The packs can be off-loaded directly to the roof, or to a storage area, which should be dry and well away from traffic. Packs may be stacked up to 2.5m high with wooden bearers every 2m: bearers should be placed above each other.

Handle AS35 panels carefully to avoid marking the weather sheet or liner. Lift panels from the pack - do not drag them. Carry panels by the male (filled) edge - do not lift panels by the female edge or just the top sheet. See table 13 for the weight of panels.

Observe site health and safety procedures and the results of manual handling and other assessments.

Preparation
Before fixing any panels check the squareness and accuracy of the steelwork. Determine the direction of the prevailing wind. Check panels for damage before fixing and remove any excess insulation from side and end laps.

Installation
These installation sequences describe the general methods for laying and fixing AS35 insulated roof and wall panels.

Single tier roof

1. Lay the first panel with the female edge to the gable, away from the prevailing wind. Use a string line to lay the panel straight and true. Fix the panel.
2. Apply 6 x 5mm butyl sealant along the top of the male crown. The surfaces receiving the sealant must be dry: joints in the sealant must be lapped by 25mm not butted.
3. Lay the second panel with its female crown over the male crown of the first panel. Fix the panel.
4. Stitch the lap with self drilling fixings.
5. Continue to lay panels along the roof, checking the alignment of the cladding and correcting any deviations.
   
6. Fix flashings. Use foam filler pieces and butyl sealant to form weathertight junctions.

Double tier roof
On a two tier roof lay the panels in the order shown in figure 42.

1. Lay panel one with the female edge to the gable, away from the prevailing wind. Use a string line to lay the panel straight and true. Fix the panel at every purlin except the top one.
2. Apply three runs of 6 x 5mm butyl sealant to the head of panel one, one on each side of the fixing line and one 15mm from the end of the lap.
3. Apply a run of 6 x 5mm butyl sealant to the male crown of panel one for the length of the lap (figure 43).
4. Lay panel two with the female edge to the gable and the tail lapping panel one. Fix the panel with one fixing in each main valley at every purlin.
5. Tail stitch the end lap.
6. Apply a run of 6 x 5mm butyl sealant to the male crown of panels one and two (figure 44).
7. Lay panel three with its female crown lapping the male crown of panel one. Fix the panel at every purlin except the top one.
8. Stitch the side lap with self drilling fixings at 450mm centres.
9. Apply three runs of 6 x 5mm butyl sealant to the head of the panel (as panel one).
10. Apply an additional run of 6 x 5mm butyl sealant along the female crown of panel three for the length of the lap (figure 45).
11. Lay panel four with its female crown lapping the male crown of panel two and its end lapping the head of panel three. Fix the panel with one fixing in each main valley at every purlin.
12. Stitch the side lap with self drilling fixings at 450mm centres.
13. Tail stitch the end lap.
14. Continue to lay panels along the roof, checking the alignment of the cladding and correcting any deviations.
15. Fix flashings. Use foam filler pieces and butyl sealant to form weathertight junctions.

Figure 42: Roof panel laying sequence




Figure 43: Sealant to panel one


Figure 44: Sealant over panels one and two



Figure 45: Sealant to panel three

Wall panels

1. Set the first panel upright against the framing at the corner of the building with the female edge to the corner. Make sure the panel is vertical.
2. Fix with one fixing in each main valley at each side rail.
3. Apply a run of 6 x 5mm butyl sealant along the male crown.
4. Set the second panel upright with its female edge lapping the male edge of panel one.
5. Fix with one fixing in each main valley at each side rail.
6. Stitch the lap with self drilling fixings at 300mm centres.
7. Continue to lay panels along the wall, checking the alignment of the cladding and correcting any deviations.
8. Fix flashings. Use foam filler pieces and butyl sealant to form weathertight junctions.

Cutting panels
Where panels have to be cut on site:

• Use a powered reciprocating or circular saw. Do not use an abrasive.
• Support the panel along the line of the cut.
• Protect the pre-coated finishes of the panel.
• Clean any swarf or debris from the pre-coated finish of the panel immediately.

Completion
When all the AS35 panels have been installed check:

• All fixings are correctly fitted and tightened;
• The fixings do not distort the panels;
• All fixing caps are fitted;
• Minor scratches have been treated;
• The surface of the roof is clean and free of any swarf or debris.