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ThermaSteel Interlocking AssemblyThermasteel Assembly Manual - Download



1. Study the appropriate drawings before beginning construction and assembly.

2. Unload the flatbed trailer at the job site.

3. Stack the panels for each floor so that they are in the necessary sequence for erection.

Note: Panels are usually set starting at one corner of the building and proceeding in a counter-clockwise fashion. 

4. Verify that the dimensions of the slab or subfloor are in accordance with contract documents and coordinate with shop drawings.

Note: Dimensions should be within the tolerances stipulated by the design professional and/or by good construction practices. 

5. Locate conduit stub-ups (if any) and drill holes in baseplate.



A level work area is recommended. This area should be cleared of debris and a baseline marked at the bottom and left hand side of the assembly area.


Preparation of the Foundation

1. Attach panels to the foundation using wood plates or steel channel track per local code.

2. Set steel tracks in a waterproof inhibitor such as roofing felt, foam tape, etc.

Note: Size and spacing of anchors shall be determined by a design professional based on building code requirements.

3. Caulk and set baseplates or track to building dimensions and secure to the slab or subfloor using anchors as per the design drawings.

Note: Verify the plates are level and the corners are square. If the foundation is not level, shim and grout with cement to obtain a level baseplate (track). Do not try to obtain a level wall by shimming the panels.

4. Once the bottom baseplates (track) are set and level, verify each panel dimension along the baseplate.

5. Nail attachment plates to both sides of wood baseplates or put two screws per stud for track.

6. Locate the attachment plates to fall at each panel joint and each steel stud when using wood plates.


Wall Assembly

The usual method of assembly is to pre-assemble wall sections and set them in place. Sections are usually pre-assembled in 12–16 feet (3658–4877 mm) sections.


1. Once the assembly area is cleared and marked, consult the floor plan and determine which sections are to be assembled and in what sequence.

2. Using the element numbers as reference, obtain the necessary panels and lay them out with the interior face down.

3. If specified, caulk joints and push the shiplaps together.

Note: Each lap joint can be gaped open up to ½” inch (6.4 mm) as needed to adjust for discrepancies in wall length.

4. Check the section for overall dimensions and for squareness.

5. Once satisfied with the alignment, screw the panels together through the leading overlap edge metal as shown by the applicable engineering drawing or by attaching shear plates as indicated in the IAPMO ES 128 report.

6. If any, locate conduit stub-ups on panel and drill up from panel bottom.

Note: Mark the location of the conduit stub-ups on subfloor.


Top Plates

1. Follow the applicable guidelines and procedures in the assembly and installation of wall plates.

2. Tie sections together using wood top plates or C-channel steel top track per the specification drawings.

3. Cut the top plate or track onsite to allow overlap to the center of the next panel section steel stud at 16 or 24 inches (406 or 610 mm).

4. Fasten attachment plates to the top plate or track so that the attachment plates will fall at each panel joint and vertical steel stud in the panel.

5. Drill the top plate or track to match conduit or wiring chase locations, if any, in the assembled section before attaching the plate or track to the panels.

6. Caulk the wood plate or track (or panel end) and attach the top plate or track to the wall section by placing screws in the shear plates or track, depending on what is used.

Note: This connection is temporary and is used only to keep the top plate in place during erection of the walls. The top plate is permanently secured to the wall sections after the floor or roof system has been set, which loads the wall.


Setting the Wall

1. Caulk the top of the baseplate (or track) and raise the assembled wall section into place.

2. Connect the panels to the baseplate per the engineering drawings and installation guide.

3. Attach the overlapping top plates (or track) to each other per the engineering drawings and installation guide.

4. Temporarily brace the top of the wall to the ground or floor so it stands true and plumb.


“C” or composite openings for doors, windows, etc.

Some panel openings are assemblies consisting of two or more components. These are shipped disassembled and must be assembled onsite. Refer to the data sheets provided and assemble these sections before setting them in place. As in all assemblies, carefully check the unit for overall dimensions and squareness before setting it into wall section.


Assembly of Panels

All bottom plates (or track) must be level before the panels are set.

Note: If shimming is necessary to obtain level bottom plate (or track), shim (and grout) under the plate and not between the panel and plate.


Before making the final connections to the erected wall the walls must be plumb.


Once the panels are in place for one floor the overall dimensions and squareness of the building should be checked before proceeding with the assembly of any upper floor deck or roof system.



Protect panels from high winds and sharp impact.


Inspection of Panels

  • Panels have been checked for density and fusion quality and for dimensions before shipment, but should be checked for damage and spot-checked for dimensions as they are unloaded and stacked.
  • As a general rule, any defect in the polystyrene core of the panel, such as small cuts or nicks will not affect the integrity of the panel. Damage to the metal will affect the panel strength and integrity and can result in a rejected panel.


Onsite Changes

In general, any changes deemed necessary onsite must be cleared with the manufacturer before the changes are made.


Buckles Or Dents

Reject any panel with vertical steel members that have any buckles or dents. The panel can be salvaged by cutting out the damaged section and inserting a wood or metal building stud. Fill gaps with insulation. Bends may be straightened in the horizontal metal at the top and bottom edges of the panel. Straighten any bends or dents in the leading edge overlap metal.


Electrical Boxes

Use a hot knife or other acceptable cutting tool. Do not exceed the box dimensions and where possible, locate the box beside a vertical steel channel for screw attachment. Boxes should have recessed ears or brackets behind the wall cladding.


Wiring or Conduit Chases

If chases provided are not used, vertical chases may be cut into the polystyrene with a hot knife or other acceptable cutting tool. Vertical chases shall be cut a minimum of two inches (51 mm) from any vertical steel channel. Do not exceed half the panel thickness in depth or one inch (25 mm) in width when making these cuts. Horizontal chase cuts may be extended behind the vertical metal by drilling with a one inch (25 mm) bit near mid-depth of the panel.


Safety Considerations

The panels may be handled by one or two workers. The following rules should be followed:

  •    Gloves should be worn at all times when moving panels. The metal edges must be handled carefully to avoid cuts.
  •    Do not remove panels in high wind conditions; the surface of the panel will catch the wind and can create a potentially hazardous condition.
  •    If high winds are possible, panels must be sheltered, weighted or otherwise protected from moving.