Architectural Flashing Supply
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Tier 2 · Fabrication Technician

Mechanical joining, soldering and fasteners

Rigid and loose seams, what solder and rivets each do, which sheet metals can be soldered and with which fluxes and fasteners, and the lead, flux and fire hazards of soldering. Worked examples size blind rivets and lay out a seam; the last lesson diagnoses joint defects.

4 lessons · about 51 min · 11 diagrams · 6 videos

Version 1.1.0

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Lessons

0 of 4 complete

  1. Lesson 1 · 15 min · 12 slides · 14 questions

    Mechanical joining, soldering and fasteners: principles and terminology

    The three ways sheets are joined, rigid against loose seams, what solder and rivets each do, the words of the trade, and the lead, flux and fire hazards that come with soldering.

    You will be able to: Define rigid and loose seams, soft soldering, flux, tinning, sweating, blind rivets and grip range, explain why solder seals and rivets carry load, and state the lead, flux and fire safety boundaries.

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  2. Lesson 2 · 12 min · 12 slides · 11 questions

    Mechanical joining, soldering and fasteners: materials, standards and design constraints

    Copper, coated copper, galvanized, stainless and zinc each solder differently; Galvalume and aluminum are not soldered. Fluxes, fastener compatibility, and why the project spec decides.

    You will be able to: Say which sheet metals can be soldered and how, which must not be, which flux and fastener metals suit each, and which limits come from CDA, manufacturers, owner standards and the project spec.

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  3. Lesson 3 · 14 min · 12 slides · 12 questions

    Mechanical joining, soldering and fasteners: methods and worked application

    A sequence from the sources for a riveted and soldered lap: clean, flux, tin, lap, rivet and solder from the wet side. Four worked examples size rivets by grip and lay out a seam.

    You will be able to: Follow a documented sequence for a riveted and soldered lap, size a blind rivet from the stack thickness and its listed grip, set out a rivet row, and record every assumption, unit and inspection point.

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  4. Lesson 4 · 10 min · 11 slides · 7 questions

    Mechanical joining, soldering and fasteners: defects, verification and case study

    What unfilled laps, ridged beads, green stains, rusting rivet stems, loose rivets, buckling and cracks tell you, how to inspect a joint, and a stainless seam case study.

    You will be able to: Diagnose a soldered or riveted joint defect from its symptom, name the published cause and corrective options, inspect a joint against a checklist, and document the evidence for review.

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Practical task

Build a job packet for joining two lengths of 20 oz copper flashing with a riveted and soldered lap seam, then show how the same joint changes when the spec calls for Galvalume: choose the joint, rivet, solder and flux, set out the sequence and the checks, and analyse one defect.

Hand in

  • A decision rationale: the joint type, solder, flux and rivet chosen, each with its source, and why Galvalume is not soldered
  • A sketch or marked-up section of the lap: sheets, rivets, solder, the wet side and the direction water flows
  • An assumptions sheet with units: sheet thickness from the AFS material register, the stack, the listed rivet grip and hole, the rivet layout and the iron weight, each labelled CDA, manufacturer, practitioner or AFS
  • A sequence for the seam, from reading the spec to washing off the flux
  • A quality checklist for the finished joint, including the sample cross-section and the lead and flux safety steps
  • A defect analysis for one plausible defect: symptom, cause, corrective option and the evidence a reviewer would need

Rubric

CriterionMeets the standard when
SourcesEvery number and rule names whose it is: CDA, GSA, a manufacturer, a practitioner, the AFS register or the project spec.
CalculationThe stack is added correctly from register thicknesses and checked against a listed grip, with units.
Metal compatibilityRivets, mandrels and flux suit the sheet; Galvalume is fastened and sealed per the spec, not soldered.
SequenceClean, flux, tin, lap and screw tight low end to high end (Jenkins, roof work), swap the screws for rivets, solder from the wet side and wash off, in order.
VerificationThe checklist covers gap, solder fill, residue, rivet tails, rivet metal and a cross-section of a first seam.
SafetyLead hygiene, flux PPE from the safety data sheet and fire control are written into the packet.

Module quiz

10 questions drawn from a bank of 44; a new set each attempt. Pass mark 80%.

1. What does GSA say the patch-solder method must never be used to repair?
2. What should the flame heat when soldering with a flame-heated copper?
3. What is the largest gap Jenkins allows in the lap?
4. What does WJE recommend to confirm solder sweated through a stainless seam?
5. Where does CDA use a riveted lap seam on its own?
6. In the aluminum example, which rivet fits the 0.064 in stack?
7. In the copper example, where does the stack fall against the AD42ABS grip?
8. Which solder does CDA name as the common solder for uncoated copper?
9. What does a rivet's grip range describe?
10. According to GSA, what is solder used for in a joint?