I n s u l a t e d Pa n e l s

CI/SfB (47) Nh2 January 2004

roof tile
Insulated Panel System

Insulated Panels to the Power of

Insulation Built-in

Traditional roof construction supported by modern technology

Insulated Panel System

Application
Product Application Product Benefits Steel Support Structure Application Timber Support Structure Application Mansard Application Capella Over-Roofing Application

Application

Product Data and Specification

Product Data and Specification

Load Span Tables Fasteners Model Specification Timber Structure Application

10

Panel Dimensions and Specifications

Construction Details

Site Handling, Storage and Installation

Construction Details
Eaves and Boundary Details Ridge, Valley and Hip Details Lean-To, Mansard Details Change in Roof Slope Details Penetration Details

18

Panel & Tile Lenght Table

Apex Fillers

Site Handling, Storage 34 and Installation

Safety Site Handling and Storage Fixing Method Cutting Panels

Panel & Tile Length Table Apex Fillers

44 46

a traditional appearance, with all the benefits of lightweight fast track construction

Application
The Kingspan Roof Tile Insulated Panel is a through fixed roof panel suitable for industrial, commercial, retail and leisure projects with a roof pitch of 12 or more. The Roof Tile panel offers a traditional appearance, with all the benefits of lightweight fast track construction. The panels provide exceptional performance in fire situations and are LPCB approved to LPS 1181.

KIngspan Roof Tile

80% lighter than traditional tiled roofs

Benefits
Speed of Construction

Single-fix installation gives 50% faster construction times than built up alternatives Eliminates the need to fix individual tiles Fixes directly to purlins - no need for battens, roof felt and separate insulation materials No wet trades required

Insulated Panel

Fire Rated - LPCB approved to LPS 1181 Complies with Part L Building Regulations effective from April 2002 Guaranteed U-values Lightweight - 80% lighter than traditional tiled roof construction offering savings on roof support structure Warm roof construction provides 100% consistent thermal performance Low air leakage rate can reduce heating costs by over 20% Fixes to all types of roof structure

KIngspan Roof Tile

Construction Applications
The Kingspan Roof Tile design details and components can be applied to all forms of construction. Its design flexibility allows its use on conventional timber sub-structures as well as all contemporary steel construction. Kingspan Roof Tile complements these construction methods and offers a versatile cost effective alternative to traditional roofing techniques.

Steel Support System

Kingspan Roof Tile is fastened to conventional cold rolled and hot rolled steel sub-structures in the same way as any insulated panel. Kingspan Roof Tile has all the advantages of a composite panel; it provides excellent spanning capacity and stiffness. Purlin centres in the region of 2 metres are easily accommodated in most situations, providing cost effective use of cladding and supporting structure. Kingspan Multibeam provides the ideal design solution for the secondary steel in this type of application.

Timber Trusses & Timber Purlin Systems

Kingspan Roof Tile may be fastened to timber purlins and traditional timber truss construction. When fastening to timber purlins, self drill fasteners of correct dimension and threadform ensure connection integrity between the panel and the support structure. When using the Kingspan Roof Tile with conventional timber truss construction, the Kingspan Tile Lath provides the connection interface. Kingspan Tile Lath is a steel top hat section purlin spanning between the timber trusses; it is positioned generally at centres up to 1.5 metres to ensure best design interaction with the truss design. Advice to designers on the use of Kingspan Tile Lath is outlined on page 16 of this handbook.

Construction Applications

Mansard System
Many commercial buildings call for the functionality of a flat roof construction but still require attractive traditional appearance to suit the aesthetic needs of the designer and the local planning needs of the project. Kingspan Roof Tile, used on a mansard construction in conjunction with Kingspan Topdek insulated membrane faced panel, provides an attractive and innovative design solution. Conventional tile systems cause complexity for the structural design of the mansard steelwork, due to weight and fixing considerations. Kingspan Roof Tiles spanning capability and light weight uses conventional detailing methods to produce the desired effect while ensuring that insulation integrity is maintained.

Kingspan Capella Flat to Pitched Over-Roofing System

The Kingspan Capella system is a unique and innovative method of providing a pitched over roof refurbishment for existing flat roofing. The design concept converts failing conventional flat roofing systems to a more attractive pitched roof, without imposing undue load on the existing construction. Kingspan Roof Tile complements this system by providing a complete change in the visual appearance of the building envelope, thus enhancing the function and value of the refurbishment scheme.

KIngspan Roof Tile


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liner seals can be easily installed during construction to provide a high degree of air and vapour seal to the building envelope

Product Data
Applications
The minimum pitch to ensure water run off and best self cleaning of the tile surface is 12 . The sealing and construction details shown in this handbook are applicable to all roof pitches above this minimum pitch.
Overall panel width (mm) Weight kg/m2 0.7/0.4 Steel 1141 12.58 1150 14.10
o

Dimensions & Weight

Dim A - core thickness nominal (mm) Dim B - overall dimension (mm) 45 85 80 120

1000mm cover width 200mm 40mm

B

The panel is available in two insulation thicknesses. Changes to Building Regulations in May 2004 demand that the minimum U value for roofs is to be 0.25 W/m2.K. Where the panel provides all insulation for the roof structure, the 80mm core thickness provides this value. Where insulation may be provided elsewhere in the construction, such as in the Capella over roof system, the 45mm panel will provide additional insulation and the structural stiffness required to take advantage of the spanning properties needed for cost effective construction. Panel Side Lap
45/80mm

Core Thickness - Dimension A

Factory applied side seal Site applied butyl (SX0006BG) seal for high humidity applications and air sealing

Materials
Kingspan Roof Tile sheets comprise steel facings encapsulating a fire rated rigid urethane insulation core. The steel facings are available in a number of material options to suit specified design conditions. Weather Side Coating External weather side coating is of a high performance polymer coating 50 micron thickness on a primer coat. Available colours are Terracotta and Anthracite.

Internal Liner Coating A variety of finishes are available to suit the internal conditions of the building. Standard bright white liner enamel is satisfactory for normal internal environments. Liner enamel is a 22 micron thick coating providing an easy clean surface. Where internal conditions are more demanding, such as high internal humidity or clean conditions Plastisol or Foodsafe coatings are available, subject to minimum quantity. Steel Substrate External Face 0.7 mm nominal thickness hot dipped coated steel to Grade Fe 220 G to BS EN 10147. Steel Substrate - Internal Liner 0.4 mm nominal thickness hot dipped coated steel to Grade Fe 220 G to BS EN 10147.
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Product Data and Specification

Product Data
Available Lengths
Kingspan Roof Tile is manufactured cut to length in a continuous manufacturing process. Standard lengths are available between 1.8 and 16.0 metres. 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.

Tile Pitch
Kingspan Roof Tile is manufactured with standard end laps and pitch length. Manufactured panel length is therefore a multiple of the pitch. The pitch length of the Roof Tile is 325mm with a standard eaves overhang of 150mm. In circumstances where the panel length is greater than the roof pitch the panels are site cut at the apex and the junction covered by the apex flashing.
h Length Tile Pitc

Panel L ength

Product tolerances
Panel size to suit the projects needs can be chosen from the length table on page 41 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

Implications of Panel Length

When the distance from eave to apex dictates the use of panel end laps, consideration should be given to the relative position of the nearest purlin. When considering timber truss construction, the appropriate panel length is chosen from the table on page 41, and the Kingspan Tile Lath positioned to suit the recommended detail (Ref 11.1). When considering conventional steel or timber purlin construction, panel length will dictate the position of the end lap relative to the supporting steel. Timber Truss Construction - Ref 11.1
Position Kingspan Tile Lath to suit joints

Ideally it is advantageous to position the purlin to suit the general end lap detail (Ref 11.2). However, should this not be possible then the use of a purlin extension plate may be considered providing loading conditions for the connection are satisfactory (Ref 11.3). All well designed roofing schemes benefit from good setting out. Kingspan Technical Services can provide advice on this and all aspects of the design and installation of Kingspan Roof Tile.

General Panel End Lap - Ref 11.2

End Lap with Extension Plate - Ref 11.3

Position purlin to suit panel joint positions

Lap extension may be required with existing steelwork

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Product Data
Insulation Core
insulation core providing a non-deleterious closed cell insulation.

No flash over No flame spread No flame propagation

Air leakage
Less than 10m3/hr/m2 to comply with Building Regulations when fitted in accordance with good detail and site workmanship. Low air leakage specifications are available on a project-by-project basis.

Acoustics
Kingspan Roof Tile panels have a single figure weighted sound reduction Rw = 25dB. Sound Reduction Index (SRI)

Seals
Factory Applied Side Joint Tape All Kingspan Roof Tile panels are supplied with a vapour control tape to side laps. Site Installed Seals Additional liner seals can be easily installed during construction to provide a high degree of air and vapour seal to the building envelope.

Frequency Hz 63 125 250 500 1k 2k 4k 8k

SRI dB 14 14 19 24 27 34 43 52

Performance
Thermal Insulation
Panel Thickness nominal (mm) 45 80
U - Thermal transmittance W/m2K l - Long-term Thermal conductivity W/m2K

Specification Specifications are available from Kingspan Technical Services Department on: Telephone: 042 9698529
U-value W/m K l = 0.020 0.45 0.25
2

Email: sales.ire@kingspanpanels.com

Quality
Kingspan Roof Tile system is manufactured from the highest quality materials, using state of the art production equipment to rigorous quality control standards, complying with ISO9002 and EN29002 standards, ensuring long term reliability and service life.

Biological Kingspan Roof Tile panels are immune to attack from mould, fungi, mildew and vermin. No urea formaldehyde is used in the construction, and the panels are non-deleterious. Fire Kingspan Roof Tile is approved by the Loss Prevention Certification Board (LPCB) to LPS 1181. Kingspan Roof Tile panels have a core which has been specially formulated to provide the following benefits: Load Span Table - Uplift
Span (m) Single Double Continuous 1.0 10.71 9.95 14.82 1.2 7.50 6.98 10.35 1.4 5.57 5.18 6.56

Guarantees & Warranties

Kingspan will provide product warranties and guarantees on an individual project basis.

Delivery
All deliveries (unless indicated otherwise) are by road transport to project site. Off-loading is the responsibility of the cladding contractor or installer.
1.6 3.93 4.02 4.44 1.8 2.79 3.22 3.15 2.0 2.07 2.65 2.33 2.2 1.59 2.23 1.78 2.4 1.25 1.91 1.40

Load Span Table - Downward

Span (m) Single Double Continuous 1.0 13.31 8.68 13.11 1.2 9.19 5.98 9.05 1.4 6.71 4.35 6.61 1.6 5.00 3.29 4.77 1.8 3.48 2.57 3.31 2.0 2.50 2.05 2.38 2.2 1.85 1.67 1.76 2.4 1.40 1.38 1.33

Product Data and Specification

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Stable protective char

Product Data
Fastener Positions & Types
Standard Fastener Layout

*Additional fasteners to suit wind uplift conditions

Panel End Lap

*
Panel Side Lap - Conventional

Panel Joint on centre of purlin flange

Direction of Lay
The panels are manufactured to suit a left to right direction of lay. The panels must be back lapped when sheeting hips and valleys. The back lap fixing positions must change as noted below in detail (Ref 13.1).
Back lap

Direction of lay

Panel Side Lap - Back Lap - Ref 13.1

Direction of lay

Back lap

Direction of lay

Fastener Reference
Specification Type Panel Thickness (mm) 45 80 Panel Thickness (mm) 45 80 Self-Drilling/Tapping Fasteners to Cold Formed Purlin FX90 (Austenitic Stainless Steel, Grade 304) FX91 (Austenitic Stainless Steel, Grade 304) Stitching Screw FX95 (Austenitic Stainless Steel, Grade 304) FX95 (Austenitic Stainless Steel, Grade 304) Self-Drilling/Tapping Fasteners to Hot Rolled Purlin FX190 (Austenitic Stainless Steel, Grade 304) FX191 (Austenitic Stainless Steel, Grade 304) Self-Drilling/Tapping Fasteners to Timber (min. Embedment 50mm) FX290 (Austenitic Stainless Steel, Grade 304) FX291 (Austenitic Stainless Steel, Grade 304)

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Model Specifications
Roof Panel Application
This specification covers the use of Kingspan Roof Tile on buildings with the normal internal environment comprising of an air leakage rate less than 10m3/hr/m2 and a class 2 humidity to BS EN ISO 13788 (Offices & Shops).

Seals and Fillers

Side Lap All side laps are dry lapped, ensuring good location of the panel during construction. End Lap All end laps to be 150mm long, sealed with a continuous strip of butyl seal SX0006BG across the full width and 10mm down from the top step. Fillers Where fillers are to be used to close off the profile of the panel e.g. under the ridge and verge flashing, they are to be made from black MP insulant.

Materials
Insulation Core insulation core providing a non deleterious closed cell insulation. CFC free in compliance with the Montreal Protocol. Steel Substrate External Face 0.7 mm nominal thickness hot dipped coated steel to Grade Fe 220 G to BS EN 10147. Weather Side Coating External weather coating colour to be Terracotta high performance polymer coating, 50 micron thickness. Steel Substrate - Internal Liner 0.4 mm nominal thickness hot dipped coated steel to Grade Fe 220 G to BS EN 10147. Internal Liner Coating Standard bright white liner enamel 22 micron thick coating providing an easy clean surface.

Assembly
Primary Cladding Fastening All primary fasteners must be of high thread self drill tapping type manufactured from stainless steel. The number of roof fixings and their location must be as recommended by Kingspan and must be able to resist suction loads calculated in accordance with BS 6399 - 2: 1997. A minimum of two fixings at intermediate supports and three at end laps and panel ends must be provided, with a washer of 19mm specifically developed for Kingspan Roof Tile. Location of fixings are noted on detail (Ref 14.1). External Side Laps The panels include a factory applied side tape to the panel edge. External side laps are dry lapped and unstitched. A tight sidelap fit is ensured by careful positioning of the panels during fitting as shown on detail (Ref 14.2). Where an air leakage rate less than that required by Part L (10m3/hr/m2) refer to Kingspan Roof Tile low air leakage specification. Panel End Laps External end laps to be 150mm long and sealed full width of the profile with a single line of butyl mastic SX0006BG (Ref 15.1). A minimum of three fasteners are required at end laps (Ref 14.1).

Performance
Thermal U-value of 0.25 W/m2K for a panel thickness of 80mm derived from an aged thermal conductivity of 0.02 W/m2K. Fire External surface SAA to BS476: Part 3, Class 0 internal face, based on a satisfactory index of performance when tested to BS476: Parts 6 & 7. Complies with insurance approval LPS 1181.

Fasteners
Primary Fasteners All fasteners must be high thread self-drill self-tap screws fitted with 19mm stainless steel washers. The screws will be manufactured from austenitic stainless steel and have a colour matched low profile head. On fixing the profiles the primary fasteners will be placed in the concealed sidelap and the valley of the profile. Stitchers Stitching screws for flashings will be austenitic stainless steel to resist corrosion. Stitchers will be fitted with 14mm stainless steel washers. Panel Dimensions
1000mm cover width 200mm 40mm

Accessories
Apex Detail Purpose designed semi-circular ridge capping, M.P. insulant fillers detailed to suit panel end/apex purlin relationship ref: FRTR__MP. Internal apex trim sealed to the structure to form the primary air seal (Ref 15.2).

Detail 14.2 Side Lap

A B Screw ref: FX91 at each purlin Factory applied seal

Detail 14.1 Fastener Positions

* Third fixing at end lap positions and optional for high wind uplift at intermediate positions

Product Data and Specification

15

Model Specifications
Standard Verge Flashing External ridge trim bedded on verge filler ref: FRTV05MP-325 and fastened at 400mm centres. Internal corner trim to suit, sealed to the panels to form the primary air seal, see detail (Ref 15.3). Supports Kingspan Multibeam purlins not exceeding 2.0 m centres. Flashings All external flashings to be in 0.7 mm thick in finish to match the outer skin of the panel. All flashings and flashing end laps to be sealed with butyl mastic. Inner flashings to be manufactured in 0.7 mm steel with the same finish as the panels inner skin. Structure Check that structure is in a suitable state to receive cladding before commencing fixing. Subcontractor must confirm acceptance to main Contractor and CA. Steel frame to be generally in accordance with BS5950: Part 2 1992. Handling Handle packs/sheets/panels as recommended by Kingspan Limited. When lifting packs by mechanical means, protect the panels from damage. Obtain agreement from Kingspan before lifting packs using fork-lifts. Provide suitable protection between the forks and the underside of the pack. Position slings beneath pack bearers and provide strong backs at top and bottom of packs at sling positions. Where necessary, use lifting beams with the correct number of slings. Land packs gently and evenly on the bearing surfaces to avoid impact damage. When handling panels, do not hold or lift the panel by the top sheet overhang, always grip the insulated section of the panel. Lift panels from the pack without dragging them on the panel below. Carry the panel on edge. Storage Store packs/sheets/panels as recommended by Kingspan. Store packs on the ground with a slight slope along the pack, on timber bearers not more than two metres apart, with at least 100mm between the ground and the underside of the pack. Provide spacing battens on the lines of the bearers between each level of packs and do not stack packs more than three packs high. Where packs are to remain outside for prolonged periods, provide weatherproof covers, ensuring free circulation of air around the packs. Check that the supporting structure is of adequate strength to support the weight of the pack. Lash the pack to the structure to prevent slippage and movement. Detail 15.3 Verge Detail
Profiled filler Fire rated canister applied insulation Verge trim Air seal internal trim to panel liner SX0006BG Cleader angle Screw ref: FX95 at 400mm ctrs

Detail 15.2 Ridge Flashing

Fire rated canister applied insulation Screw ref: FX95 at 400mm ctrs Half-round ridge flashing Profiled filler Air seal internal trim to panel liner SX0006BG

Multibeam purlin

General Fixing of Panels Cut sheets to give clean, true lines with no distortion. Remove burrs and any lubricant. Cut openings in sheets for outlets, vent pipes, flues, etc. to the minimum size necessary. Reinforce edges of openings as specified, or in the absence of such specification, as recommended by the cladding manufacturer. Ends of sheets and end laps to be fully supported. Check correct speeds for standard twist drills and self drilling fastenings and ensure that correct drilling speeds are used. Drill all holes and install all fasteners perpendicular to the surface of the cladding. Holes for primary fastenings for steel and aluminium sheets to be 1.5mm larger than diameter of fastening unless self-drilling type with pilot point is used. Install fastenings in the correct position and to the correct tightness. Ensure that the fastening threads are not stripped, the fastenings are watertight and the sheeting is secure but not buckled or distorted. Remove all drilling swarf, dust and any other foreign matter before finally fixing sheets into position. Protect sheets adequately during site storage, fixing and up to Practical Completion against mechanical damage, corrosion and disfigurement. Rectify any defects in an approved manner and as quickly as practicable to minimise damage and nuisance. Check all visible fastenings on completion and adjust as necessary. Safety The contractor is to determine and use safe working methods throughout the installation and construction period which comply with relevant HSE and CDM regulations.

Detail 15.1 End Lap

Sealant ref: SX0006BG Multibeam purlin
mm 150

4mm PVC seal full width of purlin Screw ref: FX91

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Construction Application
Timber Support Structure
Roof Tile panels can be supported upon any form of timber structure that will support a traditional slate or tile roof. Use of Kingspan Tile Lath steel top hat as the basis of the construction will ensure an efficient solution. Load span and dimensional details are shown below to assist engineering design. The use of steel top hat purlins is advised because:-

The primary cladding can be fixed using standard self drilling, self tapping screws. Whether in steel or timber the purlins will be small, however it is easier to make an effective fixing to the rafter using a steel top hat section than with a small timber purlin. Kingspan Tile Lath
50mm 25mm

The only ways in which the design of the timber supporting structure will differ from a traditional roof design will be:60

The minimum width of timber will need to be selected to suit the size of screw used to fix the top hat to the timber. The reduced weight of cladding will give a saving under dead plus snow loading, but makes wind uplift more critical. The spacing of the purlins will need to be taken into account when checking the actual and permissible stress in the rafter.
25mm 25mm

Kingspan Tile Lath steel top hat section is available in 1.5mm galv. steel to BSEN 10147 in 3m lengths.
Truss Centres 600mm 400mm Allowable downward load kN 6.30 9.50 Allowable wind uplift load kN 4.18 6.30

The following will need to be checked in the same way as they would be with a traditional roof namely:-

Has the timber fabricator been given all the information he requires? Does the roof need to be strapped down to the wall? Will the roof provide adequate support to the head of the wall? If trussed rafters are used for the supporting structure, the information required by the fabricator is listed in BS 5268: Part 3 Code of practice for trussed rafter roofs, clause 11.

Note: Fastener capacities connecting Tile Lath to timber truss should be checked by the project engineer

Also, when the completion of the roofscape requires the use of loose timbers such as hip and valley members, common rafters and ceiling joists, it is possibly wise to require that the fabricator design these members and their fixings to the trussed rafters. However, responsibility will normally remain with the building designer to ensure that:-

Identical information will be required where prefabricated timber joists are used for the supporting structure. In addition, the fabricator will need to know:-

The trussed rafters are adequately anchored down to the walls to prevent uplift under wind loading. The walls are adequately tied back to the roof structure in compliance with the Building Regulations and the relevant parts of BS 5268, and that additional roof bracing is provided where necessary to ensure wall stability.

The nature, size and spacing of the purlins. The type, size and spacing of the screws fixing the purlins to the rafters, and whether they are to be turned into pre drilled holes. Under the normal contractual arrangements the fabricator will design and supply the individual trussed rafter components and detail any bracing required to maintain their stability under load.

Lintels are adequate to carry the truss loads, particularly concentrated loads from hip girders etc.

Product Data and Specification

17

liner seals can be easily installed during construction to provide a high degree of air and vapour seal to the building envelope
18

Construction Details
Eaves Detail - Half-Round Gutter
Kingspan Roof Tile panel 80mm - 0.25W/m2K

FX91 fixing screw

Air seal - SX0008BG 8mm butyl seal Min. 150mm half-round external gutter (for setting out of gutter see drawing18.2)

Fire rated canister applied insulation Preformed corner unit 70mm - 0.32W/m2K SX0004BG 4mm butyl seal Fire rated canister applied insulation Internal cover flashing External soffit flashing
# Air seal - SX5001BW Vapourflex sealant is to be applied over any breaks in secondary steelwork i.e. to give a continuous bearing face

Air seal - SX0008BG 8mm butyl seal

SX0004BG 4mm butyl seal

Eaves Detail - Gutter Set Out

s odule mM 325m m 50m

m 150m

Overhang to suit panel module

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Construction Details

m 20m m 60m

Construction Details
Eaves Detail - Half-Round Gutter Timber Framework

FX291 fixing screw Kingspan Roof Tile panel 80mm - 0.25W/m2K

Air seal - SX0008BG 8mm butyl seal Min. 150mm halfround external gutter

Timber purlin

Internal closure flashing Timber roof trusses Timber fascia board Timber soffit Timber batten to support soffit Site applied expandable seal ref: SX1015AB
Note: For setting out of gutter see drawing 18.2

Wall tie

Eaves Detail - Metal Gutter

FX91 fixing screw

Kingspan Roof Tile panel 80mm - 0.25W/m2K

Air seal - SX0008BG 8mm butyl seal Gutter arm support sealed to roof panel with SX0903BG 9mm x 3mm butyl seal Kingspan Roof Tile gutter profile (for setting out of gutter consult Roof Tile gutter data sheet)

Fire rated canister applied insulation # Eaves closure flashing Architectural wall panel 70mm - 0.32W/m2K Kingspan eaves beam

Air seal - SX5001BW Vapourflex sealant is to be applied over any breaks in secondary steelwork i.e. to give a continuous bearing face

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Construction Details
Eaves Detail - Metal Gutter with Soffit
Kingspan Roof Tile panel 80mm - 0.25W/m2K FX91 fixing screw Air seal - SX0008BG 8mm butyl seal Gutter arm support sealed to roof panel with SX0903BG 9mm x 3mm butyl seal Kingspan Roof Tile gutter profile Eaves closure flashing Fire rated canister applied insulation Preformed corner unit 70mm - 0.32W/m2K SX0004BG 4mm butyl seal Fire rated canister applied insulation SX0004BG 4mm butyl seal Internal cover flashing External soffit flashing
# Air seal - SX5001BW Vapourflex sealant is to be applied over any breaks in secondary steelwork i.e. to give a continuous bearing face Note: For setting out of gutter consult Roof Tile gutter data sheet

Air seal - SX0008BG 8mm butyl seal

Valley Gutter Detail

Kingspan Roof Tile panel 80mm - 0.25W/m2K FX91 fixing screw Air seal - SX0008BG 8mm butyl seal Insulated valley gutter

116mm head tie

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Construction Details

Construction Details
Boundary Detail - Brickwork Parapet

Kingspan Roof Tile panel 80mm - 0.25W/m2K FX91 fixing screw Parapet capping

Air seal - SX0008BG 8mm butyl seal

Lead flashing or similar by others Site applied expandable seal ref: SX1015AB

Air seal - SX0008BG 8mm butyl seal

Kingspan eaves beam

Boundary Detail - Metal Parapet

Kingspan Roof Tile panel 80mm - 0.25W/m2K FX91 fixing screw Air seal - SX0008BG 8mm butyl seal PIR insulation board Parapet flashing with 150mm sealed butt straps

Fire rated canister applied insulation

SX0004BG 4mm butyl seal SX0008BG 8mm butyl seal

Air seal - SX0008BG 8mm butyl seal Architectural wall panel 70mm - 0.32W/m2K Kingspan eaves beam

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Construction Details
Ridge Detail - Half-Round Ridge Capping

dules e mo m Til 325m

m 100m

m 20m

Half-round ridge capping with 150mm sealed butt straps Fire rated canister applied insulation FX95 fixing at 400mm centres

Fully sealed ridge filler ref: FRTR__MP* FX91 fixing screw Kingspan Roof Tile panel 80mm - 0.25W/m2K

Internal ridge flashing with 150mm overlap sealed with air seal - SX5001BW Vapourflex or gun-grade sealant Air seal - 8mm butyl sealant (ref: SX0008BG)

* For filler references see sheet 41

Note: On single length sheets set ridge and adjust eaves to suit (see eaves details)

Ridge Detail - Angle Ridge Capping

dules e mo m Til 25m 3

m 100m

m 20m

Plain wing ridge capping with 150mm sealed butt straps Fire rated canister applied insulation FX95 fixing at 400mm centres

Fully sealed ridge filler ref: FRTR__MP* FX91 fixing screw Kingspan Roof Tile panel 80mm - 0.25W/m2K

Internal ridge flashing with 150mm overlap sealed with air seal - SX5001BW Vapourflex or gun-grade sealant Air seal - 8mm butyl sealant (ref: SX0008BG)

* For filler references see sheet 41

Note: On single length sheets set ridge and adjust eaves to suit (see eaves details)

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Construction Details

Construction Details
Ridge Detail - Monopitch

Monopitch ridge capping

FX91 fixing screw Fully sealed ridge filler ref: FRTR__MP (for filler references see sheet 41) Kingspan Roof Tile panel 80mm - 0.25W/m2K #

Fire rated canister applied insulation

SX0004BG 4mm butyl seal Air seal - SX0008BG 8mm butyl seal

Architectural wall panel 70mm - 0.32W/m2K

# Air seal - SX5001BW Vapourflex sealant is to be applied over any breaks in secondary steelwork i.e. to give a continuous bearing face

Hip Valley Gutter Detail

Ends of panel to be touched up with edge protection lacquer

Panel to be cut to suit site requirements

150mm

Multibeam purlin Cleader angle to suit structural engineers requirements External cover flashing to cover site cut edge and deflect water into gutter

3 runs of 4mm butyl sealant Insulated hip valley gutter

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Construction Details
Verge Detail - Curved Trim

Curved verge trim Verge filler ref: FRTV05EP-325 Fire rated canister applied insulation Kingspan Roof Tile panel 80mm - 0.25W/m2K

SX0004BG 4mm butyl seal

Cleader angle

Architectural wall panel 70mm - 0.32W/m2K Air seal - SX0008BG 8mm butyl seal Rafter

Verge Detail - Streamline Trim

Roof Tile verge trim Verge filler ref: FRTV05EP-325 Fire rated canister applied insulation Kingspan Roof Tile panel 80mm - 0.25W/m2K

SX0004BG 4mm butyl seal

Cleader angle

Kingspan wall panel 70mm - 0.32W/m2K Air seal - SX0008BG 8mm butyl seal Rafter

25

Construction Details

Construction Details
Verge Detail - Angle Trim

Angle verge trim Verge filler ref: FRTV05EP-325 Fire rated canister applied insulation Kingspan Roof Tile panel 80mm - 0.25W/m2K

SX0004BG 4mm butyl seal

Cleader angle

DW wall panel 70mm - 0.32W/m2K Air seal - SX0008BG 8mm butyl seal Rafter

Verge Detail - Overhang Soffit

Verge filler ref: FRTV05MP-325 Roof tile verge trim Fire rated canister applied insulation Cleader angle SX0004BG 4mm butyl seal Air seal - SX0008BG 8mm butyl seal Architectural wall panel 70mm - 0.32W/m2K Kingspan Roof Tile panel 80mm - 0.25W/m2K

PIR insulation board

Cleader angle External cover flashing

Air seal - SX0008BG 8mm butyl seal SX0004BG 4mm butyl seal SX0004BG 4mm butyl seal Extended cleader angle RW wall panel 60mm - 0.33W/m2K

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Construction Details
Verge Detail - Brickwork

Curved verge trim Verge filler ref: FRTV05EP-325 Kingspan Roof Tile panel 80mm - 0.25W/m2K

Site applied expandable seal ref: SX1015AB

Cleader angle

External brickwork cavity wall Air seal - SX0008BG 8mm butyl seal Site applied expandable seal ref: SX1015AB

Verge Detail - Brick Parapet

Lead flashing or similar tucked into brickwork

Verge flashing Verge filler ref: FRTV05EP-325 Kingspan Roof Tile panel 80mm - 0.25W/m2K

Cleader angle

External brickwork cavity wall Air seal - SX0008BG 8mm butyl seal Site applied expandable seal ref: SX1015AB

27

Construction Details

Construction Details
Hip Detail - Half-Round Ridge Capping

Half-round ridge flashing Weather seal - sealing tape ref: SX2H02BS Fire rated canister applied insulation Internal ridge flashing FX91 Fixing screw FX95 fixing screw Air seal - SX0008BG 8mm butyl seal Kingspan Roof Tile panel 80mm - 0.25W/m2K Cleader angle

Hip Detail - Angle Ridge Capping

Plain wing ridge flashing Weather seal - sealing tape ref: SX2H02BS Fire rated canister applied insulation FX95 fixing screw FX91 Fixing screw Internal ridge flashing Air seal - SX0008BG 8mm butyl seal Kingspan Roof Tile panel 80mm - 0.25W/m2K Cleader angle

28

Construction Details
Lean-To Detail - Brickwork

External apron flashing Lead flashing by others tucked into brickwork Fully sealed profile filler ref: FRTR__MP FX91 Fixing screw Kingspan Roof Tile panel 80mm - 0.25W/m2K Site applied expandable seal ref: SX1015AB Internal liner flashing Fire rated canister applied insulation

Air seal - SX0008BG 8mm butyl seal

Rafter External brickwork cavity wall

Lean-To Detail - Cladding

DW wall panel 70mm - 0.32W/m2K

External lean to flashing

Fully sealed profile filler ref: FRTR__MP Air seal - SX0008BG 8mm butyl seal Fire rated canister applied insulation Internal liner flashing

Kingspan Roof Tile panel 80mm - 0.25W/m2K

Air seal - SX0008BG 8mm butyl seal

29

Construction Details

Construction Details
Mansard Detail

Kingspan Roof Tile panel 80mm - 0.25W/m2K

FX91 fixing screw Air seal - SX0008BG 8mm butyl seal

Kingspan Roof Tile panel 80mm - 0.25W/m2K # Fire rated canister applied insulation Kingspan eaves beam Internal cover flashing to eaves beam joint

# Air seal - SX5001BW Vapourflex sealant is to be applied over any breaks in secondary steelwork i.e. to give a continuous bearing face

Change in Roof Pitch Detail

Kingspan Roof Tile panel 80mm - 0.25W/m2K

Zed flashing and cover flashing to be riveted together Zed flashing to provide weather protection Fire rated canister applied insulation

External cover flashing

Air seal - SX0008BG 8mm butyl seal SX0008BG 8mm butyl seal

Sealed profiled filler ref: FRTR__MP Air seal - SX0008BG 8mm butyl seal Internal cover flashing

30

Construction Details
Rooflight Detail - Velux Type

Kingspan Roof Tile panel 80mm - 0.25W/m2K

Roof Tile upstand to be formed using fibre glass Upstand units supplied by Aperture Ltd - Tel: 00 44 161 681 4455

Velux type rooflight

FX91 fixing screw

Downslope Vent Detail

Kingspan Roof Tile panel 80mm - 0.25W/m2K

Roof Tile upstand to be formed using fibre glass Upstand units supplied by Aperture Ltd - Tel: 00 44 161 681 4455

Smoke vent

FX91 fixing screw

31

Construction Details


32

Roof Tile panels can be supported upon any form of timber structure that will support a traditional slate or tile roof

Construction Details
Ridge Vent Detail

Ridge Vent

Sealed profile filler ref: FRTR__MP Fixing ref: FX95 at 400mm centres Fixing ref: FX91 Air seal - SX0008BG 8mm butyl seal Kingspan Roof Tile panel 80mm - 0.25W/m2K Air seal - SX0008BG 8mm butyl seal

Roof Penetration Detail - Flue Pipe

Seal Flue pipe (by others)

Flexible pipe flashing (by others)

Kingspan Roof Tile panel 80mm 0.25W/m2K

Sealed profile filler ref: FRTR__MP

Consult Kingspan Technical Services where temperatures exceed 50C

33

Construction Details


34

It is important, for safety and to minimise the risk of handling damage and delay, to ensure that the panels are loaded onto the roof in the correct location and orientation

Site Handling, Storage and Installation Methods

1.1 Adequate safety apparatus must be in place, e.g. safety netting, leading edge protection, guard rails and walkways. 1.2 Never walk on panels that are not fixed at the down-slope end. Do not walk on spans of panels that are not fully fastened to a purlin on either side. If necessary, walk over the support. 1.3 The risk of falling presented by the presence of apertures and other gaps and holes in the roof area must be suitably addressed. The table on the right gives the maximum length of panel that can be carried by a given number of men based on a maximum weight per man of 25kg, over a range of thicknesses and lengths. and exterior surfaces and must therefore be handled in a way that avoids damage. When transporting panels by hand, they should be carried on edge with the side overlap edge uppermost.

2. Site Handling & Storage

2.1 Packs up to 6.0m long can be unloaded using a mechanical fork lift truck. Forks must be spaced no less than one metre apart It is imperative that the forks do not coincide with the pack bearers, and that suitable protective material is placed between the forks and the pack to avoid damage. 2.2 Packs of panels that will not be used immediately must be placed in an area designated for storage, preferably under cover. The storage surface must be flat and well drained. Packs must be carefully placed on timber battens or similar supports; these must be placed at maximum centres of 2m and give a ground clearance of at least 100mm. Stacks must be no more than three packs high with pacing battens between them positioned to correspond to the pack bearers. To avoid ponding and moisture build up, panels must be stacked on a slight slope. 2.3 Where panels are to be stored outside for long periods of time they must be sheeted down with a suitable weatherproof tarpaulin. This must cover packs completely and allow free circulation of air around the packs. 2.4 Where packs are to be loaded on to the roof, they must be placed at locations that are structurally strong enough to support their weight. This usually means placing the packs over the rafter backs with a limit of one pack per rafter. It is important to ensure that the weight of the pack is evenly supported by all of the purlins, additional supports may also be required to prevent purlin damage. Do not place packs in an overhanging position. Kingspan Roof Tile panels are not handed but do have a projecting end lap. It is important, for safety and to minimise the risk of handling damage and delay, to ensure that the panels are loaded onto the roof in the correct location and orientation. When the panels have been placed, they must be securely retained in position by lashing to a sufficiently strong element of the structure. On pitches of roof which are steep enough to present a risk of the pack sliding down-slope, suitable measures must be taken to prevent this occurring.
35

3. Panel Fixing Method

3.1 The Roof Tile panel is fixed using standard equipment available through the fastener supplier. 3.2 The equipment comprises a screw gun with adjustable depth set or an adjustable torque screw gun, depending on the type of fastener to be used. Details of the equipment differ slightly from supplier to supplier instructions for the use of specific equipment is available from the manufacturer. 3.3 Low profile headed screws of both carbon steel and stainless steel may require an adapter and bit or a special drive head consult the screw manufacturer for details. 3.4 See contract details for fixing types, quantities and locations. Be aware that the number of fasteners used locally across the roof will change depending upon where on the panel is being fixed (middle or end) and the local wind uplift conditions.

Site Handling, Storage and Installation

1. Safety

2.5 Kingspan Roof Tile panels are supplied with fully finished interior

Site Handling, Storage and Installation Methods

4. Cutting of Panels
4.1 Panels must be cut using a toothed blade type saw such as a jigsaw. 4.2 Do not use abrasive cutting tools as the heat and sparks produced will damage the coating of the panels. 4.3 Panels must be adequately supported (padded trestles or similar) while cutting. Do not cut panels over other panels, as the swarf produced may damage the steel coating and if allowed to become wet will cause rust stains. For similar reasons, always brush away swarf immediately. 5.4 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 Where these are bowed or distorted so that they do not give a straight bearing surface of 50mm min width, flange extension plates will be required. 5.2 Valley and boundary wall gutters must be securely fixed in position where applicable. 5.3 As work progresses across the roof, areas to be regularly walked over or where materials are to be temporarily stored should be identified and protected. Traffic should use walkways to avoid damaging the finish on the panels.

5. General Fixing Notes

5.1 Steel (or timber) must be lined and levelled in accordance with the requirements of the contract document. Check the roof steelwork (or timber) visually for any damage or distortion, paying particular attention to lines of purlin that will support panel ends and end laps.

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 result in damage to the paint.

Number of Men (Based on a max. weight of 25kg per man) Thickness (mm) 45 80
Note:

Weight (kg/m2 ) 15.29 16.97 1.6 1.4 3.2 2.9 4.9 4.4

Maximum length (m) 6.5 5.8 8.1 7.3 9.8 8.8 11.4 10.3 13.0 11.7

A 5% margin of safety has been included Panel weights based on 0.7mm outer and 0.4mm liner

36

Site Handling, Storage and Installation Methods

6.1 Where there are end laps between panels, fasten flange extension plates to the lap purlins to ensure correct support of the panel end. 6.2 Fit the internal ridge trim, sealing overlaps with 6mm butyl seal SX0006BG. 6.3 Fit the internal verge trim to the purlins, ensuring that the edge of the flashing is square to the line of the purlins and the outer leg is on the wall cladding line. Seal joints in the flashing using 6mm seal SX0006BG. Seal the junction with the internal ridge trim and the valley gutter or eaves flashing as appropriate. c) Fix the panel in line with the remaining purlins in the locations indicated in the project details. If the panel finishes at the ridge, fix at every trough. If there is a panel to fix up slope, do not fix the top of the panel at this stage. d) Apply a bead of 6mm butyl seal SX0006BG to the end lap, 10mm down from the top step, making sure that the seal extends from edge to edge of the panel and follows the profile faithfully. e) Install the next panel so that it is in line with the first. The panels must be positioned so that the end lap profile step butts closely together at both sides. Note do not walk on panels that are not yet fixed. f) Fix the panel through the end lap into the purlin extension plate b) Using a screw gun, fix the panel to the first purlin using the screws at the outer positions first, followed by in the locations indicated in the project details. a) Place the first panel so that it is correctly positioned in line with the edge of the roof and in relation to the eaves or gutter, ensuring that the seals are trapped. Note do not walk on panels that are not yet fixed.

in the locations indicated in the project details. g) Where the lap fasteners are up-slope or down-slope of the purlin, place fasteners in the locations indicated in the project details into the purlin. h) Fix the rest of the panel in line with the remaining purlins in the locations indicated in the project details. If there is a panel to fix up slope, repeat steps d to h. i) The internal verge trim must be fixed to the underside of the

panel at 500mm centres. This can be fixed at this stage or may be left until later using rivets or stitchers (see page 13) from the inside. 6.4 Apply a bead of 6mm butyl sealant SX0006BG to the internal verge trim so that it will correspond to the position of the first rib of the first row of panels laid. 6.5 Apply a bead of 6mm butyl sealant SX0006BG to the internal ridge trim and valley/eaves junction, so that the panel liner will bed onto the seal, to prevent air leakage at these junctions. 6.6 Where there are end laps between panels, apply a strip of 4mm PVC seal to the purlin flange extension plates so that the up-slope and down-slope panels will have equal contact areas.

Site Handling, Storage and Installation

37

6. Laying Main Area of Roof

6.7 First row of panels :

Site Handling, Storage and Installation Methods

g) Install the next panel so that it is in line with the first. The panels must be positioned so that the end lap profile step butts closely together at both sides and the side lap is a good tight fit. Note do not walk on panels that are not yet fixed. h) Fix the panel through the end lap into the purlin extension plate in the locations indicated in the project details. i) Where the lap fasteners are up-slope or down-slope of the

purlin, place fasteners in the locations indicated in the project details into the purlin. j) Fix the rest of the panel in line with the remaining purlins in the

locations indicated in the project details. If there is a panel to fix up slope, repeat steps f to j. k) Repeat steps a to k until a gap less than one panel width

remains, checking and correcting alignment and squareness every fourth panel. 6.9 Closing the Last Edge If a gap of less than 225mm, measured from the extreme edge of the panel to the edge of the roof, remains to be filled: a) 6.8 Intermediate rows of panels. a) Extend the beads of sealant applied to the eaves, ridge and Use a long legged internal flashing to finish off the roof. This

flashing must tuck under the last panel and must be sealed to it and stitched or riveted to it at 500mm max centres. The vertical leg of the flashing must be on the sheeting line for the wall cladding. b) The up-slope and down-slope ends of the flashing must be sealed to the internal ridge trim and gutter/eaves flashing respectively. c) Fix through the edge trough of the last panel into every purlin. d) The end laps of the flashing must be sealed and riveted to maintain air tightness. e) The last panel must be fixed through the last insulated trough to every purlin.

purlin extension plates. b) Check the condition of the factory applied side joint seal on the adjacent row of panels. If damaged trim off damaged edges. c) Place the down slope panel to overlap the adjacent fixed panel. Adjust the panel so that its eaves edge is in line with the eaves edge adjacent panel and the steps on the side lap are fitting tightly. Note do not walk on panels that are not yet fixed. d) Using a screw gun, fix the panel to the first purlin using the screws at the outer positions first, then in the locations indicated in the project details, trapping the seals. e) Fix the panel in line with the remaining purlins in the locations indicated in the project details. If there is a panel to fix up slope, do not fix the top of the panel at this stage. f) Apply a bead of 6mm butyl seal SX0006BG to the end lap,

10mm down from the top step, making sure that the seal extends from edge to edge of the panel and follows the profile faithfully.

38

Site Handling, Storage and Installation Methods

a) Fit the internal verge trim to the purlins, ensuring that the must be positioned so that the end lap profile step butts closely together at both sides and the side lap is a good tight fit. Note do not walk on panels that are not yet fixed. k) Fix the panel through the end lap into the purlin extension plate

edge of the flashing is square to the line of the purlins and the outer leg is on the wall cladding line. The leg length of this flashing must be long enough to pass under the liner of the last panel. Seal joints in the flashing using 6mm seal SX0006BG. Seal the junction with the internal ridge trim and the valley gutter or eaves flashing as appropriate. b) Extend the beads of sealant applied to the eaves, ridge and purlin extension plates.

at the locations indicated in the project details. l) Where the lap fasteners are up-slope or down-slope of the

purlin, place fasteners in the locations indicated in the project details into the purlin. m) Fix the rest of the panel in line with the remaining purlins in the

c) Apply a bead of 6mm butyl sealant SX0006BG to the internal verge trim so that it will seal against the final panels. d) Cut the panels to be used to the required width using a jigsaw. e) Check the condition of the factory applied side seal on the adjacent row of panels. If damaged, trim off trailing edges. f) Place the down slope panel to overlap the adjacent fixed panel.

locations indicated in the project details. If there is a panel to fix up slope, repeat steps i to m. n) The panel must be fixed through the last trough to the purlins (through the internal verge trim). The panel must also be fixed to the internal verge trim @ 500mm centres either by stitching or by riveting from inside the building.

Adjust the panel so that its eaves edge is in line with the eaves edge of the adjacent panel and the steps on the side lap are fitting tightly.

7. Verge Finishing
7.1 Starting from the bottom of the roof, fit the first length of flashing to the wall and tile panel. The flashing should be detailed so that it extends by 50mm past the second tile crown, and its length adjusted so that the last length to be fitted up-slope is greater than 1.5m long. A profile filler FRTV05MP-325 must be placed between the flashing and the tile profile crown. Fix with fasteners (see page 13) every other step. 7.2 Lay the next section of flashing, sealing the lap with SX0006BG, over-lapping the down-slope section by 150mm and making sure to include the profile filler FRTV05MP-325 over the tile crown. After making sure the flashing is correctly aligned, fix to every other step with fastener (see page 13). 7.3 Repeat step 7.2 until the ridge is reached. Complete the same

Note do not walk on panels that are not yet fixed. g) Using a screw gun, fix the panel to the first purlin using the screws at the outer positions first, then in the locations indicated in the project details, trapping the seals. h) Fix the panel in line with the remaining purlins in the locations indicated in the project details. If the panel finishes at the ridge, fix at every trough. If there is a panel to fix up slope, do not fix the top of the panel at this stage. i) Apply a bead of 6mm butyl seal SX0006BG to the end lap,

operation on the opposing slope. At this stage, the verge trims on each slope must be cut back from the apex point. The verge apex unit can then be fitted, overlapping the continuing verge fillers up to the apex.

10mm down from the top step, making sure that the seal extends from edge to edge of the panel and follows the profile faithfully.
39

Site Handling, Storage and Installation

If the gap is larger that 225mm:

j)

Install the next panel so that it is in line with the first. The panels

Site Handling, Storage and Installation Methods

8. Hip Fitting
8.1 Ensure that an adequate raking support (see project details) is provided between the ends of the purlins. 8.2 Starting from the down-slope end, fit the internal hip trims to the raking supports using rivets or similar low profile fasteners to hold it in place. Overlap lengths of trim and seal with butyl beads SX0006BG. At the apex, cut the internal hip trim to fit the intersecting internal ridge trims and seal the junction with butyl beads SX0006BG. 8.3 Fitting the panels: a) Starting from the down-slope end, offer the first panel up into k) Using a screw gun, fix the panel to the down-slope purlin using the screws at the outer positions first, followed by in the locations indicated in the project details, trapping the seals. l) Fix the panel in line with the remaining purlins and the raking

support in the locations indicated in the project details. If there is a panel to fix up slope, do not fix the top of the panel at this stage. m) Where the lap fasteners are up-slope or down-slope of the purlin, place fasteners in the locations indicated in the project details into the purlin. n) Repeat steps g to m until the hip is fully sheeted.

position (no seals) and mark the panel where it needs to be cut, leaving the minimum gap needed to guarantee a good fit. b) Remove the panel from the roof. Cut the panel to fit the hip, supporting the panel on padded trestles to prevent damage to the coating. c) Apply the seal to the eaves beam/gutter and to the internal hip flashing (do not apply the seal beyond where this panel will fit). d) Place the down-slope panel to overlap the adjacent fixed panel. Adjust the panel so that its eaves edge is in line with the eaves edge of the adjacent panel and the steps on the side lap are fitting tightly. Note do not walk on panels that are not yet fixed. e) Using a screw gun, fix the panel to the first purlin using the screws at the outer positions first, followed by in the locations indicated in the project details, trapping the seals. f) Fix the panel in line with the remaining purlins and the raking 8.4 The panels should be detailed to give the minimum practical gap at the ridge. This gap is to be insulated with Kincora Multifoam 1GFR foam, cutting off any excess. 8.5 Apply SX2H02BS to the outer profile. Work the seal into the profile using a blunt wedge and or rollers and wheels. Care must be taken that this seal is installed correctly. 8.6 Starting from the eaves, install the hip capping, trapping filler FRTH05E at each side, fixing at the crowns of the tile profile. Lap the next section of filler onto the the last by 150mm, using two strips of 6mm butyl seal SX0006BG, continuing to trap fillers and fix in the same way. 8.7 At the ridge, apply the ridge/hip closure piece, lapping onto the ridge cappings and hip flashings by a minimum of 150mm and sealing with two strips of 6mm butyl on each. Ensure all fillers are in place to ensure a correct seal, including that at the top of the raking valley.

support in the locations indicated in the project details. If there is a panel to fix up-slope, do not fix the top of the panel at this stage. g) Offer the next panel up into position (no seals) and mark the panel where it needs to be cut, leaving the minimum gap needed to guarantee a good fit. h) Remove the panel from the roof. Cut the panel to fit the hip, supporting the panel on padded trestles to prevent damage to the coating. i) Extend the beads of sealant applied to the eaves, ridge and

purlin extension plates. j) Apply a bead of 6mm butyl seal SX0006BG to the end lap,

10mm down from the top step of the down-slope panel, making sure that the seal extends from edge to edge of the panel and follows the profile faithfully. Apply a bead of 6mm butyl seal SX0006BG to the internal hip flashing (do not apply the seal beyond where this panel will fit).
40

Site Handling, Storage and Installation Methods

9.1 Ensure that an adequate raking support (see project details) is provided between the ends of the purlins. 9.2 Starting from the down-slope end, fit the insulated gutter to the raking supports using rivets or similar low profile fasteners to hold it in place. Join the lengths of gutter as described in the contract details. At the apex, terminate the gutter as required in the contract details, ensuring an airtight seal to the internal ridge trim. 9.3 Fitting the panels: a) Starting from the down-slope end, offer the first panel up into screws at the outer positions first, followed by in the locations indicated in the project details, trapping the seals. f) Fix the panel in line with the remaining purlins and the raking

support in the locations indicated in the project details. If there is a panel to fix up-slope, do not fix the top of the panel at this stage. g) Offer the next panel up into position (no seals) and mark the panel where it needs to be cut, leaving the minimum gap needed to guarantee a good fit. h) Remove the panel from the roof. Cut the panel to fit the valley, supporting the panel on padded trestles to prevent damage to the coating. i) Extend the beads of sealant applied to the eaves, ridge and

position (no seals) and mark the panel where it needs to be cut, leaving the minimum gap needed to guarantee a good fit. b) Remove the panel from the roof. Cut the panel to fit the valley, supporting the panel on padded trestles to prevent damage to the coating. c) Apply the seal to the eaves beam/ gutter and to the valley gutter flange (do not apply the seal beyond where this panel will fit). d) Place the down-slope panel to overlap the adjacent fixed panel. Adjust the panel so that its eaves edge is in line with the eaves edge of the adjacent panel and the steps on the side lap are fitting tightly. Note do not walk on panels that are not yet fixed.

purlin extension plates. j) Apply a bead of 6mm butyl seal SX0006BG to the end lap,

10mm down from the top step of the down-slope panel, making sure that the seal extends from edge to edge of the panel and follows the profile faithfully. Apply a bead of 6mm butyl seal SX0006BG to the valley gutter flange (do not apply the seal beyond where this panel will fit). k) Using a screw gun, fix the panel to the down-slope purlin using

the screws at the outer positions first, then in the locations indicated in the project details, trapping the seals. l) Fix the panel in line with the remaining purlins and the raking

support in the locations indicated in the project details. If there is a panel to fix up-slope, do not fix the top of the panel at this stage. m) Where the lap fasteners are up-slope or down-slope of the purlin, place fasteners in the locations indicated in the project details into the purlin. n) Repeat steps g to m until the hip is fully sheeted. 9.4 Treat the cut edges of the panels, including the foam, with Akzo Nobel Steelseal Primer 4VQ series to the required thickness, using a paint brush. This must completely cover the cut edge of the steel (outer and liner) and the exposed foam. Allow the paint to dry for the prescribed period. 9.5 Apply Akzo Nobel Steelseal Topcoat 5VF series of the colour required in the contract document to the primed areas using a paint brush. The quantity applied should be in line with the manufacturers recommendations. Allow the paint to dry for the prescribed period.

Site Handling, Storage and Installation

41

9. Raking Valley

e) Using a screw gun, fix the panel to the first purlin using the


42

For efficient and secure installation

Site Handling, Storage and Installation Methods

10.1 Panels at the ridge must be fixed to the top purlin at the locations indicated in the project details. 10.2 The panels should be detailed to give the minimum practical gap at the ridge. This gap is to be insulated with Kincora Multifoam 1GFR foam, cutting off any excess. 10.6 Continue this process until the other end of the ridge is 10.3 Cut the verge trim to clear the ridge filler so that the filler butts against the verge filler. The length of any section of ridge capping should be at least 10.4 Fit the end closure filler under the ridge flashing, so that it is flush with the edge of the notch. This filler must be bedded in silicone sealant SX0400ST and a 6mm bead must be applied to the top surface before fitting the flashing. Fit the ridge filler, cutting it so that it butts up to the verge trim tightly and point this junction with silicone sealant SX0400ST. Fit the first section of ridge flashing to the roof so that it overlaps the verge ridge unit by 50mm past the end of the verge trim notch, fitting the ridge fillers FRTR__MP and trapping them. Fix the ridge flashing at 400mm centres into the tile crown using fasteners (see page 13). 1500mm to maintain a good appearance. Finish the ridge at the far end as it was started if a verge, or as described under hips if a hip. reached. under the ridge capping flange. The flashing must overlap the previously fitted one by 150mm. Seal the lap with two beads of 6mm butyl sealant SX0006BG and fix the ridge capping through the filler to the crown of the tile profile at 400mm centres using fasteners (see page 13).

Site Handling, Storage and Installation

43

10. Ridge Finishing

10.5 Fit the next ridge flashing to the roof, trapping the profile fillers

When detailing the apex junction the designer must either ensure that the chosen panel length is long enough to provide a sound practical junction detail

44

Panel & Tile Length

Panel Length

100mm

325mm 50mm

150mm

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 apex flashing. When detailing the apex junction the designer must either 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 apex 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)

No. of Tiles 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Tile Length 325mm 2100 2425 2750 3075 3400 3725 4050 4375 4700 5025 5350 5675 6000 6325 6650 No. of Tiles 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Tile 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 Length 325mm 11850 12175 12500 12825 13150 13475 13800 14125 14450 14775 15100 15425 15750 -

Panel End Dimension

50mm

45

Panel & Tile Length

It is important, for safety and to minimise the risk of handling damage and delay, to ensure that the panels are loaded onto the roof in the correct location and orientation

46

Apex Fillers
When detailing the apex, due consideration has to be taken over the relationship of the cut panel with the apex flashing in order to maintain the correct line. Depending on this relationship the base dimension of the filler must vary. The angle of the roof tile causes a 20mm variation in depth, three fillers are used to cover the situations noted below with base depths of 5mm, 15mm and 25mm. The following details show different situations that can occur.

25mm Ridge Filler at Lowest Point

15mm Ridge Filler at Mid Point

5mm Ridge Filler at Highest Point

The following table provides guidance on filler choice.

Distance along Tile (X) 0 - 65mm 66 - 195mm 196 - 325mm Base dimension (A) 5mm 15mm 25mm Filler Ref FRTR05MP FRTR15MP FRTR25MP

A Dim X Dim

Filler

47

Apex Fillers

Kingspan Insulated Roof & Wall Systems

Roof Systems
KS1000 RW Trapezoidal KS1000 TS Tile Support KS 500/1000 ZIP Kingzip KS1000 LP Lo-Pitched KS1000 CR Curved

KS1000 RT Roof Tile

KS1000 TD Topdek

Wall Systems
KS600, 900 & 1000 Optimo KS600, 900 & 1000 MR Micro-Rib KS600, 900 & 1000 EB Euro-Box KS600, 900 & 1000 FL-S Flat (Stucco)

KS600, 900 & 1000 MM Mini-Micro

KS600, 900 & 1000 CX Convex

KS600, 900 & 1000 WV Wave

KS600, 900 & 1000 LS LongSpan

KS1000 RW Trapezoidal

Controlled Environment Systems

KS1100/1200 CS

Kingspan Limited UK: Telephone: +44 (0) 1352 716110 Fax: +44 (0) 1352 716161 Email: info@kingspanpanels.com Ireland: Telephone: +353 (0) 42 96 98500 Fax: +353 (0) 42 9698572 Email: sales.ire@kingspanpanels.com Details for other countries; Belgium, China, Czech Republic, Germany, Hungary, Netherlands, Poland, visit our website kingspanpanels.com or our group website kingspan.com