Tiffany Haney
Metal decking pans are often used in construction to form a 'deck' surface onto which concrete is later poured. This process results in a very strong floor surface. Metal decking pans can be installed using various methods, including welding, power-driven fasteners, or self-drilling screws. The installation process can be dangerous and intricate, so it is important to receive the necessary safety training and follow construction best practices. Proper fastening is critical to ensure the deck functions as intended and provides wind or seismic protection, acts as a concrete form, or offers bracing to joists or beams.
Characteristics and Values Table for Installing Decking Pan
| Characteristics | Values |
|---|---|
| Safety | All workers must receive the necessary safety training and equipment before attempting to install decking pans. |
| Installation Process | The installation process includes hoisting bundles of metal decking, spreading metal decking, and attaching metal decking. |
| Fastening Techniques | Welding, power-driven fasteners, and self-drilling Screws are the three methods used to fasten decking pans to structural framing. |
| Welding | Requires skill and experience, forming a strong attachment by penetrating supporting beams or joists. |
| Screw Sizes | #10 screws for sidelap attachment, #12 and #14 screws for support fastening. |
| Power-Actuated Fasteners (PAFs) | Resemble short nails, driven into supporting structures using powder cartridges or pneumatic pressure. |
| Drill Type | Torque-controlled drill for installing screws properly without stripping them. |
| Metal Deck Types | Roof deck, composite deck, and form deck are available in varying depths, widths, and gauges. |
| Shakeout Process | Involves manually dragging and spreading sheets of metal decking to their permanent positions, ensuring the first sheet has the male leg facing the center of the building. |
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What You'll Learn
Safety precautions
Installing decking pan, especially metal decking, is a dangerous and intricate process that requires careful safety precautions. Here are some essential safety measures to follow when installing decking pan:
Training and Safety Equipment:
Before starting any decking installation work, it is critical that you and your team receive the necessary safety training and have access to the appropriate safety equipment. This includes understanding the hazards associated with working within a Controlled Decking Zone (CDZ) and mastering proper installation techniques. All workers should be aware of potential slip hazards and learn safe navigation techniques on the decking. Regular education sessions and training programs can help emphasize the importance of vigilance and taking precautionary steps to avoid accidents.
Use of Personal Protective Equipment (PPE):
All workers involved in decking installation should wear appropriate PPE, including protective clothing, gloves, eye protection, and respiratory protection if necessary. This helps shield against potential hazards such as falling debris, sharp edges, and dust inhalation.
Hoisting, Landing, and Spreading:
Adhering to safety standards during the hoisting, landing, and spreading of decking bundles is crucial. Ensure that the level directly underneath the roof is completed before beginning the installation. When hoisting decking bundles to the roof level, use proper equipment and follow safe handling procedures to avoid injuries and damage. The shakeout process involves manually dragging and spreading one sheet of metal roof decking at a time to its permanent position. Ensure that the first sheet installed has the male leg facing closest to the center of the building, allowing the female side of each subsequent sheet to drop over the male side easily.
Fastening Techniques:
When fastening decking pans to the structural framing, you can use welding, power-driven fasteners, or self-drilling screws. Each method requires specific skills and techniques to ensure safety. Welding, for example, requires experience and careful inspection to ensure it is performed correctly. Power-driven fasteners, such as Power Actuated Fasteners (PAFs), should be used with the appropriate amount of force depending on the strength and thickness of the decking material. Self-drilling screws should be installed with a torque-controlled drill to ensure proper installation without stripping the screw.
Guardrails and Barriers:
Install guardrails and perimeter safety cables to prevent falls, especially on open-sided floors. These safety measures are essential during the installation process and should comply with Occupational Safety and Health Administration (OSHA) standards and regulations.
Regular Inspections and Maintenance:
Conduct regular inspections and maintenance of the decking to identify potential safety hazards. Look for missing or loose connections, corroded fasteners, rotting wood, or other signs of deterioration. Annual inspections can help target potential damage points and ensure the long-term safety and integrity of the decking structure.
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Shakeout process
Steel pan decking is a broad category referring to the use of corrugated metal pans to form slabs of concrete. It is not a specific product, so you cannot buy pan deck alone. You can buy pan decking once you know the type, gauge, and finish required. The Engineer of Record (EOR) should dictate the pan decking gauge requirement for the specific job.
The shakeout process is an important part of installing a metal roof deck. It involves manually dragging and spreading one sheet of metal roof deck at a time to its permanent position. Once the metal decking bundles are hoisted to the roof level, you can begin the shakeout process. Most types of metal roof decking have a male leg on one side and a female leg on the other side. It is crucial that the first sheet is installed with the male leg facing closest to the center of the building. Every subsequent sheet will then be oriented the same way, allowing the female side of each sheet to easily drop over the male side. The shakeout process is complete when the sheets are spread and permanently fastened to the steel frame.
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Welding
There are different types of welds used in decking installation. One common type is the plug weld, which is used to fasten the metal decking to the steel framing. This type of weld must be performed by a light gauge certified welder. The welder uses a welding machine and a weld rod to burn through the decking and create a puddle weld about the size of a nickel. This process takes approximately 5 seconds per weld and results in a strong bond between the decking and the steel beam.
Another type of weld used in decking installation is the arc spot weld, also known as a puddle weld. When using this method, it is crucial that the weld penetrates the supporting joist or beam, and the puddle forms above the deck surface. The diameter of the effective fusion area for arc spot welds is typically at least 1/2 inch. This type of weld usually takes 3 to 6 seconds to complete but can take longer for thicker sheets or multiple sheets.
It is important to note that welding galvanized decking requires extra precaution due to the poisonous zinc fumes that are produced. A mask respirator should always be worn during this process. Additionally, proper inspection is necessary to ensure that the welding has been performed correctly.
While welding is a strong and effective method for installing decking pans, there are alternative fastening methods available, such as screws and power-actuated fasteners. These methods may be faster, less expensive, and require less skill to implement. Ultimately, the choice of fastening method depends on the specific requirements and constraints of the project, as well as the engineer's specifications.
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Power-driven fasteners
To use a PAF, first set the power regulation on your installation tools and perform a trial fastening. Then, using a powder actuated tool that operates similarly to a gun, trigger the charge to push the piston. The piston will then slam the PAF through the metal deck layer, fusing the fastener shank to the base steel supports.
Compared to welding, PAFs require less skill and can be a cheaper option for attaching certain kinds of metal decks. However, they may require special licensing or certifications to operate. It is important to consult the manufacturer's instructions and ensure proper safety precautions are taken, such as wearing a mask respirator to avoid poisonous zinc fumes when welding galvanized decking.
When choosing between welding and PAFs, consider the engineer's specifications, the thickness of the metal deck, and the required level of skill and hassle. While welding creates a very strong attachment, it takes longer and requires a certain level of experience. PAFs provide a strong connection similar to welding but with less hassle and are suitable for a wide range of steel decking applications.
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Self-drilling screws
When using self-drilling screws, it is important to select the appropriate screw size for the material you are drilling into. For example, when drilling through thin wooden boards or aluminum alloy plates, you should apply manual pressure while using a screw that is the appropriate size. This will ensure seamless penetration and secure fastening.
To install decking pans with self-drilling screws, you will need a screw gun. The type of screw gun depends on the scale of your project. For smaller jobs, a cordless handheld screw gun is often preferred. However, for larger projects exceeding 10,000 square feet, a stand-up screw gun is more suitable.
It is important to note that attaching a deck to structural framing using self-drilling screws is not a common method. This technique is typically used for roof deck systems rather than floor deck systems. Additionally, always refer to the manufacturer's instructions for specific guidelines on screw placement and any other special considerations.
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Frequently asked questions
A decking pan is a metal floor deck or roof deck that relies on proper fastening. It can be made from corrugated steel plates, with concrete later poured on top to form a strong floor surface.
There are three main methods to install decking pans: welding, power-driven fasteners, and self-drilling screws.
Welding creates a strong attachment between metal deck panels, penetrating into supporting beams or joists. The process usually takes 3 to 6 seconds but may take longer for thicker decks. Weld washers can be used to protect thinner sheets of deck from burn-through.
It is critical that you and your team receive the necessary safety training and equipment before starting any work with decking pans. The Steel Deck Institute recommends reviewing safety data sheets, applicable rules, and regulations to ensure safe handling, installation, and use of steel decking.
