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LokRolld e s i g n a n d i n s t a l l a t i o n g u i d e

R IGI S SMETSY

R IGI S SMETSY

LOKROLL - Standing seam roof system

Contents

Page 1-3 Introduction / Fixing tools

Page 4-5 Liner sheets

Page 6 General Construction

Page 7 Structural Deck Construction

Page 8 Perforated Liner Construction

Page 9-11 Standard Components

Page 12-13 Components for Illustrated Constructions

Page 14 Properties

Page 15 Aluminium Paint Systems

Page 16 Load Span Tables

Page 17 Fixing Capacities

Page 18 Vapour Control

Page 19 Fire

0 Expansion

Page 21 Production Tolerances

Page 22-23 Rooflights

Page 24-38 Inspection & Maintenance / Health and Safety / Handling

Page 39 Miscellaneous

Page 40-42 Installation - Measurement & Setting Out

Page 43-44 Verge details

Page 45 End Lap System Detail

Page 46 Ridge Detail

Page 47 Eaves Detail


Lokroll Dimensions

Roll Locking Action

Note: Template required for correct fixing, see page 2

1

The Lokroll system is available in 0.7 mm gauge plastisol/aluzinc steel or 0.9 and 1.2 mm gauge aluminium. Besides supplying the latter in plain mill finish or stucco embossed, other finishes and colours are available to add to the overall aesthetic appeal of the roof application as well as prolonging the life of the sheet.

Each sheet is positively anchored to the structure by means of a screw fastener in the concealed channel. The following sheet engages with the under lap rib and ‘rolls’ into its final location. The fixing screws are fully protected from the weather and are hidden from sight.

Corogrid Bar & BracketThe Corogrid brackets and support bar are manufactured from high quality 1.25 mm hot-dipped galvanised mild steel to BS EN 10143: 1993. The brackets, which incorporate a neoprene thermal break to reduce the effect of thermal bridging, are available in a range of heights to suit different thicknesses of insulation (or the pitch or roof required). In refurbishment applications the profile depth of the existing cladding will also determine the height of the bracket required.

ProfileThe Lokroll system is produced in a 500 mm cover

width.

Roof PitchBecause of the true standing seam concept of the Lokroll system the following pitches may be

maintained:

NB. Above falls must be achieved after consideration of loadings and deflection. Ensure gutter straps and edge flashing details at the eaves do not reduce the above roof pitches to avoid ponding of water at the sheet edge

Fixing ToolsFixing tools can be supplied with every contract and are refundable upon return.

It is essential that the following tools are supplied with every contract for Lokroll to ensure that the product is fixed correctly. It is important that they are utilised in the correct manner to guarantee absolute efficiency.

Profile Template

The template is manufactured in plastic and is positioned adjacent to the fixing point when the sheet is being fixed to ensure there is no spread of cover width.

It is essential that the template is used correctly.

To assist the operator, this tool is handed and the underlap side is clearly marked. It is imperative that this tool be used the correct way around. The number of templates required depends on the sheet length.

IntroductionContinuous sheet ridge to eaves 1.5°

Welded end lap joint 1.5°

Welded roof penetrations 1.5°

End lap joints with sealants and fixings 5.0°

2


Turn - up - Tool

Turn - down - Tool

Specifically designed to turn down the

pan of the profile at the eaves detail.

Turndown must be a minimum of 10˚

TURN

UP

TURN UP

TURN DOWN

Specifically designed to turn up the pan

of the profile at the ridge/hip detail.

3

Liner Sheet 20/200/1000

The 20/200/1000 profiled liner, with its 1000mm cover width provides an extremely cost effective solution in applications where the loading/span requirements are kept to a minimum. Available in 0.5mm/0.7mm gauge steel or 0.5mm/0.7mm gauge aluminium in a variety of finishes (depending on order quantity) the liner sheets can be supplied with either pan or fully perforated.

20/200 is available crimp curved if required, contact o u r Technical Department for details.

Walking boards should be used during installation, as they are not intended to support foot traffic. Fix the 20/200/1000 profiled liner sheet to the purlins with self-drilling screws in alternate troughs. Stitch side laps through crown of profile at 450mm centres and then seal side laps with continuous 50mm x 1mm Polybond Tape to provide air seal. Lap end laps by 150 mm and seal with 9 x 3 mm butyl tape or 3mm mastic bead.

When using a perforated liner or in high humidity applications a vapour barrier will be required to act as an air seal. End/side laps, ridge, eaves, verges and all penetrations should be sealed with continuous EPDM butyl tape.

4

30 30 20

1000

143

200

30

20


Liner Sheet 20/100/1000

The 20/100/1000 profiled liner is particularly suited to the Lokroll system. Available in 0.7mm gauge steel or 0.7mm / 0.9mm gauge aluminium in a variety of finishes (depending on order quantity) the liner sheets can be

supplied with either pan or fully perforated.

Walking boards should be used during installation, as they are not intended to support foot traffic. Fix the 20/100/1000 profiled liner sheet to the purlins with self-drilling screws in alternate troughs. Stitch side laps through crown of profile at 450mm centres and then seal side laps with continuous 50mm x 1mm Polybond Tape to provide air seal. Lap end laps by 150 mm and seal with 9 x 3 mm butyl tape or 3mm mastic bead.

When using a perforated liner or in high humidity applications a vapour barrier will be required to act as an air seal. End/side laps, ridge, eaves, verges and all penetrations should be sealed with continuous EPDM butyl tape.

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BARRIER TAPE (When Lokroll is used in aluminium)

A closed cell foam tape 50mm wide, 3mm thick, supplied in 25 metre long rolls, to provide a thermal break between purlins and Lokroll cladding. Required for single skin and built up insulated applications. Wider tapes can be supplied for larger

hot rolled heavy duty steel support sections.

RIDGE FILLER AND SHROUD

A pressed aluminium section designed to fill and close off the open pan of the Lokroll. Holes are added to assist trickle ventilation. Supplied in mill finish, or coloured to match the external Lokroll coloured sheet. For angled ridges, or hips, special skew cut

ridge closures can be supplied.

RIDGE RETAINER

A 3 metre long aluminium extrusion to locate and retain the ridge closure into position. Fixed to the Lokroll standing seam with two Bulbtite rivets. Supplied in mill finish. Sections to be joined over

the Lokroll standing seam

RIDGE SUPPORT ZED

A 3 metre long aluminium pressing which supports the large verge flashings

EAVES FILLER

To close the corrugations in the profile, it is held in place by the drip angle

50

3

Standard Components

9

EAVES DRIP ANGLE

A 3 metre long aluminium extrusion, to locate the eaves closure, deflect wind blown rain and to strengthen the Lokroll sheet end. The eaves drip angle must always be fitted. Supplied in mill finish, it is fitted with a minimum of 3 bulbtite rivets.

FIXING SCREW/WASHERS

(Only used in aluminium construction)

An aluminium spreader washer, 80mm long, cut from an aluminium extrusion, strengthens the Lokroll fixing channel giving support for the screws above the

slotted holes. Supplied in mill finish.

A nylon bearing washer, 50mm diameter, helps to overcome frictional drag effects between the Lokroll sheet and thermal barrier tape (or breather membrane for a built up insulated application).

Fixing screws are stainless steel Corofix LSSF32, complete with a 16mm diameter sealing washer.

VAPOUR BARRIER

W e supply two types of vapour barrier. ULTRA2000 is a 2 x 50m, virgin polyethylene with a reinforcing grid of high density polyethylene. Supplied in rolls, 2 metres wide and 50 metres long. Weight per roll is 50.5 Kg (0.25 Kg/m2). This is generally used in conjunction with perforated liner panel systems.

An enhanced version of vapour barrier is Talfoil - an aluminium encapsulated membrane for use in areas of high humidity e.g. swimming pools.

RIVETS

Bulbtite, or Avdel TLR, type supplied in boxes of 100. Colour caps can be supplied to match the Lokroll coloured sheet. These rivets are required for fixing

the ridge retainer, gable starter, gable support

2

30

60

10


40mm

40mm

VAPOUR BARRIER TAPE

All joints of the vapour barrier and edges at eaves,

ridge and verge position to be sealed with butyl mastic

tape. Supplied in 22 metre long rolls 12mm wide and

2mm thick.

BREATHER MEMBRANE

The breather membrane is a spun bonded, micro

perforated, vapour permeable membrane supplied in

rolls up to 2.6 metres wide and 100 metres long.

COROGRID SPACER BAR

Corogrid support bars are manufactured from high

quality 1.25 mm Z35 hot-dip galvanised mild steel to

BS EN 10143 : 1993. The support bars feature a

unique dimpled fixing zone, which ensures fastener

security. Available in lengths of 1, 2 and 3 metres

(effective length) the bars have a spigot end to

maintain a continuous level of support.

COROGRID BRACKET

Corogrid brackets are manufactured from high quality

1.5 mm hot-dip galvanised mild steel to BS EN 10143

: 1993 (formerly BS 2989 : 1992). The base of the

bracket incorporates a neoprene thermal break which

minimises thermal bridging and acts as a vapour seal.

Brackets are available in a range of heights from

60mm to 250mm which is usually determined by the

thickness of insulation specified or pitch of roof

required. In refurbishment applications the profile

depth of the existing cladding will also determine the

height of bracket required.

Standard Bracket Heights (mm): 60, 80, 100, 120, 140,

160, 180, 200, 220, and 240.

Other bracket heights are available subject to quantity

11

Component Product Weight (kg/lm)

Top Sheet (0.7mm steel ) RigiSystems Lokroll 4.10

Top Sheet (0.9mm aluminium) RigiSystems Lokroll 1.82

Liner Sheet ( 0.4mm steel ) 20 / 200 / 1000 3.77

Liner Sheet ( 0.7mm steel ) 20 / 100 / 1000 6.60

Liner Sheet ( 0.9mm aluminium ) 20 / 100 / 1000 2.92

Component Description Code

Bar & Bracket Corogrid

Tissue Faced Rockwool Acoustic Slab (60 kg / m3 ) Thickness - 30mm TFVH/65/12060

Insulation to a 0.040 Lambda value (0.25 ‘U’ Value)

200mm thickness

Vapour Barrier 2m Wide x 50m Long Roll VBAR/01/02050

Polyethylene

Breather Membrane Standard Roll Size 1.6m x 100m

(other sizes available) BTHR/03/16100

Fixing Steel Lokroll to Bar and Bracket 2 No. Carbon Steel Self

or Main Purlins Drilling Screws 5.5mm FIX/LCS/55025

long with 16mm diameter

Twinseal Washers

Fixing Aluminium Lokroll to Bar and Bracket 2 No. Stainless Steel Self

or Main Purlins Drilling Screws 5.5mm FIX/LSS/55025

long with 16mm diameter

Twinseal Washer

Fixing Steel Liner to Thin Gauge Purlins 2 No. Carbon Steel Self Drilling

(1.4mm – 3.6mm thick) Screws 5.5mm x 32mm long FIXLCS/55038

Fixing Aluminium Liner to Thin Gauge Purlins 2 No. Stainless Steel Self

(1.4mm – 3.6mm thick) Drilling Screws FIXLSS/55030

5.5mm x 30mm long

Fixing Corogrid Bar and Bracket to Steel / Aluminium 2 No. Stainless Steel Self Drilling

Liner + Purlin (1.4mm – 3.6mm thick) Screws 6.3mm x 35mm long

with 16mm diameter Twinseal FIXLCS/55025

Washer and nylon bearing pad

Components for Illustrated Constructions

12


Stitching Steel Liner Sheet Self Drilling Stitcher Screws

6.3mm x 22mm long FIXSCS/63025

Stitching Aluminium Liner Sheet Aluminium Bulbtite Rivets

4.8mm x 12mm FIXRSS/48012

Grip Range 0.5mm - 6.4mm

Jointing Tape for Vapour Barrier 12mm Wide x 2mm Thick

Cross Linked Butyl Rubber VBAR/02/12222

22.5m long roll

Thermal Barrier Tape (for aluminium construction) Flexible tape 75mm wide x 33mm long TAPE/FX/75X33

Isolation Tape when using single skin Barrier Tape

Aluminium Lokroll to Galvanised Purlins 50mm Wide x 3m long roll BARR/01/50320

End Lap Sealant for Steel / Aluminium RigiSystems Lokroll Butyl Mastic

(> 50 roof - pitch) 19mm Wide x 3mm Thick TAPE/BM/06X02

Component Description Code)

13

Properties

Aluminium LokrollLokroll sheets are manufactured from aluminium alloy of the 3000 series containing magnesium and manganese for increased strength and

durability.

The alloy is designated as:

• EN AW- 3004 (Al Mn1 Mg1) or

• EN AW- 3105 H28 (Al Mn 1 Mg 0.5): to

BS EN 485-2 : 1995.

Minimum 0.2% proof stress being 200N/mm2.

Steel LokrollThe substrate used is hot dipped galvanised steel with a coating mass of 275g/m2 and a minimum yield strength of 220 N / mm2 to BS EN 10147.

The Table below Shows Comparison of BasicProperties of Both Metals

Density Modulus of Thermal Thermal Expansion Melting Point

Material (kg/m3) Elasticity (kN/cm2) Conductivity (W/m°C) in mm per°C (°C)

Aluminium 2705 6900 214 24 x 10-6 650

Steel 7850 21000 55 12 x 10-6 1900

For properties of Aluzinc, Stainless Steel, Zinc and Copper contact Technical.

14


Although aluminium is both stable and durable in most

environments, there may be the need to apply a colour

paint finish for very aggressive situations or for

aesthetic reasons, below are listed a few paint coat

options:

PVF2

This product is a primer with a Class 1 polyvinylidene

fluoride/acrylic paint system applied to a coating

thickness of 25mm. It is an extremely durable system,

giving excellent flexibility and chemical resistance,

combined with the highest possible performance with

respect to gloss retention, chalking and colour change.

However, it is easily scratched and must be handled

with care. It can be supplied with a strippable plastic

film as additional protection for site use.

ARS (Abrasion Resistant Surface)

The system is a primer with a polyamide modified

polyurethane paint to a coating thickness of 28mm,

this has very good durability and weatherability. Its

ultra violet performance is superior to that of plain

polyester. The main benefit of the system is that it

gives a surface that is highly resistant to abrasion.

Colourbond

This is an alkyd-amino based coating of 40mm

thickness applied by spray with electro-static attraction

to the metal and finally stove cured. This results in

some ‘wrap around’ at the edges, which ensures that

there are no exposed cut edges and is therefore useful

in aggressive environments. Due to the nature of the

process, sheets are limited to a maximum length of

6m.

Backing Coat

This is normally a 2mm lacquer coating with 6mm

chromated epoxy coating providing limited protection

and preventing damage to the top coat when in the

coil or in stacks of flats / sheets. It is not intended for

external exposure.

The ‘Decorative Life’ is the time period when a

decision to repaint may be required. The figures are

based on marine or industrial environments and may

be extended by 5 years for suburban or rural

environments.

The ‘Ultimate Life’ is based on a marine or severe

industrial environments and may be extended to 40

years for suburban or rural environments.

Aluminium Paint SystemsDecorative Life Ultimate Life Scratch Stain Colour Weathering Chalking

System (years) (years) Resistance Resistance Fastness Aluminium Resistance

ARS 15 25 Excellent Good Good Good Good

PVF2 15 25 Good Excellent Excellent Excellent Excellent

Colourbond 15 25 Good Good Good Good Moderate

15

Load Spans - Steel LokrollLokroll is generally used in a multi-span configuration. The load/span graphs below are characteristic working

loads in kN/m2 based on sheets being continuous over at least three spans.

Deflection under stated safe superimposed loading will not exceed span/200.

Deflection under stated safe uplift loading will not exceed span/90

16

1.00 1.25 1.50 1.75 2.00

Downward 4.88 4.40 3.73 3.13 2.45

Wind uplift 4.47 3.83 2.48 2.11 1.79


Ultimate Fixing Capacities

Structural steel Z35 Material

Screw 1.6mm 2.0 mm 2.5mm 2.8mm 3.2mm

5.5mm Diameter No 2pt 4.1 5.1 7.4 9.6 10.7

6.3mm Diameter No 3pt 4.1 5.3 7.6 8.3 9.9

Pull Out Strength (kN)

Sheet 16GB 19GB 29GB*

0.7mm Steel 5.6 5.7 6.9

0.7mm Aluminium 2.6 3.5 2.3

0.9mm Aluminium 3.2 4.1 2.6

* 16,19,29 = washer diameter (mm)

Washer Pull Over Values (kN)

Single Sheet (kN) Double Sheets (kN)

0.7mm Steel 0.98 2 x 0.7mm Steel 2.10

0.7mm Aluminium 0.65 2 x 0.7mm Aluminium 1.30

0.9mm Aluminium 1.00 2 x 0.9mm Aluminium 1.95

Stitcher Pull Out Values

Sheet (kN) Failure Mode 0.7mm Steel

2 x 0.7mm Aluminium 1.50

2 x 0.9mm Aluminium 1.53

Top hat to 0.70mm Steel Deck 1.53 Rivet pulled through aluminium sheet

Top hat to 0.90mm Steel Deck 2.20

Top hat to 1.10mm Steel Deck 2.20 Rivet failure

Top hat to 1.25mm Steel Deck 2.24

Pull Out Values For Bulbtite Rivets Type 6604/6/3W

We recommend a safety factor of 2.0 be applied to the above capacities to bring them into line with

characteristic working loads.

Materials yield - steel 220 N/mm_

- aluminium 200 N/mm_

17

Relative humidity is the ratio of water held in a given volume of air to the maximum amount that could be held at that temperature. If the temperature of the air is raised, the amount of water held is unchanged, but the amount required to saturate the air is increased. So, an increase in temperature causes a decrease in the relative humidity for this given volume of air.

Conversely, a reduction in temperature reduces the amount of water required to saturate the air and so the relative humidity increases. As the temperature continues to fall, the relative humidity will eventually rise to 100% and become fully saturated - this is known as the dew point. The surplus water in the air cannot be held as a vapour and is expelled as water droplets leading to condensation.

When moist air comes into contact with a cold surface the above cycle deposits water droplets on the surface causing surface condensation. This can occur in a ‘cold roof’ construction where vented flutes are incorporated to the underside of the top sheets.

The Ziplok system greatly reduces this risk by incorporating a high level of insulation, which is compressed tightly to the underside of the top sheet. This reduces the risk of air pockets and prevents the top sheet from becoming too cold. Furthermore, the seamed joints allow a natural venting of the roof system.

Humid air exerts a greater pressure than dry air, and will attempt to enter the roof construction through any available apertures. When condensate is formed in the cool zones of the roof this is known as interstitial condensation. Here, there is a local drop in pressure due to the removal of water vapour from the air. A minute distance away the air is warmer and contains a large quantity of water vapour and is therefore under

higher pressure. The high-pressure air will migrate to

where the pressure is lower, and more condensate is

formed. This process is continuous as long as the

temperature and relative humidity is maintained. To

combat this, a vapour barrier is required on the warm

side of the insulation in the roof build-up to prevent

humid air from gaining access to the cool zones of the

roof. In standard standing seam roof constructionsa sealed liner will act as a vapour control layer (see

P5 Liner Sheets). However in high humidity

applications or acoustic applications where a

perforated liner is used an additional vapour barrier will

be required.

Before installing a separate vapour control layer, any

water must be removed and the surface kept clean,

dry, smooth and free of any dirt and swarf. The vapour

control layer is spread loose, flat and without wrinkles

in the same direction as the liner sheet. End and side

laps should be sealed with a continuous run of 12mm

x 2mm cross-linked butyl rubber tape. The minimum

width of lap should not be less than 150mm. Where

puncture damage has occurred, good-sized patches

must be applied over the area ensuring a continuous

double bead of sealant all around the hole.

Our BBA Agrément Certificate No.99/3605 proposes a

choice of three VCL products:

• TALCHECK – 0.3mm thick lightweight

polyethylene with a Water Vapour Resistance of

272MNs/g, or

• ULTRA 2000 – 0.4mm thick reinforced

polyethylene with a Water Vapour Resistance of

522MNs/g, or

• TALFOIL – Reinforced foil vapour barrier with a

Water Vapour Resistance of 25,000MNs/g.

Vapour Control

18


Buildings should provide a safe environment and

building materials should not increase the risk of fire,

or increase hazards resulting from fire.

If a fire breaks out in a building there is a rapid build up

of heat, smoke and fumes. An aluminium roof is

weakened by the heat and the sheets will collapse

inwards allowing the heat and fumes to escape

because of its low melting point (650 °C). This reduces

the heat damage of the building structure, increases

the chances of occupants to locate the exits, and

assists fire fighters in gaining access to the source of

the blaze.

By contrast, a steel roof remains intact by virtue of its

meting point (1900 °C). The resulting increase in

temperature and toxic fumes can increase the loss of

life and the extent of damage.

AA ClassificationThe external skin is tested in accordance with BS476:

Part 3 and is given a designation in the range AA to

DD. The first letter refers to fire penetration

performance should there be a fire on the roof

deposited from adjoining burning premises. The

second letter refers to the resistance of surface spread

of flame resulting from the fire on the roof. Aluminium

achieves the designation AA, the highest possible

rating.

Class O ClassificationIf there is a fire in a building, the wall or ceiling lining

material must not help to spread the fire. The statutory

requirements of the Building Regulations approved

document B define the highest product performance

classification for a lining material as class O. To attain

this class, a material has to achieve the highest index

performance when tested in accordance with BS476:

Part 6 (for coated aluminium I = 3 & i = 1.5), and a class

1 rating when tested in accordance with BS476: Part

7. Aluminium satisfies this class O rating.

IgnitabilityBS476: Part 5 is a test for ignitability. Materials are

classified as ‘easily ignitable’ - X or ‘not easily ignitable’

– P. Aluminium receives the better rating, P.

Fire

19

By inspection a RigiSystems Lokroll sheet 20m long with a mill finish could experience an expansion of 20 x 1.08 = +21.6mm in hot weather and a contraction of 20 x 0.36 = -7.2mm in wintry conditions. It is important, therefore, that all roof details take account of all such possible changes in length, especially where the sheets meet abutments or gutters.

Aluminium Lokroll

When lengths of Lokroll exceed 5m in a light colour/mill finish or 7m in a dark colour (based on aluminium) it becomes necessary to make provision for thermal expansion and contraction. This is achieved by locating the fixing screws in slots, which are punched on site with a purpose made hand tool. A standard slot is 40mm long, longer slots can be

produced (where necessary) by punching two

overlapping slots. An extruded aluminium cover

washer reinforces the fixing position. (check also for

steel)

To allow thermal movement to operate with the

greatest efficiency sliding resistance / friction should

be minimised. Although the Corogrid brackets anchor

the sheets to the roof structure they do not restrict

thermal movement and the sheets are free to slide on

the brackets. To control this movement a “Fixed

Point” should be created and it is usually best to locate

it near the ridge so that the flashing is mounted on a

static base allowing the sheet to expand into the

eaves. Consequently, the drip angle needs to be

positioned carefully with adequate clearance to allow

for downslope movement due to summer expansion

and upslope movement due to winter contraction.

On shallow roof pitches of up to 3° and sheets up to

25m long the “Fixed Point” can be achieved by drilling

through the small roll edge of the sheet and the head

of the halter bracket and inserting a blind rivet to create

a locking mechanism. On steeper pitches and longer

sheets a stronger “Fixed Point” is required by bolting

through the upstand of the sheets and the web of the

Corogrid bracket which is then hidden by the ridge

foam filler block and aluminium shroud.

Expansion

Coefficient of Expansion Typical Temperature Overall Movement Movement about ambientMaterial x 10-6 per °C Range (°C) (mm/m) Temperature (mm/m)

Aluminium

Mill or Light 24 -10 +50 1.44 -0.36 +1.08

Aluminium

Dark Colour 24 -10 +70 1.92 -0.36 +1.56

Steel

Light Colour 12 -10 +45 0.66 -0.18 +0.48

Steel

Dark Colour 12 -10 +70 0.96 -0.18 +0.78

For other metals please contact Technical.

The table above shows the expansion of sheets thatcan be expected in the UK due to temperature changes.

The ambient temperature during sheet installation has been assumed to be 5 °C. When sheeting during very cold weather the temperature range base should be decreased to -20 °C to assess tolerances for sheet movement.

The table below shows the expansion of sheets that can be expected in the UK due to temperature changes

7

20


Production TolerancesMinimum Sheet Length = 1m

Maximum sheet Length = 27m

Cover Width +/- 2mm

Edge Squareness 1% of sheet cover width

Length (Upto 10m long) +10mm / -5mm

Length (Over 10m long) +10mm +(1mm per metre length over 10m) / -5mm

21

Barrel Rooflights

These translucent panels can run longitudinally along

the ridge or transversely from the ridge to the eaves of

the roof.

The interface between the roof system and this

rooflight is minimised and the purlin spacing is not

compromised by any structural inadequacy of the

rooflight. The level of illumination may be controlled by

selection of the width of the rooflight without being

influenced by the roof sheet module.

GRP multi-vaults lap at the sides to form units of

unlimited length, the double skin construction is

formed on site from identical inner and outer sheets

separated by metal spacers and foam fillers. The

rooflight is closed by insulated, opaque, white GRP

end panels, which lap on to the end of the translucent

sheets. Downslope daylighting units should be

mounted on their own kerbs with their sides flashed

using standard verge components.

Rooflights

22


Roof Openings

Small penetrations such as vent pipes and flues can be accommodated within the width of a Lokroll sheet. Openings can be created by means of a welded collar or a flexible Dek-Tite soaker. In such cases it is important to ensure that the drainage of the sheet is not blocked and therefore a channel at least 50mm

should be left at each side of the penetration. For large openings, the seams will need to be cut and welded and the complete soaker system supported on a

framework.

Drumming

The impact of rain or hail on a roof will always produce a noise, this sound energy (vibration) is then transmitted through the construction to the inside of the building. BS 5427: Part 1: 1996 states that this noise can be reduced by the introduction of a flexible insulation layer directly under the outer sheets. The insulated Lokroll system deadens such sounds with absorption by virtue of the soft insulation being

compressed to the underside of the roof sheet.

Lightning Protection

A close liaison should be ensured between the architect, the builder, the lightning protection system engineer and the appropriate authorities throughout the design stages to meet or exceed the requirements of BS 6651: 1992. Modern buildings use metal extensively in their structure and there is considerable benefit in utilising such metal parts to maximise the number of parallel conducting paths. The Lokroll roof

system combined with the steel frame of the building

can be used to provide a principal lightning protection

system.

Fall Arrest Systems

Omnis provide a range of fall arrest systems which complement the Lokroll system. For further advice contact us.

23

Colour Coated Steel – Inspection & Maintenance RecommendationsMaintenance

Inspection is based on good practice and should be carried out annually throughout the life of the building. An inspection record should be maintained.

Proper and regular maintenance of coated metal claddings will considerably extend their functional life. Planned inspections, commencing shortly after installation, will ensure that any remedial action can be carried out before the problem becomes too serious.

As claddings are exposed to the elements, and in particular sunlight, the anticipated repaint decision varies with the colour chosen. The lighter colours absorb less ultra-violet than darker colours and hence will deteriorate less. Watch for changes in conditions of the coating particularly when the re-paint decision time approaches.

Check for:

• Blockages in gutters

• Debris

• Dirt where cladding is not naturally cleared by

rainwater

• Mould growth in extreme conditions

• Damage to the coating which can cause substrate

corrosion

• Swarf, rivet stems and any other items which can

rust

• Conditions of fasteners

• Cut edge corrosion

Cleaning

To prolong the lifetime of the cladding it should be cleaned as part of the general maintenance procedure, the following should be carried out:

• All blockages must be removed and cleaned from

gutters.

• Remove any debris from cladding that may result in

corrosion.

• Wash down and clean dirt infected areas.

• Washing may be carried out with a hose and soft

bristle brush.

• If necessary a good quality household detergent or

proprietary cleaner may be applied, following

manufacturers recommendations.

• Always rinse with clean water.

• Always wash from top to bottom.

• Do not use organic solvents or abrasive cleaners.

• Prior to cleaning remove tar or similar substances

with mineral spirit.

• Any coating damage should be treated and a touch-

up paint applied.

• A suitable treatment should be applied to any

corroded cut edges and then sprayed with a

protective lacquer.

• High-pressure water jets are not recommended, as

mastic or fillers could be dislodged, leading to other

problems.

Scratches to Surface of the Sheet

Clean the area around the damage and check for damage to the galvanised layer. If the damage is limited to the coating only, lightly abrade the area, degrease and repair with a proprietary paint or paste.

If the galvanised surface is damaged, then the area of the damage, plus approx. 20mm all round, should be rubbed with a fine wire brush or medium emery cloth, to remove all traces of rust. The area should be thoroughly cleaned, degreased and a ‘cold galvanising’ paint applied. When dry, a suitable primer and finishing paint should be applied.

Sheet Edge Peel

Sometimes the cut edge of Plastisol coated sheets shows signs of delamination (edge peel) well in advance of the anticipated life of the sheet. This will usually be limited to 5-10mm from the sheet end, and it is therefore not detrimental to the performance of the sheet. When first noticed, the loose Plastisol should be removed and repair carried out, ensuring that the coating covers at least the damaged area plus 20mm. Cutting sheets with the correct, sharp tools will minimise the likelihood of peel.

24


Colour Coated Steel – Health & Safety Data SheetProduct Name PVC (Plastisol)

Composition Steel coil; Electrozinc; Hot Dipped Galvanised or Hot Dipped in Zinc/Aluminium also

Aluminium in coil coated with PVC Plastisol and backing coat

Intended Use Exterior cladding walls and roof, general engineering

Health HazardsPVC compositions under normal conditions of

storage are safe to use and are not toxic.

However, some of the pigments within the paint

and pre-treatment systems contain Strontium

Chromate and basic Chromium Chromate.

Exposure limits have been established by the

Health and Safety Commission for both of these

substances and should always be observed.

Substance OEL OEL

8 HR (a) 10 MIN (b)

StrontiumChromate 0.05 mg/m3 As Cr

BasicChromium 0.05 mg/m3 As CrChromate

(a) Long term exposure limit - 8 hours time

weighted average.

(b) Short term exposure limit - 10 minute time

weighted average.

(c) Control limit

(r) Recommended limit

(skin) There is a risk of absorption through

unbroken skin.

Further information regarding OEL and the

assessment of occupational exposure to harmful

materials including exposures is given in H.S.E.

guidance note E.H. 40.

Precautions in Handling and Use(a) Protective clothing should be worn to prevent

laceration of the skin.

(b) Suitable eye protection should be worn in

accordance with the Protection of eyes act

1974.

(c) Hot work such as cutting, welding or brazing

should be controlled to minimise the risk from

emission of harmful fumes. To avoid inhalation

of these fumes respiratory equipment should

be used.

(d) High levels of dust and other harmful

substances can be given off by dry sanding.

This applies to both mechanical and hand

grinding operations.

If such operations cannot be avoided, respiratory

equipment should be worn.

First Aid ProcedureEye Contact Rinse with clean water for at least

fifteen minutes. If after this period

the eyes still give problems, seek

medical attention.

Skin Contact Wash skin thoroughly using a

recommended skin cleaner. If

after rinsing the skin is still giving

problems, seek medical attention.

Fire PreventionUnder normal circumstances PVC Compositions

are non-flammable but may be consumed by fire.

Below is the current occupational exposure limits

for PVC Plastisol.

8 HR 10 MIN

TWA (a) TWA (b)

Carbon Monoxide 50 ppm 400 ppm

Hydrogen Chloride 5ppm 5ppm

Chromium(hexavalent) 0.05 mg/m3 –

Compound

Iron Oxide fumes(AS Fe) 5.00 mg/m3 10.0 mg/m3

Zinc Oxide fumes 5.00 mg/m3 10.0 mg/m3

Aluminium Oxide 10.00 mg/m3 20.0 mg/m3

25

Steel – Health & Safety Data SheetFire ServiceIn the event of a fire appropriate respiratory apparatus should be used to avoid contact with fumes.

This health and safety data has been compiled using the following guidance.

• Toxic Substances – A Precautionary Policy EH18

• Occupational Exposure Limits 1984 EH40

• Monitoring Strategies for Toxic Substances EH42

• Carbon Monoxide EH43

• Dust in the Work Place, General principles of Protection EH44

• Protection Eye regulations 1974:S1 1681 HMSO

• Guidance Note EH44 – Dust in the Workplace: (With amendments) HMSO

• Respirators for protection against harmful dust, gases and Scheduled agricultural chem

– BS2091: 1969 (with amendments) BSI

• Specification for Filtering Facepiece dust respirators – BS6016: 1980 BSI

• Recommendations for the selection, use and maintenance of Respiratory protective

equipment BS4275: 1974 BSI

• DHSS Special Security Act 1975 CM37 – Report by the Industrial Injuries Advisory Council

on the question whether Lung cancer in workers in certain occupations should be

Prescribed under the Act April 1986 HMSO

• Exposure Limits (latest annual editions) HMSO

• Guidelines on the safe handling of Chromate Pigments and Chromate – containing paints. PMA

26


Steel – Health & Safety Data SheetProduct Name Fluorocarbon (PVF2)


Aluminium in coil coated with Fluorocarbon (PVF2) and backing coat


Health HazardsUnder normal conditions of storage PVF2 is not

toxic, however, one should avoid exposure of the

coated sheet or coil to naked flames, welding or

disc grinding. This will give off fumes and may

cause respiratory irritation, irritation of the skin,

chest, tightness and coughing, which may persist

for a few days after exposure. The main entry into

the body of these decomposition by-products is

by inhalation and one should avoid inhalation of

fume at any time.

Pigments within the pre-treatment and primer

systems contain Strontium Chromate and basic

Chromium Chromate. These two substances are

listed below for which occupational exposure

limits have been established by the Health and

Safety commission.

Substance OEL OEL

8 HR (a) 10 MIN (b)




weighted average.


weighted average.

(c) Control limit



unbroken skin.









1974.





be used.










medical attention.





Fire PreventionUnder normal circumstances Fluorocarbon (PVF2)

compositions are non-flammable but may be

consumed by fire. Below is the current

occupational exposure limits for Fluorocarbons.

8 HR 10 MIN

TWA (a) TWA (b)




Compound


Hydrogen Fluoride 3 ppm 6 ppm

Epichlorohydrin 2 ppm 5 ppm

Aluminium Oxide 10 ppm 20 ppm

Fire ServiceIn the event of a fire appropriate respiratory

apparatus should be used to avoid contact with

fumes.

27

Steel – Health & Safety Data SheetProduct Name Polyester


Aluminium in coil coated with Polyester and grey backing coat


Health HazardsPolyester compositions under normal conditions

are not toxic. Pigments within the pre-treatment

and primer systems contain Strontium Chromate

and basic Chromium Chromate. Exposure limits

have been established by the Health and safety

commission for both of these substances and

should always be observed.

Substance OEL OEL

8 HR (a) 10 MIN (b)




weighted average.


weighted average.

(c) Control limit



unbroken skin.









1974.





be used.










medical attention.





Fire PreventionUnder normal circumstances Polyester

compositions are non-flammable but may be

consumed by fire. Below is the current

occupational exposure limits for Polyester.

8 HR 10 MIN

TWA (a) TWA (b)


Hydrogen Chloride 5ppm 5ppm


Compound



Aluminium Oxide 10.00 mg/m3 20.0 mg/m3

Fire ServiceIn the event of a fire appropriate respiratory

apparatus should be used to avoid contact with

fumes.

28


Steel – Site SafetySteel is not hazardous nor an injurious substance. It isnot combustible and does not emit toxic fumes and isductile at all normal operating temperatures (it will notshatter or crack). All normal mandatory Health & SafetyRegulations must be followed. The precautions beloware particularly applicable to working with standingseam sheets.

• Gloves should be worn when handling metalsheets

• Eye protection should always be worn duringcutting and drilling operations

• In windy conditions all unfixed, or partially fixedsheets and flashings must be adequately securedto ensure they are not dislodged and become ahazard to people and property. In addition, it may bedangerous to carry materials in such conditions,especially when working above ground level

• Lokroll sheets must NEVER be used as a workingsurface during construction, unless they are fullyfixed in strict accordance with ourrecommendations. Otherwise separate, securedstaging must be provided for site personnel

• Individual sheets must be seamed as soon as theyare in place, for safety reasons and to offerprotection to the insulation from rain

• At the end of a fixing run the last sheet should betemporarily secured using pressed verge clipsscrewed to the halter brackets

• To avoid localised deformations of the pan of thesheet it is recommended that only the upstands ofthe seams should be walked on

• Boards and roof ladders are always preferred ratherthan walking directly on the sheets

• Non-roofing trades should be provided withwalkways when access across a sheeted roof isrequired

• Where sheets are to be stacked on the roof, theymust only be placed over a main frame and be wellsecured when not being used. Care should betaken to avoid over-loading the structure andpermission of the Structural Engineer must besought beforehand.

OpeningsUse cones and tapes to indicate roof openings

awaiting roof lights, hatches and protrusions etc.

29

• Store stacks off the ground and on a slope so that,

should rain penetrate the covering, the water will

drain away

• Inspect the storage site regularly to ensure that

moisture, despite the above precautions, has not

penetrated the stack

• Care should be taken to avoid condensation

staining between the sheets

• Do not store sheets where people will walk across

them

Handling Individual Sheets

Single sheets are relatively light, but long sheets can be difficult to handle in windy conditions Sheets up to about 14 metres long can usually be handled by two operatives. A third operative is required for sheets up 21 metres, and a fourth for sheets up to about 28 metres. These are approximate figures, and may need amendment in windy weather, or on roofs with difficult access. Sheets should be carried on their side.

After the works have been completed all damaged and waste materials (including packaging) should be disposed of in accordance with appropriate Health and Safety Regulations.

Steel – Site Safety, Handling & StorageOff-Loading

Lokroll is delivered to site in packs which can weigh up to about 3 tonnes. Packs up to 10 metres long may be off-loaded by forklift truck; cranes are needed for greater lengths. The crane should lift by means of nylon slings (never chains) and the pack should never project more than 4 metres beyond the last sling. Slings should never be more than 6 metres apart, and for long packs it is essential to use spreader

beams.

This general advice is offered for guidance only. Each lift needs to be done by appropriately trained personnel using the correct and serviceable equipment.

Storage

A suitable site for storage should be selected to avoid unnecessary handling of sheets and or components and the following precautions strictly adhered to:

• Do not leave uncovered stacks lying in the open,

store under cover and away from open doorways

• If stacks cannot be kept under cover, erect simple

scaffolding around them and cover with a

waterproof sheet, tarpaulin or polythene. Leave

space between cover and sheets to allow air to

circulate

30


MaintenanceMill finish aluminium does not require maintenance to

restore its appearance, it is normally accepted in its

weather condition.

Coated finishes do not require any special

maintenance, although washing with clean water or a

sugar soap solution may be advantageous in dusty or

industrial areas.

Roofs should be given periodic inspections and the

accumulation of debris, falling leaves, etc. should be

removed before it can block drainage and promote

corrosion. Damaged sheets or flashings should be

removed and replaced at the earliest opportunity, to

minimise damage due to ingress of storm water.

Maintenance and cleaning personnel must use

scaffold boards on all roofs. Always provide load-

spreading measures at the ridge and at the eaves in

order to avoid local deformations from excessive foot

traffic especially at the point of access to the roof.

Aluminium sheets must be isolated from any other

materials that may cause galvanic corrosion. Any

contamination or exposure to corrosive materials must

be removed. Any moisture trapped in the construction

must be removed.

CleaningUpon completion of each section of the roof it should

be thoroughly cleaned to remove all swarf, rivet

mandrels, screws, washers, rivets etc. Any of these

items could cause unsightly rust stains. Cement or

mortar droppings should be removed immediately or

they will leave permanent stains. Marks from oil,

grease etc should be removed by washing with a mild

detergent, remembering to rinse thoroughly with clean

water.

Sometimes coated sheets are protected by a thin

plastic film, which must be removed immediately after

fixing. Long exposure to ultra violet light can harden

the film and make it difficult to remove, leaving sticky

deposits which collect dirt and spoil the appearance of

the roof. Should adhesive marks remain, these can be

removed by using BT8 Thinner (SBP6 Solvent)

available from SG Bailey Paints Ltd.

It is recommended that periodical inspections should

be made for damage. Should debris be causing

obstructions, it should be removed and the area

washed down with a mild detergent and rinsed

thoroughly with clean water. In some areas

(particularly industrial ones and where cladding is sheltered directly below a soffit) it may be necessary to clean the installation periodically to restore its appearance to remove corrosive deposits. This can be carried out by hosing with water using a neutral detergent.

Colour-Coated SurfacesUse special non-abrasive, biologically degradable cleaner compatible with the coating system and rinse thoroughly after cleaning. It is often worthwhile waiting, since weathering and dirt accumulation will reduce colour differences. This process will be faster on a natural finish surface than on coloured material.

Removing Dirt

Use an abrasive agent with a pH value of between 5 and 8. When using special cleaning agents, make sure that they are ecologically compatible. Always rinse off with water.

Repairs to Painted SurfacesIn the case of aluminium, minor scratches and abrasions do not require repairs, except where the scratches become visually unacceptable. However, it should be noted that site repairs on scratches can not always be justified on aesthetic grounds as the repaint is usually more prominent than the scratch. Air drying paints will never be a perfect match for factory stoved paints, the gloss levels will probably differ and they will certainly age differently. Larger areas of damage

must be site painted to disguise unsightly patches or exposed metal. In these cases the damaged areas should be cleaned and painted with an approved touch up paint to match the sheet finish.

In all cases, small areas should be painted using a small soft artists brush. 'Daubing' with a decorator's brush will never be successful.

When painting over coated areas, preparatory measures and type of coating must be coordinated with the existing paint system on the advice of a paint specialist. PVF2 coated sheets should only be touched up with air drying PVF2 paint such as DURANAR ADS. Trained specialists can only apply this paint system. Use the standard air drying touch up paint provided.

Aluminium - Inspection & Maintenance Recommendations

31

For minor scratches and small repairs apply the paint

provided sparingly using a pencil brush in two coats,

allowing 15 minutes between coats. The paint should

be touch dry in 30 minutes. Do not paint in damp

conditions or when rainfall or condensation is

expected within 2 hours. Only paint when the

temperature range is within 5 - 30°C. Care must be

taken to comply with Health & Safety Regulations as

recommended by the paint and solvent

manufacturers.

Repairs Of Minor Damage Preparation - Weathered material

Clean the area to be painted with a mild detergent

solution and rinse with clean water, then thoroughly

dry off with a clean cloth. If surface damage has

occurred, prepare the area with fine wet and dry paper

taking care to feather in the edges to the original

surface. After final preparation, de-dust the area using

a lint free cloth or a proprietary tack rag.

New material Wipe the immediate area to be painted with a clean

cloth moderately soaked with an industrial safe solvent

e.g. Panel Wipe. When the solvent has flashed off,

wipe the area again with clean lint free cloth. If primer

has been used to cover any areas of bare metal, lightly

flat the surface using 400-grade wet and dry paper,

finally de-dust the area using a lint free cloth or a

proprietary tack rag.

Paint Suppliers

S G Bailey Paints Ltd

Griffin Mill Estate

London Road

Thrupp

Stroud

Gloucestershire

GL5 2AZ

Tel: 01453 882237

PPG Industries UK Ltd

Building Products Division

PO Box 359

Rotton Park Street

Ladywood

Birmingham

B16 OAD

Tel: 0121 4559866

Aluminium - Inspection & Maintenance Recommendations

pH

Strong StrongWeak WeakNeutral

ACIDS

THE pH SCALE

ALKALIS

1 2 3 4 5 6 8 9 10 11 12 13 147

32


Product Name Mill Finish Aluminium

Composition Aluminium Alloy, in sheet, plate or coil form


Health HazardsWhen handling the product in sheet or coil form, there

is a risk of laceration of the skin, inhalation of

aluminium dust may cause shortness of breath and

aggravate bronchial conditions. Occupational Exposure

Limits have been established for aluminium dust by

the Health and Safety Commission. This limit is

detailed below O.E.L. should always be observed.

Substance OEL OEL

8 HR (a) 10 MIN (b) Notes

Aluminium 10 mg/m3 20 mg/m3 as dust

(a) Long term exposure limit - 8 hour time

weighted average.


weighted average.

(s) Occupational Standard Limit.

(m) Maximum Exposure Limit

(c) Manufacturers Data

(d) Limits in mg/m3, all other data in parts per

million ppm.

(skin) There is a risk of absorption through unbroken

skin.

Further guidance on OEL and the assessment of

occupational exposure to harmful materials including

mixed exposures, is given in HSE guidance note EH40.

Precautions in Handling and UseProtective clothing should be worn to prevent

laceration of the skin. Avoid inhalation of dust, this

should be achieved by the use of local exhaust

ventilation and good general ventilation. If this is not

sufficient to maintain concentrations of dust particles

at a level below the OEL, suitable respiratory

protection must be worn.

First Aid ProcedureEye Contact Irrigate copiously with clean fresh

water, holding the eyelids apart.

Skin Contact Wash skin thoroughly with soap and

water or use a proprietary skin cleaner.

Fire PreventionIn plate, sheet or coil form, material does not burn. In

powder or chip form, use dry powder

or sand. Do not use water or halogen extinguishing

agent.

Unusual Fire HazardsWater, oxidisers and many other chemicals react

explosively in contact with molten aluminium fine

chips, turnings and dust in air may explode if ignition

source is present.

Relevant Referencesa) H.S.E. Guidance NotesEH18: Toxic Substances - a Precautionary Policy

EH40: Occupational Exposure Limits 1991

EH42: Monitoring Strategies for Toxic Substances

EH43: Carbon Monoxide

EH44: Dust in the Work Place, General Principals of

Protection

Aluminium – Health & Safety Data Sheet

33



water for at least ten minutes, holdingthe eyelids apart.

Skin Contact Wash skin thoroughly with soap andwater or use a proprietary skin cleaner.

Fire PreventionUnder normal conditions of storage and use, Polyestercompositions are not flammable but may be consumedby fire. The major productsof combustion/decomposition of Polyestercomposition are detailed below.

Current Occupational Exposure Limits

8 HR 10 MIN(Products ofCombustion) TWA (a) TWA (b) Notes

Chromium(Hexavalent) 0.05 mg/m3 As CrCompounds



Lead Oxide 0.15 mg/m3 -

Relevant Referencesa) H.S.E. Guidance NotesEH 18: Toxic Substances - a Precautionary Policy

EH 40: Occupational Exposure Limits 1991

EH 42: Monitoring Strategies for Toxic Substances

EH 43: Carbon Monoxide

EH 44: Dust in the Work Place, General Principals ofProtection.

Product Name Organic Coatings: Polyester and ARS (Polyurethane based)

Composition Aluminium Alloy, Sheet or coil coated with a Primer, Polyester top coat and backing coat.

The Organic top coat is typically between 1.15% and 3.69% by weight of product


Health HazardsWhen handling the product in sheet or coil form there

is a risk of laceration of the skin. Polyester

compositions under normal conditions are not toxic.

Pigments within the pre-treatment and paint systems

may contain one or more of

the substances listed below. The Health

and Safety Commission have established occupational

exposure limits, these limits should always be

observed.

Substance OEL OEL

8 HR (a) 10 MIN (b) Notes

BasicChromium 0.05 mg/m3 - As CrChromate

Aluminium 10 ppm 20 ppm

LeadChromate 0.15 mg/m3 -Pigment

(a) Long term exposure limit - 8 hour time

weighted average


weighted average.

(s) Occupational Standard Limit.

(m) Maximum Exposure Limit.

(c) Manufacturers Data.

(d) Limits in mg/m3, all other data in parts per

million ppm.

(Skin) There is a risk of absorption through unbroken

skin.

Further guidance on OEL and the assessment ofoccupational exposure to harmful materials includingmixed exposures, is given in HSE guidance note EH40.

Precautions in Handling and UseProtective clothing should be worn to preventlaceration of the skin. Avoid inhalation of dust. Thisshould be achieved by the use of local exhaustventilation and good general ventilation. If this is notsufficient to maintain concentrations of dust particlesat a level below the OEL, suitable respiratoryprotection must be worn.

34


Aluminium – Health & Safety Data SheetProduct Name Organic Coating: Fluorocarbon (PVF2) based

Composition Aluminium Alloy, sheet or coil coated with Epoxy or Acrylic Primer, Fluorocarbon top coat and

a backing coat. The Fluorocarbon Organic top coat is typically between 1.15% and 3.69% by

weight of product


Health HazardsWhen handling the product in sheet or coil form there

is a risk of laceration of the skin. Fluoroplastics are

extremely inert biologically and hazards are only likely

to occur with decomposition by heat. The composition

of thermal decomposition products is not well defined.

The condition resulting from exposure to these

products is known as Polymer Fume Fever. This is a

temporary influenza-like condition that appears some 4

to 5 hours after exposure to sublimates or thermal

decomposition of Fluoroplastics.

The temperature of burning tobacco or equivalent heat

is sufficient to produce the physical Pyrolytic changes

in the otherwise inert Polymer. Respiratory irritation

may occur. The acute illness may be alarming and

uncomfortable when it is severe, but it is short in

duration and without known long-term ill effects.

When subjected to elevated temperatures e.g., during

welding, flame cutting, sawing, machining and other

mechanical work of the solid cured resins, fumes may

be produced containing thermal decomposition

products of the resin e.g., Amines and/or unreacted

Epichlorohydrin. These products can be irritating to the

skin and to the respiratory tract where they may cause

chest tightness and episodes of coughing which may

persist for a few days after exposure.

The principal mode of entry into the body of these

decomposition products is by inhalation and their

inhalation should be prevented. Fluorocarbon (PVF2)

under normal conditions of storage is not toxic.

Pigments within the pre-treatment and paint systems

may contain one or more of the substances listed

below. The Health and Safety Commission have

established occupational Exposure Limits. These limits

should always

be observed.

Substance OEL OEL8 HR (a) 10 MIN (b) Notes

BasicChromium 0.05 mg/m3 - As CrChromate

Aluminium 10 ppm 20 ppm

Lead 0.15 mg/m3 -

(a) Long term exposure limit - 8 hour timeweighted average

(b) Short term exposure limit - 10 minute timeweighted average.

(s) Occupational Standard Limit.(m) Maximum Exposure Limit.(c) Manufacturers Data.(d) Limits in mg/m3, all other data in parts per

million ppm.(Skin) There is a risk of absorption through unbroken

skin.

Further guidance on OEL and the assessment of

occupational exposure to harmful materials including

mixed exposures, is given in HSE guidance note EH40.

Precautions in Handling and UseProtective clothing should be worn to prevent

laceration of the skin. Avoid inhalation of dust. This

should be achieved by the use of local exhaust

ventilation and good general ventilation. If this is not

sufficient to maintain concentrations of dust particles

at a level below the OEL, suitable respiratory

protection must be worn.


water for at least ten minutes, holding

the eyelids apart.

Skin Contact Wash skin thoroughly with soap and

water or use a proprietary skin cleaner.

35


Fire PreventionUnder normal conditions of storage and use,

Fluorocarbon compositions are not flammable but may

be consumed by fire. The major products

of combustion/decomposition of Fluorocarbon

composition are detailed below.

Current Occupational Exposure Limits

8 HR 10 MIN(Products ofCombustion) TWA (a) TWA (b) Notes

Chromium(Hexavalent) 0.05 mg/m3 As CrCompounds

Epichlorohydrin 2 ppm 5 ppm


Lead Oxide 0.15 mg/m3 -

In the event of fire, appropriate respiratory

protective equipment should be used by fire fighters.

Relevant Referencesa) H.S.E. Guidance NotesEH 18: Toxic Substances - a Precautionary Policy

EH 40: Occupational Exposure Limits 1991

EH 42: Monitoring Strategies for Toxic Substances

EH 43: Carbon Monoxide

EH 44: Dust in the Work Place, General Principals of

Protection.

36


Aluminium - Site SafetyAluminium is not hazardous nor an injurious

substance. It is not combustible and does not emit

toxic fumes and is ductile at all normal operating

temperatures (it will not shatter or crack). All normal

mandatory Health & Safety Regulations must be

followed. The precautions below are particularly

applicable to working with standing seam sheets.

� Gloves should be worn when handling metal sheets

� Eye protection should always be worn during cutting

and drilling operations

� In windy conditions all unfixed, or partially fixed

sheets and flashings must be adequately secured to

ensure they are not dislodged and become a hazard to

people and property. In addition, it may be dangerous

to carry materials in such conditions, especially when

working above ground level

� Lokroll sheets must NEVER be used as a working

surface during construction, unless they are fully fixed

in strict accordance with our recommendations.

Otherwise separate, secured staging must be

provided for site personnel

� Individual sheets must be fixed as soon as they are

in place, for safety reasons and to offer protection to

the insulation from rain

� At the end of a fixing run the last sheet should be

temporarily secured using pressed verge clips screwed

to the halter brackets

� To avoid localised deformations of the pan of the

sheet it is recommended that only the upstands of the

seams should be walked on

� Boards and roof ladders are always preferred rather

than walking directly on the sheets

�Non-roofing trades should be provided with

walkways when access across a sheeted roof is

required

� Where sheets are to be stacked on the roof, they

must only be placed over a main frame and be well

secured when not being used. Care should be taken to

avoid over-loading the structure and permission of the

Structural Engineer must be sought beforehand.

OpeningsUse cones and tapes to indicate roof openings awaited

roof lights, hatches and protrusions etc.

Aluminium – Site Safety

37

Off-LoadingLokroll is delivered to site in packs which can weigh up

to about 3 tonnes. Packs up to 10 metres long may be

off-loaded by forklift truck; cranes are needed for

greater lengths. The crane should lift by means

of.nylon slings (never chains) and the pack should

never project more than 4 metres beyond the last

sling. Slings should never be more than 6 metres

apart, and for long packs it is essential to use spreader

beams.

This general advice is offered for guidance only. Each

lift needs to be done by appropriately trained

personnel using the correct and serviceable

equipment. RigiSystems strongly recommend the use

of specialist lifting companies who should be given full

responsibility for the safe offloading of the product.

StorageA suitable site for storage should be selected to avoid

unnecessary handling of sheets and or components

and the following precautions strictly adhered to:

• Do not leave uncovered stacks lying in the open,

store under cover and away from open doorways

• If stacks cannot be kept under cover, erect simple

scaffolding around them and cover with a

waterproof sheet, tarpaulin or polythene. Leave

space between cover and sheets to allow air to

circulate

• Store stacks off the ground and on a slope so that,

should rain penetrate the covering, the water will

drain away

• Inspect the storage site regularly to ensure that

moisture, despite the above precautions, has not

penetrated the stack

• Care should be taken to avoid condensation

staining between the sheets

• Do not store sheets where people will walk across

them

Handling Individual SheetsSingle sheets are relatively light, but long sheets can

be difficult to handle in windy conditions. Sheets up to

about 14 metres long can usually be handled by two

operatives. A third operative is required for sheets up

21 metres, and a fourth for sheets up to about 28

metres. These are approximate figures, and may need

amendment in windy weather, or on roofs with difficult

access. Sheets should be carried on their side.

After the works have been completed all damaged and

waste materials (including packaging) should be

disposed of in accordance with appropriate Health and

Safety Regulations and in accordance with

Environment Agency guidelines.

Aluminium – Site Safety, Handling & Storage

38


End LapsThe RigiSystems Lokroll cladding system has been

designed to provide a single sheet length running from

ridge to eaves.

Long lengths can be end lapped on site by cutting the

rib or standing seam.

End laps are required where:

� Large vents or ducting penetrate the RigiSystems

Lokroll, requiring a larger soaker

� Rooflights are positioned at mid slope, requiring a

soaker

� There is restricted access on site t handling long

sheet lengths

� The overall roof slope exceeds the maximum sheet

length

� There is a restriction in headroom, preventing the

RigiSystems Lokroll sheets being rotated and roll

locked into position.

End laps should be positioned upslope from a purlin at

approximately 150mm with a minimum overlap of

200mm.

For a pitch greater than 5° the overlap joint must be

fixed with Bulbtite rivets and sealed with Silka flex IIFC

sealant. For a more secure overlap and any pitch below

5° site welding will ensure that there are no

penetrations of the external weathering skin.

Miscellaneous

Bulbtite Rivets

39

Installation – Measurement & Setting OutSetting Out LineThe roofing drawings should show the datum for setting out; this will usually relate to a frame, rafter, wall, or prominent feature. It is important that the Lokroll sheets are set out correctly relative to the setting out line, otherwise verge flashings may not fit, openings could be in the wrong place, etc.

Setting Out The BracketsUsing two fasteners into light gauge purlins, the bracket support and fastener assembly has a proven minimum safe working load of 3kN. To calculate the maximum centres of the brackets along the support bar the main purlin centres in metres (M) is required along wit the design wind uplift loading in kN/m_ (W). The following formula is then applied:

Maximum bracket = 3

spacing

M x W

For example purlins at 2 metre centres with a design

wind uplift loading of 1.4 kN/m_:

Maximum bracket = 3

spacing = 1.07 metres

2 x 1.4

The brackets should be fixed at convenient centres

below the calculated maximum e.g. 1-metre spacings.

Installing The Bar & Bracket SystemFollowing the installation of the liner sheet and

continuous vapour control layer the brackets are fixed

in place at the predetermined centres using standard

self-drilling fasteners. For steel purlins up to 3.5mm

thick the use of Corofix® Topex 14 self-drill screws are

recommended and Corofix® Topex-24 fasteners for

hot rolled sections.

For refurbishment applications the use of Corofix®

Topex High Thread fasteners is recommended to

provide firm independent support and maximum

stability. To prevent damage to the existing structure

the pre-drilling of 5.8mm diameter clearance holes is

advised.

A requirement of new Building Regulations is to

achieve an insulation layer that is ‘reasonably

continuous’ over the building envelope. With mineral

fibre insulation it is essential that all edges are closely

butted together and that there are no gaps or holes.

When the Corogrid brackets are fixed in place install the first layer of insulation with staggered butted joints taking care to ensure the insulation layer is continuous and without any gaps. Due to the unique way the Corogrid system is fixed (i.e. the brackets are fixed prior to the application of the support bar) the continuity of the insulation is maintained.

When the brackets are fixed in place, the support bar is simply rotated into a secure position at 90° to the brackets. A bracket should always be positioned within 75mm from the leading end of a support bar so that the joint is not subject to bending.

The second layer of insulation is installed over the Corogrid bar and bracket system again with staggered butted joints to ensure a continuous insulation layer is created.

Note: Template required for correct fixing, see page 2

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The Eaves Setting Out Line

The drawings should show the intended position of the end of the sheets at the eaves. On conventional roofs, it is usually best to set out a string line at the eaves and set out the sheets from that line. Any tolerance in the sheet lengths will then be hidden under the ridge flashing.

However some roofs, such as barrel vaults and bowed ridges, have two eaves lines and no ridge flashing. In these cases a string line is still helpful as a guide, but any discrepancy in length is best shared between the two sides. The tolerance in the length of a Lokroll sheet is quite small.


Installation – Ridge DetailBecause Lokroll is installed to roof pitches as low as 1.5°, special provisions are made at vulnerable details, i.e. the ridge. The pan of the sheet is turned up using a special tool, and the profile filler is held in a metal shroud to give the filler rigidity and to protect it against degradation by ultra-violet light.

The filler assembly is located in a ridge retainer section which is rivetted to every profile crown. The flashing is attached to the ridge retainer at maximum 300mm centres.

Installation – Eaves DetailWeather ProtectionAll the rainwater which falls on the roof must eventually drain away at the eaves. It is important that this

water should discharge cleanly into the gutter and not be blown back through the seams or under the sheets. The seams are closed at the eaves by means of profiled foam filler blocks. A drip angle is used to prevent water being blown back under the roof. The profiled fillers are positioned directly over the drip angle, which in turn is rivetted to the trough of the RigiSystems Lokroll sheets with at least two rivets per sheet. These fasteners also retain the fillers. On very shallow slopes (3° or less) it is useful to turn down the ends of the sheets so that discharge is more complete and there is less risk of dirty stains forming at the end of

the sheet.

Thermal MovementOn most roofs, the fixed point is at the ridge. This means that the maximum amount of movement takes place at the eaves and due allowance must be made for this. The sheets must be long enough to discharge into the gutter at all times and the clearance behind the drip angle must be sufficient to allow unrestricted movement.

The Drip AngleThe drip angle serves two other functions. It has the aesthetic value of holding the sheets in a good straight line and it provides structural support in the event of the end of the sheet being subjected to foot traffic. The drip angle is 30mm x 60mm deep and made of 2mm thick aluminium.

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Installation – Verge DetailLokroll requires a starter bar, which is manufactured

from 1.6mm thick galvanised steel. The starter bar is

fixed to the Corogrid spacer bar using self-

drilling/tapping screws incorporating a 16mm diameter

bonded washer. After securing the starter bar, the first

tier of Lokroll sheet can be installed. This is achieved

by rolling the sheet over the starter bar and securing

the sheet with a washered fixing in the underlap of the

profile. the fixing template must be used to ensure the

integrity of the installation and to maintain the cover

width.

After the first sheet has been installed, the gable

retainer clip is attached. The gable retainer clip is a way

of installing the verge flashings with few visible

penetrative fixings. It is fixed to the Lokroll seam using

‘Bulbtite’ rivets at 400mm centres. As additional surety

in this location a single run of 15 x 2mm butyl mastic

strip is sandwiched between the Lokroll sheet and the

gable retainer clip and similarly between the gable

retainer clip and the verge flashing.

The opposing end of the roof slope does not require a

support section but otherwise the assembly is

unchanged.

If aluminium Lokroll is being used, the gable starter bar

will be slotted in the same manner as the Lokroll

sheeting, with the aluminium spreader washer and

nylon bearing washers being used.

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Lokroll Start Verge - Steel

Lokroll Finish Verge - Steel

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Lokroll Start Verge - Aluminium

Lokroll Finish Verge - Aluminium

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