THE METALITH PERIMETER SECURITY SYSTEM INSTALLATION INSTRUCTIONS. Attention

Transcription

1 THE METALITH PERIMETER SECURITY SYSTEM INSTALLATION INSTRUCTIONS Thank you purchasing the Metalith Perimeter Security System. The following document provides the manufacturer s recommendations for successful construction, installation and maintenance. Please read this document in its entirety before beginning the installation process, and use it as a reference during installation. For questions, contact Infrastructure Defense Technologies at (800) For calls initiating from outside the United States, please call Attention The Metalith is an engineered product which is designed for and intended to encapsulate heavy fill media for long periods of time. A geotechnical and/or civil engineer must ensure/determine that the contemplated site for Metalith installation is properly stabilized, and has the necessary load bearing capacity to support the dead load that the product will place upon the footprint once assembled and filled. It is the responsibility of the purchaser, end user, or end user s representative to ensure that the Metalith is properly installed, and that the site is properly prepared for installation. Metalith products must be installed by a competent construction contractor. For ballast material, IDT recommends a medium to coarse sand with grain sizes ranging from 0.5 mm to 2mm (100% passing #10 sieve, 0% passing #40 sieve). The ballast material shall have a maximum dry unit weight of 130 pounds per cubic foot, a maximum active equivalent fluid pressure of 35 pounds per square foot and maximum at rest equivalent fluid pressure of 50 pounds per square foot, unless stated otherwise on an IDT issued, job-specific set of shop drawings stamped by a licensed engineer. Other suitable materials for use as fill are described within this document. Fill materials other than those stated above may be unfit for use, and IDT specifically disclaims any liability for products installed with other than recommended fill materials. In no event should fill materials exceeding a dry unit weight of 130 pounds per cubic foot be used as fill. It should be noted that any/all fill materials must be kept dry, as fill saturation may increase fill weights by as much as 3:1, which may lead to overloading of Metalith walls. 1

2 IDT has no supervisory responsibility, has no control of or responsibility for the means, methods, techniques, procedures or sequence of construction, has no responsibility for the failure of any contractor to perform the work in accordance with the design documents, and no responsibility to devise, implement or enforce any safety precautions or programs for any project involving the Metalith. The contractor shall verify that the footprint of the Metalith wall is to be placed on a level surface. Existing slope shall not exceed 1/8 per 1 0. For walls exceeding 100, inquire with the manufacturer. Proper Storage of Materials Metalith Materials must be stored indoors, in a cool, dry place while in the packaged state. Improperly stored materials are susceptible to white rust, a form of corrosion which occurs when moisture exists between stacked galvanized steel sheets. IDT specifically disclaims any liability for damage resulting from improperly stored materials. Safety We recommend that every worker involved in assembling Metalith barrier components use all of the following safety clothing and equipment: Long gauntlet gloves Safety Toed shoes Hard Hats Safety Glasses Ear Protection Long Sleeved Shirt Metalith panels contain sharp edges and caution should be taken to avoid injury. Construction Needs Front end loader with height and load capacity to fill wall (for walls over 12, a crane and bucket may be required to fill higher courses Strap cutters to break packaging bands Forklift or other appropriate equipment for unloading Ball peen hammers to strike flaring tools which widen notched fittings Appropriate safety equipment and procedures Level Steel Shims Site Preparation 2

3 Footprint must be graded, ground stabilized to handle weight, and designed for good drainage to prevent ponding under or in the wall. The Metalith wall footprint should be marked out with stakes, cones, and spray paint to match location. DO NOT PLACE METALITH WALL KITS WITHIN THE FOOTPRINT. In order to maximize drainage and stability of the Metalith, IDT recommends a 6 layer of crushed gravel at the base of the unit, beneath the first course and 12 beyond the outside of both sides of the wall. Installation: It is the responsibility of the customer or customer s representative to properly install IDT s products in accordance with the manufacturer s installation instructions and specifications. IDT is not liable for improperly installed products. Ground Preparation: It is the responsibility of the customer or customer s representative to properly level and prepare the ground upon which IDT s products are installed. Metalith Kit Contents Each Metalith Perimeter Security System kit contains the following contents: Side Sheets have notches in the larger corrugation and must always face up. The side sheet also has an offset. The offset will always be to your left. Cross Panels: These panels represent the cross structural members of the unit, and are positioned at engineer designed intervals within the wall. The larger rolled edge will always face up. Brace Panels: These panels are installed at the wall terminations for added support. End Panels: These are the terminating walls of the unit. These panels are the same size as the cross panels but have holes at engineer designed intervals in the panel. Connecting Pins: Stainless steel pins used to connect corrugated sheets within the walls. Flaring Tools: Hammer-like tools used to open the end notched sheets for perpendicular fit-up to other sheets. End Caps: Sheeting used to prevent sand spillage at the four corners of the wall. Wire Mesh: Mesh for use atop the unit to prevent wind erosion of the fill. 3

4 Metalith walls come in many standard wall heights and widths and are constructed without exterior support. The following example shows how the components of a standard 16 tall wall would be configured. Sample 16' Tall Wall 16 gauge 2' tall 16 gauge 2' tall 2 high panels made out of 16-gauge steel and used for the lower 2 wall courses 3 high panels made out of 18-gauge steel that are used for the upper wall courses. It should be noted that in many of the production sizes for the Metalith, differing panel sizes may apply. Installation Begin installation at your predetermined corner and work counter clockwise. Ensure the side of the panel that will make up the outside of the wall has the larger corrugated portions facing out. 1. Begin by flaring the cross sheets, end sheets and brace sheets. Strike the flaring tool with a ball peen hammer until the flaring tool fits flush with the surrounding metal. See illustration that follows. FLARING TOOL SUPPLIED IN KIT ***Notice both sides of the panel have a single flange. Your flaring tool will not work on these flanges. Simply strike each single flange with your hammer to give it a consistent shape with the other flanges. Now your entire panel will fit-up with the side panel. 4

5 2. Pin an end sheet and side sheet together First person Pin man Second person will work on exterior side Third person will work on the interior side (The second and third persons will compress the sheets together so that the first person can align the predrilled holes for pinning). Insert a pin by aligning the predrilled holes and dropping or pushing the pin into place. DO NOT USE A HAMMER TO FORCE THE PIN INTO THE HOLE AS THIS WILL PERMANENTLY DAMAGE THE PANEL! 3. At the next set of holes, pin another end sheet facing the opposite direction. Now pin a brace sheet in between the end sheets. 4. Install all of the cross sheets facing the same direction except for the last end sheet. 5. Continue this method of moving counter clockwise along the full length of the wall and then along the backside until the first course is complete. 6. Put end caps (polyethylene film) in all four corners. End caps should be cut 4 longer than the height of the wall. 7. Once the first course is completely assembled, check to make sure the wall is aligned and completely level. Nudge any units that are out of alignment. Make sure the wall is level by placing a level across the wall every 8 and adding steel shims under the three-way connections when required. Course ONE must be level and square before installing course TWO. 8. Fill the first course with ballast starting at the middle of the wall. *Care should be taken to dump the ballast into the center of the bins and not near the edges so the wall does not move/shift.* Leave 6 of space below the top of the completed course to facilitate assembly of the next course. A single base unit (course) shall be filled with suitable ballast material. During filling, the material shall be compacted in the containment system to a minimum of 70% of the standard Proctor maximum dry density in accordance with ASTM D698. Ballast material shall consist of medium to coarse sand with grain sizes ranging from 0.5 mm to 2mm (100% passing #10 sieve, 0% passing #40 sieve). The ballast material shall have a maximum dry unit weight of 130 pounds per cubic foot, a maximum active equivalent fluid pressure of 35 pounds per square foot and maximum at rest equivalent fluid pressure of 50 pounds per square foot. Large aggregate, rubble, and clay balls are not recommended for fill. Aggregate and rubble can become projectiles themselves. Large rock intensifies the force of an explosion and can cause severe damage to the inside of the revetment wall. 5

6 Use the same installation procedure as the first course until you reach your desired height. 9. When the wall is complete, apply the wire mesh to the top of the unit, which will serve as a cap. In areas where annual rainfall is of concern, a metal roof supplied by IDT (as an option at an additional price) or other engineer specified cover should be used to prevent overloading of the Metalith walls. The diagram below provides an illustration of the wall. Note: End configuration contains Brace Panel(s). Intermediate configurations do not. Never attempt to construct a Metalith barrier wall by starting at both ends and building toward the center. 6

7 Post Erection Inspection Guidelines Once the Metalith barrier is built it must be inspected periodically. Here s a list of things to look for during inspection: 1. Fill materials leaking - Look for material leaking from the bins. In bad cases the roof option or cap may have to be removed, fill added, and then the Metalith barrier system will have to be capped again or roof option installed again. If the leak is from the corner, the polyethylene film may have torn. This can be repaired from the inside or outside. 2. Erosion - Once the Metalith barrier is constructed it may disrupt the existing drainage patterns. Existing drainage may need to be changed to prevent eroding of any surface or base barrier materials. 3. Metalith Barrier Leaning - If the barrier wall system begins to lean dangerously, it must be torn down, the surface material re-stabilized and the barrier wall system rebuilt. This should not occur if the unit is properly installed, on level ground, properly drained, and properly maintained. S 4. Metal Corroding Monitor pin hole connections and apply a light oil if corrosion is noticed. 5. Cap - Manufacturer s roof option is strongly recommended in areas where rainfall is an issue. Infrastructure Defense Technologies 6550 Revlon Drive Belvidere, Illinois Phone: Fax: info@infrastructure-defense.com URL: 7