If at First You Don't Succeed...

Despite what your mother told you, in cladding, looks count.

So Many Problems, So Little Time

Where to start? First, there are the numerous misplaced expansion bolts and empty holes. Three tries are highlighted with yellow arrows. Several other empty holes are also under the angle bracket. You have to wonder if this guy measured anything? Second, where's the weld washer on the bolt to the steel mullion (left red arrow)? Without a weld washer, the bolt might slip under wind load. I'm sure the guy was thinking with all the holes in the concrete, the whole damn wall will fall down first, so why bother welding.

And finally, what's that big slot in the front of the steel mullion (right red arrow)? This slot, not shown in either the drawings or calculations, occurs at the highest stress area of the mullion. It will reduce the section properties of the mullion and the mullion might be overstressed. The real question is why put that slot in at all? Were these mullions left over from another job or what?

Like I Said, No Problem

Stick with me on this one. Its a bit long, but a real classic. This tale starts with ALT asking for information on an epoxy glue to be used to attach a stiffener to a panel. The contractor wanted to use this epoxy instead of screws, studs, or welds.

Try #1: The cladding contractor's first response was to send us a report from the epoxy manufacturer. Unfortunately, the report was for epoxy on copper. Since the application was for aluminum, we asked again.

Try #2: The second response was a testing report (for aluminum). However, the last line of the report stated "[co-using] metal [fasteners with the epoxy] is required. " Huh? Wasn't the purpose of the report to prove that the epoxy works and fasteners aren't required? We pointed this out to the contractor who said they would get back to us.

Try #3: The third response, a letter by the epoxy manufacturer answering our questions from the second report, ended with "co-using metal fixings are required for your safety ". Double huh? Again, we pointed out that the documentation submitted to prove the epoxy could be used as a substitute for screws, called for screws to be used in addition to the epoxy.

Try #4: The fourth response was "[We] confirm that [the epoxy] could apply for this financial of metal fixed to correspond with the requirement of [the contractor] for the way of adhesion on the unit of aluminum panel." Triple huh? We have asked for further clarification.

Try #5: We're waiting.

Four Strikes and Counting

Strike 1: Original anchor didn't fit on the studs. Strike 2: Make the slots bigger. "Anybody seen my torch?" Strike 3: Still doesn't fit. Burn the studs off and weld it. "Anybody seen my torch?" Strike 4: Now, the anchor doesn't work structurally. (Big slots and weak weld.) Better start over. "Anybody seen my torch?"

Third Time's a Charm

The three steps to happiness for this anchor were: 1. Forget to put the insert in the slab before pouring the concrete. (The anchor should be aligned with the galvanized vertical tube.) 2. Hack out the concrete and put in a remedial insert too far to the left. 3. Hack out the concrete again and put in another insert to anchor to.