Kingspan Profiles & Sections drawn cill positions can be
C

checked.
N

Cill construction will consist of studs fitted to the jamb studs with a minimum of four fixings, dependant on
U

drawings. These will be the full length between base track and cill height. The cill track (either a section of base
or head track, as specified) will then fit above these studs, fixed at each end and at any studs that will fall in the
zone under the cill (according to the stud centres in the bay).

The lintel position can then be ascertained from the cill using the structural opening dimension shown on the
Kingspan Profiles & Sections drawings. The lintel is fitted in much the same way as the cill except the same
method of accommodating deflection as the general stud must be adopted.

The installer must check Kingspan Profiles & Sections drawings for cill and lintel constructions and make
provision for any compound constructions required by design.

Mid Span Restraint (Noggins)

Mid span restraint is also known as noggins; this consists of a section of stud that is cut and inserted between
two vertical studs. It is fixed and fastened in place using a section of flat strap fixed both sides with fixings into
both stud and noggin. The flat strap will come in 3m lengths and will serve to tie together a run of studs that
have mid-point restraints. As the name implies the restraints will be at the mid-height point of the structural bay,
but will not run across any structural openings. There may be occasions to use solid noggins in each bay. Such
instances will be as noted on Kingspan Profiles & Sections drawings.

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 SFS Installation Manual

Boarding Conditions
There are many variants of boarding types that will be fitted to the SFS on either side to create the final finishes
of the building. Board installation must not damage the SFS and boarding material must not be installed with
fixings going through into the deflection zone of the steel. In both cases the main contractor should be notified in
order to assess the situation and order any remedial works required. There should be careful consideration
given to the type of board used as to its air tightness abilities and its acoustic protection.

9.3 Detailed Installation – Worked Example

This scenario is based on a Kingspan 150mm system fitted to edge of substrate with a 20mm overhang over
edge of substrate. There is a drawn offset from the gridline at that edge that is equal to front edge of steel +
20mm. Height of structural bay is 2.5m, width of the bay between structural columns is 8m. There are two
structural openings 1m x 1m with a cill height of 850mm. The method of head blocking is slotted stud. For a
rectangular building, over two storeys, the information given will be for a structural bay of the building covering
both storeys. The structure may be any combination of structural steel or concrete.

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Figure 3 - Elevation Drawing

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Gridlines
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A sample of gridline provision in a rectangular building is given in Fig 2. Gridline references are applied to
drawings to pinpoint a particular component or area, in this case the position of the SFS frame. The site
engineer will be responsible for either step 1 or step 1 and 2 of the following:

Step 1
The site engineer will provide gridline marks/ points on the slab, usually a spray mark that has the gridline letter
or number by the side. The perimeter gridline (from which the Kingspan drawing will identify the position of the
SFS) will require a series of grid points marked with an agreed offset, usually 1m. This is because the edge grid
may be covered by the steel or may even exist outside of the primary frame. The engineer will acquire these
positions using dumpy level measuring equipment. The site engineer will also calculate and mark a datum point
on the structural columns; the point will provide a measurement either to SSL, structural slab level or FFL,
finished floor level. From this a calculation can be made to position the cills and heads of any structural
openings.

Step 2
The gridline points can be connected, a temporary fixing can be inserted into the points and a stringline can be
tied to each end. When sprayed with a marking spray paint it will leave a straight clear line that can be used to
measure to the SFS.

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Figure 4 - Building Plan and Gridlines
Step 3
Calculate dimension from the offset grid parallel to the slab edge to the inside face of the SFS wall. Using a
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measuring tape, make marks of the position across the bay. Then connect the marks using a stringline and
spray paint or a Chalkline, depending on which provides best results on the substrate.
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Figure 5 - Position of SFS from Grid

Step 4
Prepare floor track – acoustic mat – if using a neoprene strip it needs to be fixed to the underside of the track.
The track should be turned over, the neoprene stretched out and cut to fit the track. The neoprene should be
fixed with pan head or wafer head fixings at 1m centres to hold it in position. If using acoustic mastic, 2 beads
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should be run along the underside of the track at 1/3 points across the track. This will then squeeze out to the
edge of the track when the track is fixed to the substrate.

If fixing to ground floor slab, a damp proof membrane may be required under the base track. This should be
agreed between the installer and main contractor prior to commencing work.

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Figure 6 - Acoustic Mat

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Step 5
Place floor track with the inside face of the track along the Chalkline – fix with the KPS specified fixings, 1 at
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each end of the track section (within 100mm of the track edge) and 1 in the middle. Check that the track has
sufficient bearing on the substrate.
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Fixings into concrete will normally be a Tapcon masonry screw. This will require the concrete to be drilled out
with an SDS drill and bit before the fixing is installed using SDS gun and suitable hex head bit. Fixings into steel
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will either be a fine thread hex head tek screw fixed using a tek gun and suitable hex head bit, or a shot fired
fixing (check with KPS engineers for fixing specifications, locations and quantities). It may be preferable to
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temporary fix tracks to steel with gas nails but these must not be used for the final fit.
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Size and cut (if required) then fit further track sections to complete the bay.
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Section Plan
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Figure 7 - Track Fixing

Step 6
Use a small section of stud or a block within or against the track to form a bed that can site the laser level, take
care to ensure that the bed is level before siting the laser. The level can be positioned on the back edge of the
track and will fire up to the underside of the substrate/ slab above. A series of points can be marked along the
tracks in the bay and a string/ chalk line can provide a line to fit the head track, as in Step 3.

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Ensure bed is level!

Figure 8 - Positioning Laser

Step 7
Fit head tracks – acoustic mat may be required as in Step 4. Fixing as in Step 5.

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Step 8
Measure the dimensions between the webs of the tracks in a few places along the bay. Deduct the deflection

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tolerance as specified by KPS and cut some stud sections. If an accurate survey has been done then studs may
be delivered to the correct size. Place stud inside web of track and twist into position. Using a 6‟ spirit level it will
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be possible to check that the tracks are in line by placing the level against the leg of the stud. If the stud is out of
plumb (see Section 3 for guidance on tolerance) then the track positions may need to be adjusted. Undertake
final check of track position back to engineer‟s gridline.
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Figure 9 - Cut Size of Stud

Step 9
Calculate and prepare all full height studs, check that structural height is not out of tolerance. From gridline at
edge of bay perpendicular to slab edge, using KPS drawing dimension, measure to edge of nearest structural
opening and mark on track. Twist jamb stud into position, orient the stud so that the web of the stud provides the
edge of the window/ door. Measure across the structural opening and fit the stud at the other side of the
window.

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Figure 10 - Positioning Studs

Step 10
From the edge of the structural bay twist the full height studs into approximate position, according to the KPS
set out positions (normally 600mm centres). Mark stud position then complete track fixings into substrate top

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and bottom according to KPS specification. Where lengths of track abut each other there will be a requirement

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for extra fixings within 100mm of either edge of track.

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Figure 11 - Head & Base Track Connections

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Step 11
Move the studs into the final positions, ensure that the base of the stud is within 10mm of the web of the base
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track.
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a. Check position of studs

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b. Check that studs are plumb

c. Check the required amount of deflection
d. Fix through both sides of the head track, ensuring that fixings go through the slots in the stud as per
detail A21

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Figure 12 - Stud Bearing

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Figure 13 - Slotted Stud
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Step 12
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Repeat with all standard studs and jamb studs. Fix all studs into the base track with specified wafer/ pan head
fixings, in the middle of both track and stud leg, fix on both sides.
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Figure 14 - Stud to Track Fixing

Step 13
Openings – nesting (when required)
a. Fill jamb stud with Rockwool inside the web (when required)
b. Cut track section (as specified on KPS drawing) 25mm short of the exposed stud length (exposed
means the clear dimension between the head and base track)
c. Slide the track over the stud edges, ensure that there is the 25mm gap at the top of the track, this will
allow the top track to maintain deflection
d. Fix the track to the stud at 300mm centres on both sides with specified wafer/ pan head fixings. Ensure
that track edges do not protrude into the opening

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Figure 15 - Jamb Insulation (check requirement with Main Contractor)

Step 14
Cill construction
Site engineer will provide a series of datum points on the structural columns. These will give an offset to either
SSL structural slab level or FFL finished floor level, usually 1m. KPS drawing will show a dimension from SSL to

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cill of opening, e.g. 850mm. The Installer will calculate the dimension and mark the structural column at the cill
point. The laser level can be set up on a tripod with the laser point fixed at the level of the mark, the point can be

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then transferred to the jamb studs and to further openings and columns.

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Figure 16 - Setting Out Cill Level

Step 15
Mark web of jamb studs inside opening with position of cill.
a. Fit full length cripple studs – cut a section of stud and fix into jamb stud and base track, 2-3mm below
the mark, repeat at other side. 4 wafer/pan head fixings to connect cripple stud to jamb stud. Refer to
standard details.
b. Fit full height studs – from 2-3mm below mark down to web of base track, similar fixing regime plus
fixings into either side of base track.

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Figure 17 - Full Height Cripple Studs

Step 16
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Using specified cill track – cut to the width of the structural opening less 5mm. Slide over the cripple studs and
fix on both sides with specified fixings. Ensure that track is square and that there is no tilt in cill position, use
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spirit level to check.

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Figure 18 - Setting Cill Member

Step 17
Follow stud centre regime from main studs and fit studs between the cill and the base track, ensure that the
studs are a tight fit between. Use specified fixings and fix on both sides of tracks.

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Step 18
Head construction – Measure given height of structural opening from cill position and mark web of studs. Follow
Step 15A – ensure that the studs do not foul the deflection zone, or that there are any fixings that may foul the
deflection zone. Follow Step 16.

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Figure 19 - Construction at Head

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Step 19
Studs within the head section – cut them to size allowing for deflection. If there is room (over 600mm) then fit
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slotted studs, if not, double fix at head track of window, ensure that studs are vertical and will not foul deflection.
Board fixings will hold the studs in place. Refer to guidance in the technical manual for further information.
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10 OVERSAIL SFS
10.1 Site Preparation
Slab/Steel Checks
Before commencing installation, Kingspan Profiles & Sections drawings should be checked for
„CONSTRUCTION‟ status, if the drawings are not at this status then the Installer takes a risk of remedial works
or changes after the steelwork has been installed. The working area should be checked to ensure that there is
clear access to the workface, that the structure is as drawn and that there are no major deviations from the
drawn dimensions of the structural bays. The quality and integrity of the substrate should be checked and the
alignment of the structural elements assessed to ensure that the SFS can be installed properly. Checks to
ensure that there is nothing to impede fitting the SFS should be carried out. If there are any issues with the
above, the main contractor should be notified before commencing installation, to avoid any abortive works or
remediation costs.

Understanding and mapping of deviations in the slab and position of the columns are critical to the oversail
system as these will provide the fixing points for the oversail brackets. The alignment of the brackets and the
studs is vital to ensure a plumb, correctly aligned façade. Mapping the workface can be achieved by the use of

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string lines both horizontally and vertically which can be set to provide a grid. If any issues arise from the

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variations within the substrate provided, the main contractor and Kingspan Profiles & Sections should be notified
to receive advice and instruction. Localised packing, shimming or alteration of any bracketry is strictly prohibited

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and may only take place on approval from Kingspan Profiles & Sections.

Gridline Set Out

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The contractor‟s site engineer will be responsible for providing gridlines across the slab that will directly relate to
the Kingspan Profiles & Sections elevation drawings. These grids will be sprayed on marks at regular intervals
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that can be connected using string lines and spray paint. The grids will not necessarily be on the drawn position
but may be off-set by a nominated dimension (usually 1 metre). The grids that are required are the parallel
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gridline to the edge of the slab, the intersecting gridlines that will provide positions of brackets, studs and
structural openings and datum marks on the structural columns that can be used to ascertain cill and head
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heights.
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Bracket Identification
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Kingspan Profiles & Sections will provide a bracket set-out drawing showing where and how the bracketry will
be fitted. Generally the brackets will be face fixed to the front of the primary structure or fixed onto the structural
edge. If the structural position or vertical span in between structural levels changes from floor to floor then the
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size and type of bracket may also need to change. The sizes and types of bracket will also be drawn.
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10.2 Basic Installation Principles

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Bracket Installation
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Using the Kingspan Profiles & Sections bracket set-out drawing the positions of the brackets can be measured
off the gridline marks provided by the site engineer. The external string line grid will have determined whether
there is a need for packing the bracket. If a need is identified, the condition must be reported to Kingspan
Profiles & Sections engineers to assess the effects on the fixing and bracket design. Attention must be paid to
the width of the stud and the amount of lateral adjustment allowed while still retaining the ability to get fixings
into stud and bracket. The outside edge of the stud section will be the critical dimension from grid and will be the
key alignment point for the oversail SFS system.

The start point will be from one end of the elevation and at the first structural level. The first bracket should be
positioned and the hole centres marked on the face of the primary structure. Using the required drill type the
substrate is drilled as marked according to the fixing manufacturers‟ recommendations. It is the responsibility of
the Installer to ensure that all fixings are installed following the manufacturer‟s guidelines. In cases where resin
anchors are to be used, the Installer is advised to ensure that each fixing is checked for suitability and
compliance prior to loading.

The next bracket positions can be determined and brackets fitted in the same way, checking that the front edges
of the brackets are in line and that the brackets are perpendicular to the slab edge, if they are not then it may
cause the studs to kick out of line. It is advisable to fit a small area of brackets and then to fit some vertical

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studs. This will help to determine the proper sequence of fitting without having to remove brackets etc. If
brackets have to be fitted close together, around structural openings for example, there may not be enough
room to properly fit and fix the studs, a practical sequence of working must be devised. Also the brackets may
need to align themselves in different ways around structural openings. The brackets on upper floors can be
offered into position, aligned using a stringline and then fixed into place.

General Stud Installation

It is advisable to set up a cutting area and identify it as a Hearing Protection Zone. Proper setup of a work bench
to site the metal cutting equipment and to support the individual sections will help to avoid accidents and manual
handling risks. One of the advantages of Oversail systems is that section pieces can be accurately determined,
rolled and provided to the correct size. This will limit the amount of on site cutting and waste. Piece parts should
be referenced in a sequential simple method, when marked on the sections it should be simple to select the
required pieces.

The first stud from the end of the elevation should be selected and offered into position; an operative should be
in place at each bracket slab position to manage the section. If the section is very long and heavy, it may be
necessary to pre-drill a hole through one end and fix a rope that can be tied off at the top position. When the
stud is approximately in place it should be clamped to each bracket using hand clamps. The dimension at each

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bracket point to gridline should be checked. The stud should be eased into the correct position and checked at

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points with a 6‟ spirit level to ensure that it is level and plumb.

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When the stud is properly aligned it should be fixed to the brackets using the specified fixings in the correct
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pattern and methodology as detailed on Kingspan Profiles & Sections drawings.

Further studs should be installed working along the elevation, up to the first jamb opening. Care must be taken
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around structural openings to ensure that both bracket and stud are orientated in the correct manner to avoid
fouling.
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Tracks
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There may be track sections fitted to the top and bottom of the system, the bottom position of the studs should
have been predetermined. When enough of the studs are in position a full length of track can slide over the stud
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ends and fixed at each stud position. Alternatively, one stud can be installed at 3 or 4m intervals and the track
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can be fitted to both, providing an easy base housing for the studs in between, saving time in aligning the
bottom of the studs.
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Setting Out Structural Openings

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The jamb studs will have been set from the engineers‟ gridlines to provide the width of the structural opening.
The contractor‟s engineer is responsible for putting datum lines on the structural columns. These marks will
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have an offset to the structural slab usually 1metre from structural slab level, (SSL). A simple calculation can be
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made to work out the position of the window cill from the datum mark. The position of the cill height can be
marked on the column before transferring the mark across the studs to the relevant structural opening using a
laser. On occasion the datum mark will be given offset to finished floor level, (FFL).

Cill construction will consist of studs fitted to the jamb studs with a minimum of four fixings; these will be the full
length between base track and cill height. The specific cill and lintel studs may need to be of such a length that
they will require their own bracketry to support them. The cill track (either a section of base or head track, as
specified) will then be fixed to these studs and at the cripple studs at each end.

The lintel position can then be ascertained from the cill level using the structural opening dimension shown on
the Kingspan Profiles & Sections drawings. The lintel is fitted in much the same way as the cill except that the
studs will be fitted to the top brackets or housed by a piece of track.

Deflection Conditions
The provision for deflection within an oversail system is within the bracket fixed to the studs. The face of the
bracket that fits to the stud will be slotted to accommodate deflection and the face of the bracket that goes to the

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substrate will be hard fixed. The studs will be fitted with the locking nut washered and fixed in the middle of the
slot, turning back the pressure on the nut by ¼ turn. This will allow the slab to deflect independently of the SFS.
DO NOT OVERTIGHTEN BOLTS THROUGH DEFLECTION SLOTS.

Mid Span Restraint

In many oversail situations, to prevent racking of the system it is prudent to use mid-span restraint (also known
as noggins or dwangs). The use of mid-span restraint will be determined under structural calculation and shown
on the Kingspan Profiles & Sections elevation drawings. This consists of a section of stud that is cut and
inserted between two vertical studs. It is fixed and fastened in place using a section of flat strap fixed either side
with fixings into both stud and noggin. The flat strap will come in 3m lengths and will serve to tie together a run
of studs that have mid-point restraints. With the oversail system, multiple noggins may be required. The
specification and setting out of these noggins will be given in Kingspan Profiles & Sections drawings.

Boarding Conditions
There are many variants of boarding types that will be fitted to the SFS on either side, to create the final finishes
of the building, including Kingspan K15 insulation and cement particle board. Board installation must not
damage the SFS and boarding materials cannot be fixed across vertical studs which may be operating
independently of each other in deflection. There should be careful consideration given to the type of board used
and the methodology of fixing as to its air tightness abilities and its acoustic protection.

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11 CLEATS, BRACKETS & ANCILLARIES

11.1 Jamb Cleats
When required under structural calculation, stiffening cleats may be required at the top and bottom of a jamb
stud. Kingspan Profiles & Sections supplies a generic cleat for both top and bottom conditions. These should be
ordered at the same time as the steel as post fixing may not be possible. The position of the cleat should be
checked with Kingspan Profiles & Sections drawings prior to installation.

Top Cleat
The cleat will have a slot in one face that will be fixed through the stud with an M8 bolt, nut and washers. The
requirement and position of the cleat will be denoted by a specific symbol on the elevation drawings. An
isometric at the foot of the elevation drawing will display pictorially how the cleat is fitted. Once the jamb stud is
fitted into position in the correct position, the cleat can be offered into position and a mark can be made at the
midpoint of the slot to identify the position of the moving connection.

Drill the clearance hole in the stud, then position the cleat and fix the top leg of the cleat through the top track
into the substrate with the specified fixings. Fasten the cleat through the clearance hole into the stud using the

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M8 bolt, nuts and washers on either side. Repeat the process on the other side of the structural opening.

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Bottom Cleat

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Bottom cleats are fixed to the jamb stud using standard SDS fixings. They will be fixed through the base track
into the substrate using the specified fixings. PR
11.2 Lintel & Cill Cleats
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When required under structural calculation, cleats may be required at the connections from jambs to lintels and
cills. These will be generally 50x50x2mm cleats, supplied in stock lengths of 3 or 4m and cut to size on site.
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Lintel Cleat
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When a lintel track is fixed into position to the cripple studs at the sides of the opening, it can be given extra
support by fixing cleats at the corners of the structural opening. The cleats can either be fixed above or below
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the tracks according to Kingspan Profiles & Sections details. Fixings will be as specified on the Kingspan
Profiles & Sections elevation drawing.
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Cill Cleat
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Cill cleats are fitted in the same way as the lintel cleats under the cill track. Care taken to fix the cleat from the
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opening side (cleat can be clamped in place with a hand clamp or a prop), to prevent the fixings fouling the
window/door.
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11.3 Flat Strap

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‘V’ Bracing Above Windows

When specified there may be a requirement for bracing above structural openings. This will take the form of
diagonal flat strap fixed at the top of the jamb studs and at the middle of the lintel track section, forming a “V”
shape. Under no circumstances can the flat strap be fixed to the head track. This will be required on each side
of the SFS and will use fixings as specified. The use of V Bracing will be detailed and set out on Kingspan
Profiles & Sections drawings.

11.4 „Z‟ Bars

If it has been identified that the structural frame (concrete or steel work) will not provide the required bearing
surface for the SFS system, a potential solution is to mount the SFS system on Z bars. This must be considered
by Kingspan Profiles & Sections engineers before a detailed solution is suitable for construction. The Z bar will
act as a bearing/ fixing point for the SFS and will be fixed back into the substrate with the specified fixings.

The Z bar is supplied in 3m lengths to be cut to size on site. Attention must be paid to Kingspan Profiles &
Sections drawings to assess quantities of sections, lengths of section and the quantity and arrangement of
fixings required.

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11.5 Face Fix Angles

Where supporting angles fixed to the slab edge are specified, a specific fixing arrangement and angle
specification will have been provided by Kingspan Profiles & Sections. This method of supporting tracks is
generally not recommended due to the conditions of the slab edge. Any instance where this may be required
must be communicated to Kingspan Profiles & Sections for calculation prior to material procurement or
construction. Remedial works may be required if the adequacy of the detail is not checked by Kingspan Profiles
& Sections.

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12 INTERFACING ELEMENTS
12.1 External Sheathing Board
When specified, a sheathing board may be fitted to the external face of the SFS. There will be project specific
details and issues that the Installer must be familiar with. In all boarding conditions, the installer must fit the
board to the manufacturer‟s recommendations. The guidance given below is for general fitting where no
specification or alternative method has been made known;

General Guidance

1. Leave a 3-5mm gap between boards – cover joints with a foil tape or fill with an acoustic sealant.

2. Fixings should be at 300mm centres around perimeter of board section, 600mm centres along the
vertical studs.

3. First fixing should be 80mm from board end and 15mm from edge of board to centre of the fixing.

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Installation

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1. Read and understand method statements and risk assessments before commencing installation. It will

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be necessary to set up a safe system of work and potentially enclose the board cutting area,
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appropriate signage must be used to divert traffic from these areas. Also, check any specific detailing
through Architect‟s drawings.
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2. Measure from edge of structural column to the centre of the appropriate stud or opening edge. Work out
best orientation of board – board size is 2400mm x 1200mm, boards can be fitted horizontally. Ensure
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that the maximum area can be covered, this will prevent waste.
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3. Cut the board using a circular saw with extraction. Note any specific health and safety issues relating to
the task and ensure that all PPE required is in use.
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4. If there is no slab to rest the board, temporary fixings that are fixed 60% of the way into the substrate
will provide a platform to rest the board on. However 1 operator should hold the board in place until
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sufficient fixings have held the board in place.

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5. Fix a fixing at each corner of board using a SDS gun or battery drill, usual fixings are a wing-tipped self-
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drilling screw, these fixings will have a ribbed and countersunk head that will enable them to bed into
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the board leaving a flush finish.

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6. Repeat process for second section of board, where possible try to brick course boards ensuring that
joints do not travel along several boards. Prior to fitting second board put temporary fixings tight to the
top of the first board 60% of the way into the steel. These will act as a platform to rest the second board
on and will provide a line and gap for board expansion. When the second board is fitted these fixings
must be removed.

Repairs
Should there be any boards that get damaged or broken while in situ, they can be easily removed and a new
section of board cut and refitted.

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Bridging Across Columns and Edges

Column Interface
The sheathing board should span 600mm, the normal column is 200-300mm wide. There will be an SFS stud on
either side of the column so the sheathing board can be fixed to both studs. However where a structural column
meets a structural slab there may not be a fixing point, some form of angle/ top hat section may be needed to
provide a fixing point.

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Note; where there will be a cavity behind the sheathing board, then Insulation should be installed to prevent a
cold bridge.
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Slab/Steel Edge Interface

Assuming covering a 1st floor slab with SFS tracks on both sides of substrate. Generally the head track will
have a 70mm leg. The initial piece of board will be cut to size with 25mm of board onto the 70mm leg of track.
However, no fixings should go into the track. The last fixing up the board should be into the stud below the leg of
the track by at least the deflection distance.

There should then be a gap left of equal or greater than the deflection allowance before the next board is fitted.
This board should then be fitted above this gap with fixings only into the top track in between the stud areas.

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The board can then span upwards with the next fixings into the base track on the slab above. The gap between
boards can be filled with a compressible sealant or with foil tape.

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When a sufficient area of board has been positioned and checked for line then final fixing can take place.
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Sealant or foil tape should be applied to assist in the production of a thermally performing, airtight system. The
sealant will be provided in a cartridge that can be applied using a mastic gun, the foil tape will generally be
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provided on a 50m roll with adhesive to one face.

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12.2 Masonry
When the external finish to the building is masonry, the brick work will be tied back into the SFS system.
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General masonry detail when fixed to SFS is using a stainless brick tie channel fixed through required insulation
(type and thickness according to performance specification). The brick ties can then be twisted into place to tie
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into the brickwork, leaving a cavity of the required depth between brick and insulation.
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Typical components are a stainless ancon type brick channel 25mm width with 14mm legs, supplied in 3m
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lengths. These are fixed back into the SFS using a stand-off threaded fixing and rubber washer to the required
dimension usually fixed at 450mm centres along the vertical studs. The insulation will generally be a rigid board
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foil faced on both sides, joints in the boards will be covered with a foil tape.
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1. Cut insulation board using a hand saw if required. The insulation boards do not need to meet at stud
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positions.

2. If required cut the brick tie channel – the channel can oversail from slab to slab, ensure that it is not
fixed into the top track. There can also be gaps between each channel, Installer must ensure that there
will be channel correctly fitted to enable the required amount of brick ties to be twisted into position.

3. Installer must take care not to fit a brick tie channel to the jambs of any openings. The SFS will have
been designed to provide a specific stud within 70-225mm of the opening for brick tie fixing.
st nd
4. 1 erector holds board in place and brick tie channel in position, 2 erector will push the stand-off screw
through a predrilled hole in the brick tie channel and through the insulation before fixing into the steel
with a SDS gun. This will be repeated at required centres along the brick tie channel.

5. Use small off cuts of channel above and below openings, try to ensure that full lengths of channel are
used between slabs.

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6. Care must be taken to ensure that there is adequate drainage above structural openings; this is
dependent on the position of the frame of the window/ door within the wall system. Where required a
collector track should be fitted diagonally above the opening extending past each side to the nearest
SFS stud. Water will then run off and be carried away from the opening. Alternatively, the insulation can
be cut short of the head and a cavity tray can be fitted.

7. There may be a requirement for firebreaks at each slab. These will be fixed back through the system
and will fill the cavity behind the brick according to the performance specification.

8. Foil tape across all board joints to help seal the system.

12.3 Render
Insulated Render systems – applied directly to the sheathing board covering the SFS. The type of insulant will
be an EPS (Polystyrene), Mineral Wool (Rockwool) or a rigid board phenolic. The thickness of material will be
determined by the project performance specification, according to the size of the wall zone and the required “U”
value (thermal performance). The
insulation will come as a board, generally

D
1m x 0.5m in size; the boards can easily
be cut to any specific requirements.

TE
Each render system will have its own

IN
specific details and methods of
PR application, generally bags of powder will
be mixed with water to form a liquid
adhesive. This will be spread across the
IF

back of the board before pushing the

board into place. Often the adhesive will
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be supplemented with fixings in a

specified pattern, these fixings will go
through into the sheathing board and do
LL

not need to fix through the SFS. The

fixings will be a SDS screw type that can
O

be fixed with a SDS gun.

TR

NHBC require a cavity based render system that requires specific arrangements of top hat sections to form the
N

cavity. The system suppliers should be contacted for specific details on these systems.
O
C

12.4 Rainscreen
N

A rainscreen system will be fixed back to the steel using a form of bracket and rail. There are several types of
finishes that are available to be fixed in this ventilated system including hung slates, terracotta tiling, high
U

pressure laminates, zinc panels and aluminium panels. Generally, the installation will consist of the SFS
framework with a cement board as previously detailed.

A series of brackets (commonly known as helping

hand brackets) will be fixed through the cement
board into the vertical SFS studs at specified
centres with SDS screws.

A carrier rail will be fitted to the brackets, checked

and adjusted with a stringline to ensure that the
front line of the rail is perfectly aligned.

Kingspan insulation will then be fitted according to

the specification requirements.
Depending on the type of finish, a horizontal batten
may be fitted to the carrier rails before final fixing of
the finish.

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 SFS Installation Manual

The arrangement of the carrier rails, horizontally or vertically, will have an effect on the design and specification
of the SFS. The Installer is advised that specific reference to the specification of the cladding system and
Kingspan Profiles & Sections Designers & Engineers is required in these conditions

D
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IN
PR
IF
ED
LL
O
TR
N
O
C
N
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 SFS Installation Manual

13 QUALITY CONTROL
13.1 Area Sign Off
As each section of works is completed, the area should be inspected and signed off using a site specific
inspection and handover sheet, example below. The size of the area will be determined at site level; it may be
one floor of one elevation, or a complete elevation or a complete floor. There are many variants that should be
examined in conjunction with the main contractor to ensure that the critical elements are properly inspected and
signed off.

Project Area Inspected

Installer Approved By
Inspector Date
Date
Item Pass Comment Action Required

SFS Setting Out Checks

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Dimension from Grid

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Line & Level

Structural Opening Setting Out PR

Line & Level of Opening
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Fixing Checks
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SFS Fixings to KPS Standard

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Track Fixings to KPS Design

O

Jamb Fixings to KPS Design

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Cleat/Bracket Fixings to KPS

Design
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Edge Distances Observed

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Special Constructions Fixings

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to KPS Standard
N

SFS Construction Checks

U

Deflection Tolerance at Head

constant & to KPS Design
Deflection not compromised
by Fixings/Boards/Other

Edge Bearing
Jamb Construction to KPS
Design

Lintel Construction to KPS

Design

Cill Construction to KPS

Design

Brick Tie Studs (if required)

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13.2 Remedial Works

This section looks at what can be done when there are problems on site. It covers four areas; damage, incorrect
installation Installer error, incorrect installation drawing error and Architect/ contractor changes.
Damage – if there has been damage to SFS in any way, the Installer needs to assess the extent and
take steps to return the area to the drawn situation. If there has been significant follow on works then it
may be possible to add in extra studwork adjacent to the damaged studs, this may save costly stripping
out and replacing. In any damage situation where direct replacement of materials would be difficult
contact Kingspan Profiles & Sections for assistance/ advice. If possible, e-mail digital pictures of the
damaged area to the Kingspan representative, if necessary a site visit can be arranged to inspect and
offer advice.
Incorrect installation Installer error – necessary remedials may require stripping out and replacing
incorrect materials, an assessment should be made in conjunction with the main contractor and
Kingspan Profiles & Sections.
Incorrect installation drawing error – contact Kingspan Profiles & Sections immediately.
Architect/ contractor changes – the Installer should receive and agree an instruction to amend the SFS
and Kingspan Profiles & Sections should be notified in writing of the proposed changes. Should
drawings require revision an instruction should be forwarded by the Installer to Kingspan Profiles &
Sections

D
It is often a difficult task to strip out SFS as follow on trades may prevent access to fixing points, e.g. screed

TE
covers access to base tracks and boarding may cover screw heads. Where possible the inclusion of extra studs
may suffice, however this will not work if a structural opening needs to move. Most fixings will easily unscrew, if

IN
this is not possible they will need to be ground out using a 41/2” hand grinder, this will cause damage to the
Kingspan stud and track, any damaged materials should be replaced not reused. In all cases contact Kingspan
PR
Profiles & Sections for advice and assistance on best practice.

13.3 Kingspan Profiles & Sections Site Support

IF

Kingspan Profiles & Sections, as part of its commitment to quality construction, can undertake site visits and
inspections to look at the adherence of the installation to the Kingspan Profiles & Sections specification. This
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service is generally chargeable.

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Kingspan Profiles & Sections accepts no responsibility or liability for the quality and performance of the
installation. Kingspan Profiles & Sections is limited in their liabilities to the design and engineering of the Steel
O

Framing System (SFS) and the fixing specification of the SFS to the primary structure. The drawings submitted
TR

to the client constitute a minimum performance specification which must be adhered to.
N

It is the responsibility of the Installer to ensure the SFS is installed to Kingspan Profiles & Sections drawings. It
is the responsibility of the Main Contractor to ensure that all Kingspan Profiles & Sections drawings have been
O

approved by the project design team and are issued for installation at Construction status. Kingspan Profiles &
C

Sections will accept no responsibility for works carried out to drawings which are not at construction status.
N
U

Kingspan Profiles & Sections technical representatives will attend site to inspect the installation of the SFS and
to liaise directly with the Installer on the adherence of the installation to the Kingspan Profiles & Sections design.
They are also able to advise on best practice principles and to educate and inform project teams on the
subtleties of the system as provided by Kingspan Profiles & Sections. As part of this inspection a report will be
compiled; this will be sent to the Installer for action and review.

Before attending site the Kingspan Profiles & Sections Technical Representative will require
An agreed inspection date and time
Clear and unobstructed access to the areas to be inspected, and any local issues which may obstruct
the inspection
Notification of any special requirements with regards to site specific health and safety policies
Confirmation of person(s) to attend the Kingspan Profiles & Sections Technical Representative on site.
These requirements are a minimum requirement before any inspection work can be undertaken. If any of these
items are not completed, it may result in the Kingspan Profiles & Sections Technical Representatives being
unable to carry out the works as required.

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14 COSHH & TECHNICAL DATASHEETS

14.1 General Specification Notes

PRODUCTS:
Steel Framing System „U‟ Track and „C‟ Stud cold formed steel galvanised profiles

SUPPLIER:
Kingspan Profiles & Sections, Sherburn, Malton, North Yorkshire, YO17 8PQ
Tel; +44 (0) 1944 712000 Fax; +44 (0) 1944 710555
http://www.kingspanprofiles.com

Products
Cold rolled components are manufactured from pre-hot dipped galvanised steel, Z275 coating, guaranteed yield strength 390 N/mm². All
studs, joists, tracks and accessories shall be of a type, size, gauge and spacing determined by structural calculation and as shown on the
drawings, and shall be supplied by Kingspan Profiles & Sections. Unless stated otherwise in the calculations, all structural members are
designed in accordance with UK codes of practice.

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Procurement

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It is the Installer‟s responsibility to produce a cutting list and order Kingspan Profiles & Sections materials. This should be co-ordinated to
suit the desired construction programme.

IN
Drawing Approval
All drawings must be approved by the main contract Engineer and project Architect prior to construction works.
PR
Erection of Components
All systems are constructed on-site and must be installed to British Standard BS5950, BS8000 and NSSS (National Structural Steelwork
IF

Specification). Liability for the quality and accuracy of the installation rests with the Contractor and not Kingspan Profiles & Sections
Sections. Care must be taken when site cutting components square where they are to be used in right angled connections and all cut edges
should be protected. Fixing of components shall be with self-tapping screws. Screw type and size shall be as typical details or to a project
ED

specific design. All screw fixings must be installed perpendicular to the surface wherever possible. All bolt fixings are to be Grade 8.8. No
holes are to be cut or formed in Kingspan Profiles & Sections SFS without prior reference to Kingspan Profiles & Sections. Service slots can
be provided 600mm from each end of studs when requested and if deemed acceptable by Kingspan Profiles & Sections Design
LL

Department. Track members shall be securely anchored to the supporting structure as shown on the drawings. Complete, uniform and level
bearing support shall be provided to upper and lower tracks. Abutting lengths of track shall be securely anchored to a common structural
O

element and spliced, all as determined by structural calculations. Studs shall be plumbed, aligned and securely attached/located within
upper and lower tracks. Framing of wall openings shall include headers, lintels and supporting studs as shown on the drawings. Temporary
TR

bracing shall be provided where required until completion of erection. The erection contractor is responsible for the temporary stability of the
structure during construction. Joists shall be located directly over load bearing studs or a load distribution member shall be provided at the
top of the wall as determined by structural calculation. Web stiffeners are to be provided at reaction/or at points of concentration loads
N

where indicated on the drawing. All apertures (doors, windows, louvers) in panels are to be set out to structural sizes from Architects details.
O

External Walls
C

Insulation should be provided over the external face of the stud walling that is sufficiently robust to remain in place during and post
N

construction, and should be adequate thermal resistance to prevent cold bridging and interstitial condensation. Insulation should be fixed in
accordance with manufacturer‟s instructions. Consideration should be given to joints in insulation boards and the repair of damage to
U

prevent ingress e.g. taping of joints or provision of a breather membrane. Internal linings should be fixes in accordance with the
manufacturer‟s instructions and selected to achieve the specified performance for fire, thermal, and acoustic. Where masonry cladding
forms the external envelope, this should be tied back to the Kingspan Profiles & Sections studs using stainless steel wall ties and
continuous channels fixed with standoff screws as specified in the structural calculations. Additional studs are to be fitted at all jambs and
brickwork control joints to provide support for wall ties.

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14.2 COSHH Datasheet

PRODUCTS:
Steel Framing System „U‟ Track and „C‟ Stud cold formed steel galvanised profiles

SUPPLIER:
Kingspan Profiles & Sections, Sherburn, Malton, North Yorkshire, YO17 8PQ
Tel; +44 (0) 1944 712000 Fax; +44 (0) 1944 710555
http://www.kingspanprofiles.com

USE
Steel Sections – form internal/external, structural/non-structural walls, floors and ceilings. They may be supplied partially or fully assembled.

TYPICAL COMPOSITION
Steel panels are assembled from cold rolled steel sections manufactured from hot dip, zinc-coated / iron zinc coated slit steel coil to BS EN
10143:1993. The profiles are rolled in accordance with the specification for cold rolled steel profiles to BS EN 10162:2003. Cold rolled
profiles are manufactured as suitable for use in the specification of galvanised steel stud and track partitions and linings using screw fixed
gypsum walling board to BS 7364:1990 or other boards depending on the application.

D
Boards, Fastenings and Fittings may be of various proprietary materials each of which will have its own safety Information Sheet supplied by

TE
the manufacturer.

STEEL

IN
All steel is hot dip iron zinc galvanised to a coating thickness typically of 275g/m 2.

HANDLING OF PRODUCT PR
Steel sections are either handled individually or banded into bundles for ease of transportation depending on size, shape and weight.
Steel sections are loaded onto transport in a way that enables easier mechanical off-loading.
IF

In most cases the manufacturer will explain handling methods to the contractor.
ED

Any distortion or damage to the sections must be avoided during handling as this could affect structural integrity.

It is important that sufficient space is available for moving sections from the unloading point to any intermediate storage area and/or the final
LL

assembly location.
O

Where banded sections require lifting by hoists and cranes then ropes and slings should be used together with a suitable trailing tie to stop
uncontrolled swinging.
TR

STORAGE OF PRODUCT
All steel sections can be stacked either flat or on edge and must be supported along their length and width. A number of recommendations
N

are made:
i) All sections should be stored in clean, dry conditions, protected from inclement weather.
O

ii) No sections should be stored next to or in contact with dry cement, lime, plaster or mortar.
C

iii) Full bundles of sections should not be stacked more than two high with each bundle adequately separated by timber batons of
equal sizes placed at regular intervals along the length of the pack.
N
U

DISPOSAL OF PRODUCT
The disposal of steel, panel or other associated waste/scrap must be carried out by an authorised and qualified disposal agent and in any
case at a site suitable for the re-cycling of the steel section, or an authorised land fill site. The sharp edges could present a danger and must
be kept out of reach.

HEALTH HAZARDS, PRECAUTIONS & FIRST AID

Steel sections are designed to be structurally sound according to each application and are structurally capable in the assembled designed
condition only. The integrity of the assembled panel/module must not be reduced by unauthorised dismantling and/or removal of material
whether steel, board or fastenings. Panel/module assemblies are not designed to support any structure other than the finished product so
must neither be used, nor relied upon, as supports during storage or assembly.

It is the responsibility of all personnel working on or with the panels and modules to support themselves safely and, if necessary, form an
independent support system.

HEALTH HAZARD – EYE CONTACT

Extreme care must be taken when releasing and breaking open bundle strapping. When bundle strapping is cut tension is released, causing
the strapping to spring freely from the bundle which can result in eye injury. The use of tools (especially power cutting tools) on steel
sections generates potentially hazardous shavings and sparks.

Precautions
Packs and bundles must be opened whilst on the ground to avoid the possibility of their contents falling over and causing injury. A number
of protective measures are also recommended:
1. Safety footwear should be worn.

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 SFS Installation Manual

2. Suitable eye protection should be used (a) when cutting the strapping; (b) when cutting the profile and c) when using tools of any sort.
3. Safety gloves capable of protecting the skin form steel shavings and sharp edges should be worn.
4. Strapping should be restrained from springing freely whilst being cut.

First Aid
In the event of eye injury, cuts or abrasions, seek immediate medical attention. It is also recommended that if a cut is received requiring
medical or first aid attention, professional advice should be attained regarding the possible need for a Tetanus injection.

HEALTH HAZARD – SKIN CONTACT:

Lacerations of the skin can occur from sharp corners and edges or when breaking open strapping. Foot injuries could also be sustained
when walking over discarded steel debris on site (e.g. re-cut edges of sections). Steel shavings and sparks are produced when using tools
(particularly power tools).
Precautions:
1. Hand and Power tools – should be used only by those wearing suitable protection.
2. Lifting – recommended techniques must be adhered to and manual lifting should be limited to acceptable weights. Never lift any packs
that are not within the method limits.
3. Loading and Unpacking – suitable gloves and protective clothing should be worn.
4. General Handling – persons with skin problems, grazes and those known to be sensitive to mineral oils should protect hands and
exposed skin with a barrier cream or suitable gloves.
First Aid:
In the event of skin irritation or injury, immediate medical attention must be sought by an appropriately qualified person.

HEALTH HAZARD - INHALATION:

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Steel sections at atmospheric temperatures do not emit any fumes or gasses.

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PRECAUTIONS:
(As stated above).
Health Hazard – Ingestion: (not applicable)

IN
Health Hazard – Exposure limits: (not applicable)
Health Hazard – Fire and Explosion hazards: (not applicable)
PR
FURTHER INFORMATION:
Please contact the Kingspan Profiles & Sections Technical Team on 01944 712000.
IF

This information is provided in good faith on the assumption that the person carrying out the task of using the product is
ED

experienced and/or has been fully trained in the handling and use of the particular product and application.

The reader must be satisfied that they (or the person carrying out the application) are suitably responsible and that these
LL

recommendations have been thoroughly read and understood by that person.

Kingspan Profiles & Sections does not accept responsibility for any claims of consequential loss or injury to the user or third
O

party if the recommendations of this safety sheet are not adhered to.
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14.3 Cutting Tools

Steel Cut Off Saw Disc Grinder

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Evolution EVO355 RAPTOR 355mm TCT Steel Cut Hilti DEG 125-D Angle Grinder

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Off Saw

IN
14.4 Drilling Tools PR
SDS Drill SDS Cordless Drill
IF
ED
LL
O
TR
N

Hilti TE 7-C Rotary hammer drill

O

Hilti TE 4-A22 Cordless rotary hammer drill

C

Angle Drill
N
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 SFS Installation Manual

14.5 Fixing Tools

TEK Guns

Hilti ST 1800 Metal Screw Driver Hilti ST 1800-A22 Cordless Metal Screw Driver

Impact Driver

D
TE
IN
PR
IF

Hilti SID 14-A Cordless Impact Screwdriver

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NOTE – Impact drivers should NOT be used to fix tek screws to hot rolled steel.
LL

Powder actuated fixing tools (“Shot firing”)

O
TR
N
O
C
N
U

Hilti DX460 MX Powder-actuated tool with magazine Spitfire P370 Disc Cartridge Tool

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 SFS Installation Manual

15 KINGSPAN PROFILES & SECTIONS SUPPORT SERVICES

Kingspan Profiles & Sections offers a range of design and supply services operating from a number of sites
in the UK. To serve our customers with the maximum efficiency, we would be grateful if you could direct your
question to the following contacts;

15.1 Material Ordering & Production Enquiries

Customer Services
Kingspan Profiles & Sections
Pleck Road,
Walsall,
West Midlands.
WS2 9ES
Tel: 01922 728312
Fax: 01922 644460
Email: [email protected]

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15.2 Technical Enquiries
SFS Technical Manager

IN
Kingspan Profiles & Sections
316/317 Fort Dunlop, PR
Fort Parkway,
Birmingham.
B24 9FD
IF

Tel: 0121 776 5460

Fax: 0121 730 2667
ED

Email: [email protected]
LL

15.3 Sales & Commercial Enquiries

Area Sales Manager
O

316/317 Fort Dunlop,

TR

Fort Parkway,
Birmingham.
N

B24 9FD
O

Tel: 0121 776 5460

Fax: 0121 730 2667
C

Email: [email protected]
N
U

15.4 Site Support

Contracts Manager
316/317 Fort Dunlop,
Fort Parkway,
Birmingham.
B24 9FD
Tel: 0121 776 5460
Fax: 0121 730 2667
Email: [email protected]

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