roof walling installation entire manual

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Rainwater SolutionsRainwater Solutions

Fencing SolutionsFencing Solutions

Roofing & Walling SolutionsRoofing & Walling Solutions

Customer SupportCustomer Support

House Framing SolutionsHouse Framing Solutions

Structural SolutionsStructural Solutions

Home ImprovementsHome Improvements

Using Lysaght®

Roofing & Walling

Using Lysaght®

Roofing & Walling

2006 Edition



Using LYSAGHT®

Roofing & Walling

© Copyright BlueScope Steel Limited 2 February 2006

LYSAGHT®, COLORBOND®, CUSTOM ORB®, CUSTOM BLUE ORB®,INTEGRITY ® 820, EASYCLAD®, KLIP-LOK ®, LONGLINE® 305,MINI ORB®, MULTILINE®, PANELRIB®, SPANDEK ®, TRIMDEK ®,

TRIMWALL®, WALLCALD®, and ZINCALUME® are trademarks of BlueScope Steel Limited A.B.N. 16 000 011 058

The LYSAGHT® range of products is exclusively made byBlueScope Steel Limited trading as BlueScope Lysaght.

Information, brochures and

your local distributor

1800 641 417

Please check the latest informationwhich is always available at

www.lysaght.comFor further information about Lysaghtproducts included here, refer to theproduct’s technical brochure which isavailable at 1800 641 417 or you candownload it at www.lysaght.com.



Using

LYSAGHT®

roofing

and walling

2006



Pub lished by B lueScop e Lysag ht Limited

© BlueSco pe Lysag ht Limited 2006

Using Lysaght Roofing and Walling

Previously published as

Steel Roofing and Walling: Installation Manual.



PART B: INSTALLATION 27

General care, safety and handling 277.1 Sa fety 27

7.2 Ca re and sto ra ge b efo re insta lla tion 27

7.3 Hand ling clad d ing on site 27

7.4 Wa lking on roo fs 27

7.5 Marking out, cutting and d rilling 27

7.6 Clean up 28

7.7 Wa rn o ther contracto rs 287.8 Strippab le coa ting s 28

7.9 Sea la nts 28

7.10 Maintenance 29

Installing pierce-fixed cladding 318.1 G enera l insta lla tion proced ure 31

8.2 Side -lap ping &p ositioning pierce-fixed sheet s33

8.3 Pierce-fixing on crests 33

8.4 P ie rce-f ixing on va lleys (fo r wa lling on ly) 34

8.5 Pierce-fixing on sid e-laps 34

8.6 Insta lling MINI ORB 34

Installing concealed-fixed cladding 359.1 Insta lling KLIP-LOK roo fs 35

9.2 Insta lling KLIP-LOK w alls 39

9.3 Insta lling EASYCLAD HI-TEN 40

9.4 Insta lling LONG LINE 305 roo fs 42

Ends of sheets 4410.1 Turn-ups 44

10.2 Turning -d own 46

10.3 Blocking o ff rib ca vit ies 47

10.4 End -lapping 48

10.5 Expa nsion 50

10.6 Roo f overhang with ed g e stiffener 51

Flashings 5211.1 Materia ls 52

11.2 Long itud ina l fla shing s 52

11.3 Transverse flashing s 53

11.4 Flashing a t chang e o f pitch 55

11.5 Flashing la rg e roo f penetra t ions 56

11.6 Flashing sma ll roo f penetra tions 58

11.7 Flashing w a lls 59

11.8 Bushfire pro tection 61

References 62

Index 63

Introduction 1

PART A: DESIGN 2

Design preliminaries 22.1 Prod uct selection 2

2.2 Ma teria ls and finishes 2

2.3 Support spacing s 3

2.4 Maximum leng ths of roofing 3

2.5 Low roo f pitches 3

2.6 Wind fo rces on roo fs 3

2.8 Cod es and perfo rmance tests 32.9 Environmenta l cond it ions 4

2.10 Meta l a nd t imb er compa tib ility 4

2.11 Transporta tion 4

Fasteners 93.1 Ma teria ls for screws 9

3.3 Ma teria ls for b lind rivets 9

3.4 Ma teria ls for sea ling w ashers 9

3.5 Id entifica t ion of screw s 10

3.6 Sett ing o f screws 10

3.7 Q uant ity o f fa steners a nd clips 11

3.8 Re co mme nd ed fa st ene rs a nd lo ca tio ns 11

Curved, bent & tapered cladding 164.1 Spring -curved -rid g e roo f 16

4.2 Spring -a rched roof 17

4.3 Spring -curved conca ve roo fs 18

4.4 Pre-curved roo fs 18

4.5 Capped b ent rib b ed roo fs 19

4.6 Ta pered roofing 19

Insulation & skylights 205.1 Hea t contro l 20

5.2 Cond ensa t ion 21

5.3 Noise red uct ion 225.4 Insula tion ma teria ls 22

5.5 Insula tion thickness 23

5.6 Skylig ht ing 23

Roof drainage 246.1 Introd uction 24

6.2 Design o f dra inage (eaves-gu t te r system) 24

6.3 G utter fa ll 25

Contents



Contemporary and traditional –both areaccomplished with ease using LYSAGHT

building products.



1 I n t r o d u c t i o n

INTRODUCTION 1

1

Introduction

WarrantiesFor well over 100 yea rs we have co nsistent ly

manufactured the highest quality building products.

TheLYSAGHT

®

brand is synonymous with Australianbuilding.

Our cont inuing confidence in our prod ucts is show n in

the warranties we offer.

Our prod ucts are e ngineered to perform according to

our specificat ions only if they are installed to t he

recommendations in this manual and our other

publications.

Nat urally, t he wa rrant ies req uire specifiers a nd

installers to exercise due ca re in how t he products a re

applied and installed. And, owners need to maintainthe finished wo rk.

We invite yo u to a sk ab out the warranties ap plicable to

your proposed purchase, at your supplier of LYSAGHT

products.

Further information• Your supplier o f LYSAGHT products

• BlueScope Lysag ht Information Service

on 1800 641 417

• w ww.lysa g ht .co m

ScopeThis bo ok is a g uide to the installat ion o f stee l roo fing

and walling manufactured by BlueScope Lysaght. We

intend t hat it be used by a ll trad es and professionsinvolved with specifying and applying the wide range

of our products.

We refer o nly to g enuine ste el roofing and wa lling

manufactured by us and marketed under our brand

names. Our recommendations should only be used for

our prod ucts because they are based on

comprehensive testing of our profiles, base-metal-

thicknesses (BMT) a nd ma te ria l finishe s.

Specific product informationWe also have specific publicat ions for a ll of our

products, a nd yo u should use them in conjunction with

this manual.

Cyclonic conditionsIn g eneral, this bo ok refers to non-cyclonic cond itions.

Design information for cyclonic areas is in our Cyclonic

Area Design Manual.

Your suggestions

Please send your suggestions for improvements to thismanua l to BlueScope Lysag ht, Technolog y Ce ntre,

PO Box 504, Chester Hill, 2162.



2.2 Materials and finishesOur most widely used cladd ing profiles are listed in

Tab les 2.3.1 and 2.3.2. They a re a vailab le in

COLORBOND® prep ainte d ste el comp lying w ith AS/NZS

2728:1997, or in unpainted ZINCALUME® aluminium/zinc

alloy-coa te d stee l complying with AS 1397—2001.

COLORBOND® steel has either a ZINCALUME

® or st ainless

steel base meta l, with a rang e of orga nic coatings to

cope w ith exposure to a rang e of environments.

• COLORBOND® is prepa inted stee l for exterior roofing

and walling. It is the most widely used.

• COLORBOND®

METALLIC is prepa inted stee l for superior

aesthetic qualities displaying a metallic sheen.

• COLORBOND®

ULTRA is prepa inted stee l for severe

coastal or industrial environments (generally within

ab out 100 to 200 metres of the source).

• COLORBOND®

STAINLES S is prepa inted sta inless ste el forvery severe coa sta l or industrial environme nts

(g enera lly within ab out 100 met res of the so urce).

Check with your local BlueScop e Lysag ht o ffice fo r

ava ilab ility o f profiles, co lours, acce ssories; a nd for

suita bility of the product.

Tab les 2.3.1 and 2.3.2 list ge nera l informat ion for

profile selection. Refer to our pub licat ions o n spe cific

products for de ta iled spe cificat ions. There a re also

publicat ions o n ZINCALUME® steel and COLORBOND

®

prepa inted stee l from our informat ion line (Pa g e 1).

Material specifications• ZINCALUME

® aluminium/zinc alloy-coa te d st ee l

co mplying w ith AS 1397—2001. Minimum yield

streng ths are G 550 (550 MPa), or G300 (300 MPa)

depending on profile. Minimum coating mass is

AZ150 (150 g /m2 ), o r AZ200 (200 g /m2 )

depending on the product.

• Stainless steel complying w ith AS 1449—1994

(430 SS 550 or 430 SS 300).

2

Design preliminaries

2.1 Product selectionWhen you d esign ste el clad ding into your building yo u

have a wide rang e o f profiles from which to choose.

Whilst roo fing and wa lling ob viously have to kee p o ut

the we ather, they also have sig nificant e ffects on t he

loo ks, cost a nd d urab ility of a b uilding.

Other factors that affect selection a re t reat ed in

Chapte rs 2 to 6.

WallsThe d esign o f wa lling is fairly straightfo rward. O nce yo u

have made the aesthetic decision of which profile to

use, the ma in considerations are the support spacings

(Section 2.3), fixing details (Chapter 3) and the details

of flashing (Chapter 11).

RoofsThere are ma ny facto rs in de sig ning roofs including:

• the shape: is the roof to be ‘ fla t ’ or pitched

or curved ?

• the support ing s tructure and support spacing;

• the wind forces that the roof must sustain;

• the pitch which affects the looks, the profile’s

ab ility to efficiently carry rain to the g utte rs, and

fixing details;

• thermal expansion of long sheets (Chapter 10).

This bo ok doe sn’t att empt to co ver the structural

design d eta ils of supports or ae sthetics: there a re ma ny

other te xts and Australian Sta ndards that cover them.

This chapte r gives ta bles of recommend ed support

spacings, and the maximum roof length for pitch and

rainfall intensity.

2 DESIGN—DESIGN PRELIMINARIES



2 D e

s i g n p r e l i m i n a r i e s

DESIGN—DESIGN PRELIMINARIES 3

2.5 Low roof pitchesUnless the re is ad eq uate po sitive fa ll in a roof, the re is

da nge r of ponding, which can lea d to a reduced

service life, particularly in coastal areas.

At low slopes, say around 1 in 50 (1°) slope, all roof

supports must be in the one plane because slight

variations ca n result in zero or neg a tive fall. This ma y

occur even after completion of the building as the

result o f sett leme nt, timbe r wa rping or shrinking , or

extra loadings (like air conditioners).

Wherever possible, you should d esign fo r a minimum

slope of 1 in 30 (2° ). Minimum slope s a re liste d in

Tab le 2.3.1 at t he end of this chapte r).

2.6 Wind forces on roofsWinds create considerable forces on both the

topside a nd the underside of roof clad ding , and you

must consider these forces in the design and fixing of

any roo f. The fo rces a re:

• inward forces tending t o collapse the roof cladd ing

inwards, caused by wind acting directly on the

windward side; and

• outward forces tending to lift the roof cladding

from its framing, a nd t he e ntire roo f structure from

the rest of the building. Outwa rd forces can be

caused both by uplift from negative wind pressures,

outside t he b uilding ; and by p ositive wind pressure

inside the building.

G enerally the g reat est w ind forces imposed on roofs

are due to the outward forces. Because the dead

we ig ht o f roofing mat erials is relat ively small, the

outwa rd forces must be resisted by the roof fasteners.

It is very important that the battens and roof framingare ad eq uately fixed to the rafters and wa lls, and that

under extreme conditions the wall framing is anchored

to the footings. Special anchoring provisions may apply

in cyclonic areas.

2.8 Codes and performance testsAS 1562.1—1992 specifies the design and installation

of sheet metal roof and wall cladding. Our roofing

profiles sa tisfy all the req uirements o f this standa rd,

including the ability of the roof to resist outward forces

and co ncentrat ed loa ds. The testing is performedaccording to AS 4040.

2.3 Support spacingsThe ma ximum reco mmend ed support spa cing s are

show n in Ta bles 2.3.1 and 2.3.2. They a re ba sed on

test ing in acco rdance w ith AS 1562.1—1992 Design

and installation of sheet roof and wall cladding: Metal,

and AS 4040.1—1992 Methods of testing sheet roof

and wall cladding—Resistance to concentrated loads.

The spa cing s in the t ab les for roo fs are recommend ed

to produce adequate performance of roof claddings

under foo t t raffic load ing (incide nta l for ma intena nce).

For walls, the follow ing cond itions ap ply:

• building s up to 10 m hig h in Reg ion B Terrain

Category 3 conditions (Vs = 38 m/s andVu = 60 m/s);

• Cp , e = -0.65 (for wa lls), Cp, i = 0.2 a nd Kl up to

2.0, in acco rda nce with AS 1170.2—1989 SAA

Loading Code: Wind loads.

In all cases, cladd ing is fixed t o a support o f 1.0 mm

minimum b a se met a l thickness (BMT) and minimum

yield stress of G550. If you want to use metal

ba ttens thinner than 1.0 mm, seek advice from our

information line.

For support spacings in wind conditions other thanthose shown, refer to our publicat ions o n specific

products for wind pressure data.

2.4 Maximum lengths of roofingThe valleys (or pa ns) of roo fing ha ve to ca rry wa te r

to the gutters. If in heavy rain, the valleys overfill,

water can flow into the roof through the side-laps

and flashings.

Facto rs affecting d rainag e cap acity and wa terproo f-

ness of t he laps o f a p rofile include:

• the width and depth of the valleys or pans;

• the pitch of the roof—rain flows fas ter on a

steepe r pitch;

• rainfall intensity for the geog raphical area;

• the length of the roof from ridge to g utter; and

• penetrat ions that cause nearby valleys to carry

extra rain diverted from valleys obstructed by

the pene tration (Fig ure 2.4.1).

The ma ximum roof leng ths for d rainag e fo r ea ch profile

are g iven in Tab le 2.4.1 at t he end of this chapte r.



• ve ge ta ble ma tte r

• any material which will inhibit normal exposure

to the atmosphere

Paint and COLORBOND® finishesCOLORBOND

® finishes can be damaged by some types of

pa int. There can a lso b e p roblems of co lour mat ching

due to different weathering characteristics.

Cladding with severely da mag ed COLORBOND® paint are

best replaced rather than p atched up. We recommend

that you don’t touch up minor scratches with paint.

You ma y overpaint who le roo fs and p aint acce ssories

to mat ch spe cific co lours. The pa rticular p aints a nd

methods required are discussed in Technical Bulletin

TB-2, published by BlueScope Lysaght.

2.11 TransportationBecause our roofing and walling is manufactured by

continuous processes, sheet lengths can be supplied

up to the limits o f transpo rt regulations, which vary

from state to state .

Metal roofing products must comply with the

performance spe cifications, and be checked by

stringe nt te sts, in accordance with the standa rd. Such

tests have b een ca rried out o n all our clad ding s and the

results have been used in the preparation of the fixing

and installat ion reco mmend at ions in this manual.

2.9 Environmental conditionsCoate d steel products can be d amag ed b y some

environmental conditions including industrial,

agricultural, marine, intensive animal farming,

swimming pools or other aggressive conditions.

If any of our products are to be used in these

conditions, or unusually corrosive environments,

seek advice from our information line (Page 1).

2.10 Metal and timber compatibility Conta ct with, or runoff from, some ma terials can

da mag e coa ted steel prod ucts. Building s can also

be susceptible to condensation on inside sufaces.

The ma terials include certa in met als, treat ed timbers

and chemicals.

• Don’t a llow any contact of coated steel products

with incompa tible mat erials.

• Don’t a llow discharge of ra inwater f rom

incompatible ma terials onto co ate d steel products

(Ta b le 2.10.1).

• Ensure that support ing members are compatib le

with the coa ted steel prod ucts or, alternatively,

appropriate ly coated .

If there are d oubts a bo ut the compat ibility of

other products being used, seek advice from our

information line.

Incompatible materials include:• lea d

• copper

• monel meta l

• bare steel

• s ta inless s teel (except with COLORBOND®

stainless cladding)

• carbon (in pencils and some rubbers)

• green or some chemically-treated t imber

(like CCA or tanalith treatments)

• materials subject to cycles of dryness and

we tness o r which have excessive mo isture

conte nt (such as improp erly-sea soned timber)

• w et and d ry co ncre te

• soils




2 D e



Table 2.1 0.1 Acceptability of drainage from one surface onto another

CUSTOM BLUE ORB lends itself to the smooth curves of large

arched roofs. This roof has bothconvex and concave curves.



Table 2.3.1Specifications of roofing & walling profiles


12

24.0

84.0

7.4

3.5

017

017

007

007

34

34

)03ni1(°2

)05ni1(°1

0561

0502

0571

0532

0022

0082

051

002

054

005

0042

0072

0003

0033

0063

0093

051

002

07.0 7.9 013 503 84 )05ni1(°1 0081 0002 0052 051 054 - 0072 0072 054

24.0

84.0

7.4

3.5

457

457

007

007

42

42

)02ni1(°3

)02ni1(°3

0031

0002

0081

0022

0042

0003

003

004

006

007

0052

0003

0003

0003

0033

0033

003

004

24.0

84.0

3.4

9.4

618

618

267

267

92

92

)03ni1(°2

)03ni1(°2

0011

0061

0031

0581

0091

0062

051

002

003

053

0042

0072

0003

0003

0003

0003

051

002

1 detniapnuroferasessaM EMULACNIZ .leets2 .°1tahctipfoorhtiw noituacesU3 .'deneffits'fonoitanalpxerof6.01noitceSeeS4 troppusrep,teehsrepsrenetsaf5htiW5 .spilcfogninoitcnufreporprofsteehsfosdnemorfmm57ebtsumspilC6 troppusrep,teehsrepsrenetsaf4htiW

stroppusf ognicapsdednemmocermumi xaMSFOOR SLLAW

gnahrevO 3

TMB ssaM 1

htdiWllarevo.xorppa

revoChtdiw

biRhtped

hctipfooRmuminim 2 elgniS dnE lanretnI

-ffitsnUdene

-ffitSdene

elgniS dnE lanretnI -revO

gnah

mm m/gk 2 mm mm mm seerged mm mm mm mm mm mm mm mm mm

24.0

84.0

3.4

9.4

838

838

267

267

61

61

)21ni1(°5

)21ni1(°5

007

008

009

0031

0021

0071

002

052

003

053

0081

0081

0052

0072

0072

0072

002

052

06.0

08.0

1.6

0.8

838

838

267

267

71

71

)21ni1(°5

)21ni1(°5

0061

0081

0061

0081

0081

0062

002

004

003

006

0042

0042

0003

0023

0033

0063

002

004

24.0

84.0

6.4

2.5

598

598

028

028

84

84

)03ni1(°2

)05ni1(°1

0012

0052

0032

0552

0082

0503

051

002

003

053

0062

0072

0043

0063

0063

0063

051

002

24.0

84.0

06.0

9.4

6.5

9.6

234

234

234

604

604

604

14

14

14

)03ni1(°2

)05ni1(°1

)05ni1(°1

0051

0081

0032

0071

0042

0072

0012

0003

0063

002

002

003

006

006

009

0062

0092

0003

0062

0003

0043

0062

0063

0063

003

004

006

1

2

4



2 D e



Table 2.3.2 Specifications of profiles for walling only

WALLCLAD

TRIMWALL

EASY-CLAD 4P 300

EASY-CLAD 2PF 300

PANELRIB6

MINI 0RB7

MULTICLAD

MULTILINE 900

E S

I S

E S

S i n g l e

s p a n

Spacing definitions ES =Endspan

IS =InternalspanO = Overhang

I S

O

O



Figure 2.4 .1

Example of calculatingeffective roof lengths where penetrations alter the flow of water on a roof.

Table 2.4.1Maximum roof lengths for drainage measured from ridge to gutter (m)Penet rations alter the flow of wa ter on a roof. Thus, for design, you need to use an

effective ro of lengt h (Figure 2.4.1).




3 F a s t e n e r s

DESIGN—FASTENERS 9

3

FastenersWhen you select faste ners, you should co nside r the d esign life o f

the structure, b ecause the fasteners and the clad ding mate rial

should have similar life expectancies.

3.1 Materials for screwsScrew s a re a vailab le in a va riety of mat erials, finishes, co lour to

match COLORBOND® prepa inted stee l, and d esign. You should use

screws to AS 3566—2002 Class 3 (or better). Additional

information on fastener finishes is in the technical bulletin TB-16.

Table 3.1.1Materials for screws

3.2 Materials for nailsNails should b e o f g alvanised st ee l. They are only used to fix the

clips of some concealed-fixed cladding to timber supports.

3.3 Materials for blind rivetsFor COLORBOND

®STAINLES S use stainless steel blind rivets with

stainless ste el mand rels; for G ALVABO ND ® , ZINCALUME® and

COLORBOND® steels, use aluminium blind rivets. Blind rivets are

used for fixing flashings, a ccessories a nd side -lap s.

3.4 Materials for sealing washersSealing wa shers used under the head s of screws o n COLORBOND

®

finishes must be made from materials that don’t have significant

levels of conductive carbon black, particularly in marine

environments. Use wa shers, not neoprene.



3.5 Identification of screwsThe format of the number cod e is:

14 – 20 x 45Scre w g aug e Thre ad p it ch O ve ra ll le ng th of the

(Th re a d o ut sid e (t hre a d s p e r s cre w me a sure d fro md iameter) inch) und er the head (mm)

Fasteners must have a coating system to meet AS 3566 Class 3.

or

Fasteners must have a coating system to meet AS 3566 Class 4.

Ripple Teks are reg istered trad emarks of ITW Buildex.

3.6 Setting of screwsFasteners with sealing washers should be tightened only until

the w asher is g ripped firmly enoug h to provide a wea thertig ht

sea l. The faste ners should not b e o ver-tighte ned b eca use this

may split the sealing washer or deform the sheet, either of which

could lea d to wa te r pene trat ion. Take particular care when valley

fixing be cause t here is no flexibility w ith the sheet hard a g ainst

its suppo rt.

Table 3.5.1Featuresof recommended screws

Figure 3.6.1It is important that you set screws correctly

Figure 3.5 .1Typical hexagon-headed screws

10 DESIGN—FASTENERS

epyt wer cS daHe ntiopllir D

,rehsawnogaxeHref awro

MDPEenonro

&htgnelwercsnosdnepeDesu

,rehsawnogaxeH

ref awro

MDPE

enonro

&htgnelwercsnosdnepeD

esu

,rehsawnogaxeHref awro

MDPEenonro

rehsawnogaxeH MDPE

enonro syawAl

s wer csgnihctitS

nihthtiwnogaxehdettolS

.rehsaw.elbaliavaosladetarreS

MDPE

enonro eldeeN

s ®k eTelppiR daehgnilaes-f leslaicepS

Seal

Metal - Hex head, self drilling,

self tapping screw f or thin battens

Metal - Hex head, self drilling,

self tapping screw with seal

Hex head, self drilling, self tapping

screw with seal and extended drill

Timber - Hex head, self drilling,

self tapping screw with seal

Shank protection

Self drilling for metal

Self drilling for timber






3 F a s t e n e r s


3.7 Quantity of fasteners and clips

KLIP-LOK 406, KLIP-LOK 700HS and LONGLINE 305For number of clips, see equation at right.

For KLIP-LOK 406, there are 2 fasteners per clip.

For KLIP-LOK 700, there are 3 fasteners per clip.

For LONG LINE 305, there is 1 faste ner per clip.

Pierce-fixed profilesFor number of fa steners, see e q uation at rig ht (n is the numb er

of fast eners per suppo rt, as show n in the d iag rams in Tab le 3.8.1).

Side-lapsSide-lap fasteners are o ften placed at ab out 900 mm centres,

see equation at right.

3.8 Recommended fasteners and locationsReco mmend ed faste ners and the ir loca tions are in Tab le 3.8.1.

Fastener length with insulationWhere insulat ion is installed under cladd ing , you ma y need to

increa se the leng th of screws g iven in Tab le 3.8.1, depe nding o n

the de nsity a nd t hickness of the insulat ion. When the screw is

properly tightened (Section 3.6):

• INTO METAL: there should b e a t lea st three thread s protrudingpast t he support you are fixing to—but the shank prote ction

must not rea ch that support;

• INTO TIMBER: the screw must penetrate the timber by the same

amount tha t the recommende d screw w ould d o if there we re

no insulation.

Fixing to steel thicker than 3 mm• Use Hex head self drilling self tapping screws with seal with an

extended drill point; or

• in a pre-drilled ho le, use Hex head self drilling self tapping

screws with seal, of 12 gauge–14 pitch, with the length asspecified in Tab le 3.8.1.

Side-lap and accessory fasteningsFor MINI ORB and PANELRIB use 3.2 mm diameter aluminium sealed

blind rivets. For all other products use:

• S t itching screws with seal: 8–15 x 15; or

• Hex head self drilling self tap ping screws with sea l: 10-16 x 16;

or

• Sealed blind rivets: 4.8 mm diameter aluminium (not MINI ORB

and PANELRIB—see above).

Number of clips per job =

(Number o f purlins) x (Numbe r of shee ts + 1)

Number of fasteners per job (for pierced fixing) =

n x (Number of sheets) x (Number of supports)

Number of side-lap fasteners pe r sheet =

Support spacing (in mm) x Number of supports

900



KEY

† Fasteners per sheet per support

S = Sid e -la p

Table 3.8.1Guide to fasteners without insulation


Do not fix screws

less than 25mm

from the end of sheet.

EASYCLAD4P

EASYCLAD2P

1 fastener†

1 fastener†

Do not fix screws

less than 25mm


BROEULBMOTSUCDNABROMOTSUC

leetsotgnixiF

Fixing to timber

mm57.0otpu TMB

leetsotgnixiF

mm3ot>0.75 TMBr ebmitotgnixiF

tser C

dexif Hexheadselfdrillingselftapping

screwfortimber

Hexheadselfdrillingselftapping

screwfortimberwithhex.washer

head&EPDMseal

Hexheadselfdrillingselftappingscrewfortimberwithhex.washer

head&EPDMseal

Hexheadselfdrillingselftappingscrewwithhex.washer head fortimber

Hexheadselfdrillingselftappingscrew

withEPDMsealforthinmetalbattens

HexheadselfdrillingselftappingscrewwithEPDMsealandhex.washer head

HexheadselfdrillingselftappingscrewwithEPDMsealandhex.washerhead

andshankprotection

Hexheadselfdrillingselftappingscrew

withEPDMsealandhex.washerhead

14x31-31

&laesMDEP kprotectionnahs04x11-21

53x41-21

DOOWTFOS 05x11-21:

htiw & Shank protection

Shank protection

p i r g i H

DOOWDRAH 04X11-21:

htiw

yellaVdexif

61x61-01

laesMDPE&

02x21-01

61x61-01

DOOWTFOS 03x21-01:DOOWDRAH 02x21-01:

EASYCLAD

Hex head self drilling self tapping

screws with sealand hex.washer head

10-16x16


screws with sealand hex.washer head

10-16x16


screws for timber with sealand hex.washer head



3 F a s t e n e r s


Table 3.8.1 continued

Guide to fasteners without insulation

Crest: 4 fasteners†

Clip Clip

KLIP-LOK406

LONGLINE305

Clip

Clip

YTIRGETNI

leetsotgnixiF

mm57.0otpu TMB

tser C

dexif

56x11-21 86x41-21

Hexheadselfdrillingselftappingscrewswith

EPDMseal,hex.washerhead, shankprotectionandIntegritysealingplate

Hexheadselfdrillingselftappingscrewswith

EPDMseal,hex.washerhead, shankprotectionandIntegritysealingplate

Donotfixscrews

less than25mm

fromthe end ofsheet.

Do not fix screws

less than 25mm


Do not fix KL406 less than

75mm from end of sheet,do not fix Longline 305 sheets

less than 25mm from the

end of the sheet.






Valley:11fasteners†

Valley: 6 fasteners†

Number of fasteners depends onwind pressure (see brochure on

this product).Do not fix screwsless than 25mm


® ®




this product).

Do not fix screwsless than 25mm



DALCITLUM

leetsotgni xiFmm57.0otpu TMB

leetsotgni xiFmm3ot>0.75 TMB

rebmitotgni xiF

yella Vde xif

daeh-rehsaw.xehhtiw

02x21-01

daeh-rehsaw.xehhtiw

61x61-01 DOOWTFOS 03x21-01:

DOOWDRAH 02X21-01:

Self drilling self tapping screwsdaeh-rehsaw.xehhtiw

Self drilling self tapping screwsSelf drilling self tapping screws




this product).

Do not fix screwsless than 25mm


BIRLENAP

leetsotgnixiF

mm2otpu TMB

r ebmitotgnixiF

yellaV

dexif daeh-rehsaw.xehhtiw

61x61-1010

DOOWTFOS & DOOWDRAH :

02X21-

Self drilling self tapping screwsdaeh-rehsaw.xehhtiw

Self drilling self tapping screws



3 F a s t e n e r s


KEY

† Fasteners per sheet per support

S = Sid e -la p



SValley: 4 fasteners†


S

S





TRIMDEK

SPANDEKNumber of fasteners depends onwind pressure (see brochure on

this product).Do not place fasteners less than 25

from the end of sheets.



Figure 4.1 .1Spring-curved-ridge roof

Figure 4.1Typical curved and bent applications

4

Curved, bent & taperedcladding

An excellent method of cladding low-slope gable roofs is

to run continuous lengths of roofing from eave to eave,

across t he full width of t he roo f. This g ives a pa rticularly neat

and at tractive roof. It is also po ssible to spring -curve sheet s

into a concave shape.

With the except ion o f KLIP-LOK, the ridg e capp ing is eliminated

in these roofs, thus avoiding any possibility of leakage along

the ridg e. KLIP-LOK can b e used similarly, b ut the ribs a re cut

at t he ridg e and a met al cap is fitted over the cut.

4.1 Spring-curved-ridge roof Sheet s in a sp ring -curved-ridge roof remain straight e xcept

for a curve near the ridge.

The p ans o f KLIP-LOK, INTEG RITY, LONG LINE 305 and TRIMDEK tend

to oilcan (minor w aviness in the pa n) when spring curved.Apart from not loo king g ood , a n oilcanned pan may retain

wa ter which could lead to discolouration and /or de terioration

of the sheet co ating a nd a lso contributes t o thermally induced

roof noise. If some oilcanning in the pans is acceptable, these

profiles ca n be spring -curved up to a maximum slope of 1 in 30

(2°); with the spacing between the purlins at the ridge being

slig htly less tha n the internal span reco mmend ed for the profile

in Tab le 2.3.1.

Over the supports at the ridge, very slight crease marks may

appear in the pans or valleys when subjected to foot traffic.

They do n’t affect strengt h and will usually not be seen fromthe ground.

Only the shee t p rofiles reco mmend ed for spring -curving are

sho wn in Tab le 4.1.1.

Fix each sheet is first fixed to one side of the roof, and then

pulled do wn to be fixed t o t he o ther side. To minimise sma ll

laying errors, lay alternate sheets from opposite sides of the roof.

Side laps should be sealed with silicone sealant for the length

of the curve.

16 DESIGN—CURVED , BENT AND TAPERED ROO FING

Capped bent ribbed roofs(for example KLIP-LOK)

Spring curved-ridge roof Sheets straight except fora curve near the ridge

Spring-arched roof Sheets curved in a radiusfrom eave to eave

Spring-curved concave roof Sheets curved concavely in a radius

Pre-curved roofingSheets curved by machine beforeinstallation

Spring curved-ridge roof

Sheets straight except fora curve near the ridge

Spring-arched roof Sheets curved in a radiusfrom eave to eave

Spring-curved concave roof Sheets curved concavely in a radius



4 C u r v e d , b e n t &

t a p e r e d

DESIGN—CURVED , BENT AND TAPERED ROO FING 17

Table 4.2.1Recommended radii for convex spring curving

Table 4.1.1Minimum spacing of purlins at ridge for spring curved-ridge roof (mm)

Figure 4.2.2 Seal length for side lapson spring-arched roof

At the crest of a n arch the roo f is flat , which is ob viously below

the sp ecified minimum roof pitch. Therefo re side laps should b e

sea led over the crest of the arch until there is sufficient pitch to

g ive a de q uate drainag e (see Tab le 2.3.1). The leng th o f sea l is

shown in Figure 4.2.2.

Over the supports very slight crease marks may appear in the

pans o r valleys when subjected to foot traffic. They do n’t affect

strength and will usually not be seen from the ground.

If end laps are necessary they should not be locat ed at or near

the crest of the arch and ea ch sheet leng th must span a t least

three purlin spacings.

Figure 4.2 .1Calculation of radius

4.2 Spring-arched roof

Sheets in a spring-arched (convex) roof are curved in a radiusfrom eave to eave. sPANDEK, CUSTOM ORB and CUSTOM BLUE ORB ca n

be spring-curved for an arched roof. Tab le 4.2.1 show s the

accepta ble rad ii.

The t op face of a ll purlins must accurat ely follow and be

ta ng ential to the rad ius of the arch. The radius of curvat ure can

be calculat ed from the formula in Fig ure 4.2.1.

R a d i u s

Seal lengthmeasured on roof



Table 4.3.1Radii for spring curved concave roofs

Figure 4.3 .1Spring-curved concave roof

4.4 Pre-curved roofsPre-curved co rruga te d roo fing is po pular for a esthe tics (such as

a bullnosed veranda h roo f), or for function (such as a g utte rless

eave design). CUSTOM BLUE ORB can be curved to a rad ius as smallas 300 mm. We d on’t reco mmend pre-curving for ot her profiles.

MINI ORB can be curved to a rad ius to as small as 150 mm, though

it isn’t recommended for roofing.

Beca use of the spacing of curving rolls, there is usually a straight

portion a t the end o f the sheet beyond the curve (often 50 to 110

mm for CUSTOM BLUE ORB , and about 50 mm for MINI ORB). Allow

for this in your de sig n. It ca n be trimmed off if necessary.

If a pre-curved section of cladding is to be joined to a straight

section, you should order the curved and straight sheet s at the

same t ime, a sking for them to be matched in production.

End-lap the she ets a s de scribed in Section 11.4 (End-lapping).

Our CUSTOM BLUE ORB brochure gives more details.

Profiles with wide pans manufactured from high tensile steel

(such as KLIP-LOK and INTEG RITY 820) are susceptible to local

buckling of the pans a nd a re the refore not recommended for

spring -arched roofs. These p roducts ca n be mad e spe cially from

soft steel (G300) to overcome the problem.

Each sheet is first fixed to one side of the roof, and then pulled

do wn to be fixed to the o ther side. Alternate sheets are laid from

oppo site sides of the roo f.

4.3 Spring-curved concave roofsRoofing can be spring-curved into concave shapes.

Tab le 4.3.1 shows t he a ccept ab le ra dii.

18 DESIGN—CURVED , BENT AND TAPERED ROO FING



4 C u r v e d , b e n t &

t a p e r e d

DESIGN—CURVED , BENT AND TAPERED ROO FING 19

4.5 Capped bent ribbed roofsTray clad ding can b e used in continuous leng ths from e ave t o

eave b y cutting the ribs and bend ing t he pans at the ridg eline.

The same process is used on Mansa rd roo fs. Cap s are fitte d o ver

the cut ribs, which open up when the pans are bent. Fitting the

rib caps can be time-consuming and care must be taken with

sealing to avoid any possibility of leakage.

The ribs must b e cut sq uarely, with a met al cutting b lad e in a

power saw, set to the depth of the rib minus 2 mm.

In some state s pressed stee l caps can b e o bta ined to suit

KLIP-LOK ribs, thoug h the rang e o f ang les is limited . Ca ps can be

handmad e to suit a ny angle from flat sheet.

KLIP-LOK is most frequently used for cap ped bent ribb ed roofs,

but LONG LINE 305, TRIMDEK or even SPANDEK can be used. For these

two profiles the rib caps can be made from pieces of rib profile

cut from a short length of cladding.

4.6 Tapered roofingWe can taper LONG LINE 305 in its width, at either end,

to produce a sheet that lends itself to a wide range o f roof

de signs. The m a ximum red uction in widt h is 50%. The t a pe r can

be left-hand or rig ht-hand (Fig ure 4.6.1). G et our ad vice for long

spans or high loadings.

Figure 4.5.1Capped bent ribbed roof

Figure 4.6.1Tapered LONGLINE 305



Figure 5.1 .1Heat transmitted into a building

You o ften co nside r insulat ing a building to reduce:

• heat ing f rom the sun in summer;

• loss of heat from inside in winter;

• condensation on the inside of the roofing and walling; and

• noise from rain, thermal expansion and contraction, and

other sources.

Usually, when one of these four is treated, there is also a

beneficial effect on the others.

You nee d t o co mpa re the initial cost o f installing insulat ion w ith

the sa ving s in costs of hea ting a nd co oling . There are also g ains

for the environment when you save energy.

AS 2627.1—1993 Thermal insulation of dwellings, thoroughly

treats the subject, including comprehensive tables of

recommend ed thermal resistance (R values) for over 1000 towns

througho ut Australia.

5.1 Heat controlIn summer building s g et ho t from the sun and w e w ant t o co ol

the inside; in winter we often hea t the inside and wa nt to avoid

losing tha t heat .

Factors in cont rolling hea t include:

• the orientation of the building relative to the sun;

• external shading from trees or other buildings;• design o f the building, especially ventilation and sealing

at doors and windows;

• the colours and surface g loss of the cladding.

The first three fa cto rs are o utside the sco pe o f this bo ok. Heat is

absorbed into a sheet o n one side, a nd some of that ab sorbed

hea t is re-rad iated from t he o ther side (Fig ure 5.1.1).

• Light-coloured o r shiny surfaces don’t ab sorb much heat,

and they radiate little.

• Dark-coloured or dull surfaces absorb a lot of heat,

and they radiate a lot. This doe sn’t stop you using da rkercladdings because you can use reflective foil laminate

under the cladding.

5

Insulation & skylights

20 DESIGN—INSULATION AND SKYLIGHTING



5 I n s u l a t i o n &

s k y l i g h t i n g

DESIGN—INSULATION AND SKYLIGHTING 21

Comparison of thermal performanceTa ble 5.1.1 show s therma l pe rforma nces o f different insulation

systems by showing the heat that ma y be expecte d through roofs

of new materials.

Heat control methodsIn roofs, a simple, inexpensive a nd very effect ive met hod is to

drape a membrane of reflective foil laminate over the supports

be fore laying the clad ding. The laminate ca n also provide a

vapo ur barrier to minimise co nde nsation. If the memb rane is

allowed to drape 50 to 75 mm between the supports the air

space b etwe en the memb rane and the roof clad ding will further

improve he at insulation (Fig ure 5.1.2).

Add itional hea t insulat ion is ofte n a chieved by using b ulk

insulation blankets or batts (Figure 5.1.3).

The sa me p rinciples ap ply to w alls, thoug h the fo il is not drap ed .

5.2 CondensationWhen the air in a b uilding in conta ct w ith me ta l clad ding is

warmer than the cladding, water vapour (moisture) in the air can

condense o n the inside of the cladd ing.

Water vapour passes fairly freely through most building liningsinto the ceiling and wall spaces where it may directly contact

the clad ding .

Conde nsation can lead to d eterioration of building compo nents

and sta ining of ce iling and wa lls. If insulat ion b lankets o r ba tts

are we t, or even slig htly da mpened by conde nsation, its

efficiency is reduced markedly.

The amo unt of condensation depends upon the a mount of wat er

vapour in the air and this varies with climatic conditions. Activities

within a building can a dd substa ntially to the a mount of wa ter

vapour, and typical domestic situations include bathing,

showering, cooking, washing and drying clothes and dishes, and

breathing. It is essential to vent substantial amounts of water

vapour to outside the building.

Table 5.1.1 Approximate thermal transmission (for comparisons only)

Figure 5.1.2 Reflective foil laminate is simple,cheap and very effective

Figure 5.1.3 Typical roof insulation withfoil and blanket

Surfmist

Wilderness

Woodland Grey

Night Sky



• being careful abo ut design deta ils in valleys

(whe re heat te nds to b e reta ined ); and/or

• insulat ing the roof space to reduce the thermaldifferential. In tropical areas it may be better to

insulat e t he ce iling rather t han t he roo fing (which

can a lso red uce noise).

5.4 Insulation materialsTypical insulat ion ma te ria ls are reflect ive foil lam inate s,

insulation blankets or batts made from fibreglass,

and boa rds mad e from polystyrene. Remember

that the colour of clad ding a lso has a marked effect

(Section 5.1).

Foil laminatesFoil laminates reflect heat and can double-up as a

vapour barrier to control condensation. Where they are

used as a vapour barrier the joints between successive

strips are overlapped a bout 100 mm, and sealed with

a tape impervious to moisture.

Blankets and battsBlankets and batts minimise heat convection and are

availab le w ith the laminate bo nded to the fibreglass.

They a re also effe ctive in red ucing no ise.

Insulation blankets must be protected from moisture,particularly around the e dg es of the roof a nd even

more particularly at the b ott om e nd o f the cladding

where rainwate r run-off can be blown ba ck under a

low-pitched roof. If the blanket overhang s the b ott om

support, it ma y even come into conta ct with wat er in

the g utter, where the insulat ion w ill abso rb moisture

and remain damp for extende d pe riod s, thus lead ing to

det erioration of the coa ting o n the underside of the

roofing and reducing the effectiveness of the insulation.

Insulat ion b lankets up t o a nominal thickness of up to

100 mm for pierce-fixed cladding

and KLIP-LOK 700; a nd up t o 50 m m fo r KLIP-LOK 406 and

all other concealed-fixed profiles will compress

sufficiently over the roo f supports to allow normal

procedures to be used for fixing. However, you may

need to increase the length of fasteners slightly to

allow for the thickness of the compressed blanket

be tw ee n the clad ding a nd suppo rt, see Tab le 3.8.1.

Polystyrene boardsExpande d and extruded polystyrene is also used for

the same purposes a s blankets a nd b att s. The b oa rds

are more rigid a nd relat ively less compressible whichdema nd different fixing t o tha t mentioned a bo ve. Seek

ad vice from manufact urers of po lystyrene insulat ion.

To minimise t he risk of co nde nsat ion on t he und erside

of roo fing, a vapour barrier is often used t o prevent

conta ct o f wa rm moist air with the roo fing – reflective

foil laminate is comm only used.

To minimise t he risk of co nde nsat ion on t he und erside

of the laminate, the laminate must be draped between

roof supports so tha t the cold cladd ing is not in contact

with the laminate (except at the supports).

5.3 Noise reductionRain noiseTo red uce rain noise on me ta l roo fing, a n insulat ion

blanket can be placed over the foil laminate described

above, before laying the roofing. It is important that

the laminate is pulled tight enough to hold the blanket

hard ag ainst the underside of the roofing so as to

dampen the rain-induced vibration at the point of

impact. If the blanket is not hard against the roofing

the noise reduction will not be as g oo d.

For purlin spa cing s over 1200 mm: first lay w ire

mesh o ver the p urlins, tighte n and fix it, b efore laying

the membrane.

Thermally-induced noiseRoofing expands a nd contracts due to tempe rature

changes in the cladding, and particularly rapid changes

can be caused b y passing clouds or a strong breeze.

For example: if a passing cloud suddenly shades the

roof from the sun, the cladding temperature could drop

about 3°C after 30 seconds in shade and about 10°C

after 2 minutes in shade.

Therma lly-induced noise is cause d b y slipping a t

fasteners where the roof expands relative to its

suppo rts. The slipp ing is contro lled by t he friction

bet wee n the roof a nd its supports. When the sta tic

friction is overcome impulsively, sounds are produced

— sometimes as loud as a pistol-shot — the higher the

friction, the louder the sound.

The noise can b e reduce d b y:

• placing a material with low coefficient of friction

between the roofing and its supports (for example

PVC tape or strips of foil laminate);

• choosing steel supports rather than timber (lower

coefficient of friction);

• choosing light coloured roof ing;

• ve nt ing t he ro o f sp a ce ;

• including a n expansion joint (Section 10.5);

22 DESIGN—INSULATION AND SKYLIGHTING



5 I n s u l a t i o n &

s k y l i g h t i n g

DESIGN—INSULATION AND SKYLIGHTING 23

5.5 Insulation thicknessInsulation blankets and batts can cause cladding

to bo w o ut bet wee n the fasteners. To minimise this

problem, the maximum thickness of blankets and

ba tts should be 100 mm for pierce-fixed cladd ing

and KLIP-LOK 700; and 50 mm for KLIP-LOK 406 and all

other concealed-fixed cladding.

5.6 SkylightingOne o f the simplest met hods o f g etting nat ural lig ht

through a stee l roo f is the inclusion o f translucent

sheets which match the steel profiles.

It is preferab le to use profiled tra nslucent cladd ingin single widths so that they can overlap, and be

supported by, the steel cladding on both sides. It is

also preferable to position the lengths of translucent

clad ding at t he top o f a roof run so the high end can

lap under the capping or flashing a nd the low e nd can

overlap a stee l shee t. This is beca use the translucent

cladding will readily overlap a steel sheet but the

reverse is difficult.

Building reg ulations req uire a safety mesh to be fitted

under translucent cladding.

Because of its greater thermal expansion, translucent

cladding should be fixed using oversized holes and

sealing washers recommende d by the clad ding

manufact urer. When used with conce aled fixed

clad dings, ensure the fa steners do not p enetrate the

stee l clad ding. There a re translucent products a vailab le

that e asily accommoda te this. Don’t exceed t he

maximum support spacing specified by the translucent

clad ding manufact urer.

Skylig hting increa ses t he t ransmission of so lar he at .

G enera lly spea king , hea t tra nsmission is proportional to

light transmission, so the mo re sunlig ht tha t ente rs a

building the hott er it will be . Clear, uncoloured

fibreglass has good light transmission of about 65%but

this means on a typical summer day, with peak solar

radiation o f 850 W/m2, transmission through a clear

fibreg lass skylig ht w ould b e a bo ut 550 W/m2.

Translucent fibreg lass clad ding is a vailab le to mat ch

CUSTOM ORB, INTEG RITY 820, KLIP-LOK 406 and 700,

LONG LINE 305, SPANDEK and TRIMDEK. Polycarbonate

clad ding is also a vailab le fo r CUSTOM ORB and TRIMDEK.

Note: Use of transluscent sheeting may result in lowe rlimit stat e ca pa cities.

On KLIP-LOK roofs the translucent cladding should be

pierce-fixed.

Figure 5.6.1Placement of translucent sheets - pierce fixed decks

Figure 5.6.2 Placement of translucent sheets - concealed fixed decks



6.1 IntroductionThe de sign of roof drainag e a ims to p rote ct peo ple, property

and the building. A thorough design includes:

• The roofing material and its profile

• The pitch of the roof and any penetrat ions that

reduce the capacity of the profile to carry rain

efficiently to the gutters

• The catchment area of the roof, including g utters.

Adjacent roofs a nd w alls can a ffect t he cat chment,

but are not considered in this book.

• The gutters: their location (at ea ves or elsewhere:

Fig ure 6.1.1), cross-sectional area, a nd g radient

• The dow npipes: their cross-sectional area, q uantity

and locat ion relative t o t he g radient

• Disposa l o f wa ter from the downpipes

• O ve rflo w p re ca ut io ns

6.2 Design of drainage (eaves-gutter system)This section outlines a p rocedure for de sig ning the d rainag e o f a

roo f using an e aves-g utter system. It is assumed tha t t he g utters

will have a gradient steeper than 1:500. Box gutter systems can

be more comp lex and a re thoroughly trea ted in AS/NZS

3500.3.2:1998.

1. Decide on the average recurrence interval (ARI). Where

significant inconvenience or injury to people, or damage to

property (including contents of a building), is unlikely (typical

of a n ea ves-g utte r syste m) a minimum ARI can b e 20 yea rs.

If these cond itions are likely (typical of box gutters) 100 years

is recommended .

2. Det ermine rainfall intensity for the site from Tab le 6.2.1.

More d at a are in AS/NZS 3500.3.2:1998.

3. Sketch a roo f plan showing d imensions in plan view, pitch of

roof, layout of ridges and valleys.

4. Check that the e ffective roof lengt hs don’t exceed the

capa city o f the roofing profile (Section 2.4).

6

Roof drainage

24 DESIGN—ROOF DRAINAG E



6 R o o f d r a i n a

g e

DESIGN—ROO F DRAINAG E 25

Table 6.2.1Design rainfall intensities

Figure 6.1 .1Typical gutters

5. Calculate t he catchment area of the roof from the plan.

To a llow for the slope o f the roo f, increa se the plan area by

1%for every deg ree of pitch up to 40° . For pitches o ver 40°

refer to AS 3500.3.2:1998.

6. G et the effective cross-sectional area o f the gutter you intend

to use fro m Ta ble 6.2.2.

7. Using the cross-sectional area o f the gutter on the graph in

Figure 6.2.2, determine the catchment area per downpipe.

8. Calculate (as a first te st) the minimum number of d ownpipes

req uired for the selected g utter using the eq uation:

Round the number o f do wnpipes up to the next w hole number.

9. On the plan, select locations for the downpipes and the

high points in the gutters. Where practical, the catchments

for each dow npipe should b e a bout e q ual in area; and a

hig h point should b e located at the bo ttom of any valleys

(Fig ure 6.2.3).

Calculate the area o f each catchment for each dow npipe.

10.Returning to the graph in Figure 6.2.2, with the area of your

ea ves gutter, check that t he catchment a rea for eachdownpipe, calculated in Step 9, is equal to or less than the

catchment area shown by the graph.

If a cat chment area is too big then you can:

• increase the number of downpipes;

• reposition the dow npipes and/or the high po ints;

• choose a gutter with bigg er effective cross-sectional

area, then repea t the abo ve from Step 7.

11. De cide on t he d ow npipe size. Recomme nda tions in AS/NZS

3500.3.2:1998 suggest that the area of round pipes should be

eq ual to the area of the g utter, whilst the area of sq uare o r

recta ng ular p ipes ma y b e 20% sma ller (Ta ble 6.2.2).

12.Consider measures to counter overflow of gutters into

the building.

6.3 Gutter fallInstall gutters with a generous fall to avoid ponding (which

reduces gutter life), but the fall should not be so steep as to be

ob vious to the casual o bserver. Typical fall on house g uttering is

ofte n abo ut 1:250 (12 mm in 3000 mm), thoug h a stee per fall of1:100 should g ive the g utte r a long er life.

Number of

do wnpipes (min.)

Tota l catchment area of the roof

Catchment area determined in (7)

=



Table 6.2.2 Gutter areas and downpipes

Figure 6.2 .2 Cross-sectional area of eaves gutters requiredfor various roof catchment areas (wheregradient of gutter is flatter than 1:500).(Ada pte d from AS 3500.3.2:1998)

Figure 6.2 .3 Locating high points and downpipes

26 DESIGN—ROOF DRAINAG E

Gutter



7 C a r e & h a n d l i n g

CARE AND HANDLING 27

7.4 Walking on roofsIt is important tha t yo u wa lk on roo fing carefully,

to a void d ama g e to either the roofing o r yourself.

G enera lly, keep yo ur weight evenly distribute d o ver

the soles of both feet to avoid concentrating your

weight o n either heels or toes. Alwa ys wear smoot h

soft-soled shoes; avoid ribbed soles that pick up and

hold small stones, swarf and other objects.

When you walk parallel to the ribs:

• for ribbed roofing walk on at least two ribs or

corrugations (CUSTOM ORB, CUSTOM BLUE ORB

and SPANDEK);

• fo r pan-type roo fing walk in the pans

(LONG LINE 305, KLIP-LOK 406, KLIP-LOK 700,

KLIP-LOK 700, TRIMDEK, INTEG RITY 820).

When you w alk across the ribs, w alk over or close to

the roofing supports.

Be ca reful when moving bet wee n supports. Do not

walk in the pan immediately adjacent to flashings ortranslucent sheeting. Walk at least one pan away.

Alwa ys take particular care when w alking on w et

or new ly laid sheet s — pa rticularly on ste eply

pitched roofs.

If there w ill be hea vy foot traffic on a roof, provide

a tempo rary walkway or working platform to

minimise da mag e.

7.5 Marking out, cutting and drilling

Marking outA pencil of any colour may be used except black or so-

called lead pencils. Do n’t use b lack pencils to mark

roo fing or wa lling beca use the g raphite content ca n

create an electric cell when wet and thus cause

de te riorat ion of t he finish. You ca n a lso use a string line

with chalk dust, or a fine, felt-tipped marker.

CuttingWhere possible, you should minimise site-work by

using sheets cut to length in the factory.

For cutting thin metal on site, we recommend

that yo u use a pow er saw with a met al-cutting b lad e

because it produces fewer damaging hot metal

particles and leaves less resultant burr than does a

carborundum disc.

7

General care, safety

and handling7.1 Safety It is commo nsense to wo rk safely, prote cting yo urself

and workmate s from a ccidents o n the site. Sa fety

includes the practices you use; as well as personal

prote ction of e yes a nd skin from sunburn, and hea ring

from noise.

Occupational health a nd safet y law s enforce sa fe

wo rking cond itions in most loca tions. Law s in every

state require you to have fall protection which includes

safety mesh, personal harnesses and perimeterguardrails. We recommend that you aquaint yourself

with all local codes of safe practice and you adhere

strictly to a ll law s tha t a pply to yo ur site .

7.2 Care and storage before installationRain or condensation is easily drawn between the

surfaces of stacked sheets by capillary action, or they

can b e d riven in by wind. This trappe d mo isture canno t

evaporate easily, so it can cause deterioration of the

coating which may lead to reduced life-expectancy or

poor appea rance.

If materials are not required for immediate use, stack

them neatly and clear of the ground. If left in the open,

protect them with wate rproo f covers.

If stacked or bundled product become s wet, sepa rate it

without delay, wipe it with a clean cloth and stack it to

dry t horoug hly.

7.3 Handling cladding on siteOn large building p rojects yo u can reduce hand ling

time by lifting bundles w ith a crane d irect from the

delivery truck onto the roof frame. Use a spreader

ba r for long sheet s. For small to med ium size projects,

without me chanical handling facilities, you ca n unloa d

sheets by hand and pass them up to the roof one

at a time.

For personal safety, and to protect the surface finish,

wear clean dry gloves. Don’t slide sheets over rough

surfaces o r over each o ther. Always carry too ls, don’t

drag them.



7.8 Strippable coatingsTo p rovide tem pora ry prot ection d uring production,

handling and transport, some COLORBOND® products

are co at ed with a plastic. This coa ting pe els off easily

whe n new, b ut it has a relat ively short life, e specially

in sunlight. If you don’t remove this coating at the time

of installat ion, yo u may find it very hard t o remo ve

later on.

Please dispose of the plastic in an e nvironmenta lly

responsible manner.

7.9 Sealants

Recommended sealantsNeutral-cure silicone sealants have been successfully

used with the range of steel finishes on our roofing

and walling; a nd o n flashings, capp ings, a nd g utters

mad e from the same ma terials as the clad ding .

Neutral-cure silicone sealants:

• have goo d adhesion to the c lean surface of a ll our

roofing and walling;

• are water resis tant and non-corrosive;

• are resis tant to extremes of heat and cold while

retaining g oo d flexibility;

• provide hig h resistance to ultra-violet rays (sunlig ht);

a nd

• have a long service lif e.

It is important that only neutral-cure silicone be used

with sheet steel. Other silicone sealants, often have

a vineg ar or ammonia smell, and g ive off ag g ressive

by-prod ucts during curing which are de trimenta l to

sheet stee l.

If in doubt , loo k for a messag e o n the sealant pa ckag e

like: Suitable for use with galvanised and ZINCALUME®

steel products.

Cleaning surfacesFor effective bonding, all surfaces must be clean, dry

and free from contaminants such as old sealant or oil.

Mineral turpentine is suita ble fo r clea ning the surface s

but care must be ta ken to completely remove all

residual solvent with a clean dry cloth. White spirits is

an alternative.

Sealant must be applied o n the same da y as thesurface is clea ned .

Cut mate rials over the g round and not o ver other

materials where hot particles can fall and cause

damage to finishes—especially COLORBOND® prepainted

finishes. It is best to have the exterior colour finish of a

COLORBOND® prepainted sheet facing down, however

you must the n prote ct the pa int finish from scrat ching

by yo ur work supports.

If you have to cut materials near sheets already

installed, mask them or direct the stream of hot

particles away.

Reciproca ting nibb lers are a lso w ide ly used in the

roofing trad e, a nd the y produce a n excellent cut. The

resulting small, sharp scraps can rust and damage

finishes; a nd the y ca n ca use p ersona l injury. Takespecial care to collect these scraps.

Making holesHoles are often made by drilling or cutting by hole saw

or jig saw. Mask the area a round the hole to protect

paint from damage by swarf.

7.6 Clean upSwarf (metal scraps or or abrasive particles resulting

from cutting a nd d rilling ) left on t he surfaces o f

mat erials will cause rust stains which can lead to

reduced life of the material.

• Sweep or hose all metallic swarf and other debris

from roof areas and gutters at the end of each day

and at the co mpletion of t he installation.

• If swarf has become stuck on a f inish, it can be

removed . Take g reat ca re not to remove the p aint

or the metal coatings.

• For critical applications inspect the job tw o wee ks

after completion, when rain or condensation will

have caused any remaining swarf to rust, and thus

hig hlig ht a ffected areas.

7.7 Warn other contractorsMany stains arising from swarf do so, not from the work

of roofing-installers, but from o ther contract ors working

on the job . Similarly, problems can a rise from conta ct

with incomp at ible ma terials, like copp er piping or

chemically trea ted timber. Acid clea ning of bricks ca n

also be a proble. Architects a nd b uilders need to be

aware of this, and warn contractors accordingly.

28 CARE AND HANDLING



7 C a r e & h a n d l i n g

CARE AND HANDLING 29

Figure 7.8.1Typical joints with sealant

Sealant clean upWith practice you will be able to judge the size of

bea ds thus avoiding sq ueeze-out and the subseq uent

need to clean up.

Uncured sealant can b e removed with a clean, dry rag

and any excess then removed with a cloth lightly

da mpene d w ith mineral turpent ine o r white spirits.

Excess cured sealant is best removed with a plastic

spatula t o a void d ama g e to the surface finish of

the metal.

Avoid any unnecessary smearing of sealant on

surfaces intended for painting as silicone can affect

adhesion of paint. Smeared sealant may be treated

by lightly abrading the area with a non-metallicscouring med ium.

7.10 MaintenanceFactors that most affect the long life of a roof (or wall)

are original design, the environment of the installation,

and the maintenance of the installation. Maintenance is

probab ly the bigg est factor.

Maintenance includes:

• Reg ular inspection for problems before they

become major corrosion sites;

• Regular washing down, especially near coastal or

industria l influence s;

• Removal of leaves and other debris from gutters ;

• Keep walls free of soil, concrete and deb ris near

the ground;

• Don’t overspray pest ic ide .

Joint strengthSeams sealed with sealant should be mechanically fixed

for strengt h. Fastene rs in joints should g enera lly be no

further apart than 50 mm.

The sea lant do es no t req uire sig nificant ad hesive

strengt h in itself, but it must bo nd p ositively to all the

surface s it is to sea l. To ensure comp let e sea lant cure,

the width of sealant in a lap should not exceed 25 mm

when compressed (Figure 7.8.1).

Applying sealantAlways apply the bead of sealant in a continuous line

along the centreline o f the faste ner holes. This ensures

that, when compressed, the sealant positively seals

the fastener.

Be ca reful not to entrap a ir when ap plying sealant.

Especially, don’t place a ring of sealant around fastener

holes because entrapped air compresses during

tightening o f fasteners, and ma y blow a channel

throug h the sea lant, w hich could prevent t he fastener

from b eing sealed.

FastenersUse solid or sealed fasteners, otherwise you have to

apply sealant to the hollow centre of open blind rivets.

To preserve the life o f your clad ding, is very impo rtantthat fastener mate rials are compat ible with the

cladding (Section 2.10).

ProcedureThe p referred proced ure for lap fa brication is:

1. Assemble, clamp and d rill;

2. Separate compo nents and remove drilling deb ris;

3. Clean joint surfaces as recommended ab ove;

4. Apply bead (s) of sealant;

5. Relocate components and fix;

6. Externally seal ea ch fast ener if hollow b lind rivets

are used.

To p revent p rema ture curing (which cause s poo r

bo nding), finish the joint a s soo n as p ractical after

ap plying t he be ad s of sealant. The manufact urer’s

specified sealant open times should be followed.



Maintenance of COLORBOND® prepainted steelThe p aint system on COLORBOND

® stee l sheet is very

durab le. Simple maintena nce o f the finish enhance s its

life and maintains attractiveness for longer periods.

Where the pa int finish is nat urally wa shed by ra inwa ter

(roofs, for example) there is usually no additional

maintenance needed. However areas to be washed

include soffits, wall cladding under eaves, garage

doo rs, and the underside o f eave g utters.

Washing should be done at least every six months and

more frequently in coastal areas where sea spray is

prevalent, and in area s where high levels of industrial

fallout occur. Avoid a ccumulat ion o f salty de po sits o r

industrial dirt.

Esta blish a regular routine fo r wa shing COLORBOND®

prepainted steel products. Often garage doors can be

washed with clean w ate r at the same time a s your car is

being washed. G uttering a nd eaves can be hosed

dow n when window s are being cleaned . Walls can be

hosed down while watering the garden.

Where regular maintenance doesn’t remove all the dirt,

wash the surface with a mild solution of pure soap or

non-ab rasive no n-ionic kitchen de te rg ent in wa rm

water. Use a sponge, soft cloth or soft bristle nylon

brush; be g entle to prevent shiny spots. Thoroug hly

rinse off the de tergent w ith clean w ate r.

Never use abrasive or solvent cleaners (like turps,

pet rol, kerose ne a nd p aint thinners) on COLORBOND®

steel surfaces. For advice on grease, oil or deposits

not removed by soap or detergent contact our

Information Service

30 CARE AND HANDLING



8 P i e

r c e - f i x i n g

INSTALLATIO N—PIERCE-FIXING 31

Figure 8.1.1Lay sheets towards prevailing weather

Figure 8 .1Crest and valley fixing

8

Installing pierce-fixedcladding

Pierce-fixing is the met hod of fixing sheet s using faste ners

which pass through the shee t. This is different fro m the

alternative method called concealed-fixing (Chapte r 9).

The me thod of fixing you use is de termined b y the cladd ing

profile you a re using .

You ca n place screw s throug h the crests or in the valleys,

however, to maximise watertightness, always place roof screws

through t he crests. For wa lling , you ma y fix through e ither the

crest or valley (Figure 8.1).

Always drive the screws perpendicular to the cladding, and in the

centre of the corrugation or rib.

The follow ing proced ures a re describe d fo r roo fs, but the same

g enera l principles ap ply to w alls.

8.1 General installation procedureCheck flatness, slope and overhangBefore starting work ensure that:

• the supports for your cladd ing are truly in the same plane;

• the minimum roof slopes conform to Section 2.5

(Low roof pitches); a nd

• the overhangs o f sheets from the top and bo t tom

supports d on’t exceed tho se in Tab le 2.3.1, whilst a lso

overhanging at least 50 mm into gutters.

Make any necessary adjustments before you start laying sheets,be cause they will be difficult o r impo ssible t o rectify late r.

Orient sheets before liftingFor maximum weather-tightness, start laying sheets from the end

of the b uilding that will be in the lee of the worst-anticipat ed or

preva iling w ea the r (Fig ure 8.1.1).

It is much easier and safer to turn sheets on the ground than up

on the roof. Before lifting sheet s on to t he roof, check that t hey

are the co rrect w ay up a nd the overlapping side is towards the

ed g e o f the roo f from w hich installat ion w ill sta rt.

Place bundles of sheets over or near firm supports, not at midspan of roof memb ers.



Figure 8.1.2 Check alignment occasionally

Position first sheetWith p articular ca re, po sition the first sheet be fore fixing

to ensure that it is correctly located in relation to other parts

of the building . Check that the sheet:

• is aligned with the end-wall (or its barge o r fascia),

bearing in mind the type of flashing or capping treatment

to be used; and

• aligns correctly at its ends in relation to the g utter

and ridge (or parapet or transverse wall). Roof sheets

should overhang at lea st 50 mm into g utters.

Fix the shee t a s de scribe d lat er in this chapt er.

Position other sheetsAfter fixing the first sheet in position, alig n the follow ing

sheets using:

• the long edge o f the previous sheet ; and

• a measurement from the end of the sheet to the fascia or

purlin at the gutter. It is important that you keep the

g utter-end of a ll sheet s in a st raight line.

Fix the shee t b y either:

• f ixing each sheet completely, before laying the next; or

• f ix the sheet sufficiently to ensure it can’t move, complete

laying all sheets, then return to place all the intermediate

faste ners lat er.

Check alignment occasionallyOcca siona lly check that t he shee ts are still pa rallel with the first

sheet, by t aking two measurements a cross the w idth o f the fixed

clad ding (Fig ure 8.1.2).

At about half way through the job, perform a similar check but

ta ke t he me asurements from the finishing line to aim for the final

sheet to be parallel with the e nd o f the roof. If the mea surements

are not close enough, lay subsequent sheets very slightly out of

parallel to gradually correct the error by:

• properly a lign and fix a lap, then

• f ix the other edge of the sheet , placing the fas teners

slig htly close r or further from where they wo uld normally

be if there wa s no error.

32 INSTALLATIO N—PIERCE-FIXING



8 P i e

r c e - f i x i n g

INSTALLATIO N—PIERCE-FIXING 33

Figure 8.2 .2 Clamp one end of the sheet whilst fixing the other end.

Figure 8.2.1Crest fixing

8.2 Side-lapping & positioning pierce-fixed

sheetsTo prevent moisture b eing d rawn into laps b y capillary act ion,

the e dg es o f sheets are slig htly mod ified. CUSTOM ORB and

CUSTOM BLUE ORB have the edg es o f the sheet over-curved,

ot her prod ucts like SPANDEK, TRIMDEK, INTEG RITY 820 all have flutes

formed into the underlapping rib. It is important that sheets be

lapp ed correct ly (Fig ure 8.2.1).

After fixing the first sheet, p lace the next (and subseq uent)

sheet with its side lap snug ly over the previous sheet

(Fig ure 8.2.1). Secure the shee t firmly in place until ea ch end

of the sheet has b ee n fixed. You ca n do this easily by:

• a lign the bottom edge a ccurately by a measurement f rom

the end of the sheet to t he fascia o r purlin at t he g utter;

• clamp the lap with a pa ir of vice g rips (Fig ure 8.2.2);

• a t the top of the sheet : nest le the s ide lap snugly,

check alignment, and fix the sheet with a fastener.

8.3 Pierce-fixing on crestsCrest fixing is recommended for roofs made from:

• CUSTOM ORB

• CUSTOM BLUE ORB

• SPANDEK

• TRIMDEK

• INTEG RITY 820

Crest fixing may also be used for these products when they are

used as walling.



8.4 Pierce-fixing on valleys (for walling only)Wall fasteners may be placed on the crests, but they are usually

placed in the valley of wall cladding because:

• they are less conspicuous and don’t break the aesthetic

lines of the steel cladding;

• there is no risk of the profile being d eformed,

beca use t he fastener is placed throug h the cladding

where it rests flat against its support (Figure 8.4.1); and

• wa ter penetra t ion is no t a prob lem.

Howe ver, whe n valley-fixed, t he cladd ing need s a side -lap

fast ene r in all laps, a t e ac h suppo rt. You w ill find it mo re

economical in labour, time and cost of fasteners to use a crest

fastener at e ach side lap in place o f the lap fa stener and a djacent

valley fast ene r (Fig ure 8.4.2).

8.5 Pierce-fixing on side-lapsWhere roofing and w alling a re installed a ccording to t he support

spa cings sho wn in Ta bles 2.3.1 and 2.3.2, side -lap fa ste ners are

generally not required.

You ma y need to use side -lap faste ners where the clad ding is laid

a little out o f alig nment and the we ather resistance o f a joint is

q uestionab le. De cide on the number of side-lap fasteners bywha t loo ks effective in each individua l case.

Where valley fasteners are used, you need side-lap fasteners

along each lap at each support. Alternatively a crest fastener may

be used at each side-lap, in place of the side-lap fastener and

ad jace nt valley faste ner (as ment ione d a bo ve in Section 8.4).

Side-lap fasteners are located in the centre of the crest of the

overlap ping co rruga tion (Fig ures 8.4.1 and 8.4.2).

8.6 Installing MINI ORB

A little extra care is neede d with MINI ORB to g et the best

appea rance. Detailed notes are in our brochure on MINI ORB.

Figure 8.4.2 Alternative valley fixing with crest fixing at side laps(for walls only)

Figure 8.4 .1Typical valley fixing (for walls only)

34 INSTALLATIO N—PIERCE-FIXING



9 C o n c e a l e d - f i x i n g

INSTALLATIO N—CONCEALED-FIXING 35

Figure 9.1.1KLIP-LOK clips

9

Installing concealed- fixed cladding

Concealed-fixing is the method of fixing sheets using fasteners

which do not pass through the sheet. Instea d, t he clad ding is

held in place with clips. This is different from the alte rnat ive

met hod ca lled pierce-fixing (Cha pt er 8). The me tho d o f fixing

you use is determined by the cladding profile you are using.

Co ncea led-fixing is used for:

• KLIP-LOK 700

• KLIP-LOK 406

• LONG LINE 305

• EASYCLAD

Very steep pitchesTo prevent concea led -fixed cladd ing from sliding d ow nwa rd in

the fixing clips, on very steep pitches, you should pierce-fix

throug h each sheet under the flashing o r capping, a long the to p

of the sheets.

9.1 Installing KLIP-LOK roofsUse the same general procedure described in Section 8.1

(General installation procedure). However, at t he start of

installing KLIP-LOK 406, KLIP-LOK 700 and KLIP-LOK 700, a row o f clips

is fixed to the supports before the first sheet is locat ed over

them and locked in position.

Clips

For KLIP-LOK 700 use 700 clips.For KLIP-LOK 406 use KL65 clips.

The o rienta tion of the clips is important b eca use they a re not

symme trical (Fig ure 9.1.1).

The fixing h oles a re pre-punched . O n KL65 and KL75 clips you

can use the dimples to locat e o ther fasteners where a faste ner

brea ks or a timber support sp lits.

Shortened 1st clip



Figure 9.1 .2 Fix the first row of clips

PreparationAs described in General installation procedure (Section 8.1):

• check f la tness , s lope and overhang;

• orient the sheets before lif ting. Note the overlapping rib

is tow ards the end of the building where you start

(Fig ure 9.1.3);

• Check that the overhang of the sheets from the clips,

at bo th ea ves and ridg e, is not less than the minimum

in Ta ble 2.3.1.

• The first and last supports and clips should b e at least

75mm from e ach end of the sheet to keep maximum

holding power.

Position the first sheetWith p articular ca re, po sition the first sheet be fore fixing ,

to e nsure tha t it will correctly loca te in relat ion to ot her parts

of the building . Check that the sheet:

• is aligned with the end-wall (or its barge o r fascia),

bea ring in mind the type o f flashing or capping t reat ment

to be used; and

• aligns correctly at its ends in relation to the g utter and

ridg e (or pa rapet or transverse wa ll). Roof sheet s shouldoverhang at least 50 mm into g utters.

Fix the first clipsKLIP-LOK 700

Starting method 1. Cut t he 1st clip 25 mm from t he ce ntre of t he

second to we r (as sho wn). The first to we r on t he cut clip loca tes in

the 1st rib of the first she et (Fig ure 9.1.2). This metho d is

preferred beca use you don’t have t o reach so fa r to fix the

remot e e nd of t he clip.

Starting method 2. The first to we r on the first clip loca te s in thefirst rib of t he first sheet (Fig ure 9.1.2). The clip fixes the e dg e

of the first sheet, but you must fix two clips at the start, and thus

reach out further for the first and all subsequent sheets.

The fo llow ing d escription is for Met hod 1.

ALL KLIP-LOK PROFILES

Fix the first clip on the purlin nearest the gutter, with the clip

po inting co rrectly in the d irection o f laying (Fig ures 9.1.1 and

9.1.2). Be sure the clip is 90 deg rees to the ed g e of the sheet.

Using a string line (or the first sheet as a straight edge) to align

the clips a s you fix a clip to ea ch purlin wo rking to wa rds the highend o f the roo f.

36 INSTALLATIO N—CONCEALED-FIXING





Figure 9.1.5 Clip engaged over rib of installed sheet

Figure 9.1.4 Flatten spurs in way of clips

Figure 9.1.3 Placing the first sheet

Place the first sheet1. Loca te t he first sheet over the fixed clips (Fig ure 9.1.3).

2. Using a measurement from the g utter-end of the sheet to the

fascia or purlin, position the sheet so that it overhangs the

de sired a mount into t he g utter (usually ab out 50 mm). It is

important that you keep the gutter-end of all sheets in a

straight line.

3. KLIP-LOK 406: If a spur on the ed g e of a KLIP-LOK 406 sheet fouls

a clip, flatt en the spur with a rubber ma llet to allow the clip to

sit down over the rib (Figure 9.1.4).

ALL KLIP-LOK PROFILES: Fully engage the sheet with the clips,

using vertical foo t pressure o n all the ribs over ea ch clip.

Fix the next (and subsequent) clips and sheets1. Fix the next row of clips, one to each support. Be sure the clip

is 90 deg rees to the edg e of the sheet, and the embossed

arrow on the clip p oints in the co rrect direction (Figure 9.1.1).

KLIP-LOK 700: Eng ag e the slots and ta bs on the clips.

KLIP-LOK 406 & 700: Engage the clips over the rib of the installed

sheet (Fig ure 9.1.5). If a sp ur on the e dg e o f the she et fouls a

clip, flatten the spur with a rubber mallet to allow the clip tosit down over the rib (Figure 9.1.4).

2. As before, place t he next sheet o ver its clips also eng ag ing

the edg e o f the preceding sheet.

3. Accurately position the sheet so tha t it overhangs the de sired

amount into the gutter. It is important that you keep the

g utte r-end of a ll sheet s in a straight line.

K L 6 5



Figure 9.1 .8 Check alignment occasionally

Figure 9.1.7

Engaging edges of sheets

4. Fully engag e the two sheets along the o verlapping rib.

You ca n do this by w alking along the full leng th o f the shee t

with one foot in the centre pa n of the previous sheet a nd the

other foot app lying vertical pressure to the to p of the

interlocking ribs at regular intervals. It is important tha t yo u

do n’t wa lk in the unsupported pan b eside the o verlap

(Fig ure 9.1.7). A rubb er mallet ma y help eng ag eme nt of laps

on long spans.

5. Similarly, eng ag e a ll the clips by a pplying vertical foot

pressure to the top of the other ribs over each clip.

It is essent ial tha t t he she ets interlock completely. It is impo rtant

tha t yo ur weight is fully on t he shee t yo u are insta lling .

KLIP-LOK 406 & 700: The spurs on the free e dg e o f the unde rlap pingrib must be fully engaged in the shoulder of the overlapping rib

(Fig ure 9.1.7). You w ill hea r a d istinct click a s the spurs sna p in.

Check alignment occasionallyOcca siona lly check that the sheet s a re still parallel with the first

sheet, by t aking two measurements a cross the w idth o f the fixed

clad ding (Fig ure 9.1.8).

At about half way through the job, perform a similar check but

ta ke t he me asurements from the finishing line t o a im for the finalsheet to be parallel with the e nd of t he roof. If the mea surements

are not close enough, lay subseq uent sheets very slig htly out of

pa rallel to g radua lly correct the error. To a llow this to ha ppe n,

flatt en the tab s on the ba se of subseq uent clips—the slot in the

clip w ill allow the clips to be fixed o ut of st and ard p itch.

Place the last sheetKLIP-LOK 700: If the final space is less than the full width

of a sheet, you can cut a sheet a long its leng th and shorten

the clips as appropriate.


Spurs on edge of bottomsheet must be fully engagedin shoulder of top sheet.

Don't step in this panuntil ribs are engaged

KLIP-LOK 406

KLIP-LOK 700

Later checks =

Fixed sheets

Early checks = Later checks =

Early checks =

S t a r t

F i n i s h

Purlin





Figure 9.1.10 KLIP-LOK 406

Placing last sheet wherehalf a sheet won’t fit

Figure 9.1.9 KLIP-LOK 406Placing last sheet wherehalf a sheet will fit

KLIP-LOK 406 & 700: If the final space is more tha n half the w idt h

of a sheet, you can cut a sheet a long its leng th leaving the centre

rib comp lete (Fig ure 9.1.9). Place the cut sheet o nto a row o f

clips, as for a full sheet.

If the final space is less tha n half the w idth of a sheet , fix the

edg e o f the sheet at each purlin, with a clip tha t has b een cut in

half (Fig ure 9.1.10). Co ver the g ap with the ca pping o r flashing.

9.2 Installing KLIP-LOK wallsThe insta lla tion proc ed ure for wa lls is simila r to tha t d escribe d

for roo fs (Sect ion 9.1). To e ng ag e clips, use a rubb er ma llet

(instea d of foo t pressure).

To prevent KLIP-LOK from sliding do wnw ard in the fixing clips,

you should pierce-fix throug h ea ch sheet under the flashing o r

capping, along the top of the sheets.

K L 6 5

Sheet cut longitudinally

leaving full centre rib intact

K L 6 5

Sheet cut longitudinallyleaving full centre rib intact



Figure 9.3.2 Using a clip to start

Figure 9.3 .1Using a trim channel to start

9.3 Installing EasycladYou ca n use EASYCLAD for walls, soffit linings or ceilings. Use a

similar installation procedure for all.

EASYCLAD 2PF300 (2 pans per sheet) and 4P300 (4 pans pe r sheet)

are pierce-fixed through the underlapping e dg e o f ea ch sheet.

The fasteners in one sheet a re concea led by the lead ing e dg e o f

the next. For the last sheet, a trim channel is used.

If you are using EASYCLAD with the ribs horizontal, start installing

from the b ott om o f the wa ll so that the joints bet wee n panels

te nd to shed w at er (Fig ure 9.3.6).

You ca n use either of two metho ds to fix the first pane l: a C D39

trim channel or CD40 starting clips.

Start method 1 – Using a trim channelWith pa rticular ca re, fix a trim channe l at e ach supp ort.

Be careful to locate it correctly in relation to other parts of the

building (see Section 8.1 Position first sheet).

• Use t rim channel CD1 with EASYCLAD 4P300.

• Use trim channel CD39 with EASYCLAD 2PF300.

The first EASYCLAD pa nel is held in place by fitting it into t he fixed

trim channe l (Fig ure 9.3.1).

Start method 2 – Using clipsWith pa rticular ca re, fix starting clips a t e ach supp ort. B e ca reful

to locate them correctly in relation to other parts of the building

(see Section 8.1 Position first sheet).

Hook the lip o f an EASYCLAD sheet under t hese clips (Fig ure 9.3.2).


Support

Recommendedfastening

T r

i m

c h a

n n e l

Support

Trim channel Easyclad panel

Support

Easyclad panelCD40 Starting clip





Figure: 9.3.5 Using trim channel to finish

Figure 9.3.6 Start external walls from the bottom

Figure 9.3.4 Starting for subsequent sheets

Figure 9.3.3 Indents on edge of sheet help to locate screws

Fixing Easyclad panelsLoca te the first pa nel either in its trim cha nnel or unde r the clips

(depe nding on the start method you used).

Fix the underlapping side of the panel, to each support,

through the flat edge, with the recommended fastener

(Chapte r 3). The indenta tions along the e dg e help you locat e

the faste ners (Fig ure 9.3.3).

Fit subsequent panels by hooking the lip of your next sheet

under the folded-ba ck edg e o f the previous panel before fixing

in the sa me wa y a s b efore (Fig ure 9.3.4).

Usually the last EASYCLAD pa nel will have t o b e cut in width t o suit

the b uilding. The pa nel may req uire expo sed pierce-fixing . If you

use a trim channel at the end of the EASYCLAD walling, position it

and pierce-fix with the last pa nel (Fig ure 9.3.5).

Indentations to

locate screws

Support

Trim channel

Panelfastening

Last panel cut to width

Pierce fixingin valley

Support

Weather side Inside



Figure 9.4 .3 Place top fixing clips

Figure 9.4 .2 Placing first sheet

Figure 9.4 .1LONGLINE 305 clips

9.4 Installing LONGLINE 305 roofsFor LONG LINE 305 (standard width, fluted or tapered) use the same

general procedure described in Section 8.1 (General installation

procedure). However, at the start of installing LONG LINE 305, a ro w

of clips is fixed to the supports before the first sheet is located

over them and locked in position.

ClipsThe 2 clips are show n in Fig ure 9.4.1.

Preparation

Cut a ll starting /finishing clips and discard the unwant ed pieces(Figure 9.4.1).

As described in General installation procedure (Section 8.1):

• check f la tness , s lope and overhang, and

• orient the sheets before lif t ing. Note the overlapping

rib is towards the end of the building where you start

(Fig ure 9.4.2).

Fix the first row of clips

With pa rticular ca re, de te rmine the loca tion of t he first sheet and

mark the edge of the sheet on the purlins (see Section 8.1

Position first sheet).

Fix the first clip on the purlin. Using a string line (or the first sheet

as a straight edge) fix the other starting clips for the first sheet.

Place the first sheet1. Loca te the first sheet over the fixed clips (Fig ure 9.4.2).

2. Using a measurement from the g utter-end of the sheet

to the fascia or purlin, position the sheet so that it overhangsthe desired amount into the gutter. When setting the first

sheet, remember that it is important you keep the gutter-end

of all sheets at a constant distance from the e dg e of the

g utter or fascia.

3. Bend the t ab of a ll clips over the rib (Fig ure 10.4.3).


Top fixing clipStarting/finishing clip

Cut clip across big holeand discard section shown

with dashed line

Bend tab downover rib

Overlappingrib

Underlappingrib

D i r e c t

i o n o f

l a y i n g





Figure 9.4.6 Lock all ribs with button punch

Figure 9.4.5 Placing subsequent sheets

Figure 9.4.4 Flatten rib for top fixing clips

Fix the next (and subsequent) clips and sheets1. Using t he rib closing t oo l, flat te n the rib of the first (previous)

sheet at each purlin where the top fixing clips will fit

(Fig ure 9.4.4).

2. Place top fixing clips over ea ch flatt ened rib a nd fix to the

purlins (Figure 9.4.5). With a felt-tipped pen, make a small

mark in the pan to enable you to locate the clips in the later

locking operation with the button punch (Figure 9.4.6).

3. Place the next sheet over the edg e of the preceding sheet,

(Figure 9.4.5). Accurately position the sheet so that it

overhangs the desired amount into the gutter. It is important

that yo u keep the g utter-end o f all sheets at a constant

distance from the edg e of the g utter or fascia.

4. Fully enga g e the sheet w ith the clips, using foo t pressure on

the ribs o ver each clip. You ca n do this by wa lking along the

full leng th of the sheet with one foo t in the tray next to t he

overlapp ing rib and the o ther foot app lying pressure t o the

to p o f the interlocking ribs a t reg ular intervals.

For walling applications use a rubber mallet instead of the weight

on your feet.

Check alignment periodicallyCheck alignment as described in Section 8.1 (General procedure).

Place the last sheetAssess how t he last shee t w ill fit as d escribe d fo r installat ion o f

KLIP-LOK (Figures 9.1.8 and 9.1.9).

Fix a cut st art ing/finishing clip to the purlins.

Place the last shee t o ver the sta rting /finishing clips, flat ten the rib

at each purlin, and bend the tab of all clips over the rib.

Lock all ribsAll lapped ribs must be locked along their length, by button

punching at no g reate r than 900 mm centres (Fig ure 9.4.6). You

must butt on punch throug h the hole in each to p fixing clip—you

loca te the clip w ith the p en ma rk mad e p reviously. When

ope rating the punching too l, stand on the pan o f the o verlapp ing

sheet to ensure that the sheets are fully engag ed.

3 0 m m

Ribmust touch



Figure 10.1.2 Turning-up CUSTOM ORB

Figure 10.1.4 KLIP-LOK tool ready for turn-up

Figure 10.1.3 Turning-up ( TRIMDEK shown)

10

Ends of sheets

This chapte r describe s how you ca n treat t he end s of sheets to

maximise waterproofing, or to stop vermin entering.

10.1 Turn-upsAt the high end of roofing, wind can drive water uphill, under the

flashing o r capp ing, into a b uilding . To m inimise this prob lem,

you turn up the valleys (or pa ns) at the hig h end of roo fing . The

process is called turning-up (or stop-ending).

All roo fing o n slop es b elow 1 in 2 (25°) should b e t urned -up.

Turn-up to ols are a vailab le for a ll our roo fing p rofiles e xcep t

CUSTOM ORB and LONG LINE 305 when it is ta pered (Fig ure 10.1.1 on

the next pag e).

You can t urn-up sheet s be fore or aft er they a re fixed o n the roo f.

If you do the lat ter, you must ha ve sufficient clea rance fo r the

turn-up tool at the top e nd of the sheets (ab out 50 mm).

Turning-up CUSTOM ORB

With pliers, multi-grips or a shifting spanner closed down

to a pproximately 2 mm, grip the valley corrugations 20 mm

in from the end of the sheet and turn up as far as possible

(Fig ure 10.1.2). Be ca reful not t o te ar the shee t.

Turning-up TRIMDEK and SPANDEK

Slide the turn-up tool onto the end of the sheet as far as it will

g o. Holding t he too l ag ainst the end of the sheet, p ull the handle

to turn up the tray a bo ut 80° (Fig ure 10.1.3).

Turning-up KLIP-LOK

You g et the b est results by first cutting o ff the corner of the

down-pointing leg of each female rib. Do this before you placethe sheets on the roo f.

• With the hinged turn-up tool open: position the tool on the

sheet with the locat ing p ins hard a g ainst the e nd of the sheet.

• Hold the handles together to c lamp the tool onto the tray,

and pull them t o t urn-up the t ray 90° (Fig ure 10.1.4).

44 INSTALLATIO N—ENDS OF SHEETS

C o m p le ted t u r n - u p s

CUSTOM ORB



1 0 E n d s o f s h e e t s

INSTALLATIO N—ENDS OF SHEETS 45

Figure 10.1.5 Using the backing tool for flush turn-up on KLIP-LOK

Flush turning-up KLIP-LOK

In normal turning-up of KLIP-LOK, the tops of the ribs protrude

past t he turned up tray. Conseq uently the turn-ups cannot be

positioned hard ag ainst a fascia o r wall, or the ends of the sheets

on either side of the ridg e ca nnot b e b utte d to g ethe r. This is

usually of no consequence because the turn-up is completelycovered by a flashing or capping. However, if you want the ribs

not to protrude past the turn-up, you can make a flush turn-up.

You nee d a n extra 40 mm in sheet leng th for flush turn-ups.

1. Cut the to p of ea ch rib b efore turning-up the p ans (Fig ure

10.1.5). Turn-up t he p ans a s de scribe d b efo re.

2. Position the ba cking to ol in the tray and hold it hard ag ainst

the turn-up with a foot.

3. With a rubb er mallet, fold the protruding ‘ears’ flush aga inst

the b acking too l.

Figure 10.1.1

Turn-up and turn-down tools

4 0 m m

'Ear' flattened

'Ear' awaitingflattening

SPANDEK

TRIMDEK

Turnup

LONGLINE 305

Turn-up &turn-down

INTEGRITY 820

Turn-up &turn-down

Turnup

Turndown Backing

tool

KLIP-LOK 406



Turning-up LONGLINE 305

Flush turn-ups are usually used on LONG LINE 305 . Cut off a portion

of the fe male rib fo r at least 50 mm. For a flush turn-up, you also

need t o cut the crown of the centre rib for at lea st 50 mm.

Holding the e nd of the too l ag ainst the e nd of the sheet, pull the

hand le up 90° . If turning -up flush, fold t he p rotruding ‘ea rs’ flush

ag ainst the turn-up to ol with a rubb er ma llet (Fig ure 10.1.6).

Figure 10.2.2 Turning-down the gutter end( LONGLINE 305 shown)

Figure 10.2.1Turning-down the gutter end( TRIMDEK shown)

Figure 10.1.6 Turning up LONGLINE 305

10.2 Turning-downAt the low end of roofing, wind or capillary action can cause

wa ter to run ba ck up the unde rside of the clad ding. To minimise

this prob lem, yo u turn dow n the valleys (or pa ns) at the low end

of roo fing. The p rocess is called t urning -do wn (or lipping).

All roo fing on slope s b elow 1 in 5 (10° ) must b e turned-dow n.

Turn-do wn t oo ls a re ava ilab le for all our roofing profiles exce pt

CUSTOM ORB, SPANDEK and tapered LONG LINE 305 . The valleys of

CUSTOM ORB corrugated cladding can be turned down with

multig rips, pliers o r a shifting spa nner (Fig ure 10.1.2).

Turning -do wn is usually do ne a fte r the clad ding is fixed on t he

roo f, provided there is no o bstruction to the o peration of the

turn-down tool.

• Push the turn-down too l over the end of the tray, as far as it

will go .

• Hold the tool hard ag ainst the end of the tray and push the

handle to form a t urn-do wn ab out 20° .


E d g e o

f s h e e t

t u r n e d -

d o w n

20°

50 m m

50 m m

90°

Fold 'ears' against toolfor a flush turn-up

Part of ribremoved





Figure 10.2.3 Cut SPANDEK on low slopes.

Figure 10.3.3 Profiled closed-cell infill at eaves

Figure 10.3.2 Fitting rib end-stops afterinstallation of sheets

Figure 10.3.1Fitting rib end-stops duringinstallation of sheets

SPANDEK overlapsWhen SPANDEK is laid on slopes of 5 degrees or less, cut back

the co rner of the under-sheet, a t t he d ownhill end of t he sheet,

to bloc k cap illiary a ction (Fig ure 10.2.3).

10.3 Blocking off rib cavitiesDust, insects, b irds, rod ents a nd w ind-driven rain can ente r

a building through the cavities und er ribs. To minimise t hese

problems the cavities can be blocked off. Rib end-stops are

availab le for KLIP-LOK; strips of plastic foam ca n be used for

ot her p rofiles.

Fitting KLIP-LOK rib end-stops during sheet installationFix the rib end-stops to the side of the eaves support after the

KLIP-LOK clip ha s be en se cured in position. Alig n the rib end -stop swith the upstands of the fixing clips (Figure 10.3.1).

Fitting KLIP-LOK rib end-stops after sheet installationBend the flat of the end-stops 90° . Push an end-stop into the

space under each rib until the flat is wedged firmly between the

underside of the clad ding a nd suppo rt (Fig ure 10.3.2).

Infill stripsClosed -cell, foa m-plastic infill strips a re ava ilab le t o mat ch the

top or bo ttom profile o f our roof cladd ings.

At the lower end of cladding, the strip is sandwiched under the

roof cladd ing . Similarly, a t the upper e nd, t he strip is sand wiched

bet wee n topside of t he roofing and the underside of the flashing

or ca pping (Fig ure 10.3.3).

Don’t use infill strips that can ab sorb wa ter beca use reta ined

moisture ca n lead to det erioration of the sheet coa ting. Avoid

using infill strips ma de from, or trea ted with, flamma ble

mat erials, pa rticularly in a reas p rone t o bushfire (Section 11.8).

Where roof pitches are be low 1 in 5 (10° ), you should incorporate

infill strips to maximise waterproofness.

Approx.5 mm

Cut back corner

Approx.5 mm

E n d s

t o p s

f a s t e n

e d t o

b a t t e n

2

1



Figure 10.4.1Fixing at end laps

10.4 End-lappingBecause our roofing and walling is manufactured by continuous

processes, sheet lengths can be supplied up to the limits of

transport regulations which are frequently long enough to cover

roofs without end-lapping the sheets.

If you contemplate using sheets that are shorter than the full

span, and o verlap them, you need t o co nsider:

• the roof s lope, because it a f fects the amount of overlap

(se e Ta b le 10.4. 1);

• the method of fixing of the cladding to its supports ,

beca use it a ffects the maximum leng th of sheet

(see Se ct ion 10.5 (Expa nsion joints) a nd Tab le 10.5.2).

Table 10.4.1End-laps

Fixing methods for end lapsThere are three me thod s of fixing clad ding a t end laps.

• Pierce-fixed through crests:

Position the lap centrally over the support; and the fastening

secures bo th the lap and the cladding. Space the fasteners as for

an e nd spa n (layout in Fig ure 10.4.1.a, t erminolog y and spacing

in Tab le 2.3.1). The t hermal expa nsion is a wa y from the faste ner

and t owa rds the outer ends of the sheet run.

• Pierce-fixed through valleys:

Position the lap centrally on the support, and the fastening

secures b ot h the lap and the clad ding (Figure 10.4.1.b). The

thermal expansion is away from the faste ner and to wa rds the

outer ends o f the sheet run.

• Concealed-fixed sheets:

You ca n eithe r pierce-fix throug h the crests o r the va lleys (Figures

10.4.1.a a nd 10.4.1.b), or use clips nea r the lap (Figure 10.4.1.c).

KLIP-LOK 406 sheets deform at the clips so that sheets wo n’t nest

to g ethe r. If you use clips, the lap is placed just clea r of and onthe high side o f the c lip (Fig ure 10.4.1.c). The lap is secured with

pierce-fixing throug h the valleys. The clips a llow the shee ts to slip

when they expand with heat.


(a)

Pierce-fixed

through crest

Fastened clipon purlin

2 fasteners per trayself-drilling screws

with EPDM

sealing washer

(b)

Pierce-fixed

through valley

2 fasteners per trayself-drilling screws

with EPDM sealing washer

(c)

Concealed-fixed

with

pierce-fixing

through valley

See text forspacing of fasteners

Se e T able 10 .4.1

S e e T abl e 10 .4.1

Se e T able 10 .4.1





Figure 10.4.4 Sealing end-laps on very low pitched roofs

Figure 10.4.3 Laying sequence for end-lapped sheets

Figure 10.4.2 Remove down-turn of male ribwhen end-lapping KLIP-LOK 406

To ma ke the e nd-la pp ing o f KLIP-LOK 406 ea sier: remove, for the

length of the lap, the down-turn of the underlapping ribs of the

to p a nd b ot to m shee ts in each sheet run (Fig ure 10.4.2). The cut-

back ribs are covered by the sheets of the next sheet run.

LONG LINE 305 , can be fixed using a ny of the three met hods.

The underlapping ribs have t o b e slig htly sq uashed at the lap to

allow them to nest. An end-lap tool is available.

KLIP-LOK 700HS should not b e e nd lapped . Instead , an expansion

joint must be used. (Refer to Section 10.5 below) Ideally, long

length sheets from a mobile rollformer should be used where

po ssible a s this elimat es the need for joining .

Order of layingFor profiles o ther t han LONG LINE 305, lay e ach run of shee ts in turn

from bo tto m to to p be fore moving o n to the next run. For

LONG LINE 305, lay a ll low er run of shee ts first, the n lay the upp er

sheets (Figure 10.4.3).

Spacing of supports at end-lapsFor the maximum spacing between purlins, either side of an end

lap in a roof, use the spacing given for end spans (terminology

and spa cing in Tab le 2.3.1).

End laps in pitches less than 15 degreesEnd lap s in roofs of less tha n 1 in 4 (15° ) slope should b e se aled

with a sealant.

Use two runs of sealant (Figure 10.4.4):

• one run of sealant a t the low end of the lap (to prevent

moisture b eing d rawn in by ca pillary a ction);

• the other run at the high end (to prevent condensat ion

from running do wn the underside of the t op sheet a nd

ente ring the lap ).

When the sheet s are lappe d to g ether and fixed, the compressed

sealant should just appe ar at the end of the lap.

1. With the top sheet upside down, extrude a 3 mm bead

of sealant across the underside o f this sheet a bout 25 mmfrom the e nd.

2. Posit ion the bottom sheet , then extrude a 3 mm bead of

sealant across the to p of the sheet to encapsulate the cut end

of the underlapping sheet.

3. Turn the to p sheet o ver and fit it in place.

The side -lap be tw ee n sheets of roofing ha s a cavity to prevent

cap illary a ction be twe en a djacent sheet runs (Section 8.2).

It is important that excess sealant extruded from an end-lap

do es not enter this cavity be cause, if it d oes, mo isture t hat may

have entered the side lap will not be ab le t o d rain unimpede d

down the roof slope.

*

*

*

* Downturn of male rib removedfor length of lap

1

2

3

4

1 3

*

*

2 4

1

2

3 5

4

1 2 3

54

Profiles other than LONGLINE 305

LONGLINE 305

1

Apply 3 mm bead of sealant tounderside of overlapping sheet,

25 mm from end of sheet

2

Apply 3 mm bead of sealant

to encapsulate the cut endof the underlapping sheet

3

Turn sheetover



Table 10 .5.2 Maximum distancebetween top & bottom rows of fasteners on a sheet,before expansion joint is needed

Table 10 .5.1Thermal expansion and contraction of steel cladding

10.5 Expansion

Background on thermal expansionAll metals expand and contract with changes in temperature.

Although steel is by far the least affected of all the metals

commonly used for roof a nd w all clad ding, the change s in leng th

experienced in very long runs of roo fing are significant.

On a clear hot summer day, with no wind, the steel temperature

in roof cladding can reach approximately 50°C in COLORBOND®

Off-White, 60° C in p lain ZINCALUME® and mo re than 80°C in

COLORBOND® Ebony.

Examples of the thermal changes in lengths of steel cladding that

would result from various temperature changes in the steel are

sho wn in Ta b le 10.5.1.

The a ctual expansion or contraction betw een the end o f a sheet

and the last support would only be a fraction of the figures

shown be cause the movement in the length o f fixed cladding

would normally take place from the centre towa rds each end of

the shee t. The moveme nt at ea ch end is thus only half the tot al

expansion or contraction.

Transverse thermal e xpansion po ses no problems in ribb ed

clad ding beca use each rib a bsorbs some t ransverse movement.

Expansion joints

Thermal expansion e ffects a re mitigate d by slig ht b ending offastener shanks, thermal movement of the building structure,

and slig ht flexing o f the purlins (where they a re not restrained

by cleats o r bridg ing ). Howe ver, for very long runs of roo fing ,

you should include an expa nsion joint t o overcome linea r

thermal expansion.

Tab le 10.5.2 show s the ma ximum dista nce be tw ee n the to p and

bo ttom rows of fasteners on a sheet. If the tota l leng th of two

sheets pierce-fixed through the lap, or a single sheet exceeds

this distance , then a n expa nsion joint is neede d. There should b e

no more than one pierce-fixed end-lap between expansion joints.

An expa nsion joint involves overlap ping t he e nds o f the upp er

sheets over the e nds of t he lower sheets—but with a clearance

bet wee n them (ab out 15 mm). A typical overlap is 250 mm

(this o verlap is not the same a s the overhang in Tab le 2.3.1

which doe s not ap ply to e xpansion joints). The cleara nce is

usually create d b y having all the p urlins for the roo fing on t he

high side of the joint, higher than the roofing on the low side

of t he joint. An extra purlin is neede d at the joint. A ba ffle

flashing p rovide s we at herproofing . See Fig ure 10.5.1.

Where the re is a risk of high winds, or t he ribs are b ig , you ma y

need extra flashing, including closed-cell foam plastic infill strips.






Figure 10.6.1Methods of stiffening roof overhangs

Figure 10.5.1

Expansion joint detail

Flashings provide the essential weatherproofing at theedges, and they sharpen the image of the finished job.

10.6 Roof overhang with edge stiffener For the stiffened overhang s listed in Tab le 2.3.1, you nee d to

stiffen the g utter ends of the roo fing.

Our SHEERLINE gutter, fixed through the return lip to the underside

of roo fing a t 200 mm centres will provide t he req uired stiffening .

Alternatively, you can use a 50 x 50 x 1.2 mm steel angle f ixed at

200 mm centres to the underside of the roofing ab out 50 mm

from the e nd.

250 mm

minimum o verlap

Baffle flashing.

Notch overribs & fasten tounderlappingsheet

25 mm min.clearance

300 mm

Trays turned up

Depth of

sheetingplus

15 mm

Foam infillcommonly usedwith INTEGRITY

Sheetingturned down

Steel angle 50 x 50 x 1.2 mmfixed to underside of roofing(200 mm centres).Gutter may be fixed to angle.

Sheerline gutter fixed to underside of roofing(200 mm centres)

O verhang

O v e r h a n

g



Figure 11.2.1Typical longitudinal flashings

Flashings and cappings are strips of metal formed to

wea therproof the edg es of roofing a nd wa lling. For the purposes

of t his cha pt er, only the te rm fla shing is used . The fo llow ing

sections should be considered as a guide only. For a

comp rehensive acco unt of flashing g uide lines, refer to HB39-

1997.

Similar methods of flashing are used for different cladding-

profiles. You ca n a da pt the principles to suit yo ur app licat ion.

In all cases it is important to have ample cover provided by the

flashing and proper turn-up of the cladding underneath.

Be careful when moving bet wee n supports. Do not wa lk in the

pan immediately adjacent to flashings or translucent sheeting.

Walk at least one pan away.

BlueScope Lysaght has a range of standard flashings. We can alsosupply custom flashings to your req uirements – ask your loca l

service ce ntre for d eta ils.

11.1 MaterialsIt is very important that flashings be made from materials that are

comp at ible w ith t he clad ding (Section 2.10).

Lea d flashing is not recommend ed , how ever it will usually be

retained when re-roofing, because it is usually cemented into the

structure. In these case s:

• the top surface of the lead f lashing must be painted with agood quality exterior paint system (to limit contamination

with lea d co mpo unds in wat er running o ff the flashing );

and

• there must be a ba rrier between the lead f lashing and the

clad ding: either a plastic strip (such as po lythene

dampcourse), or paint.

Fla shings sho uld co nform t o AS/NZS 2179.1:1994, a nd be

comp at ible w ith t he clad ding (Section 2.10).

Mate rials for flashing s a re a vailab le in ZINCALUME® or COLORBOND

®

finishes.

11.2 Longitudinal flashingsLongitudinal flashings run parallel to the pans or valleys, and are

ma de to suit the clad ding profile (Fig ure 11.2.1). They sho uld

have an e dg e turned-do wn to dip into t he pa n or valley.

Flashing Cover

The minimum recomme nde d cover o f longitudinal flashings o ver

cladding (as taken from HB39-1997) should be as follows:

11

Flashings

52 INSTALLATIO N—FLASHING S

Pierce fixed roof sheet 150mm min.

Concea led fixed roo f sheet Into full pan

(2/3 pa n co vered )



1 1 F l a s h i n g s

INSTALLATIO N—FLASHING S 53

Figure 11.3.1Typical transverse flashings

Fixing of Flashings

Long itudinal flashings shall be fa stene d at maximum 500mm

centres.

11.3 Transverse flashings

Transverse flashing s run across the p a ns or valleys (Fig ure 11.3.1).

They usually have a stiffening lip, a long the low er ed g e, w hich is

turned-dow n to dip into the p an o r valley. To ma ximise w ea ther

proofing, the bent lip is fashioned to fit the profile.

The t urn-do wn fo r transverse flashings fo r CUSTOM ORB and

CUSTOM BLUE ORB can be fashioned to fit the profile by either

notching or scribing to match the corrugations, or lightly dressed

into the valleys. The t ype of fashioning (if a ny) de pend s upon

profile shape and the type of material used to flash. Fashioning is

preferred for low-slop e roo fs.

The t urn-do wn fo r transverse flashing s for wide pa nned clad ding

is always notched or scribed to fit over the ribs.

Flashing Cover

Lysaght p rod uces a range of standa rd flashings (hip, ba rg e,

ap ron). To increa se w ea thertight ness, BlueScope Lysag ht

recommends you maximise the overlap between flashings and

claddings.

Fixing of Flashings

Transverse flashings sha ll be faste ned in accorda nce w ith HB39-

1997, as detailed below.

Notching toolsHand-ope rated notching t oo ls cut one notch at a t ime. Each tool

mat ches only one clad ding profile. There are tw o typ es of to ol;

their use depe nds on whether or not the edg e o f the flashing ha s

first been bent down (Figure 11.3.2).

Table 11 .3.1Notching tools

Every 4th rib

Every 3rd rib

Every rib

Profile Recommended Fixing SpacingCustom Orb/Custom Blue O rb Every 4th rib

Integ rity 820 Every rib

Klip-lik 406 Every rib

Klip -lo k 700 Hig h S tre ng th Eve ry rib

Long line 305 Every rib

Spa ndek Every 3rd rib

Trimdek Every rib

The a bo ve fastener spacing relates to the stitching o f flashings t o sheet ing.

It d oes not constitute the minimum number of faste ners req uired to fix the

sheeting to purlins.



Figure 11.3.2 Using notching tools

Using notching toolsAfter the clad ding is fixed a nd t he turn-ups finished, p roceed

as follows.

• Place a f lashing with the notch-edg e resting on the ribs.

• Locate your notching tool over a rib with the notching head

ag ainst the flashing.

VERTICAL TOOL: The bod y locat es along the rib.

HORIZONTAL TOO L: the lugs on the underside locates on top

of the rib.

• Ra ise the hand le to open the too l and :

VERTICAL TOOL: lift the flashing into the mo uth of the too l;

HORIZONTAL TOO L: slide the mouth of the tool over the edg e

of the flashing as far as it will go.

• Push down on the handle to perform the notching.

• Repeat for all ribs, checking in each case that the f lashing is

correctly positioned .

• If you are using a horizontal tool, bend down the tongues

bet wee n the notches over a suitab le straig ht edg e (such as a

piece o f timbe r).

Notching with tinsnipsIf notching tools are not available, flashings can be notched to

the rib profile w ith tinsnips (Fig ure 11.3.3). The p roced ure is

sometimes known as scribing. After the cladding is fixed and the

turn-ups finished, procee d as follow s.

• P lace the f lashing with the turned-down edg e rest ing

on the ribs.

• Mark out the notching using a template positioned over

each rib.

• Cut the notches with t insnips .

This proce dure is also used fo r hip ca pp ings.

Fasteners for transverse flashingsYou must prop erly fix bo th flashing s and the e nds o f all sheet s.

Where the clad ding is pierce-fixed through crests, a nd t he

po sition of t he purlin allow s it, t he fa stene rs used to fix the

sheet s, should also fix the flashing s.

On all other installations, pierce-fix your flashing to the ribs orcrests of t he sheets.






Figure 11.3.3 Using a template to mark out for notching with tinsnips

Tab le 3.8.1 show s the fa stene rs and t heir locations for the end s of

sheets (Figure 11.3.1).

Joining flashingsThe o verlap s of t ransverse flashing s should be sea led with a

recommended sealant and fastened. Before finally positioning

and fixing the lap, turn over the top p iece and a pply a 3 mm

bea d o f sealant across the flashing, a bo ut 12 mm from the e nd.

Figure 11.4.1

Typical flashing at changes of pitch

11.4 Flashing at change of pitch



Figure 11.5.1Flashing method 1: Head gutter

Figure 11.5.2 Flashing method 2: Flat tray and sleeve

11.5 Flashing large roof penetrationsPenetrations through ribbed cladding block the valleys

(or pans), and thus affect the free flow of rainwater down a roof.All flashings have to weatherproof the cladding – but on the

uphill side of large penetrations, they also have to channel

rainwater sideways into valleys that run unobstructed

to the eaves.

Four methods are described here. In all methods the ends of cut

ribs may be closed off with caps on the outside of the rib, or with

plugs inside the ribs. Plugs must be used on side-laps to allow

the anti-capillary cavity to drain.

Note: For masonry construction, Building Code Australia

(BCA) requires the use of Damp Proof Course (DPC) to ensureweatherproofing. For acceptable methods see BCA section on

weatherproofing masonry.

Support framingWherever one or more of the sheet ribs are cut, you must

provide framing to support the cut ends of the roof cladding

each side of the penetration.

Existing flashingIf you have to re-use lead flashings that are built into the

structure, special protection is needed (Section 11.1).

Method 1: Head gutter and apron flashingsThis is often the simplest method, and commonly used for

existing protrusions (Figure 11.5.1).

Method 2: Flat tray and sleeveTo avoid fitting and sealing end caps to all the sheet ribs on the

low side of the penetration, an apron flashing can be fitted to the

sleeve and sealed to the tray each side.

56 INSTALLATION—FLASHINGS





Figure 11.5.3 Flashing method 3:

Tray gutter for steeper roofs

Figure 11.5.4 Penetrations close to ridge capping

Method 3: Tray gutter for steeper roofsIf the roo f pitch is mo re tha n, say 1 in 12 (5° ), you cut t he roo f

cladding sufficiently high above the penetration to allow a tray

g utter to raise rainwater over the to p o f the sheet ribs a nd d ivert

it around the penetration (Figure 11.5.3).

Method 4: Penetration close to ridge cappingIf a roof penetration is close to a ridge capping (or flashing

above the penetration), you can fit a simple flat tray, on top of

the roofing, so t hat it extends from under the capp ing d own to a

slee ve a round the pene trat ion. A similar installat ion is show n in

Fig ure 11.6.3).



Figure 11.6.2 Small penetration with sleeve

Figure 11.6.1Small penetration

with metal skirt and sleeve

11.6 Flashing small roof penetrationsA flang ed cylindrical slee ve is a fa irly simple met hod of flashing

around small penetrat ions (such as pipe p enet rations) which fit

bet wee n the ribs of a roo f sheet, or penet rate o nly a sing le rib.

Three metho ds a re de scribe d here. Wherever roo fing is cut,

you must consider providing extra support for the roofing above

and below the penetration.

Method 1: Tapered metal skirt and sleeveThis met hod uses pa rts custom -fab rica te d from met al. There is no

positive seal between inside the building and the outside

a tmo sphe re (Fig ure 11.6.1).

Method 2: sleeveThis is oft en t he simplest me tho d (Fig ure 11.6.2). Flexible flang ed

sleeves can b e b ought for flashing around penetrations of at least

350 mm diameter. They overcome the prob lem o f capping and

sea ling the o pen end s of cut ribs. is commo nly used, thoug h

silicone sealant has a wider operating tempe rature range a nd is

available in a wider range of colours.

The flang e around the base o f the sleeve can be conto ured by

hand t o match the clad ding profile b efore it is sealed a nd fixed

to the cladding.

Be ca reful not to da m any valleys or pans so tha t rainwa ter can

drain freely from the high side of the roof penetration. Moisture

held in such areas ca n cause d ete rioration of the sheet coa ting,

reduced life expecta ncy or poor app ea rance.

Where damming of any valley or tray is unavoidable, due to

the size of the pipe penetration, treat the installation as a large

penetration (Section 11.5).

Copper penetrationsAll copper pipe penetrations through ZINCALUME

® or COLORBOND®

clad ding must b e p hysically and electrically isolate d from t he

clad ding. This can b e d one by using a sleeve o f , PVC po lythene ,

or similar plastic that is also ultra-violet stable.






Figure 11.7.1Typical header and sill flashing: profile running horizontally (elevation)

11.7 Flashing wallsCladding is usually installed with the profile running vertically or

horizontally, though sheets have been laid diagonally—the choice

is aesthetic.

Wind can drive rain hard a g ainst wa ll flashings, so it is important

that you pay a ttention to the d eta iling of flashings a round

windows, doors, re-entrant and external corners, to ensure you

g et a wat ertig ht building . You also wa nt a nea t ap pea rance.

We make wall flashings for some wall claddings (like EASYCLAD

and MINI ORB) which are some times called trims. Where these are

not suitable, custom-made flashings can be easily produced

follow ing the g eneral principles de scribe d in this section.

Walling profile running horizontally• It is usual to lay the f irst sheet at t he bottom of a wa ll and

work upwa rds to wa rds the eaves. You wa nt the w indow and

do or flashing s to fit p roperly into the valleys, so you should

locate the first sheet relative to the heads and sills of doors

and windo ws. Thus, you first have t o d ecide where the

clad ding will eventually be locate d a t the hea ds of d oorwa ys

and a t the hea ds and sills of windo ws be fore you place the

first sheet .

• Where possible, select the vertical size of windows so that theflashings a t b ot h hea ds a nd sills will coincide nea tly with the

pitch of your profile (Figure 11.7.1).

• Be sure that the crests of the profile align with each other on

ad jace nt wa lls, either side of a corner—this ensures that

horizontal fashings fit properly into all valleys.

• Where valleys create a void a t f lashings, use closed-cell foam

pla st ic infill (Figure 10.3.3).

• Where wind-driven rain can be expected, turn back the edg es

of flashing to restrict water movement past the flashing.



Figure 11.7.3 Typical flashing at window and door jambs: profile running horizontally

Figure 11.7.2 Typical corner flashings: profile running horizontally (plan view)






Figure 11.8.1Typical protection from sparks at ridge

11.8 Bushfire protectionAS 3959—1999 sets out req uirements for the d esign a nd

construction of buildings in bushfire-prone areas. It calls for

flashings to be bed ded on fire resistant insulation ma terial.

Be sure tha t flashing s fit close ly. Transverse fla shings sho uld b e

notched or scribed (Figures 11.3.1 and 11.8.1)

Walling profile running verticallyFlashings a re g enerally ea sier on job s whe re the profile runs

vertically (Figures 11.7.4 and 11.7.5).

Figure 11.7.5 Typical corner flashings: profile running vertically (plan). J amb flashings follow same principle.

Figure 11.7.4 Typical header and sill flashing: profile running vertically (elevation)



BlueScope LysaghtAmongst the publications of BlueScope Lysaght,

the following are particularly appropriate.

Technical bulletins (General)

TB-1 Steel roofing and walling products: Selection

guide

TB-2 Overpainting and restoration of COLORBOND

®

prepainted steel sheet

TB-4 Maintenance of COLORBOND® prepainted steel

roofing

TB-5 Swarf staining of steel roofing and walling profiles

TB-8 Flashing materials for ZINCALUME® & COLORBOND

®

steel sheet

TB-13 General guide to good practice in the use of

steel roofing and walling products

TB-15 Recommended steel gutter systems

TB-16 Fasteners for roofing and walling product:

Selection guide

TB-17 Selection guide for galvanised steel purlin

products

Technical bulletins (Corrosion)

CTB-1 General introduction

CTB-8 Building applications

CTB-10 Roof penetrations

CTB-11 Condensation

CTB-12 Dissimilar metals

CTB-13 Contact with timber

CTB-15 Acid cleaning brickwork

CTB-16 Immersion

CTB-17 Following trades

CTB-18 Painting lead flashing

References

Australian standardsAS 1170.1 SAA Loading Code: Dead and live loads and

load combinations

AS 1170.2—1989 SAA Loading Code: Wind loads

AS 1170.3—1989 SAA Loading Code: Snow loads (and

the Supplement)

AS 1170.4—1989 SAA Loading Code: Earthquake loads

(and the Supplement)

AS 1397—2001 Steel sheet and strip—Hot-dipped zinc-

coated or aluminium/zinc-coated

AS 1562.1—1992 Design and installation of sheet roof

and wall cladding: Metal

AS/NZS 2179.1:1994 Specification for rainwater goods,

accessories and fasteners: Metal shape or sheet

rainwater goods, and metal accessories and

fasteners

AS 2334—1980 Steel nails—Metric series

AS 2627.1—1993 Thermal insulation of dwellings

AS/NZS 2728: 1997 Prefinished/prepainted sheet metal

products for interior/exterior building applications—

Performance requirements

AS 3500.3—1990 National plumbing and drainage

code—Part 3: Stormwater drainage

AS 3566—1988 Screws—Self-drilling—For the building

and construction industries

AS 3959—1999 Construction of buildings in bushfire-

prone areas

AS 4040.1—1992 Methods of testing sheet roof andwall cladding—Resistance to concentrated loads

AS 4040.2—1992 Resistance to wind pressures for non-

cyclone regions

AS 4055—1992 Wind loads for housing

AS/NZS 4256—1994 Glass fibre reinforced polyester

SAA HB39—1997 Installation code for metal roof and

wall cladding

SAA HB106—1998 Guidelines for the design of

structures in snow areas.




R e f e r e n c e s &

I n d e x

INDEX 63

at small penetrations 58

sleeve 58

longitudinal 52

materials 52

notching 55

notching too ls 53

not ching with tinsnips 54

transverse 53

walls 59

Ggutters

areas 26

typical types 25

Hhand ling prod ucts 27

hea t control 20

holes 27

Iincompatibility. See compa tibility of

materialsinfill st rips 47

information 1

installation

alig nment of roofing 32

concealed-fixing 35

Easyc lad Hi-Ten 40

Kilp-Lok on w a lls 39

Klip-Lok 35

Longline 305 42

pierce-fixed 31

crest fixing 33

Mini Orb 34

procedure 31

side-laps 33, 34va lley fixing 34

insulation

faste ner length 11

heat 20

materials 22

noise 22

thickness limita tions 23

Llengths

roofing 3

roofing drainag e 8

transportation 4lifting roofing 31

Eeffective roof leng ths for drainag e 8

end-lapping 48

expansion 50

fixing method s 48

low pitches 49

orde r of laying sheets 49

spacing of supports 49

ends of sheets 44

bloc king rib cavities 47

end-lapping 48overhang , stiffened 51

turn do wns 46

turn ups 44

environmenta l cond itions 4

expansion 50

expa nsion joints 50

Ffasteners 9

features tab le 10

for acce ssories 11

for Custom Blue Orb 12

for Custom Orb 12for Easyclad 12

for insulation 11

for Integ rity 820 13

fo r Klip-Lok 13

for Long line 13

for Mini Orb 13

for Multiclad 14

for Multiline 900 14

for Pa nelrib 14

for side-lap s 11

for Spa nd ek Hi-te n 15

for thicker ste els 11

for transve rse flashings 54

fo r Trimdek Hi-te n 15fo r Trimwall 15

fo r Wallclad 15

identification 10

materials 9

q uantity required 11

rivets, sea ling 29

screw s, sett ing tig htness 10

sea ling wa shers 9

wa shers, sea ling 9

finishes 2

flashings 52

at change o f roof pitch 55

at copper penetrations 58

at large penetrations 56

Aalig nment o f roo fing

Klip-Lok 700HS 38

pierced-fixed 32

Australian Standa rds 62

Bblocking rib ca vities 47

bullnose d (see pre-curved roo fs) 18

bushfire protect ion 61

Ccappings. See flashings

care of products 27

clea n up 28

clips

for Easyclad 40

fo r Klip-Lok 35

for Long line 305 42

req uired q uantities 11

coa tings, stripa ble 28

COLORBOND® 2

and painting 4avoiding rust stains 28

compa tibility of materials 4

drainag e tab le 5

concealed-fixing. See installation

condensation 21

crest fixing 33

curving. See roof: curved

cutting clad ding 27

cyclonic

anchoring foot ing s 3

conditions 1

DDektite flashings 58

design 2

roof drainag e 24

roofs 2

walls 2

dissimilar metals. See compatibility

of materials

do wnpipe size. See roof: d rainag e:

downpipe size

drainag e o f roofs. See roof: drainage :

design

Index



64 INDEX

rust stains

avoiding 28

wa rn othe r contract ors 28

Ssafety 27

guardrails 27

lifting roofing 31

wa lking on roo fs 27

screws. See also fasteners

sett ing tightne ss 10

sea lant use 29

sealants 28

sea ling wa shers 9

selection of products 2

silicone sea lant . See sealants

skylighting 23solvents 30

spa cing definitions 6

Spa nde k overlap s 47

specifications

for profiles (ta bles) 6

materials 2

storag e of prod ucts 27

stripa ble coa tings 28

support spacings 3

Ttape red roofing 19

te chnical bullet ins 62testing performance 3

thermal transmission (see hea t

control) 20

translucent cladding. See skyligh ting

transportation 4

trims (see flashing s, wa lls) 59

turn do wns 46

turn-ups 44

Vva lley fixing 34

Wwa lking on roo fs 27

wa ll flashings 59

wa lls, de sig n 2

warranties 1

wa shers, sea ling 9

Mmaintenance 29

marking out 27

materials

clad ding specificat ions 2

for faste ners 9

for flashings 52

for insulat ion 22

Mini O rb 34

Nnails. See fasteners

noise reduction 22

notching. See flashings

Ppe ncils for marking out 27

performance tests 3

pierce -fixing . See installation

pitches of roo fs 3

products

profiles 6

selection 2

profiles of clad dings 6

Qq uantities of clips &fa stene rs 11

Rrainfall intensities ta ble 25

references 62

rivets. See fasteners

roof

alig nment of sheet s 32

curved 16

bullnosed (see pre-curved

roofs) 18

cappe d bent ribed 19

pre-curved 18

spring-arched 17

spring-curved 18

spring-curved-ridge 16design 2

drainage

design 24

do wnpipe locating 26

dow npipe size 25, 26

g utter areas &d ownpipes 26

roof walling installation entire manual

Documents