Troubleshooting Techniques

PROBLEM: ROOF LEAKS - Improper sealant installation.
SOLUTION:
1. Check sealant locations in endlaps and sidelaps (make certain fasteners are on the dry side of the lap.)
Tip: slide thin card or matchbook cover between the panels. Card must touch sealant before it reaches the fastener line.
2. Make sure sealant did not “snake” across sidelap. Sealant should be placed in a straight line along the edge of the underlapped panel on the wet side of the fastener line.
PROBLEM: ROOF LEAKS - Fasteners omitted at endlaps, sidelaps and at accessories such as vents, skylights, etc.
SOLUTION:
1. Check the building manufacturer’s erection guide for quantity and placement of fasteners.
2. Check for sealant under flashings and accessories.
3. Make sure the fasteners are always on the dry side of any sealant.
PROBLEM: ROOF LEAKS - Fasteners missed purlins.
SOLUTION:
1. Check alignment of fastener relative to the purlin. Remove any fasteners that missed a purlin and install an oversized fastener to seal the hole panel.
PROBLEM: ROOF LEAKS - Improperly installed fasteners around roof penetrations by mechanical contractors.
SOLUTION:
1. Check the erection guide for proper techniques of flashing. Most manufacturers have flashing units to match panel configuration. Mechanical contractors often use asphalt sealant around openings in the roof panel. Over a period of time asphalt flashings become brittle and will break when the roof panel expands and contracts.
2. Check for loose trim and flashing pieces.
3. Check quantity, location and fastener types used at flashings. If “pop” type rivets were used, make sure mandrel hole was sealed.
4. Check sealant location relative to fasteners. Fasteners should always be on the dry side of the sealant.
PROBLEM: ROOF LEAKS - Cracked, crazed or broken skylights.
1. Fastener should be rivet type or petal type instead of screws to prevent cracking fiberglass skylights. Check manufacturer’s recommended installation techniques.
2. Check sealant location to make sure fasteners are properly located relative to the sealant. Extra sealant is often needed at fiberglass skylights to fill voids that often occur due to improper nesting of fiberglass and roll-formed metal panels.
PROBLEM: ROOF LEAKS - Stripped fasteners.
SOLUTION:
1. Use a hand wrench to apply slight tightening rotation to the fastener. A stripped fastener will feel loose and some cases can be backed out by hand. Fasteners should be backed out and the hole should be filled with oversized fasteners. Sealant alone will not stop the fastener from leaking. Sealant does not heave the same characteristics that the neoprene fastener washer has and can eventually crack.
PROBLEM: ROOF LEAKS - Improper lapped panels.
SOLUTION:
1. Make sure corrugations of roof panel are securely nested and fastened. Any attempt to overlap the panels more than what manufacturing recommendations allow can cause sealant in the overlaps to not properly seal.
PROBLEM: FASTENERS WON'T DRILL. - Improper tool selection.
SOLUTION:
1. Driving tool should be 2000-2500 rpm for #8, #10 and #12-14 self drilling and for carbon steel self tapping fasteners. Driving tool should be 1800 to 2000 rpm (max) for #12-24 self drilling fasteners and for all #1/4 self drilling fasteners. Stainless steel self tapping fasteners should be driven with 600-900 rpm (non-impact type) screw guns equipped with depth sensing nose pieces.
PROBLEM: FASTENERS WON'T DRILL. - Low voltage to power tool.
SOLUTION:
1. Check extension cords for proper wire size versus length of cord. The following chart should be used as a guide to determine wire size.
CORD SELECTION
LENGTH OF CORD (FEET)
AMP OF TOOL50100150200250300
2.5181816161614
4161616141412
5161614141212
American Wire Gage (AWG)
PROBLEM: FASTENERS WON'T DRILL. - Improper socket size and worn sockets.
SOLUTION:
1. Replace worn sockets with new ones. Worn sockets can cause excessive damage to fastener finish and will not allow fasteners to seat properly in the tool.
2. Make sure magnetic drill sockets have all drill shaving removed.
Tip: shavings can be removed by pressing a small piece of sealant into the socket and then quickly extracting it. The sealant removes most of the drill shavings. Repeat until fastener seats securely in socket./p>
PROBLEM: FASTENERS WON'T DRILL. - Improper pressure on the tool.
SOLUTION:
1. Excessive pressure can cause point failure on self-drilling fasteners. When drilling through panel, insulation and purlin, apply only a small amount of pressure to penetrate the roof sheet. Don’t allow drill point to strike the top surface of purlin. Excessive force could cause the point to chip thus slowing its drill time or preventing drilling altogether.
2. Apply only enough pressure to keep drill point cutting. Low pressure will cause overheating and dulling of the point. Excessive pressure will cause gouging and point breaking.
PROBLEM: FASTENERS WON'T DRILL. - Improperly nested purlins.
SOLUTION:
1. Make sure gap between purlins is not excessive. Self-drilling fasteners have a pilot point to allow drilling through nested purlins providing the gap does no exceed. approximately 1/4″.
Tip: if purlin gap is excessive, pre-drilling the top purlin with a clearance hole will allow threads to engage only in the bottom purlin. This will help in making the joint watertight and prevent excessive fastener failure.
PROBLEM: POINTS CHIP OR BREAK WHEN DRILLING. - Improperly nested purlins.
SOLUTION:
1. Check for excessive gap in nested purlins.
2. Pre-drill top purlin if gap becomes excessive.
PROBLEM: POINTS CHIP OR BREAK WHEN DRILLING. - Excessive pressure on tool.
SOLUTION:
1. Apply only enough pressure to allow drill point to drill. Excessive pressure will cause gouging and point failure.
PROBLEM: POINTS CHIP OR BREAK WHEN DRILLING. - Improper tool selection.
SOLUTION:
1. The fastener should be driven with 2000-2500 rpm screw guns with depth sensing nose pieces.
PROBLEM: FASTENERS WOBBLE OR "WALK" ON PANEL - Tool wear.
SOLUTION:
1. Replace worn hex drivers. Worn drivers allow too much clearance between hex fastener and walls of driver will allow fasteners to wobble.
2. Check for drill shaving buildup in magnetic sockets. Remove shavings by applying small amount of sealant in socket and rapidly removing sealant to pull drill shavings loose.
3. Drive fasteners perpendicular to panel surface. Driving fastener at an uncomfortable angle or when fasteners are being driven at arm’s length, driving the fasteners perpendicular to the panel is important. Sometimes stack drilling on the ground is required prior to paneling installation to relieve tendency to walk.
4. Check for proper size of socket. It is impossible to drive a 5/16″ head with a 3/8″ socket.
5. Make sure head of fastener clears magnet in driver to allow to rest on skirt of washer head.
PROBLEM: EXCESSIVE DUMPING OF THE WALL PANEL - Improper washer diameter.
SOLUTION:
1. Select the proper washer diameter for the thickness of insulation being compressed. Small diameter washer tends to make panel dimple upon seating. Larger diameters distribute more evenly across the panel and rest in less dimpling. Refer to fastener selection chart for proper washer diameter.
2. The use of purlin blocks in roof applications will relieve some back pressure caused by compressed insulation and allow roof panel to be installed with less dimpling. Use the fastener selection guide for blanket insulation and rigid insulation as a guide to proper fastener length required.
3. Do not overdrive the fastener. Set the nose piece so that just enough force is applied to the panel to adequately seal the washer. Excessive overdriving will cause panel to dimpling and deformation of the sealing washer.
PROBLEM: STAINLESS STEEL STRIPPING - Improper tool selection.
SOLUTION:
1. Use driving tools with speeds of 800 rpm maximum.
2. Use driving tools with depth sensing nose piece.
3. Do not use impacting tools. Stressed caused by impacting tools exceed the strength of the fastener threads.
PROBLEM: THREADS PEEL OF DEFORM ON THE FASTENERS WITHOUT ENGAGING THREADS IN THE STRUCTURE. - Improper pre-drill diameter.
SOLUTION:
1. Select proper pre-drill diameter from fastener selection chart to assure proper thread engagement.
PROBLEM: THREADS PEEL OF DEFORM ON THE FASTENERS WITHOUT ENGAGING THREADS IN THE STRUCTURE. - Improper fastener selection.
SOLUTION:
1. Select proper profile of the fastener for the material being tapped. See the fastener selection guide for pre-drill diameters for various material thicknesses and thread profile. (Type A stainless fastener should be used on materials not exceeding 14 ga. [.071]. Type AB fasteners can be used on heavier purlin and girt materials up to 11 ga. Type B stainless fastener is use for material 1/2″ thick).

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