7-Step Installation Methodology
A structured, quality-controlled on-site execution framework from initial physical laser span verification to mobile roll-forming, mechanical lock seaming, and final watertight handover.
Note on Project Timelines: Exact installation duration depends on project span, total square footage, site accessibility, crane positioning logistics, weather conditions, and structural tie-beam readiness. We provide realistic schedules post physical site audit.
Site Assessment & Structural Verification
Before machine mobilization, our engineering team conducts laser-guided span measurements and structural load audits of the supporting beams to ensure compliance with architectural specifications.
- ✓ Laser measurement of span width, length, and diagonal squareness
- ✓ Verification of RCC tie-beam concrete grade and embedded insert plates
- ✓ Wind zone verification (IS 875 Part 3) and terrain category assessment
- ✓ Site access and machinery mobilization path planning
- ✓ Level variance audit across perimeter supporting beams
- ✓ Anchor bolt strength and spacing inspection
Engineering & Structural Planning
Using structural design criteria and Galvalume material properties, our structural engineers finalize the curve geometry, panel cut lengths, and lifting plans tailored to local weather patterns.
- ✓ Structural arch geometry and profile depth optimization
- ✓ Coil weight, slit width, and batch planning
- ✓ Crane positioning and safe rigging layout mapping
- ✓ Fabrication timetable synchronization with site conditions
- ✓ Material test certificate (MTC) validation for coil batch
- ✓ Engineering sign-off on arch radius calculations
Raw Material Coil Loading & Calibration
Prime quality Al-Zn alloy coated steel coils with AZ150 coating are mounted on hydraulic de-coilers at the project site. Roll-forming dies are calibrated for precise panel geometry.
- ✓ Inspection of coil packaging and moisture-free storage
- ✓ Hydraulic mandrel mounting and tension calibration
- ✓ Die clearance and roll profile calibration check
- ✓ Test blank forming and dimension verification
- ✓ Micrometer thickness verification (0.70 to 1.60 mm BMT)
- ✓ Visual check for surface scratches or coating uniformity
On-Site Continuous Panel Fabrication
Continuous straight corrugated profiles are formed through multi-station rollers and fed seamlessly into the curving machine, generating the structural arch radius in unbroken single pieces.
- ✓ Multi-pass cold roll-forming of primary panel corrugations
- ✓ Hydraulic secondary curving pass to exact arch radius
- ✓ Motorized shear cut to calculated arch perimeter length
- ✓ Protective handling and ground staging of finished arches
- ✓ Arch curvature radius template check on first 3 panels
- ✓ Diagonal and length tolerance verification (±5mm)
Ground Assembly & Modular Pre-Seaming
Individual curved arch panels are placed on padded ground jigs and interlocked in gangs of 3 to 5 panels. A motorized seamer creates an initial structural lock, forming a rigid lifting module.
- ✓ Ground jig alignment and panel overlap positioning
- ✓ First-stage mechanical seamer pass across gang seams
- ✓ Spreader bar attachment and multi-point nylon sling rigging
- ✓ Rigging safety inspection prior to crane hookup
- ✓ Seam crimp tightness and flange engagement check
- ✓ Rigging point balance and lifting line safety factor audit
Crane Hoisting & Tie-Beam Anchoring
Tandem hydraulic cranes lift the pre-seamed arch gangs smoothly onto the building tie-beams. Specialized anchor brackets fix each panel foot securely to the perimeter structure.
- ✓ Synchronized crane hoist with tag line sway control
- ✓ Guided seating onto RCC tie-beam steel embedded plates
- ✓ Structural anchoring using high-tensile fasteners and brackets
- ✓ Temporary wind-guying and lateral brace stabilization
- ✓ Anchor bracket torque specification compliance
- ✓ Plumbness and arch span symmetry audit across bays
Motorized Seaming & Watertight Handover
Electric seaming machines traverse the entire arch roof to mechanically double-lock all adjoining module joints into a continuous monolithic shell, followed by gutter integration and final sign-off.
- ✓ Full-length motorized double-lock seaming pass
- ✓ Installation of curved skylights, ridge vents, and flashings
- ✓ Gutter profile alignment and downspout connection
- ✓ Removal of all site swarf and protective masking film
- ✓ 100% seam visual inspection and acoustic tap test
- ✓ High-pressure water spray test across critical flashing zones
Ready to discuss your site feasibility and crane mobilization plan? Contact Sairaj Roofing's Pune team.
Schedule a Site Assessment Visit →