OpeningDesign / Sports_Complex

A Sports Complex in Southern Wisconsin
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Resin Panel Wall #52

Closed theoryshaw closed 8 years ago

theoryshaw commented 9 years ago

Thanks @andyeck1, for the chat...

Here's how the composition of the Resin wall is shaping up...

@kraut34 we had to push the exterior plywood up to 7/8 for rigidity. It was either that or go with 3/4" plywood with vertical coil straps every 24" between plywood.

tfodden commented 9 years ago

I’m not sure about the order of the air barrier and insulation. Do we need mineral wool or could it be plastic (polyiso or polystyrene)? If it needs to be in the order that you have it here, then we are looking at a sheet air barrier instead of a liquid-applied. And I’m wondering about fastening it through the mineral wool. I’ll send you some info on the product that I would recommend in that case.

TF

From: Ryan Schultz [mailto:notifications@github.com] Sent: Friday, June 26, 2015 2:49 PM To: OpeningDesign/Sports_Complex Subject: [Sports_Complex] Resin Panel Wall (#52)

Thanks @andyeck1 https://github.com/andyeck1 , for the chat...

Here's how the composition of the Resin wall is shaping up...

@kraut34 https://github.com/kraut34 we had to push the exterior plywood up to 7/8 for rigidity. It was either that or go with 3/4" plywood with vertical coil straps https://www.google.com/search?rlz=1C1CHFX_enUS591US591&espv=2&biw=1920&bih=911&tbm=isch&sa=1&q=coil+straps&oq=coil+straps&gs_l=img.3...6181.7363.0.7554.6.6.0.0.0.0.141.527.4j2.6.0....0...1c.1.64.img..1.5.464.JjnTO33sc6E every 24" between plywood.

— Reply to this email directly or view it on GitHub https://github.com/OpeningDesign/Sports_Complex/issues/52 . https://github.com/notifications/beacon/AMTOm-lxUarSN45OjK8S_0RGDi38Kgdoks5oXaQpgaJpZM4FM8l6.gif

theoryshaw commented 9 years ago

Hi Tony, yes i think it can be extruded polystyrene if the exterior plywood is fire retardant.

theoryshaw commented 9 years ago

Yes, please send along what you recommend in this situation. Perhaps put in the dropbox and provide a link here. thanks.

kraut34 commented 9 years ago

Why does the exterior plywood need to be 7/8" thick? On Jun 26, 2015 5:01 PM, "Ryan Schultz" notifications@github.com wrote:

Hi Tony, yes i think it can be extruded polystyrene if the exterior plywood is fire retardant.

— Reply to this email directly or view it on GitHub https://github.com/OpeningDesign/Sports_Complex/issues/52#issuecomment-115902583 .

andyeck1 commented 9 years ago

The plywood would need to be 7/8” thick to span 4’-0”

Thank you,

Andy Eck, SE, PE

Ntrive – Structural Engineering

Office Number: 630-318-1725 x701

Mobile Number: 630-886-4688

280 Shuman Blvd, Suite 270

Naperville, IL 60563

-Check out our website at: http://ntrive.com/ ntrive.com

From: kraut34 [mailto:notifications@github.com] Sent: Friday, June 26, 2015 5:12 PM To: OpeningDesign/Sports_Complex Cc: Andy Eck Subject: Re: [Sports_Complex] Resin Panel Wall (#52)

Why does the exterior plywood need to be 7/8" thick? On Jun 26, 2015 5:01 PM, "Ryan Schultz" <notifications@github.com mailto:notifications@github.com > wrote:

Hi Tony, yes i think it can be extruded polystyrene if the exterior plywood is fire retardant.

— Reply to this email directly or view it on GitHub https://github.com/OpeningDesign/Sports_Complex/issues/52#issuecomment-115902583 .

— Reply to this email directly or view it on GitHub https://github.com/OpeningDesign/Sports_Complex/issues/52#issuecomment-115906478 . https://github.com/notifications/beacon/AL66hweTBZwOU_bbcdBOTxSK6STuhEZ4ks5oXcXJgaJpZM4FM8l6.gif

theoryshaw commented 9 years ago

I know I asked this before, but just want to make sure. Is it possible to engage those exterior C Channels in the following method, in order to lesson the thickness of that ext. plywood?...

https://www.dropbox.com/s/jqw01pc85xw379u/20150627%20-%20resin%20wall%20question.pdf?dl=0

kraut34 commented 9 years ago

I don't see a problem with that. Anything we can do to minimize the thickness of the plywood would be great.

I terms of insulation, I think polystyrene is a lot more expensive than the 1st type you proposed. On Jun 27, 2015 8:41 AM, "Ryan Schultz" notifications@github.com wrote:

I know I asked this before, but just want to make sure. Is it possible to engage those exterior C Channels in the following method, in order to lesson the thickness of that ext. plywood?...

https://www.dropbox.com/s/jqw01pc85xw379u/20150627%20-%20resin%20wall%20question.pdf?dl=0

— Reply to this email directly or view it on GitHub https://github.com/OpeningDesign/Sports_Complex/issues/52#issuecomment-116049640 .

tfodden commented 9 years ago

Stonewood recommends using Revealshield by Vaproshield (http://www.vaproshield.com/) as the air barrier. I highly recommend this company. However, Revealshield is black. Are these resin panels at all translucent? TF

kraut34 commented 9 years ago

The panels are not translucent. I think black is the way to go, so the 1/4" spacing has a black background.

Toby Krause Krause Custom Builders 920-285-6490

On Wed, Jul 1, 2015 at 3:33 PM, tfodden notifications@github.com wrote:

Stonewood recommends using Revealshield by Vaproshield ( http://www.vaproshield.com/) as the air barrier. I highly recommend this company. However, Revealshield is black. Are these resin panels at all translucent? TF

— Reply to this email directly or view it on GitHub https://github.com/OpeningDesign/Sports_Complex/issues/52#issuecomment-117817534 .

tfodden commented 9 years ago

Back to the Revealshield: If we need our exterior cladding to meet NFPA 285, then we need to use Revealshield because that's the one that Stonewood has successfully tested with. If we don't need to meet NFPA 285, then we can save some $$ by using Vaproshield's "Wrapshield". And if we are going to use mineral wool, that's what you are going to see at the joints anyway, not the air barrier.

What is the width of these joints? And what's our Construction Type?

Thanks! TF

kraut34 commented 9 years ago

I would think the vapor barrier has to be the outer most layer, so it protects the mineral wool from weather and UV. Joints are 1/4" and they are fastened to galvanized c channels.

Toby Krause Krause Custom Builders 920-285-6490

On Thu, Jul 2, 2015 at 5:07 PM, tfodden notifications@github.com wrote:

Back to the Revealshield: If we need our exterior cladding to meet NFPA 285, then we need to use Revealshield because that's the one that Stonewood has successfully tested with. If we don't need to meet NFPA 285, then we can save some $$ by using Vaproshield's "Wrapshield". And if we are going to use mineral wool, that's what you are going to see at the joints anyway, not the air barrier.

What is the width of these joints? And what's our Construction Type?

Thanks! TF

— Reply to this email directly or view it on GitHub https://github.com/OpeningDesign/Sports_Complex/issues/52#issuecomment-118180883 .

tfodden commented 9 years ago

Actually, the mineral wool is fine with moisture. That’s why they use it in curtainwall systems. The air barrier needs a solid backing, so needs to go on the sheathing. We’ll use a self-adhesive type – save on headaches.

But it occurs to me that the galvanized c channels will be visible since I’m sure they need to run through (past) the joints. Yes?

I’ll get some info on the mineral wool and figure out where to post it.

TF

From: kraut34 [mailto:notifications@github.com] Sent: Thursday, July 02, 2015 5:24 PM To: OpeningDesign/Sports_Complex Cc: tfodden Subject: Re: [Sports_Complex] Resin Panel Wall (#52)

I would think the vapor barrier has to be the outer most layer, so it protects the mineral wool from weather and UV. Joints are 1/4" and they are fastened to galvanized c channels.

Toby Krause Krause Custom Builders 920-285-6490

On Thu, Jul 2, 2015 at 5:07 PM, tfodden notifications@github.com wrote:

Back to the Revealshield: If we need our exterior cladding to meet NFPA 285, then we need to use Revealshield because that's the one that Stonewood has successfully tested with. If we don't need to meet NFPA 285, then we can save some $$ by using Vaproshield's "Wrapshield". And if we are going to use mineral wool, that's what you are going to see at the joints anyway, not the air barrier.

What is the width of these joints? And what's our Construction Type?

Thanks! TF

— Reply to this email directly or view it on GitHub https://github.com/OpeningDesign/Sports_Complex/issues/52#issuecomment-118180883 .

— Reply to this email directly or view it on GitHub https://github.com/OpeningDesign/Sports_Complex/issues/52#issuecomment-118184099 . https://github.com/notifications/beacon/AMTOm83StxBlTCgL7J5qNawiltJl7jT-ks5oZbGVgaJpZM4FM8l6.gif

theoryshaw commented 9 years ago

Hi @tfodden ....sorry, just back from family vacation.

Construction type is 2B.

Yes, you will see the vertical channels through the joint.

Tony, do you recommend mineral wool or polystyrene is this application? If we go with mineral wool, can we achieve the necessary comprehensive strength, since we're fastening the channels through the insulation into the plywood and horizontal girts.

I need to do research on whether we need to satisfy NFPA 285.

tfodden commented 9 years ago

Whether we can use polystyrene is going to depend on whether we need to meet NFPA 285. I believe that if our exterior walls are under 40 feet high, we're exempt. But I haven't looked to see how it's written in the latest IBC and I believe things have changed.

Do we need to carry the insulation behind the channels or can it be placed BETWEEN the channels? Mineral wool will compress under the fasteners.

tfodden commented 9 years ago

Something I'd like you to consider in the cavity wall system. If we use these (http://www.interra-facade.com/cascadia-clip) instead of the C-Channels, then we can break the insulation BETWEEN these carriers instead of running the insulation behind the carriers (and compressing it). These clips do not conduct heat so no thermal bridging.

theoryshaw commented 9 years ago

Thanks for the phone chat @tfodden.

It's looking like we're using C Channels fastened directly to exterior plywood with mineral wool in between the vertical channels. The VaproShield will be between the channels and the ext. plywood.

@tfodden will be provide us the necessary depth of the mineral wool and the air cavity.

@andyeck1 Since C channels will now be deeper than 1 5/8", do you think we can go down to 3/4" ext. plywood?

Thanks Gentlemen. Ryan

andyeck1 commented 9 years ago

Ryan, What depth are you using now?

theoryshaw commented 9 years ago

Let's do a 2.5" section, similar to issue #53

tfodden commented 9 years ago

Actually, the depth of the cavity should be based on (1) the thickness of insulation you want; (2) the depth of the C Channel. Is that the 2.5" in the above comment? The mineral wool that I would like to use has a black face but is not available any thinner than 2.5". We can go with insulation thicknesses of 1" and 2", but the face color would be kind of a dark butter. I am proceeding to check other manufacturers. 2 questions: How wide are the joints between the resin panels; how deep is the venting layer at the front of the cavity? 1" sounds typical.

KevinZinsmeister commented 9 years ago

The same 250S125-33 section specified in issue #53 should be used. The plywood should be APA rated sheathing with a 32/16 span rating. The predominant nominal thickness for this span rating is 15/32".

tfodden commented 9 years ago

Then it sounds as if we are looking at 1.5" thick insulation and a nominal 1" venting space. The insulation won't have a black facing but at least it's not white.

theoryshaw commented 9 years ago

@tfodden as reflected below, the joints are 1/4". The bottom joint however, is 3/4" per Stonewood recommendations.

https://www.dropbox.com/s/nyi7vd4tdeg5end/20150707%20-%20resin%20panel%20detail.pdf?dl=0

Due to the thinness and shadow at the 1/4" location you probably won't even precive or see the insulation.

At the bottom 3/4" joint you might see the insulation. If it's obtrusive, perhaps we can go with the brake metal cover plate there.

theoryshaw commented 9 years ago

@KevinZinsmeister

Can we go with a U-channel like the following?.. http://www.johnsonrollforming.com/pdf/U-Custom.pdf

The return or lip of the c-channel will interfere with the placement of insulation.

tfodden commented 9 years ago

Are those aluminum or steel? It sounds kind of custom ($$$).

From: Ryan Schultz [mailto:notifications@github.com] Sent: Tuesday, July 07, 2015 1:09 PM To: OpeningDesign/Sports_Complex Cc: tfodden Subject: Re: [Sports_Complex] Resin Panel Wall (#52)

@KevinZinsmeister https://github.com/KevinZinsmeister

Can we go with a U-channel like the following?.. http://www.johnsonrollforming.com/pdf/U-Custom.pdf

The return or lip http://www.clarkdietrich.com/sites/default/files/imce/images/products/Framing-Exterior/CurtainWall/C-Stud.jpg of the c-channel will interfere with the placement of insulation.

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theoryshaw commented 9 years ago

Was thinking it would be galvanized cold-rolled steel:

Something stock like: http://www.cemcosteel.com/steel-framing/non-structural-non-load-bearing/accessories/furring-channels/cold-rolled-channel-crc or http://www.clarkdietrich.com/products/bridging-bracing/u-channel-crc

Nothing custom.

theoryshaw commented 9 years ago

or... http://www.steelconsystems.com/sites/default/files/submittal/250UChannel-54.pdf

tfodden commented 9 years ago

How about Z-girts?

tfodden commented 9 years ago

eh. Maybe z-girts don't come that shallow.

KevinZinsmeister commented 9 years ago

A standard 250T125-33 will work. Let me know if that works for you.

theoryshaw commented 9 years ago

@tfodden

In plan, I feel the Z-girts would not allow for a clean face to attach storefront and sealant--would have to put some additional blocking in there.

image

image

tfodden commented 9 years ago

I get what you're saying.

tfodden commented 9 years ago

What thickness of Stonewood panels are we using? They come in 8mm, 10mm, 13mm, with custom thicknesses available. (13mm = 1/2").

theoryshaw commented 9 years ago

I pinged JR Hughes from http://usehughes.com/ to help us size the panels.

JR, as you can see from the following elevations here: https://www.dropbox.com/s/g1jjek4nqah3v7t/20150707%20-%20progress%20set%20-%20Xcel_Sports%20Complex.pdf?dl=0

...the panel sizes will be both a full 4'x8' and 4'x4'. They will be supported on U-channels every ~24" o.c. as illustrated here: https://www.dropbox.com/s/jqw01pc85xw379u/20150627%20-%20resin%20wall%20question.pdf?dl=0

JRHughes commented 9 years ago

Good morning. If we are face fastening with color matched fasteners...we can use the 5/16" (8mm) thick panels. If its a concealed system which I do not believe it is, we would need to increase the thickness to 3/8" (10mm)

theoryshaw commented 9 years ago

@tfodden, Toby asked if we could remove the exterior mineral wool all together. If we have 8" of batt in the cavity, per the following code, I interpret that we still have sufficient U-value:

http://publicecodes.cyberregs.com/icod/iecc/2009/icod_iecc_2009_5_sec002.htm

Would you concur?

tfodden commented 9 years ago

OK, let’s see. We’re Climate Zone 6. Metal Building (or even going with Metal-Framed building), a U-value of 0.064 translates to an R-value of 15.625. Geez, you guys get away with murder here. No sweat – our batt insulation is R-5 per inch, so we’re way above the required. What I don’t like is that the dew point is going to be inside the wall, within the batt insulation. That’s where all the moisture from the showers, sweat, and breathing will condense. I’m not really sure whether 1-1/2” of mineral wool would make a difference but I’ll graph it out this evening (gotta remember how first).

TF

From: Ryan Schultz [mailto:notifications@github.com] Sent: Wednesday, July 08, 2015 4:29 PM To: OpeningDesign/Sports_Complex Cc: tfodden Subject: Re: [Sports_Complex] Resin Panel Wall (#52)

@tfodden https://github.com/tfodden , Toby asked if we could remove the exterior mineral wool all together. If we have 8" of batt in the cavity, per the following code, I interpret that we still have sufficient U-value:

http://publicecodes.cyberregs.com/icod/iecc/2009/icod_iecc_2009_5_sec002.htm

Would you concur?

— Reply to this email directly or view it on GitHub https://github.com/OpeningDesign/Sports_Complex/issues/52#issuecomment-119735756 . https://github.com/notifications/beacon/AMTOmycunT05eOPDtmy1Z6r0pPuJOsjhks5obY21gaJpZM4FM8l6.gif

theoryshaw commented 9 years ago

Hi @KevinZinsmeister / @andyeck1

The State is asking for a structural documentation on whether our 5/16" resin panel meets wind loading requirements.

Could you guys shoot me a quick structural analysis?

Structural properties here: http://stonewoodpanels.com/images/pdf/Stonewood_Exterior_Specifications_042914.pdf

Spacing of U-Channels illustrated below...

2015-09-14 16 08 18

KevinZinsmeister commented 9 years ago

What kind of documentation is the state looking for? A letter or calcs?

theoryshaw commented 9 years ago

Calcs. thx.

theoryshaw commented 9 years ago

Also, @KevinZinsmeister since the 250S125-33 U Channel is attached to the horizontal girts, could we use exterior gyp. bd or densglass verses the plywood you specified above?

JRHughes commented 9 years ago

Ryan,  You might have to use the Fire Rated Gyp board to pass any wall assembly test.  JR Hughes Hughes Group,Building Relations & Opportunity Consulting, Sales, Marketing. UseHughes.M 847-712-5671 : O 847-991-8910   Web I Flickr I Facebook I Twitter I

  From: Ryan Schultz <notifications@github.com>

To: OpeningDesign/Sports_Complex Sports_Complex@noreply.github.com Cc: JRHughes JR@UseHughes.com Sent: Tuesday, September 15, 2015 12:35 PM Subject: Re: [Sports_Complex] Resin Panel Wall (#52)

Also, @KevinZinsmeister since the 250S125-33 U Channel is attached to the horizontal girts, could we use exterior gyp. bd or densglass verses the plywood you specified above?— Reply to this email directly or view it on GitHub.

theoryshaw commented 9 years ago

Thanks JR, yes, that why I was asking. I was under the impression that the fire retardant plywood would suffice, but in conversation with the permit reviewer, we might have to entertain gyp. bd or densglass.

tfodden commented 9 years ago

We can use 5/8” Type X Sheathing.

TF

From: JRHughes [mailto:notifications@github.com] Sent: Tuesday, September 15, 2015 12:47 PM To: OpeningDesign/Sports_Complex Cc: tfodden Subject: Re: [Sports_Complex] Resin Panel Wall (#52)

Ryan,
You might have to use the Fire Rated Gyp board to pass any wall assembly test. JR Hughes Hughes Group,Building Relations & Opportunity Consulting, Sales, Marketing. UseHughes.M 847-712-5671 : O 847-991-8910 Web I Flickr I Facebook I Twitter I

From: Ryan Schultz notifications@github.com To: OpeningDesign/Sports_Complex Sports_Complex@noreply.github.com Cc: JRHughes JR@UseHughes.com Sent: Tuesday, September 15, 2015 12:35 PM Subject: Re: [Sports_Complex] Resin Panel Wall (#52)

Also, @KevinZinsmeister since the 250S125-33 U Channel is attached to the horizontal girts, could we use exterior gyp. bd or densglass verses the plywood you specified above?— Reply to this email directly or view it on GitHub.

— Reply to this email directly or view it on GitHub https://github.com/OpeningDesign/Sports_Complex/issues/52#issuecomment-140479593 . https://github.com/notifications/beacon/AMTOmxhHw8TLBPJXkKEt09IYRTp6x0a-ks5oyFEEgaJpZM4FM8l6.gif

theoryshaw commented 9 years ago

For reference and if interested, here's an email I just sent the State--if you care to wade through this ocean. ;)

Hi Don,


Was wondering if you could let me know if the following logic makes sense and if the resultant proposals at the end of this email would suffice for code compliance?




  • 1406.2 Combustible exterior wall coverings. Combustible exterior wall coverings shall comply with this section.

    • Exception: Plastics complying with Chapter 26.


(Here, I understand, per the expectation, that if our specified FRP Panel (Fiber Reinforced Polymer Panel) complies with Chapter 26 we are not required to comply with the subsections of 1406.2- that is subsections 1406.2.1 - 1406.2.4)





(From my understanding, since our ‘plastic’ is FRP Panel (Fiber Reinforced Polymer Panel) that section 2612.6 is the section we must satisfy to comply with the ‘plastic exception’ from 1406.2)


2612.6 Exterior use. Fiber reinforced polymer or fiberglass reinforced polymer shall be permitted to be installed on the exterior walls of buildings of any type of construction when such polymers meet the requirements of

  1. Section 2603.5 and is...

  2. fireblocked in accordance with Section 717….

  3. The fiber reinforced polymer or the fiberglass reinforced polymer shall be designed for uniform live loads as required in Table 1607.1 as well as for snow loads, wind loads and earthquake loads as specified in Sections 1608, 1609 and 1613, respectively.


(From my understanding, if we satisfy exceptions 2612.6.2.1-2612.6.2.4 below, we do not have to comply with the 1-3 requirements outlined in section 2612.6 stated above.)


Exceptions:


  • 2. When installed on buildings that are 40 feet (12 190 mm) or less above grade, the fiber reinforced polymer or the fiberglass reinforced polymer shall meet the requirements of Section 1406.2 and shall comply with all of the following conditions:

    • (complies) 2.1. Where the fire separation distance is 5 feet (1524 mm) or less, the area of the fiber reinforced polymer or the fiberglass reinforced polymer shall not exceed 10 percent of the wall area. Where the fire separation distance is greater than 5 feet (1524 mm), there shall be no limit on the area of the exterior wall coverage using fiber reinforced polymer or the fiberglass reinforced polymer.

    • (complies) 2.2. The fiber reinforced polymer or the fiberglass reinforced polymer shall have a flame spread index of 200 or less. The flame spread index requirement shall not be required for coatings or paints having a thickness of less than 0.036 inch (0.9 mm) that are applied directly to the surface of the fiber reinforced polymer or the fiberglass reinforced polymer.

    • (see 717.2.6  below) 2.3. Fireblocking complying with Section 717.2.6 shall be installed.

    • (I will send structural calculations for this - pending) 2.4. The fiber reinforced polymer or the fiberglass reinforced polymer shall be designed for uniform live loads as required in Table 1607.1 as well as for snow loads, wind loads and earthquake loads as specified in Sections 1608, 1609 and 1613, respectively.





717.2.6 Architectural trim. Fireblocking shall be installed within concealed spaces of exterior wall finish and other exterior architectural elements where permitted to be of combustible construction as specified in Section 1406 or where erected with combustible frames, at maximum intervals of 20 feet (6096 mm), so that there will be no open space exceeding 100 square feet (9.3 m3). Where wood furring strips are used, they shall be of approved wood of natural decay resistance or preservative-treated wood. If noncontinuous, such elements shall have closed ends, with at least 4 inches (102 mm) of separation between sections.


  • Exceptions:

  • 1. Fireblocking of cornices is not required in single-family dwellings. Fireblocking of cornices of a two-family dwelling is required only at the line of dwelling unit separation.

  • 2. Fireblocking shall not be required where installed on noncombustible framing and the face of the exterior wall finish exposed to the concealed space is covered by one of the following materials:

    • 2.1. Aluminum having a minimum thickness of 0.019 inch (0.5 mm).

    • 2.2. Corrosion-resistant steel having a base metal thickness not less than 0.016 inch (0.4 mm) at any point.

    • 2.3. Other approved noncombustible materials.


Proposal 1: (Instead of plywood on these exterior walls, I would like to propose using exterior gypsum board instead. From my understanding, if we satisfy exception 717.2.6.2.3 and use Gyp. Bd., which is noncombustible, we do not need fireblocking)


Proposal 2: (Or if we still go with the fire-retardant plywood, we would need to fireblock at maximum intervals of 20 feet (6096 mm), so that there will be no open space exceeding 100 square feet (9.3 m3).  With 12ft walls, that would mean we would need to fire block vertically every 8.3ft. (12ft X 8.3ft = 100sf).


Thanks for your Help,

theoryshaw commented 9 years ago

Would still like @KevinZinsmeister / @andyeck1 judgement on whether we can use Gyp. bd or densglass based on the hort. girt spacing and U-Channel furring. Thanks.

KevinZinsmeister commented 9 years ago

1/2" gyp board fastened w/ 1" Type S-12 screws @8" oc at edges, ends and intermediate members is acceptable.

theoryshaw commented 9 years ago

Thanks Gentlemen.

tfodden commented 9 years ago

It will need to be 5/8" gyp sheathing if you need the fire-resistance rating.

KevinZinsmeister commented 9 years ago

Use 1-1/4" S-12 screws if using 5/8" gyp

theoryshaw commented 8 years ago

Toby @kraut34,

Something on par with this: http://www.clarkdietrich.com/products/curtain-wall-framing/structural-track where there's no return lips on the flanges and where the corners are hard corners, not rounded.

Toby, whatever you source, please post the cutsheet here so @KevinZinsmeister can verify that it will work structurally.

Thanks, Ryan