ACOUSTIC INSULATIONCONSTRUCTION MEMBRANESGEOSYNTHETIC ENGINEERING

METAL ROOFING TILESTHERMAL INSULATION

TIMBER CLADDINGVIBRATION ISOLATION

INNOVATION BUILT ON EXPERIENCE

PROSPAN WRS warm roof system

PARTNERSHIPS IN ACTION

The HistoryThe A. Proctor Group Ltd, has been involved in thermal insulation solutions for over 40 years. They were instrumental in the warm roof concept and have considerable experience in the application of warm pitched roofs and the associated risks.

Working closely, and in conjunction with Kingspan Insulation, the partnership has developed ProSpan Warm Roof System (WRS) to provide technically advanced solutions to warm pitched roofing utilising the most modern of technologies and years of experience.

The Warm Roof ConceptAs thermal insulation requirements grow on a regular basis, the industry is put under pressure to meet these requirements and the associated stringent U-values. Coupled with this is the desire for developers to utilise the site to provide maximum accommodation at minimum footprint dimensions. This has led to the increased use of the roofspace with room in the roof applications. The loft space can be utilised for additional bedroom accommodation or even office space for the increasing demand for workspace in the home.

The SolutionThe ProSpan Warm Roof system is fabricated to fit appropriate rafter centres and to utilise the very low conductivity characteristics of polyisocyanurate insulation. The system provides a one-board solution to ensure easier application and faster installation times. The system provides a robust and energy efficient solution.

To meet the variety of needs in the market place, various thicknesses are available to provide U-values as required.

Advantages• The roof structure is kept warm therefore moving the dewpoint further out of the building.• Less thermal bridging as insulation is placed over the rafters to reduce any cold bridges.• No requirement for complicated, ventilated airspaces.• Services in the loft are kept at the same temperature, protecting from freezing.• Rafter dimensions can be specified from a structural requirement and not dominated by the depth of insulation.• Less insulation required over rafters, therefore providing easier fixing.• Roofspaces can be utilised for additional accommodation during construction or roof designed to allow easy roof conversion at a later date.• Ease of installation.• User-friendly.• Low thermal conductivity.• Low vapour transmission rate.

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INNOVATION BUILT ON EXPERIENCE

A. Proctor Group Head Office(The Haugh Blairgowrie)

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Partnerships in Action

Contents

Introduction to Warm Roof System Concept

ProSpan WRS

Details

Details

PR Nail Calculation Form

Roofshield

U-Value

Condensation

CONTENTS

WARM ROOF SYSTEM

Warm RoofsTraditionally the UK Construction Industry has not utilised the roof space and has specified cold roofs requiring ventilation above the insulation. This has led to a number of technical risks including condensation in the roofspace. If the ventilation is blocked up or inadequately specified; condensation on the underside of the non-permeable underlay; or in worst cases, mould growth on the rafters has been evident.

Increased thermal insulation required in roofs has led to even colder roof spaces, thereby increasing the risk of condensation in these types of roofs. Pipes freezing and damage to items stored in the loft have been common risks.

The warm roof alleviates the requirement for ventilation, provides a warmer structure – thereby reducing the risk of condensation, eliminates the cold bridge and associated risks of condensation and provides much needed additional accommodation space or flexibility to convert the loft at a later date. Services and items in the loft can be stored without risk of damage in the longer-term.

Breather Membranes (Roofshield)With the insulation placed over rafters, the risk of condensation moves outside the building and therefore a breather membrane should be specified as the underlay.

Roofshield is one of the highest vapour permeable underlays on the market and has BBA certification for the warm roof (96/3220) and should be utilised as the underlay in this system.

Roofshield can be placed below the counterbattens or above the counterbattens depending on local trades’ preference. Installation above the counterbattens does provide advantages of ease of fixing and less potential of ponding at eaves behind fascia boards. When utilising the breather membrane below the counterbattens appropriate measures should be taken to ensure no ponding at this area.

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Insulation Fixings (PR Nails)With insulation placed over the rafters, counterbattens should be fixed into position utilising stainless steel helixical nails – PR Nails. PR Nails are designed as a normal nail with a head which can be hammered in with a normal hammer and requires no specialist fixing tools.

Their length should be designed depending on pitch, weight of outercovering, wind load and depth of insulation above the rafter. Please see Page 8 for further details and an easy to fill in Fax Back Sheet to The A. Proctor Group Tech Desk will provide the number of fixings required per m2.

Vapour Control LayersThe ProSpan Warm Roof System utilises closed cell foam which has a low permeability. The use of foil facing on BOTH sides of the board further enhances its vapour resistance. Any gaps or penetrations should be adequately sealed with sealant or PU foam to provide a convection tight system.

The risk of condensation in the roof can be minimised by the utilisation of a vapour control layer fixed to the underside of the rafter directly behind plasterboard. In this instance, Procheck 300 is the preferred specification and should be utilised with the ProSpan WRS, depending on building use.

Care and attention to any penetrations and taping of overlaps will provide increased vapour resistance and more energy efficiency from the point of view of airtightness.

PROSPAN WRS

Prospan PropertiesThe ProSpan WRS is a high performance CFC/HCFC free rigid polyisocyanurate insulation of typical density 32kg/m3.

Manufactured to BS EN ISO 9001:2000

The board is faced both sides with low emissivity foil facing material, increasing the thermal efficiency of the adjacent airspaces.

Thermal Conductivity – 0.023W/mKWater Vapour Resistance (including facings) – >100MNs/gCompressive Strength – exceeds 140Kpa @10% compressionThickness Available – 110 to achieve 0.2 U-value a120 to achieve 0.18 U-value(U-value condensation risk calculations available from Techdesk)

Fire Test ResultBS 476: Part 3: 1975 SAA RatingBS 476: Part 7: 1997 Class 1 Rating

Health and SafetyProSpan Warm Roof System is chemically inert and safe to use. A leaflet on this topic which satisfies the requirements set out in the Control of Substances Hazardous to Health Regulations 1988 (COSHH) is available from our Technical Services Department.

Please note that the reflective surface on this product is designed to enhance its thermal performance. As such, it will reflect light as well as heat, including ultraviolet light. Therefore, if this board is being installed during very bright or sunny weather, it is advisable to wear UV protective sunglasses or goggles, and if the skin is exposed for a significant period of time, to protect the bare skin with a UV block sun cream.

Warning – do not stand on or otherwise support your weight on this board unless it is fully supported by a load bearing surface.

1200mm

600mm up to 1200mm

Plan View

Side View

Section View

50mm60mm

25mm

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ENGLISH DETAILS

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Tiles

Tile Battens

Roofshield

Counter Battens

Prospan

Rooflight

Roof window

Cut Prospan to fit tight against roof window trimmers and seal gap filler

Valley

Cut Prospan to line of valley. Form rebate to set over valley boards.

Gutter lining on separating layer.

SCOTTISH DETAILS

Slates

No Tile Battens

Roofshield

Softwood Sarking

Prospan

Eaves

Ridge

Rebate edges of Prospan sit on rafters

Use insulation to ensure continunity of insulation

Cut Prospan to fit tight at ridge and seal with gap filler

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PR NAIL CALCULATION FORM

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PR Nails are used as structural batten fixing, normally being fixed through the counter-batten, the insulation sarking and then a minimum of 35mm (preferably 50mm) into the rafters.

The density of fixing (the number of fixings per M2) must be enough to resist both the wind suction and the sliding load.

Please photocopy the form below, fill in the answers and fax back to 01250 872727.

Alternatively you will find an online form at www.proctorgroup.com

Date

Contact Name

Company

Telephone

Facsimile

E-mail

Counter-Batten Thickness: Recommended 25mm thick mm

Insulation Thickness: The thickness of the insulation above the rafters mm

Underlay Specified

Additional Material thickness: mm

Counter-Batten Centres: mm

Roof Pitch: You can round this figure up or down to the nearest 10O O

Name

Weight kg/m2

Wind Exposure:

Town: Postcode:

Would you consider its’ exposure to the wind to be: Sea

Country

Town

Is the building height over 15 metres: Yes No

What is the area of the roof? needed to calculate total number of fixings required

M2

Building dimensions: Length

Breadth

Height to eaves

To be filled in by The A. Proctor Group: From these answers we can calculate that you require:

Quantity Length Centres

Fix every mm up the counter-batten

Signed

Date

Roof Finish:What sort of tiles/slates are to be used:This as with the roof pitch is needed in order to calculate the sliding load. At best we need to know the laid weight in kg/m2, at worst the name of the slate/tile to be used.

ROOFSHIELD

IntroductionIt is important in warm roof applications that the pitched roof underlay is breathable. Roofshield is part of the ProSpan WRS and provides excellent moisture vapour permeability whilst affording secondary protection while the primary covering is installed.

FunctionsThe underlay must perform four functions:

1. Secondary drainage layerWind blown rain and snow which finds its way below tiles and slates, or through side laps in metal sheets, drips onto the continuous underlay and drains safely down into the gutter and out of the building. Roofshield performs this function.

2. Temporary waterproofingDuring construction, and in the event of future damage of slates or tiles, the underlay protects the insulation and building fabric below. Roofshield performs this function.

3. Condensation control Warm moist air which rises up from within the building and into the roof construction, can pass freely through the breathing underlay.

If condensation forms on the underside of the primary covering, then the drops of water falling onto the underlay would run down into the gutter. Roofshield performs this function.

4. Wind The roofing underlay should provide a barrier to minimise the wind load generated and the wind gusts acting on the slates and tiles and prevent wind driven snow or dust entering the roofspace. Roofshield performs this function.

Physical Properties Test Method Result

Nominal Weight 175 g/m2

Nominal Thickness 0.6 mm

Tensile Strength: 56 days aged @ 60oC BS 2782:320A

along the roll 6.37 kN/m

across the roll 4.60 kN/m

Nail Tear Resistance MOAT No: 27 : 5.4.1

along the roll 156 N

across the roll 131 N

Burst Strength, wet/dry BS 3137 488 kN/m2

Water Vapour Resistance BS 3177 0.09 MNs/g

Moisture Vapour Permeability BS 3177 2409 g/m2/day

Resistance to Water Penetration

(Eosin Test)

BS 4016 Pass

Fire Resistance to Spread of Flame DIN 4102 B2

Head of Water BSEN20811 1135mm

GeneralRoofshield is a spunbond polypropylene fabric manufactured in the UK. It has a unique three layer construction to provide good tear resistance, UV stability, vapour permeability, wind resistance and water resistance.

It is covered by Warm Roof Certification 96/3220 and cold roof certification 99/3648.

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U VALUE

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Construction TypeProSpan WRS 120mmElement: Pitched roof, ceiling at rafter line - Roof with ProSpan and Roofshield Warm pitched roof Internal surface emissivity: High External surface emissivity: HighBuilding use: House or flatElement Description Thickness Thermal Thermal Vapour Vapour Conductivity Resistance Resistivity Resistance (mm) (W/mK) (m2K/W) (MNs/gm) (MNs/g)1 Outside Surface resistance - - 0.100* - -2 Concrete tiles 15.0 1.500 - - -3 Cavity - tiling battens 25.0 R-value - - - 4 Roofshield 0.6 0.000 0.000 150.00 0.09 5 Cavity - counter battens 25.0 R-value 0.160 - 0.006 ProSpan WRS - over rafters 60.0 0.023 2.609 2000.00 100.007 ProSpan WRS - between rafters 60.0 0.023 2.609 1666.67 100.008 Cavity - base of rafters 40.0 R-value 0.340 - 0.009 Gyproc Wallboard 12.5 0.210 0.060 60.00 0.7510 Inside surface resistance - - 0.100 - -U-value: Combined Method: 0.18 W/m2K (Calculated in accordance with BS EN ISO 6946*this substitutes for Rse and the resistance of layers 2-3 because of the ventilated air layer (layer 3)

Construction TypeProSpan WRS 120mmElement: Pitched roof, ceiling at rafter line - Roof with ProSpan, Roofshield and Sarking Warm pitched roof Internal surface emissivity: High External surface emissivity: HighBuilding use: House or flatElement Description Thickness Thermal Thermal Vapour Vapour Conductivity Resistance Resistivity Resistance (mm) (W/mK) (m2K/W) (MNs/gm) (MNs/g)1 Outside Surface resistance - - 0.40 - -2 Slates 10.0 1.500 0.007 249.60 2.503 Roofshield 0.6 0.000 0.000 150.00 0.09 4 Softwood Sarking 18.0 0.130 0.138 100.00 1.80 5 ProSpan WRS - over rafters 60.0 0.023 2.609 2000.00 100.006 ProSpan WRS - between rafters 60.0 0.023 2.609 1666.67 100.007 Cavity - base of rafters 40.0 R-value 0.340 - 0.008 Gyproc wallboard 12.5 0.210 0.060 60.00 0.759 Inside surface resistance - - 0.100 - -U-value: Combined Method: 0.19 W/m2K (Calculated in accordance with BS EN ISO 6946 Construction TypeProSpan WRS 110mmElement: Pitched roof, ceiling at rafter line - Roof with ProSpan and Roofshield Warm pitched roof Internal surface emissivity: High External surface emissivity: HighBuilding use: House or flatElement Description Thickness Thermal Thermal Vapour Vapour Conductivity Resistance Resistivity Resistance (mm) (W/mK) (m2K/W) (MNs/gm) (MNs/g)1 Outside Surface resistance - - 0.100* - -2 Concrete tiles 15.0 1.500 - - -3 Cavity - tiling battens 25.0 R-value - - - 4 Roofshield 0.6 0.000 0.000 150.00 0.09 5 Cavity - counter battens 25.0 R-value 0.160 - 0.006 ProSpan WRS - over rafters 50.0 0.023 2.174 2000.00 100.007 ProSpan WRS - between rafters 60.0 0.023 2.609 1666.67 100.008 Cavity - base of rafters 40.0 R-value 0.340 - 0.009 Gyproc Wallboard 12.5 0.210 0.060 60.00 0.7510 Inside surface resistance - - 0.100 - -U-value: Combined Method: 0.20W/m2K (Calculated in accordance with BS EN ISO 6946*this substitutes for Rse and the resistance of layers 2-3 because of the ventilated air layer (layer 3)

Construction TypeProSpan WRS 110mmElement: Pitched roof, ceiling at rafter line - Roof with ProSpan, Roofshield and Sarking Warm pitched roof Internal surface emissivity: High External surface emissivity: HighBuilding use: House or flatElement Description Thickness Thermal Thermal Vapour Vapour Conductivity Resistance Resistivity Resistance (mm) (W/mK) (m2K/W) (MNs/gm) (MNs/g)1 Outside Surface resistance - - 0.40 - -2 Slates 10.0 1.500 0.007 249.60 2.503 Roofshield 0.6 0.000 0.000 150.00 0.09 4 Softwood Sarking 18.0 0.130 0.138 100.00 1.80 5 ProSpan WRS - over rafters 50.0 0.023 2.174 2000.00 100.006 ProSpan WRS - between rafters 60.0 0.023 2.609 1666.67 100.007 Cavity - base of rafters 40.0 R-value 0.340 - 0.008 Gyproc wallboard 12.5 0.210 0.060 60.00 0.759 Inside surface resistance - - 0.100 - -U-value: Combined Method: 0.20 W/m2K (Calculated in accordance with BS EN ISO 6946

CONDENSATION

How The Profile Graph Works

Key Point to Watch:Ensure any condensation risk is above the breather membrane.

Condensation Risk Analysis (no account taken of thermal bridges)

Internal / External Conditions: 20.00c @ 55.0%RH / -5.00c @ 95.0%RH Buildup period 31 days Interface Dewpoint Vapour Saturated Winter Annual Condensation Temp Temp Pressure V.P. Buildup Buildup (0C) (0C) (kPa) (kPA) g/m2 g/m2

1 Outside Surface resistance -4.8 -5.6 0.38 0.41 - - No2 Tile including batten space -4.1 -5.3 0.39 0.43 - - No3 Roofshield -4.1 -5.3 0.39 0.43 - - No4 Cavity - counter battens -2.6 -5.3 0.39 0.49 - - No5 ProSpan WRS - over rafters 6.7 4.4 0.84 0.98 - - No6 ProSpan WRS - between rafters 17.8 10.7 1.28 2.04 - - No7 Cavity - base of rafters 19.3 10.7 1.28 2.23 - - No8 Gyproc wallboard 19.6 10.7 1.29 2.28 - - No9 Inside surface resistance - - - - - - -

Condensation Risk Analysis (no account taken of thermal bridges)

Internal / External Conditions: 20.00c @ 55.0%RH / -5.00c @ 95.0%RH Buildup period 60 days Interface Dewpoint Vapour Saturated Winter Annual Condensation Temp Temp Pressure V.P. Buildup Buildup (0C) (0C) (kPa) (kPA) g/m2 g/m2

1 Outside surface resistance -4.8 -5.6 0.38 0.41 - - No2 Slates -4.8 -5.3 0.39 0.41 - - No3 Roofshield -4.8 -5.3 0.39 0.41 - - No4 Softwood sarking -4.1 -5.0 0.40 0.43 - - No5 ProSpan WRS - over rafters 5.8 4.5 0.84 0.92 - - No6 ProSpan WRS - between rafters 17.7 10.7 1.28 2.02 - - No7 Cavity - base of rafters 19.2 10.7 1.28 2.23 - - No8 Gyproc wallboard 19.5 10.7 1.29 2.27 - - No9 Inside surface resistance - - - - - - -

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INNOVATION BUILT ON EXPERIENCE

The HaughBlairgowriePerthshirePH10 7ER

telephone01250 872 261

fax01250 872 727

emailaskthermal@proctorgroup.com

www.proctorgroup.com

apg5752

ACOUSTIC INSULATIONCONSTRUCTION MEMBRANESGEOSYNTHETIC ENGINEERING

METAL ROOFING TILESTHERMAL INSULATION

TIMBER CLADDINGVIBRATION ISOLATION