Construction Notes – It's essential that the slab or foundation you're working off be level and square. Because this system attaches to a sill plate or steel channel, the sill plate also has to be as level as possible. If it's not, you'll have to install it on a bed of leveling mortar. Don't try to level the panel with shims. Here are highlights to consider when out in the field:

1. The two most important tools you'll use are a screwgun (if it's cordless, be sure you have extra backup batteries) and a caulking gun for the adhesive. You might use an industrial applicator, as discussed in Chapter 2 under "Tools."

2. Throughout this system you'll be using shear plates to secure the panels. Inside and outside angle shear plates are used on corners and partitions and flat shear plates are used to attach wood top plates to the wall panel and when attaching the wall panel to a wood sill plate. This is when the screwgun will come in handy.

3. When adjusting for wall length, you can leave gaps up to ¹/₄ inch at each joint. Then if there are still gaps after you've adjusted and fastened the panels, seal them with an insulating spray foam.

4. To secure the panels, you'll need top plates. Either use a plate that's long enough to cover the distance of the wall or install a plate that reaches halfway into the next panel. As with conventional framing when installing a double plate, always overlap the top plates at the corner. One last thing: Be sure to predrill your plates for electrical and plumbing before installing.

5. When cutting in the rough openings for doors and windows, the framing can be done with a "C" channel or wood. If you plan to double up on your framework, be sure you allow enough on the cut for the double thickness. There's nothing more discouraging than discovering that the rough opening is too large or too small when you're ready to install a window, for instance. Measure twice, cut once!

6. When using the panel for a roof application, sheath the surface with ¹/₂-inch plywood before installing the roofing material.

7. The metal used in the panels could be sharp; make sure you and your workers wear gloves when moving them.

8. Because you're dealing with a lightweight panel, it's not a good idea to work in high wind conditions – you may find yourself airborne!

9. Interior sides of panels must be sheathed with some form of cladding to give a minimum 15-minute fire rating. It's usually ¹/₂-inch wallboard.

Manhours – A 3¹/₂ inch x 4 foot x 8 foot panel weighs roughly 45 to 48 pounds, so it's comfortable for one person to handle. But for installation, it's better to have a two- or three-man crew. Since window and rough openings are premolded to plan specifications at the plant, there's no labor to figure for cutouts. A 40 foot x 24 foot (128 linear foot or 960 square foot) building can be installed in about 5 manhours with a crew of two – and that includes bracing. That's 192 square feet per manhour. This manhour figure is based on having experience with the system. The first time out, I'd figure around 162 square feet per manhour with a crew of two.

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