Cladding installation is a critical process that requires precision, adherence to manufacturer guidelines, and a thorough understanding of material properties. The provided documentation outlines key procedures for installing Duraclad composite cladding and Westman Steel’s metal roofing and siding systems. These products are designed for durability, fire resistance, and aesthetic appeal, making them suitable for a wide range of residential and commercial applications.
This article compiles and organizes the installation instructions from the source material, offering a comprehensive, step-by-step guide for professionals and DIY enthusiasts alike. It emphasizes correct seam lapping, fastening techniques, alignment checks, and finishing procedures, all of which are vital for ensuring the longevity and performance of the cladding system.
Pre-Installation Considerations
Before beginning the installation process, it is essential to prepare the site and verify all materials are present. According to the manufacturer's guidelines, a material checklist must be completed to ensure all components, including trims, fasteners, and cladding sheets, are accounted for and staged in a convenient location near the installation site.
The roof squareness must also be verified. At the corner where an eave and gable meet, measure eight feet along the eave purlin and six feet up the gable edge. If the distance between these two marks is exactly ten feet, the roof is square. This step is crucial for ensuring proper alignment of the cladding sheets. If the roof is not square, adjustments may need to be made sheet by sheet, taking advantage of tolerances in the side laps, or by trimming the sheet along the gable and using an after-applied gable flashing to reduce visual impact.
It is also important to determine the type of cladding being installed and follow the appropriate procedure. Different types may have specific requirements for fastening, sealing, and alignment. For example, gable trim must be fastened at 36-inch intervals, and it is crucial to seal and fasten the cladding sheet along the gable to prevent water ingress.
Installation of Trims and Flashings
The installation of roof trims and flashings is an essential step in ensuring a weathertight and aesthetically pleasing finish. These components include gable trim, eave trim, corner and ridge boxes, and valley flashings.
Gable Trim (Before Applied): Install the gable trim by fitting the pieces in place and fastening through both the top and bottom nailing flanges at maximum 36-inch intervals. It is important to properly seal the cladding sheet along the gable using sealer tape to prevent water from migrating under the sheet and into the building.
Eave Trim (Before Applied): Eave trim is installed before the roof sheets. To ensure proper fit, determine the wall panel depth (e.g., 3/4 inch) and fasten the top nailing flange of the eave trim to allow space for the wall panels plus an 1/8-inch clearance. At least three fasteners should be used per 10’6” length of trim.
Corner and Ridge Boxes (If Required): These are optional and installed after the eave and gable trims. Manufacturers typically provide specific instructions for these components, which should be followed closely.
Dormer and Valley Flashings: Where required, install valley flashings with support along their entire length. Without proper support, the flashing will not lie flat, making it impossible to create a weather-tight seal between the roof sheet and the flashing.
Cladding Installation Procedures
Sheet Placement and Alignment
When placing the roof sheets, it is important to begin at the eave on the end of the building farthest from the prevailing winds. The sheets should be extended approximately 1 inch over the gable edge and 1 to 2 inches over the eave. Overlapping the sheet ends by at least 6 inches is necessary, and these overlaps should occur at a purlin for support. It is recommended to lay the sheets one by one from the eave to the ridge before starting the second row.
To ensure proper alignment, check sheet alignment every four to five rows by chalking a line square to the eave. This helps maintain a straight and even appearance across the roof surface.
When walking on the roof, avoid stepping on the ribs. Instead, step on the purlins to prevent damage to the sheeting. On windy days, extra care should be taken to prevent the sheets from buckling or becoming difficult to control. A board or ladder can be used against the fascia board to pull the sheets up the roof using vice grips and a rope. This method is not recommended for long sheets.
For wall cladding, the installation process begins at the side wall at the corner. It is crucial to use a level to plumb the wall sheets before fastening. The seam lap must be checked to ensure a snug fit. The first two fasteners should be run through the girt to hold the sheet in place. Additional fasteners should be installed using the correct screw placement, ensuring that the sheets are square and laid evenly. Continue fastening the wall sheets around the building, finishing with the gable ends.
Fastening Techniques
Proper screw placement is vital for securing the cladding sheets to the building structure. The seams and overlaps must be fastened in accordance with the manufacturer’s specifications to ensure structural integrity and weather resistance.
Roof Sheet Fastening: Identify the proper seam lap and screw placement to fasten the sheets to the building. Fasteners should be spaced according to the manufacturer’s guidelines, typically at regular intervals to prevent sagging or warping.
Wall Sheet Fastening: For wall cladding, the first two fasteners should be run through the girt to hold the sheet in place. Additional fasteners should be installed using the correct screw placement, ensuring the sheets are square and laid evenly.
Ridge Cap Installation
The ridge cap is an essential component that protects the roofline from water ingress and provides a finished appearance. There are several ridge cap and venting options available, and the manufacturer typically specifies the required space at the top of the roof sheeting to accommodate the vent.
The installation process involves the following steps:
Chalk the Ridge Cap Location: Chalk the location of the ridge cap on both sides of the roof to ensure accurate placement.
Install Closure Strips: Depending on the application, install closure strips or vented closure strips along the chalk line using adhesive.
Place Ridge Cap or Vents: Place the ridge cap or vented ridge cap on top and fasten through the top of the cladding rib and through the closure strip. If using vents or vented ridge caps, ensure that the closures do not block any drainage holes.
Apply Caulking for Standard Ridge Caps: For standard ridge caps, apply a generous bead of caulking to the overlapping portion and place the next ridge cap on top. Repeat this process for the entire roofline.
Connect Vents for Longer Roofs: For ridge caps longer than the length of a single vent (typically 10 feet), butt two vents together with the connector flange underneath at the joint. Both vent and end panels fit between the two tabs on the connector flange. End panels are used when vents are installed individually.
Finishing and Clean-Up
After the cladding sheets are installed, it is important to perform caulking and clean-up to ensure a professional finish and prevent premature deterioration.
Caulking: Caulk around windows and doors to create a weather-tight seal and enhance the appearance of the building.
Cleaning: Use a soft bristle broom to sweep the cladding sheets and remove any steel shavings or dirt. Steel particles left on the cladding can rust quickly, often staining the paint finish and giving the impression that the roof sheet has rusted. Dirt left on the sheets can hold moisture and accelerate the deterioration of the paint system.
Conclusion
The installation of Duraclad composite cladding and Westman Steel’s metal roofing and siding requires careful planning, adherence to manufacturer guidelines, and attention to detail. Proper alignment, fastening, and sealing are essential for ensuring the longevity and performance of the cladding system. By following the step-by-step procedures outlined in this guide, professionals and DIY installers can achieve a durable, aesthetically pleasing, and weather-resistant finish suitable for a wide range of residential and commercial applications.