UK
January 2008
Roof Tile
Insulated Roof Panel System Installation Guide
Insulation Built-in
Introduction
This document describes in full the installation procedures and good practice which should be adhered to when installing the Kingspan Roof Tile insulated panel system. This installation guide should be read in conjunction with the project specific design drawings and method statements. Care should be taken to ensure that this guide is read and understood in its entirety prior to any site work commencement. Should any procedure not be understood, or, if the works being undertaken are not covered by this guide, please consult envirocare Technical Services on 0800 5870090. This guide is to supplement the training course offered to all installers by Kingspan, which is recommended prior to any product installation. Installation details given in this guide are current recommendations for Part L2 Building Regulations (England & Wales) and Section 6 (Scotland) compliance effective from April 2006 and those required for compliance with LPCB certified systems. It is the responsibility of the fixing contractor to ensure that project specific details are compliant to Part L2 Building Regulations (England & Wales) and Section 6 (Scotland), prior to any site installation.
Safety Issues
The installation of roof and wall panels on any building must be planned carefully to ensure the work can proceed in safety. The roofing and cladding contractor must carry out the necessary Risk Assessments and prepare the Method Statements to suit each particular project for their client taking into account the detailed fixing recommendations of this installation guide. This method statement should indicate who is responsible for safety, and particularly what safety equipment will be used for each stage of the work and the sequence of work from delivery to installation to ensure compliance with current CDM, health and safety issues/ requirements for the safety of site operatives. Although this installation guide is deemed to be correct at the time of publication, Kingspan Limited will accept no responsibility for any errors, omissions or misinterpretation of the information within. We reserve the right to amend the information at any time in the future.
For further guidance on the above, we refer you to the following current publications and information sheets available from the H.S.E. Health & Safety Executive. Contact - The H.S.E. Infoline on 0845 3450055 Web: www.hse.gov.uk. Construction Design & Management Regs The Working at Height Regulations Height Safe - Essential Health & Safety Information for People Who Work at Height Management of Health & Safety at Work Lift Operators and Lift Equipment Regs Manual Handling Regulations Health & Safety at Work Act 2007 2005
Receiving Deliveries
Kingspan panels are factory-packed according to panel dimensions, to ensure arrival on site in pristine condition. Panels packed horizontally. Pack size varies according to panel thickness and panel length. All packs labelled clearly identifying product type and pack weight. Whole pack protected with various materials - Fluted cardboard at bottom/top - Protective film to weathering face of panels - 2 No. sheets of fluted cardboard between each panel (full length) - Fluted cardboard at both ends - Plastic hoods at both ends - Polystyrene blocks on one side of pack - Cardboard corners on both sides of pack (on top panel - full length of pack) - Pack shrink wrapped in plastic film, secured with sticky tape.
Note: In addition during winter period, cardboard sheets or foil wrapping are used on both ends and both sides of pack.
Packs delivered on timber pallets with gaps for offloading using forklift, crane forks or lifting beam with slings. Fully timbered crates are available on request at an extra cost, please contact our sales office.
Customer name, address etc Panels packed horizontally - sides and ends protected Number of panels varies Factory packed Gap for forklift offloading
Notes: Roof Tile panels are stacked weather face down. Roof Tile panels have a protective film applied to the weathering face which needs to be removed prior to installation.
*Packs of panels up to 9 metres can be safely off-loaded with front loaders with the following provisos: 1. Minimum number of panels in a pack is 3. 2. Ground to be level and reasonably firm. 3. Speed of truck to be 5mph maximum - Extreme care to be taken.
2m max
3m max
3m max
2m max
Safe Storage
To ensure panels remain in prime condition while stored onsite, the following precautions should be taken: At ground level: Allocate safe, clean, trade-free area. Prevent personnel from walking over packs. Store panels on a slight slope ensuring any penetrating rainwater drains off. Inspect packs regularly. Where panels are to be stored for more than 3 months, call the envirocare Technical Services on 0800 5870090.
Slope to drain water off panels
Exercise caution when opening packs stored at an angle. There is a danger of panels sliding to the side and in the direction of slope. Individual panels will have low tack adhesive tabs in between and some may have protective film applied (depending on the type of coating) which needs to be removed prior to installation.
2m
2m
At roof level: When storing panel packs on loading platforms check that the scaffolding is sufficient and capable of supporting the weight of the packs. Prior to installation panel packs must be securely tied to the loading platform to prevent movement.
Packs of panels that have had the packaging removed at ground level and need to be lifted to the roof level, will require banding. A propriety band/sling system should be used, taking care not to damage the panels.
Product Data
Panel & Tile Length
325mm Panel le ngth
A - Core Thickness (mm) B - Overall Dimension (mm) Weight kg/m2 0.7/0.4 steel
45 85 12.58
60 100 13.23
*These panel thicknesses are recommended for Part L2 (England & Wales) and Section 6 (Scotland) based on the minimum U-value requirement
100mm
50mm 160mm
When using Kingspan Roof Tile panels, consideration must be taken when ordering the required length of panel. Use the table to select the panel length nearest to that required. Variance in the panel length is taken up under the ridge flashing. When detailing the ridge junction the designer must ensure that the chosen panel length is long enough to provide a sound practical junction detail. In practical terms a shortfall of length no greater than 40mm from the ridge line will ensure good insulation continuity of the infill insulation. Where this is not the case the next panel size up must be chosen and the surplus length cut to suit the site dimension. Panel Lengths (mm) with Standard 160mm Cut Back
No. Of Tiles 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Tile Pitch No. Of Length Tiles 325mm 2100 2425 2750 3075 3400 3725 4050 4375 4700 5025 5350 5675 6000 6325 6650 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Tile Pitch Length 325mm 6975 7300 7625 7950 8275 8600 8925 9250 9575 9900 10225 10550 10875 11200 11525 No. Of Tiles 36 37 38 39 40 41 42 43 44 45 46 47 48 Tile Pitch Length 325mm 11850 12175 12500 12825 13150 13475 13800 14125 14450 14775 15100 15425 15750 mm 50
Available Lengths
Kingspan Roof Tile is manufactured cut to length in a continuous manufacturing process. Standard lengths are available between 2.10 and 15.75 metres.
Note: Roof Tile panels must be installed in one single length, eaves to ridge. Where roof slope lengths exeed the maximum panel lengths please contact our Field Service Engineers.
Consideration must be given to lifting and handling methods, especially where steeper roof pitches are contemplated. In practical terms advanced handling techniques should be considered if lengths over 6.0 metres are being considered. Panel length is defined as the overall length of the outer sheet including the end overlap.
Panel le ngth
Components
Kingspan Roof Tile Panel
Primary/Main Fastener
Secondary/Stitching Screws
Gun-Grade Sealant
Kingspan Roof Tile System Product Data
Product Data
Panel End Cut Back
All panels are produced with a standard cut back of 160mm, but can be supplied to special order with a cut back of 100mm.
Note: If 100mm end lap cut backs are required this reduces panel lengths shown in table by 60mm (only available for panels up to 6325mm in length).
Cut ba c 160mmk
Product Tolerance Panel size to suit the projects needs can be chosen from the length table on page 6 of this handbook.
Cut to Length Liner Sheet Length Cover Width Thickness End Square -0.05% -0.1% -0mm -2mm -3mm +0.1% +0.1% +3mm +2mm +3mm
Good practice recommends a fully boarded scaffold around the perimeter of the building with loading platforms for panels, triple hand rails and toe board, as well as walkway stagings and safety nets, to ensure compliance with current CDM, health and safety issues/requirements. Due to the steepness of pitch roofs, we do not recommend loading packs of panels onto purlins (Kingspan Multibeams). We recommend the use of mechanical handling systems for the movement and lifting of panels into position. Always check the current certification of the crane, crane forks, lifting beam, slings, forklift or specialist lifting equipment prior to carrying out off-loading/hoisting operation (i.e. with correct current SWL Certification). Propriety personal protective equipment and clothing should be worn including gloves to avoid cuts and abrasions to operatives. We recommend that any panel cutting done on site is preferably carried out at ground level or alternatively at roof level depending on roof pitch in a designated area/safe working environment.
Before starting any project it is important that the project specific contract drawings are available on site, giving the details at the various interfaces on the project. (i.e. eaves, ridge, verge etc.), including the panel fastener requirement diagram giving the exact fixing type, quantity and location. Prior to commencing any installation the configuration and dimensional accuracy of the supporting structure should be compared with the approved plan drawings. Check roof pitch is a minimum of 12 - after deflection. Kingspan Roof Tile is manufactured to a module length based on a tile pitch length of 325mm see table on page 6. Cutting panels to length on site may be required.
Note: Roof Tile panels must be installed in one single length, eaves to ridge. Where roof slope lengths exeed the maximum panel lengths please contact our Field Service Engineers for further assistance.
10
Steel (or timber) must be lined and leveled in accordance with the requirements of the contract document. Check the roof steelwork (or timber) visually for any damage or distortion. Valley and boundary wall gutters must be securely fixed in position where applicable.
Air/Vapour Sealing Building Perimeter See Typical Construction Details on pages 21 to 26. Check cleader angle is installed to verge with air seal vapour flex sealant applied at joints. Apply 8mm non-curing gun-grade sealant to the top face (6mm to the gable cladding face in due course).
Where practical check that the purlin centres coincide with a multiple of the tile pitch length, so that the primary fastener is located in the same position throughout the slope. As work progresses across the roof, areas to be regularly walked over or where materials are to temporarily stored should be identified and protected. Traffic should use walkways to avoid damaging the finish on the panels. At all times during the fitting of the roof, the painted panel surface must be kept clean and clear of debris and small objects that may present a scratching or abrasion hazard. Care must be taken at all times not to drop objects on the roof or slide panels etc. across the surface of the roof, as this is likely to result in damage to the paint.
Roof Tile gutter apply vapour flex sealant between Kingspan Eaves Beam joints - apply 8mm non-curing gun-grade sealant to the top face of Kingspan Eaves Beam (6mm to front face in due course). Boundary wall gutter - install gutter and apply 8mm non-curing gun-grade sealant to gutter wing. Check internal ridge flashing is installed with 150mm overlap, sealed with vapour flex or gungrade sealant and apply air seal - 8mm noncuring gun-grade sealant.
10
11
Lay the first panel at the edge of the roof area to be clad, ensuring it is correctly aligned, levelled and the right way round for lapping. Remove the protective film.
Note: Panels are manufactured to suit a left to right direction of lay.
Internal ridge flashing with 150mm overlap sealed with air seal, Vapourflex or gun-grade sealant Air seal - 8mm noncuring gun-grade sealant
P1
Cleader angle
Directi on of lay
Cleader angle provided by others Air seal - 8mm gungrade non-curing sealant Air seal - 8mm non-curing gungrade sealant Air seal - 6mm approx bead of non-curing gungrade sealant
Note: If air sealing line is required within the building line this should be the responsibility of the contractor.
12
b
Internal ridge flashing
Fix first panel (P1) with 3 No. main fasteners (minimum) per purlin (Kingspan Multibeam).
a
Apply bead of 8mm non-curing gun-grade sealant to ridge, verge and eaves positions before first panel is installed
Install the recommended main fasteners by through fixing panel at each purlin location to the standard fastener layout positions.
Note: The number of fasteners will vary dependant on the wind suction load. Quantities should be calculated by the Roofing and Cladding Sub-Contractors with the assistance of the Project Structural Engineer/LPCB Specification Requirement. Number of fasteners will vary, minimum 3 no., when fixing to cold rolled purlins. Do not over-tighten fastener - refer to the fastener suppliers recommendations for settings. Any drilling swarf must be removed from the panel to prevent damage to the coating/corrosion.
Refer to item 4
13
When the panel is fully fixed site apply a 6mm bead of non-curing gun-grade sealant (preferably white) at the base of the side joint for air sealing. Site apply a 6mm approx non-curing gungrade sealant to top of panel at the side joint as per detail above for weather sealing. (See panel side lap detail). Site apply a 6mm approx bead non-curing gun-grade sealant at panel side joint in line with eaves and ridge air sealing line.
e
Apply a 6mm approx bead of non-curing gungrade sealant at panel side joint in line with eaves and ridge air sealing. P1
c
Apply a 6mm approx. bead of non-curing gungrade sealant (white) at the base of side of the side lap for air sealing.
Directi on of lay
d
Apply a 6mm approx bead of non-curing gun-grade sealant to top of panel at the side joint for weather sealing.
14
See item c
Lower the next panel (P2) into position pushing the panel in an upwards direction, ensuring the Roof Tile module interlocks and the panels are lined/levelled and square to one another. Check that the side joints are tight together at the eaves and ridge positions. Install the recommended main fasteners by through fixing panel at each purlin location to the standard fastener layout positions (as previous).
g
Fix second panel (P2) with 3 no. main fasteners per purlin (minimum).
P2 P1
Push panel in
up el an p sh Pu
See item e
Directi on of lay
f
Lower the next panel (P2) into position pushing in an upwards direction, ensuring the Roof Tile module interlocks and the panels are lined/levelled and square to one another. Check that the side laps are tight together at the eaves and ridge positions.
15
See item d
See item c
Install side lap stitchers at 325mm centres positioned near the base of the step of every tile (see detail).
res ent mc m 5 32
Half-round ridge trim See item i Ridge trim inner with 150mm overlaps sealed Stitching screws as required
j
Fix ridge flashing
Apply a 6mm approx bead of non-curing gungrade sealant at panel side joint in line with ridge air sealing
h
Install side lap stitchers every second tile positioned near base of step at 325mm centres (every tile). See detail above.
16
i
Add the correct profile filler applying gun-grade sealant both top and bottom. The filler should be positioned 80 to 100mm behind the ridge overlap edge to prevent bird attack.
17
Ensure that every fourth panel is checked from the original setting out point, to ensure that creep does not occur. Continue to lay the panels to complete the roof enclosure. Repeat the process from 1 - 8 .
10
If the panels have to be cut on site always use a reciprocating saw (jigsaw or similar) or evolution type circular saw (with a tungsten tipped blade), do not use abrasive wheel cutters. After cutting remove swarf from the panel surface and any burrs from the cut edges. Treat any site cut edges that will be exposed with edge protection lacquer.
18
Valley Ridge Detail In-situ weathering system by specialist contractor Site applied 6mm bead of non-curing gun-grade sealant for air sealing
Air seal 8mm noncuring gungrade sealant Low profile headed panel fastener Hip rafter
Internal valley hip trim with 150mm overlap sealed with Vapour seal Vapourflex or gun-grade sealant Gun applied fire rated canister insulation Cleader angle by steelwork contractor Hip Ridge Detail Half round hip trim Colour headed rivets or stitching screws at 400mm centres Add the correct profile filler applying gungrade sealant both top and bottom. The filler should be positioned 80 to 100mm behind the ridge overlap edge to prevent bird attack Ridge trim inner with 150mm overlaps sealed Weather seal between panels with Vapourflex tape Gun applied fire rated canister insulation Stitching screws as required
19
Due to panel handing we would suggest that where panels start from hip or hip valley locations that the first panel is positioned away from the starting location at the minimum possible dimension, which would ensure that the correct working line can be achieved. The roof area behind the starting panel should be infilled by carefully back lapping the panels.
Direction of lay
Stitcher at 400mm centres Gun applied fire rated canister insulation Stitcher at 400mm centres
Profiled filler (15mm base) sealed top and bottom with gun-grade sealant Low profile headed panel fastener Air seal - 8mm non-curing gun-grade sealant
Internal ridge trim with 150mm overlaps sealed with air seal Vapourflex or gun-grade sealant
Site applied 6mm bead of non-curing gun-grade sealant for air sealing
Profiled filler (15mm base) sealed top and bottom with gun-grade sealant Low profile headed panel fastener Air seal - 8mm non-curing gun-grade sealant
Internal ridge trim with 150mm overlaps sealed with air seal Vapourflex or gun-grade sealant
Site applied 6mm bead of non-curing gun-grade sealant for air sealing
Note: Project specific construction details must be used. Please refer to the Kingspan Design and Construction Guide for further information.
21
Cleader angle by steelwork contractor Air seal - 8mm noncuring gun-grade sealant Kingspan Roof Tile insulated panel
Note: Project specific construction details must be used. Please refer to the Kingspan Design and Construction Guide for further information.
22
Kingspan Multibeam
Note: Project specific construction details must be used. Please refer to the Kingspan Design and Construction Guide for further information.
23
Air seal - 8mm noncuring gun-grade sealant Low profile headed panel fastener Cleader angle by steelwork contractor Gun applied fire rated canister insulation Kingspan Multibeam Internal valley hip trim with 150mm overlap sealed with Vapour seal Vapourflex or gun-grade sealant Hip rafter
Note: Project specific construction details must be used. Please refer to the Kingspan Design and Construction Guide for further information.
24
Verge Details
Roof Tile panel setting out position on 200mm tile width
Stitcher screws at 400mm centres Site cut panel to provide setting out point Bullnose verge flashing Profiled verge filler Panel fastener Kingspan Roof Tile insulated panel
Gun applied fire rated canister insulation Cleader angle Stitcher screws at 400mm centres 4mm butyl seal
KS1000 MR vertically laid insulated wall panel Air seal - 8mm non-curing gun-grade sealant Rafter
Note: Project specific construction details must be used. Please refer to the Kingspan Design and Construction Guide for further information.
25
Note: Project specific construction details must be used. Please refer to the Kingspan Design and Construction Guide for further information.
26
Gun Canister Applied Foam ALFAS 0191 419 0505 Kincora 0161 873 7713 GRP/PU Penetration Solutions Aperture 0161 772 1750 Jones & Woolman 01922 712111 Touch Up Paints Breakwell Paints Safety Systems Saferidge 01922 400444 0141 954 2666
Mechanical Handling Systems Clad-Boy 01900 85477 Oktopus UK Ltd 01527 570111 Kera Ltd 01684 276606 Speedy LGH Tele Handler Merlo (GT Plant Hire) Crane Hire John Sutch Cranes City Lifting Ltd Oktopus UK Ltd Midland Cranes Ltd 0151 3572906 01903 753630 0151 2368880 01708 805550 01527 570111 0845 0031322
Any queries on the above please contact Kingspan envirocare Technical Services; Tel: 0800 5870090 or your local Field Service Engineer: Northern Field Service Engineer Steve Ball 07775 633358 Billy Delamere 07747 007381 (North East) Southern Field Service Engineer Andy Veater 07919 112507 (West) Allan Kelly 07796 610009 (East) Head Office Main Switchboard 01352 716100
27
Kingspan Envirodek
KS1000 RW Trapezoidal
Kingspan Thermatile
Kingspan Thermabrick
Kingspan Thermastone
Ancillaries
Gutters, Tophats & Flashings
Kingspan Limited
UK: Telephone: +44 (0) 1352 716100 Fax: +44 (0) 1352 710161 Email: info@kingspanpanels.com Ireland: Telephone: +353 (0) 42 96 98500 Fax: +353 (0) 42 96 98572 Email: sales.ire@kingspanpanels.com Details for the following countries; Australia, Belgium, Czech Republic, Germany, Hungary, Netherlands, New Zealand, Poland, Romania, Slovakia, France can be found by visiting our website www.kingspanpanels.com or our group website www.kingspan.com
Care has been taken to ensure that the contents of this publication are accurate, but Kingspan Limited and its subsidiary companies do not accept responsibility for errors or for information that is found to be misleading. Suggestions for, or description of, the end use or application of products or methods of working are for information only and Kingspan Limited and its subsidiaries accept no liability in respect thereof.