Ashzip installation Guide 110507

1

Introduction

This fixing manual is intended to provide an overview of the procedures pertaining to the installation of the Ash & Lacy Building Systems – Ashzip product. Sheets must be fixed in accordance with this manual and relevant building regulations. The information contained in this manual is intended as guide for fixing sheets in standard applications. However, it should be noted that this does not take away any responsibility from the fixing contractor and its site operatives. Care and attention should be paid to local ground terrain, location and wind loadings. The fixing contractor is expected to produce and detail all aspects of the application and provide dimensioned working drawings with material specifications clearly shown. This fixing manual is intended for guidance purposes only and does not in any way relate to product warrantees or state codes of best practice or relevant building regulations. The manual will outline procedures from transport and delivery to site, to completion and maintenance. Ash & Lacy are a manufacture only company and as such the roofing contractor is responsible to ensure the adequacy, quality and securing of the installation against weather conditions. Specific advice can be sought from our technical department regarding warrantees etc. and CAD details and full technical design guidance also being available.

Contents

The Ashzip system 2

Transport 2

Off-loading on site 3

Preparation before work commences 5

Ashzip with Ashgrid system installation 6

Components 7

Installation tools 9

Full height halter installation 10

Halter fixing arrangement 11

Load bearing capacity & foot traffic 12

Halter direction of lay 14

Insulation & fire performance 16

Verge to verge fixing sequence 16

Zipping the sheets & method 17

Thermal expansion and fixed points 19

Ridge & Eaves Installation method 20

Verge Installation Method 21

Curved roof set out 22

Tapered sheets 23

Fixings and sealants 28

Penetrations 29

Decktite flashings 30

Span tables for Ashzip 400 full height 31

Ultimate fixing capacities 32

Site rolling operations 33

Components and tools schedule 47

Typical construction details 50

Isometric arrangements 66

2

The Ashzip System

Ashzip is a standing seam roofing system, which is designed for use on roof pitches down to 1.5 degrees. The sheets are fixed onto halter clips and then locked into position using a zipping machine. The following sheet then hides the seam overlapping the clip. Fasteners are positioned below the roof covering at the base of the halter and are therefore concealed from view. The Ashzip profile is available in cover widths of 300 and 400mm and can be produced in a tapered format to create a radial roof on plan. Movement of the top sheet due to thermal expansion is catered for by a sliding action over the head of the halter. Any joints or apertures in the roof should therefore be

designed to ensure that the movement of the sheets is not impaired in any way. For further information on thermal expansion, please contact our Technical Department. Transport and off-loading

Sheet lengths & Site Rolling

Ashzip can be produced in a factory environment or on-site depending on specific requirements, site layout and storage facilities. For sheets greater than 27m in length a police escort would be required which can take up to 10 weeks to arrange. This is where site rolling can become advantageous and cost effective. In such cases we would recommend roll-forming sheets on site at eaves level. If there is a requirement to produce sheets on site using the mobile roll former cabin suspended from a crane, it is the responsibility of the contractor to ensure that the carrying capacity of the crane is sufficient. Ash & Lacy Building Systems do not provide handling labour for site rolled products, as this is the contractors’ responsibility.

3

Off-loading on Site

When sheets are delivered to site a suitable offloading area must be made available. This not only applies to the delivery of sheets but to all other components that may be delivered separately. Access to site must also be checked and confirmed by the contractor as Ashzip can be delivered in high loads due to its low weight. It is the responsibility of the contractor to ensure that a suitable means of off-loading sheets is made available. Prior arrangements should be made with regard to manpower, cranes, spreader beams and slings. It is the responsibility of the contractor to offload sheets. Any special packaging requirements should be put in writing at the ordering stage so that we can advise any additional charges that may be incurred. When Ashzip sheets are pre-curved in a factory environment the transportation of the packs can be an issue as the pack height is limited to 2 metres (+materials and trailer). Therefore when the chord height of a pre-curved Ashzip sheet exceeds 2 metres the sheets may have to be pre-curved on site. This is dependant on sheet length compared to radius. Where there is insufficient space on site to produce pre-curved Ashzip sheets we can offer transportation on a low-level flat bed trailer. This however must be advised at quotation stage, as additional costs will be incurred that must be met by the roofing contractor. The table below is based on standard transportation and a pack height of no more than 2 metres.

As packs of Ashzip sheets can weigh up to 3 tonnes the carrying capacity of any crane should be checked prior to delivery. The projecting ends of any pack should not exceed 4m (see below).

Sheet Type No Sheets Per Pack Aluminium sheets 20 Curved aluminium sheets

12-15 (depending on radius)

Steel sheets 10 Curved steel sheets

5-10 (depending on radius)

Care should be taken to use only certified beams and sling belts for lifting packs. Chains should never be used to offload packs as this can cause damage to the sheets. Information relating to this would be available from a reputable crane hire company. Sheet packs should be stored in the same direction as the lay of roof to avoid having to turn around large lengths of sheet once sheeting commences. NB. The smaller indented seam of the Ashzip sheet goes in the direction of lay. Note – Attention should be paid to the direction in which the Ashzip sheets are roll formed on site regarding direction of lay on the roof. A typical layout is shown on the next page. Ashzip sheets should not be placed directly onto the ground under any circumstances as the ground may contain alkalis from cement spillage or be an area that has previously been used for mixing. Contact with alkalis will cause staining and any concrete or cement that comes into contact with stucco embossed material will key in to the embossments if not removed immediately. Typical set up of slings and lifting beam equipment shown below.

4 0 0 0 m m M A X O /H A N G 4 0 0 0 m m M A X O /H A N G

4

3 0 0 0 2 5 0 0

8000

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D IR E C T IO N O F L A YS H E E T C O M E S O U T O F

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5

Pre-Curved Ashzip Sheets

Additional care should be taken when handling curved sheets and placing them into position on the roof. Extra slings will be required to prevent deformation of the sheets as they are lifted into position. If the radius of the curve is tight sheets should be lifted individually or in smaller bundles of 4 or 5. In most cases curved sheets will be sent to site in smaller packs. Checking Materials Upon Receipt

Wherever possible sheets should be checked for any discrepancies upon delivery and all packaging labels checked against the delivery note. As it is not always possible to check dimensions straight away, any dimensional errors must be reported ASAP (Refer to A & L standard terms and conditions)

Storage On Site

Wherever possible sheets should be stored undercover. This can help to prevent a build up of dirt and condensation, which can lead to unsightly staining. Sheets should also be stored on a slight angle on timber bearers to allow for drainage and the circulation of air. Whenever sheets are stored on the roof structure itself, the contractor must ensure that the load carrying capacity of the structure is sufficient as packs can weigh up to 2 tonnes. Always take care when opening packs that have been stored on a roof as there is a possibility of the sheets sliding. Wherever possible do not store packs of sheets for long periods of time as this can lead to condensation build up inside the packaging, which in turn can lead to staining.

If sheets are supplied with a protective coating they should not be stored for more than 10 days as UV rays cause a chemical reaction in the adhesive and the film becomes difficult to remove. Preparation before work commences

Site rolled materials

Where site rolling takes place Ash & Lacy Building Systems will provide operatives to produce the Ashzip sheets only. It is the responsibility of the contractors to provide sufficient labour to handle the sheets to enable the roll forming machine to run continuously. When rolling Ashzip on-site, compare schedules produced by the drawing office to an actual measured length on site. This is particularly important with large curved roofs where small steelwork discrepancies can add up to tens of millimetres, and in turn affect the sheets across the overall arc length. Care should be taken to ensure that the minimum pitch of 1.5 degrees is not affected when components are put into position at the eaves. This is because dishing can occur which may lead to ponding or standing water caused by flashings and gutter arms exceeding the plane of the roof.

Special Tools

Before commencing any work, the contractor must check that all tools and machinery required for fixing the Ashzip standing seam roofing system are on site.

6

COMPONENTS & INSTALLING WITH ASHGRID SYSYEM 1. ASHZIP HALTERS The Halter is the component, which the Ashzip top sheet connects to. The notched side of the halter always faces the direction lay. In the illustration shown (Right) the direction of lay on the roof would be left to right. If Halters are fixed with the notched side of the halter facing the wrong way the sheets will not zip-up properly and the seams will run out of line. The Ashzip will not be secured properly against wind uplift if the clips are not fixed correctly.

Halters are available in two heights 85mm and 120mm. The height of Halter will depend on thermal performance requirements and the preferred method of construction.

2. ASHGRID SPACER SUPPORT SYSTEM Bar

Ashgrid AG40 is the standard bar that is used with the Ashgrid system. Manufactured from 1.25mm thick high yield galvanised steel and supplied in lengths of 1m, 2m & 3m incorporating spigot ends for easy on-site connection.

Fixing Brackets

Brackets are supplied in various heights to suit the depth of construction. Brackets are manufactured from 1.6mm thick galvanized steel to BS EN 10142 and are supplied with a For fixing brackets into thin gauge steel use Ashfix BMLS25 fixings. To ensure maximum sheet to bar fastener performance use Ashfix BMLS25 with G16 washers for walls, G19 washers for roofs and G29 washers for rooflights. 3mm thick EPDM base thermal insulator pad. The bar & bracket connection is carried out in 5 simple steps as follows:

1. Offer the bracket to the bar at an angle from the non-spigot end. 2. Slide brackets along the bar to the desired fixing positions. 3. Snap each bracket upright to lock into position at 90° to the bar. (Brackets may be repositioned by pushing the bracket back to an angle and sliding along the bar as in step 1). Install two inclined fasteners ensuring the bracket does not twist in the bar. 4. Making certain there is a bracket within 100mm of a spigot end, install other brackets to match the liner module up 1m centres maximum. (Bracket centers may need to be reduced in areas of high wind suction or heavy snow loading). 5. Engage the open end of the bar onto the spigot and push firmly for continuity and easy alignment

7

Anti Sway Brackets Roof cladding is at its greatest risk during the installation stage when it is not restrained and fixed to the supporting structure and is subjected to loading from access traffic, temporary loading and heavy sheet packs. This combined with drag forces from high winds could compound the problem further. With this in mind Ashgrid anti-sway brackets should be incorporated at loading-out positions.

Verge Components

The verge clip component is used to secure the leading edge seam of the roof. It is fixed onto the side of the Halter and over the top of the verge channel. It is not fixed through the verge channel. This is to allow any thermal movement to be accommodated by the sliding action of the seam. Expansion must be unimpeded by the verge detail and unwanted fixed points must be avoided. The verge flashing clip is riveted through the vertical leg to the verge channel. The flashing then provides a flat surface for fixing the verge flashing to. When fixing, care must be taken to avoid fixing into the side wall of the Ashzip seam, which would give an unwanted fixed point. The verge channel is used to retain the leading edge seam. There is no through fixing between this component and the Ashzip seam - it is simply placed over the first seam. The verge flashing clip is riveted through the long leg of the verge channel to tie the two components together. Refer to detail at end of manual. NB. The first seam must be zipped up before the verge channel is placed into position.

Verge Clips (58mm wide)

Verge Flashing Clip (3m lengths)

Verge Channel (3m lengths)

8

275 or 375

Single skin/un-insulated Verge Clip (58mm wide) In constructions where an 85mm Ashzip Halter is to be used (generally single skin applications), a special 85mm verge clip must be used. Instead of fixing to the side of the Ashzip Halter the verge clip is fixed to the supporting structure (see left). All other standard components remain the same. Refer to verge components fixing description for flashing clip and verge channel.

Ridge components Ridge retainer The ridge retainer is used to hold the ridge closure flashing/shroud in place. It is fixed at every seam position along the roof. Ridge Shroud The ridge shroud is used to close of the filler block. It provides and aluminium appearance and prevents pests attacking the filler block. It is held in place by the ridge retainer strip. This component can be produced in various colours to match the roof sheet when required. Ridge Filler Block The filler block is used to close of the cavity that is formed under the ridge flashing. It is protected by the Shroud/ridge closure as stated above. Eaves Components Drip Angle The drip angle is riveted to pan of the profile with 2no rivets per pan. The drip angle is used to restrain the pan of the profile and to prevent damage due to foot traffic.

Retainer (3m lengths) Shroud/Ridge closure (length to suit profile)

Drip angle (3m lengths)

9

Eaves filler block The eaves filler is used to close of the cavity formed by the seam of the profile. It is positioned before the sheets are zipped up and held into location above the drip angle. Liner Profile filler Trapezoidal liner profile filler blocks Are also available from Ash & Lacy Building Systems. These should be used in conjunction with internal closure flashings. Refer to ridge and eaves details at the end of this guide.

Hip Construction For Hip constructions special hand turn up tools are supplied. These must be ordered at the time of ordering the standard tool kit (or whichever tools are required on the project). Special ridge fillers and shroud closures are available upon special request and must be ordered at the same time as standard components. We would advise that if special fillers are required longer lead times should be allowed for special manufacture lead in times. ELECTROLYTIC REACTION Note: In some cases there may points of contact between dissimilar materials. Such as galv on aluminium, in such locations a barrier tape must be used to prevent electrolytic reaction. TOOLS

1. Zipping machine 2. Hand seamer 3. Ridge turn up tool 4. Eaves turndown tool 5. Right hand hip turn up tool 6. Left hand hip turn up tool 7. Halter Set out template

1. Zipping Machine 2. Hand crimping tool 3. Ridge turn up tool 4. Eaves turn down tool

10

Full Height Halter installation As an alternative to using the Ashgrid spacer support system within the roof buildup, Ash & Lacy also offer a single height halter option. Developed exclusively for use with the Ashzip standing seam roofing system the use of this thermally efficient halter bracket is designed to offer an easy to install solution where low U-values are required. The halter bracket is manufactured in heights of 245mm, 295mm and 345mm to offer U-values of 0.25, 0.20 and 0.16 W/m2K respectively. This method of construction significantly reduces installation time as a single component is fixed straight through to the purlin when used in conjunction with a standard liner profile. NOTE – This is the recommended method of construction, Ashgrid should only be used on tapered constructions. Insulation depths IMPORTANT NOTE FOR SETTING OUT When using a combination of full height halters and shallow halters supported of an Ashgrid a setting out template for the shallow halters should NOT be used. This is because of the tolerances in the different types of template. The majority of the roof should be

set using the full height halters and applicable template. The other halters should be aligned manually to suit using straight edge to suit and not the setting out template. This will avoid creep of the different halter types which would cause problems during installation. Setting out the roof The Ash & Lacy full height halter system is simple to set out, the halters are set out using templates as with the bar & bracket Ashgrid system. The setting out template slots over the base of the halter clip to locate it into place. Using the template 1st two halters The leading edge of the roof should be fixed without using the setting out template, instead use a straight edge such as an ashgrid bar, a zed flashing or string line to ensure that all of the leading edge halters are in line up the slope. Following halters Place the halter into the required position and lock into place by slotting the setting out template over the over the previous halter and the one that is about to be fixed. Using one hand place pressure on the centre of the setting out template and with the other fix through the outside edge of the halter. Remove the setting out template now that one side of the halter is fixed and fix through the other side as required. Complete this operation for the following halters until complete.

11

Additional component requirements Verge A verge tie is required to lock in the first two halters clips. This is shown below:- The quantity of these components will be the same as the number of verge clips. This component must be used in all verge applications including abutments. There is a full CAD illustration later in this brochure. Ridge – Creating a fixed point There are two methods for creating a fixed point. There are as follows:- Duo pitch – Tie bar at ridge location for duo pitches. Refer to CAD details at further on in this document. Mono Ridge - Use an AJC cleat at the ridge to provide a solid fixing plate. Fix 2no fixings into the base and one fixing through each side of the standing seam into the cleat. Fixing arrangements There are two fixing arrangements for the halter clip. The 245 halter requires 2no fixings, FIXED DIAGONALLY as shown.

The 295 and 345 halters require 4no fixings. The bearing surface must be at least the width of the halter base. The 245mm halter has a 60x60mm base, and the 295 & 345 halters have a base of 60mm wide by 75mm long. When fixing to a structural decking profile the full height halter clip can be connected to the deck by means of a side layed channel section. The channel can be either continuous or it can be cut and fixed in short lengths. Fixing direct to structural decks As an alternative the halters can be fixed directly to a structural deck, but the stiffening rib locations in the crown of the deck must be taken into consideration as indicated below. The rib locations will effect the fixing location and connection to the deck. WHEN FIXING HALTERS DIRECT TO A DECK THE MATERIAL GAUGE MUST BE 1.2MM THICK STEEL AS A MINIMUM AND BUTRESS THREAD FIXINGS USED. The centres of the halters may be reduced in areas to cater for localised wind zones. This is the responsibility of the roofing contractor and project engineer to ensure this happens. For warranty purposes we recommend the use of stainless steel fixings to match the Ashzip 25 yr warranty (25 yr warranty subject to application).

245mm Halter base inconjunction with D100 deck

would therefore be OK

295mm Halter base inconjunction with D100 deckwould therefore not be OKbecause fixing holes are to close to the rib edge

12

Green Roofs Where green roof applications are being installed 4no fixings must always be used irrespective of halter depth. THE ASHGRID MUST NOT BE USED IN SUCH APPLICATIONS. Fixing - General Recommendations

Caution should be exercised when storing open packs on a roof as even though the Ashzip sheets are light and have a narrow cover width, longer lengths can still have a large plan area that is subject to wind uplift. Any open packs at the end of the day should be tied down if it is not possible to install the remaining sheets. Sheets should be zipped immediately after laying to reduce the risk of sheets being subject to wind forces before they are fixed into position and attention should be paid to the last sheet. Problems can be reduced by temporarily securing the last sheet with verge clips if a roof is only partially completed. See illustration below.

Abnormal Weather conditions

The roofing contractor and main contractor must maintain checks on forthcoming weather conditions during the installation, and take due care to ensure the sheets are not exposed to abnormal wind loads during the construction process. The Ashzip sheets are only designed to take loading from above once the roof is fully installed. If the cavity is left open there is a risk that the roof can start to peel back if subjected to strong gusts of wind. The verge components on their own will not resist very heavy gusts.

Abnormal weather conditions could be considered as being when strong gusts of wind occur, extended periods of high winds or when the Met Office issues a weather warning for the area near or around the site.

Load bearing capacity and foot traffic

Although Ashzip sheets have an inherent amount of spring in them, where possible the risk of deformation due to foot traffic should be avoided. Sheets can be walked on once zipped up without the need for additional load-spreading measures but wherever possible walk on or as close to the vertical seam as possible. If there is a requirement for a roof to receive a lot of foot traffic the risk of damage to the sheets can be reduced by having a designated walkway areas with high density (180kg/m3) insulation below to take any weight. The use of walkable load bearing gutters is also suggested at the eaves to prevent any dishing and ponding of water on the top sheet at this location. Non-roofing trades should be provided with designated protective walkways when access across a sheeted roof is required. This can be shown on a layout plan and would again utilise high density (180kg/m3) insulation to take any loading caused by foot traffic. Where brickwork is being constructed above the sheets, a polythene protective covering must be used to prevent any mortar spillage damaging the sheet. If the inclusion of a high density insulation support is not possible then the use of wooden spreader planks is recommended along the seams with lattice planks perpendicular to the seam underneath. However, consideration should be given to maintenance access and any damage that may occur at a later date.

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3mm AJC CLEAT SECUREDTO EXISTING PURLIN WITH2 No. FRAME FIXINGS.

ASH

GR

ID B

RAC

KET

3mm AJC CLEAT SECUREDTO AG60 BAR WITH2 No. FRAME FIXINGS.

AG60 BAR

2 No. FRAME FIXINGS.TO EXISTING PURLIN WITH3mm AJC CLEAT SECURED

AG60 BAR

ASH

GR

ID B

RAC

KET

EXISTING PURLIN

2 No. FRAME FIXINGS.

3mm AJC CLEAT SECUREDTO AG60 BAR WITH

RAFTER

PURLIN

Typical section through loaded bar and bracket system to show loading above main frameworks

3mm AJC CLEAT SECURED TO AG40 BAR WITH 2NO FRAME FIXINGS

AG40 AG40

14

Fixing Halter Clips

Halter clips are usually set out on a modular basis and fixed symmetrically through pre-drilled holes in the base of the clip. Also refer to previous pages for the full height halter fixing arrangement. Attention should be paid to manufacturers fixing recommendations regarding widths of drilled hole diameters and torques. A setting out template, as listed in the standard tools should also be always used. Use a 400mm cover or 300mm cover setting out template for any straight or curved roof

application. Tapers will be measured and set out manually on site. Direction of Lay

Sheets are laid in one direction from one side of the roof to the other with the halter clip positioned facing the direction of lay to allow the crooked seam of the Ashzip to snap over the halter head. If the halter is pointing in the wrong direction the sheets will not zip-up correctly and ripples in the seams will appear.

3 STEP LAYING SEQUENCE Step 1 Fix the halter clip into position with head facing in the same direction as the lay

of sheet. Step 2 Rotate the seam with crooked head down to snap over halter clip head, again

ensuring this faces the same direction as the lay. Step 3 Lay the following sheet with the wide seam over the crooked seam and zip-up. Step 4 Use a barrier tape between any dissimilar materials

3

1

HALTER GROOVE TO

2

FACE DIRECTION OF LAY

ONTO HALTER CLIPSHEET IS ROTATED

DIRECTION OF LAY

ASHGRID SPACER SYSTEM

ASHGRID SPACER SYSTEM

FACE DIRECTION OF LAYHALTER GROOVE TO

HALTERS AT 400mm FOR STRAIGHTS & 403mm FOR CURVES

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Fire Performance

Ashzip sheets have a notional AA designation as defined by BS476: Part 3: 2004 and when tested in accordance with BS476: Part 6: 1989 attains an index of performance of (I<12) with a sub-indices of performance of (I<6). Our material also attains a class 1 rating as outlined in BS 476: Part 7: 1997, combining the results of these tests, Ashzip sheets may be designated class 0 for the statutory requirements of the Building Regulations approved Document B. The Ashzip system in non-combustible throughout incorporating products that offer no contribution to smoke of spread of fire. Ash & Lacy do not recommend the use of insulations that produce high levels of toxic fumes when subjected to fire. These include types such as P.U.R (Polyurethane). When a high density slab is recommended within this brochure, at a ridge detail for example it refers to a non-combustible material such as Rockwool Duo Slab. In all cases all insulants should always be non-combustible. Insulation fire performance There are two main types of insulation a Rock Mineral wool ie Rockwool or a Glass Fibre Mineral wool such a Factory clad 40. Both of these are designated as being of a mineral wool type. For fire performance Factoryclad is classified as Euroclass A1 to BS EN ISO 13501-1. Rockwool supplied materials achieve a reaction to fire classification of A1 as defined in BS EN ISO 13501-1. For information relating to fire stops within a roof void please refer directly to the material supplier and/or approved document B of the building regulations.

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Typical Verge-To-Verge Fixing Sequence

Note: Do not set out the halters for all of the roof at once. Set out in sections of 6 or 7, this allows any mis-alignment of halter to be corrected as work proceeds

Tolerances detailed in this section are set to allow free movement and expansion over the halter clip. Ashzip halter clips must be set out to the tolerances shown below. If the halter clips are set out of plane or alignment they will prevent the sheets from zipping up and from naturally expanding, causing unwanted fixed points.

1. Firstly set out the halter clips starting at

the datum point required. This is normally shown by the fixing contractor on the verge detail drawing and is a position from the gable portal or framework. The set out of halter clips must be accurate to prevent the seam rippling and running out of line up the slope. On shallow roofs care should be taken regarding the thickness build up of components at the eaves. Ponding can occur where the components are built-up and force the sheet above its natural plane.

Halters must be set out perpendicular to the roof line

PLANE OF ROOF

+/-1° MAX FROM PLANE OF SUPPORT

HALTER ALIGNMENT

+/- 3mm

Halter clips must be set out with

can cause fixed points which may lead to

LINE OF SUPPORT

+/-1° MAX FROM PLANE OF ROOF

from clip to clip

or exaggerate dishing of sheets

LINE OF SUPPORT

Mis-alignment of halters along the roof slope

Variations in halter clip alignment is limited to +/- L/200

NOTE

PLANE OF ROOF

+/- L/200a variation of no more than +/- 3mm

The L/200 limit for vertical alignment is relevant to halters up to a depth of 295mm. This equates to a dimension of 7.5mm based on typical 1.5m purlin centres. Different tolerances are required for the 345mm deep halter clip. Refer to Ash & Lacy technical department.

17

2. Next lay the first sheet over the halter clips and snap the crooked seam into position. Then close the head of the large seam with the zipping machine. When zipping, the end of each seam must be started with the hand-crimping tool (see below).

3. This allows the zipping machine to

clamp into position at the bottom of the slope.

4. Secure the sheet by placing the verge

channel over the wide seam and then fix the verge clip to the side of the halter clip. The verge channel is riveted to the top of the seams at 800mm centres (approx) care should be taken to ensure that rivets do fall within 50mm of the halter location. This will ensure expansion and contraction can occur. Verge clips should be positioned at every halter clip position along the gable (The verge clip must be used to secure the first sheet against wind uplift and should be used to temporarily secure the last sheet at the end of a days work). The verge tolerance clip is riveted through the verge channel to provide a bearing point to the verge fabrication.

5. Fixed points can now be created using

rivets or bolts. The type of fixing to be used depends on the load created at the fixed point. Please contact our Technical Department for further information.

Zipping the Sheets

It is essential to ensure that the zipping machine is in good condition and full working order for the Ashzip sheets to be zipped up properly. Also note that the sheets must be zipped up twice. This increases the tension and spring of the sheet, which reduces the risk of oil canning due to foot traffic or naturally curving sheet on site. a. Check that the correct rollers are

installed in the machine (see note g) and that they are clean and free from loose debris and indentations. Different rolls are required in the zipping machine for steel and aluminium Ashzip

b. Check that the tie bars are lubricated and can easily be moved into position

c. Check guide rollers, locking handle and cams for signs of excessive wear

d. Check for signs of damage to cable and discontinue use if damage has occurred

e. When zipping the first seam the zipping machine should be guided up the slope of the roof to prevent it tilting over and damaging the seams or falling over the verge edge. After this the zipper can be guided with minimum effort.

f. The sheets must be zipped up as laying proceeds. Do not lay several sheets and then zip up. This is for obvious health and safety reasons and load bearing capacity of the system.

g. Use the correct rollers for the correct material. Stainless steel rollers for stucco embossed aluminium and nylon rollers for coated steel and coated aluminium.

h. Sheets should be zipped up twice. i. The sheets must be zipped in a specific

direction on the slope. They must be zipped with the machine trigger handle positioned opposite to the direction of lay. This is indicated on the following page

18

Direction of lay

Slope & Zip direction

Zipping trigger handle handed to direction of lay

Direction of lay

Slope

Zipper trigger handle on this side of overlapping seam

19

Thermal expansion Thermal expansion is catered for in the Ashzip standing seam roofing system by a sliding mechanism over the head of the halter. Because there are no through-fixings other than at the ridge or highpoint of the roof, the sheets can freely expand and contract as the temperature increases or decreases. As the expansion is catered for by a fixed point at the ridge or high point of the roof sheet, the expansion is forced towards the eaves. Allowance should be made between the eaves drip angle and the vertical plane to accommodate the possible increase and decrease of sheet length caused by expansion. Having the fixed point at the ridge means that any fixings required can in most cases be concealed behind the ridge flashing and shroud and filler. Fixed points can be catered for in several ways. The method selected is determined by the load acting at the fixed points.

Types of fixed point Rivet (fig 1) If the force acting at the fixed point does not exceed 0.5kN 1no. aluminium blind rivet is sufficient. Two no. rivets can be used per Halter to increase the values up to 0.8kN per Halter. The rivet is normally located through the under lapping seam so that it can be concealed from view by the larger overlapping seam. Procedure

Drill a hole through the sheet into the halter clip head to take a blind rivet 11-12mm long. This method is applicable on roof sheet lengths upto 10m and curved roofs. Nut & Bolt (fig 2)

Forces at fixed points Forces acting upon the fixed point can be calculated as follows. This load should be considered by the specifier or roofing contractor in relation to procurement of fixings and they’re values under loading.

When using a rivet to create the fixed point fix through underlapping seam so that thefixed point is concealed.

Nuts and bolts are used when the force acting upon the Halter is greater than 0.7kN and less than 1.5kN. Use a 6mm Ø steel nut & bolt with 2no. 19mm Ø bonded EPDM washers. With such a detail the fixing is normally concealed behind the ridge flashing and shroud and is located through the upstand of the Ashzip top sheet and through into the side of the halter.

Nut & Bolt through upstandinto side of halter clip

Line of Ashjack tocarry halter clip

Fig 2

fig 1

Force = L.C. (W. sin ang°. cos ang°) F = Force S = Snow Loading in kN/m2 L = Length of Ashzip in metres W = Weight of Ashzip in kN/m2 C = Cover width of Ashzip in metres ang = Angle of roof in degrees

20

21

Ridge and Eaves Wherever there is a junction in the roof, an effective interlocking overlap joint should be created by turning the various metal components up or down using a simple tool provided with the system. This has the benefits of being easy to perform, sealant free and easily checked for correct installation. At ridges and hips, the pan of the profile should be turned up to form a physical barrier to prevent water from running back over the sheet ends. This upstand, together with nearest profile rib to the verge, is then overlapped by the perimeter flashings, which are designed to shed water over the upstands without the risk of run or blow back beneath the weatherproof detail. This requires some clear space for access (typically about 75mm). If the sheet ends are close to a wall or vertical panel, it may be necessary to fold the ends before placing the sheets in their final position. The use of profiled foam fillers closed off by an aluminium shroud is recommended to keep the weather out. This shroud prevents the foam filler from being dislodged and prevents solar degradation and attack by birds or other pests. The aluminium shrouds are fixed in position by rivets into an extruded ridge retainer, which in turn is riveted to the seams of the Ashzip sheets. There should be a clear space of at least 200 mm between the closure and the end of the turned up trough. The flashing is riveted to the ridge retainer, which supports the flashings and holds the shrouds in position.

Eaves Detail

Any water that falls onto the roof should discharge into the gutter and prevented from blowing back through the seams or under the sheets. The seams are closed at the eaves by profiled filler blocks, which are positioned directly over the drip angle, or usable flat surface, which in turn is riveted to the trough of the Ashzip sheet. Two rivets per sheet should be used. At pitches of 5 degrees or less (or exposed locations), the eaves of the sheets are also turned down into the gutter by approximately 20 degrees by using the special turn down tool. This prevents any water from running back on the underside of the sheet.

The drip angle should be positioned to allow for the expansion of the sheets. The drip angle also acts as a stiffener to the eaves, which can help prevent damage from foot traffic, although this should not solely be relied upon. We can see from the sketch below that there needs to be a gap left between the back end of the drip angle and any gutter or flashing. Typically this should be 1mm for every 1m of sheet and then add 5mm. For a 20m sheet length dim x would be 25mm.

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Verge Detail

The verge detail consists of several components as described previously. These are briefly listed below and installation is explained:-

Verge Channel Verge Clip Verge flashing clip

The leading edge seam of the Ashzip is zipped up and the verge channel is then positioned over the seam and holds the sheet into place (the sheet must be zipped up for the channel to be positioned over the seam). Fixings are not used to locate the verge channel, which allows for the sheets to expand naturally underneath. The seam and verge channel is clamped into position with a verge clip. The verge clip is then fixed through the side of the halter clip at every halter location along the verge, which again allows that the sheets to expand. The verge flashing clip is then positioned under the long leg of the verge channel and riveted through, ensuring the Ashzip sheet behind is not penetrated. When using a full height halter system the verge tie component must also be used. This is positioned at every halter clip location at the verge. It is used on all verge details including abutment details. Failure to use this component will invalidate warranties. Refer to details at the rear of this brochure.

Curved & Tapered Ashzip

Lifting Curved Sheets into Position

To prevent damage under self-weight, curved sheets with tight radii should be lifted into position in smaller bundles of 4 or 5 sheets at a time. Curved Sheets

It is not possible to rotate pre-curved sheets into position as indicated on the previous 3-step detail. Pre-curved sheets should be moved into position and lowered down between the halters vertically and snapped into position. When sheets are positioned onto the halters on a curved application they should be worked from eaves to eaves across the roof, or from the effective ridge outwards. Under no circumstances should the roof be fixed from both eaves up to the effective ridge. Set out of the Ashzip sheets does not require an increase in tolerances and distance between clips. This remains at 400mm. This is for both Pre-curved and site sprung curves. When sheets are positioned onto the halters they should be worked from eaves to eaves or from the effective ridge outwards as mentioned above. Setting out templates are sent to site upon request and should be used for setting out purposes. We strongly advise the use of this tool. On curved roofs we recommend that purlin centres be kept to a maximum of 1500mm centres. This assists with the flexing of the sheets over the curve. The halter tolerances on the setting out of a curved roof are shown on the following page. Note: In some cases there may points of contact between dissimilar materials. Such as galv on aluminium, in such locations a barrier tape must be used to prevent electrolytic reaction.

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Set out of curved roofs Note: Misaligned halters can in some cases cause fixed points along the roof sheets. This may further lead to oil canning of the sheets where they try to expand and contract but cannot.

The maximum variation in height between halters over 3 purlins is +/- L500

+/-1°

+/- L/500

+/-1°

+/- 3mm

The maximum variation in height between halters along a run is 3mm

Ashgrid & Halters must be alingned to curvature of the roof

The maximum variation in flatness of a halter is +/-1°

LINE OF SUPPORT

LINE OF SUPPORT

CURVATURE OF ROOF

CURVATURE OF ROOF

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Tapered sheets

Tapered sheet widths should be calculated by the fixing contractor against full structural steelwork drawings. Due to the fact that discrepancies in steelwork can occur it is recommended that the actual steelwork dimensions are checked against drawings before the setting out of the halter clips and subsequent installation begins. An additional 50mm should be added at each end of every sheet to allow tolerance and placement of sheets to suit any steelwork discrepancies. When calculating the cover width of tapered sheets we suggest that cover widths of between 400mm and 250mm should be used to provide optimum usage of flat sheets and to keep costs to the roofing contractor to a minimum. However wider coverwidths to suit specific job requirements are readily available.

Note - Cover widths greater than 400mm will need to be fully supported by rigid 180kg/m3 insulation slabs. When using tapered sheets the halter clips are set out along radial supports following the plane of the roof. It should be noted that the liner sheets are not supplied tapered. This means that the liner profile will have to be cut to suit on site and the edges covered with a flashing trim along the line of the rafter. The Ashgrid Spacer Support System should be ordered with short bar lengths so that it can be fixed to the shape of the roof. A 300mm strip of high density Hardrock insulation should be positioned underneath the weld joint. This provides additional support and rigidity to the sheets whilst they are being welded and subjected to high levels of foot traffic.

AA

BB

Halter above AshgridBracket and Bar

Curved tubular section

C-section cleat welded to top of curved circular sectionto provide flat fixing connection area

Cleat non-continuous

300mm Hardrock stripto be postioned centrallywhere welding takes place

Halter

Halter above AshgridBracket and Bar

Curved tubular section

C-section cleat welded to top of curved circular sectionto provide flat fixing connection area

300mm Hardrock stripto be postioned wherewelding takes place

Seam cut backand welded

Seam of nextsheet along

25

Setting out of Halters on tapers

When laying tapered sheets it is important that the halter heads are kept in line with the seam of the sheet. This is so that easy connection can be made between the halter and the sheet.

If halters are set outside the set tolerances site operatives will find it difficult to fit the sheet. The profile of the halter may be visible through the side wall of the sheet if the halters are set outside the tolerances stated. Setting out is indicated below.

Line of seam

Halters must be aligned withline of seams so that easy and

proper connection can be made

Halter heads must be strictly kept within the tolerance of+/-2 ° out of line with seam

Halter heads must not be fixed perpendicular

to ridge and eaves lines

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Tapered Ashzip – Supports Tapered Ashzip sheets will not always form a perfect curve around the roof i.e. a conical formation between rafters. To achieve this, supports must be used that are curved on plan and section. If straight purlins are used a facetted effect will be produced at the hip rafter locations. When narrow end falls below 250mm The Ashzip can be tapered from 250mm up to 600mm at the widest point with 250mm to 400mm being the most economical sheet width. In some cases the seams will not line up, which again is governed by how many times the Ashzip sheet must be split and the internal diameter/radius. Note, If the plan radius of the building does not suit the minimum and maximum sheet sizes there are two options:- 1. Special width sheets can be produced subject to production checks and structural connection details 2. Sheets can be fitted in a layered format where the minimum and maximum can be incorporated. In such cases the seams will not always line up. This is indicated to the right

This is because the natural effect of a taper would be for the sheets to curve away from the straight purlins. This is detailed below and the same principle would apply to concave tapered roofs. The red lines indicate the purlins and rafters, and the black lines, the sheets projecting away from the supports. The same effect would occur where structural decks are used, as they would lie flat between rafters.

Refer to Ash & Lacy technical for further assistance on layered format for tapers.

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10000mm3000mm

Calculating the size of Ashzip tapered sheets

Calculating the size of Ashzip tapered sheets is relatively simple. For example a fully circular building with an external diameter of 10m and an internal diameter of 3m (a donut shaped building). We can start with either the external or the internal taper size, but one will govern the other. For this example we will look at the 10m diameter first. This will give an external circumference of 31415mm.

Firstly we take 31415/500 = 62.83 so we will say 63no sheets. (This is based on 500mm wide sheets at wide end).

Then we take 31415/63 = 499mm taper at the widest end

This will now determine the taper that fits on the small or internal part of the roof which was the 3m diameter. The 3m diameter will give a circumference of 18849mm.

18849/63 = 299mm at the narrow end of the taper. 299mm therefore falls within production capacity.

It is important to calculate the width of both ends of the sheets because once the wide end has been calculated the narrow end may to small for us to manufacture.

For example if the smaller diameter was 2m and therefore the length of sheet was longer it would be the narrow end that determined the width of sheets.

A 2m diameter would give a circumference of 12566mm. If we took the original wide end of 63 sheets at 499 this would give:-

12566/63 = 199mm - Less than the ideal minimum of 250mm

So in this case would have to take 12566/250 = 50.26 so we say 51no sheets with 250mm at the narrow end. This then governs the wide end.

31415/51 = 615mm - this exceeds the maximum safe cover of 600mm and therefore would have to split part way up the roof to suit so that either the wide end cover is reduced or the narrow end increased. In such cases the seams may not be aligned at every location

10000mm2000mm

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Tapers used on straight purlins When straight purlins are used the roof will create a facetted effect at the hip locations. On such buildings the appearance of a curve can be achieved by using a combination of straight and tapered Ashzip sheets. This lends itself to buildings that have relatively shallow radii on plan (see example below). To achieve a curved effect and move away from a more facetted effect, the rafter locations have to be close together and the roof pitch low. On this particular layout there are non-symmetrical bays. The straight Ashzip sheets are laid out from the approximate centre of each bay perpendicular to the main eaves and ridge beams.

The areas left at the ends of the bays a taken up with the tapered Ashzip sheets and are worked out on the basis of minimum and maximum sheet size parameters as given in the full tapered section. If one falls below the minimum or is larger than the maximum, then the straight Ashzip sheets will have to be adjusted to suit or replaced by more tapered Ashzip sheets. This will depend on the angles of the structure below. The tighter the angles the more the facetted effect will appear.

Ridge

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Fixings and Sealant The installation of the Ashliner requires 3 fixings per sheet with 1 fixing in each edge pan and 1 fixing in the central pan using stainless steel screws type BMLS25S16 with bonded washers. The side laps need to be fixed at 450mm centres maximum with stainless steel stitcher screws type BMST22S16 with bonded washers. The end laps require a minimum lap of 150mm with 2 fixings positioned evenly across the profile sheet in the trough adjacent to the major crown as shown below (Fig 1). Halter clips must be fixed down with 2 fixings per clip into the purlin flange using stainless steel screws type BMLSHF38S16 with bonded washers. ALL FIXINGS TO BE STAINLESS!

In accordance with the MCRMA Technical Paper No. 16, to seal the end lap effectively 2 lines of sealant are required with each run made up of 6mm wide x 5mm thick bead sealant positioned 15mm from each end of the lap as shown below (Fig 2). The sealant needs to be butyl mastic HP500 cross-linked.The Ashliner side laps are sealed with a layer of polyband 50mm x 1mm. Foam fillers for the upper Ashzip sheets need to be EPDM faced. Foam fillers for the lower Ashliner need to be EPDM material throughout. CONTINUITY OF SEALS SHOULD BE MAINTAINED THOUGHOUT INCLUDING AROUND PENETRATIONS. END LAPS SHOULD NOT BE SEALED WITH POLYBAND TAPE.

150

75 75

15 15

Butyl Sealant

Fig 1

Fig 2

Fixing Locations

End Lap Section

30

150 min

Full heightbar & bracket

Top hat to spreadload over deck ribs

Box soaker

Weld Location

Structural deckstiffening tie asper instructions

Closure section abovedeck opening restraint

Closure section

Typical upstand detail for 350mm Ø Diamond SunPipe system for a standing seam roof

Isometric detail of roofing sheet

Note:- All combustible materials are to be removed from the vicinity of the joint to ensure that there will be no fire risk due

to site welding

Section A - A

Vapour control layer sealed to soaker liner

Soaker upstand min 150mm high

hardrock insulation

350mmØ

ABS Collar supplied & fitted by sunpipe supplier

to roofers upstand

Trimmers fixed to purlins

Maximum externaldimension of upstand

including flashings

2 piece adjustable

elbow

SunPipe

Weld location

Penetrations Openings can easily be incorporated in the roofing envelope when using the Ashzip standing seam roofing system. Openings are welded at the interface between the end of the Ashzip sheet and the upstand. A minimum 150mm upstand should be incorporated for weather tightness. Circular penetration detail

Soaker penetration detail

Depending upon the size of the opening full structural support should be incorporated. This is required when the opening is wider than 1 profile width. Small circular holes can be incorporated without the need for additional support and collars can simply be welded into place. Various methods of placing penetrations within the system are detailed below.

As shown to the left large soaker units require full structural support. The soaker or any penetration should have a 150mm minimum upstand and be welded into position around the edges. All penetration details should be fully sealed to comply with building regulations are air test requirements.

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Decktite Pipe Flashings Decktite pipe flashings can be used as an alternative to a welded collar. They are suited to small diameter pipe penetrations and must be small enough to fit between the upstands of the seams. Ash & Lacy offer two types of Decktite units that are suitable for use with the Ashzip standing seam roofing system. Depending on the penetration usage a more robust product may have to be utilised with minimum and maximum operating temperatures. Range Listed above are the range of decktite’s that Ash & Lacy offer depending upon which component is used the order code is on the right or the left of the table. With pipe diameters and base dims in the middle. Please consult with our distributions department for specific fixing kits required.

The Decktite units are simply fitted/molded to the profile around the penetration and fixed to the Ashzip profile using stitching screws. For normal operating temperatures black EPDM units should be used (-55°C to + 35°C) and for more extreme operating temperatures use Red Silicone Units ( -74°C to + 260°C) as indicated below.

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Full Height halter span tables for Ashzip 400

Refer to Ash & Lacy Technical department for shallow depth halter span tables SPAN TABLES ARE BASED ON THE ROOF PERIMETERS BEING FULLY ENCLOSED. THE ROOFING CONTRACTOR IS TO ACCOUNT FOR WIND ABNORMAL LOADINGS CAUSED BY UNUSUAL WEATHER EVENTS. THE ROOFING CONTRACTOR AND MAIN CONTRACTOR SHOULD MONITOR LOCAL WEATHER ADVICE TO TAKE INTO ACCOUNT UPCOMING WEATHER EVENTS

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34

Site operations

This method statement is to be read in conjunction with all relevant site drawings, machine/equipment instructions, instruction drawings, other operation method statements and health and safety risk assessments. When handling Ashzip all site operatives must wear suitable PPE. Before Mobile roll former unit (MRU) arrives on site Before site rolling at eaves can begin certain parameters must be met on site. These are as follows:

1. A flat, even hard standing surface (free

from standing water) is required. Minimum areas are to be provided to ensure safe operation can occur. The minimum required area is 10m wide x 18m long. An additional area for sheet run out will be required along with coil storage and fork lift access for coil handling.

The sheet run out area must be equal to the length of sheet + 2m (room for manoeuvring).

2 A secure compound area will be required for coil storage. The size of this area will be dependant on the size of the project. For example for a 16000m² project an area of 15x6m would be required to store all of the coils.







3 A secure compound area will be required for coil storage. The size of this area will be dependant on the size of the project. For example for a 16000m² project an area of 15x6m would be required to store all of the coils.

Any area provided for storage of coil must drain well, be free from any standing water or mud, any contact between any of these and the coil will cause damage to the coil.

4 Access to site is the responsibility of the roofing contractor and must be arranged in conjunction with the main contractor.

5 Normal site working hours for our

operatives are 8:00am to 4:30pm Monday to Friday. Additional cost may be charged to the roofing contractor for hours outside of these.

6 Sufficient labour must be provided by the

roofing contractor to carry sheets off the end of the MRU. We will only provide labour to operate our machine. To carry the sheets without the risk or creasing or other damage the contractor will require 1 man per 6m and on a curved roof 2 men at the ridge. A further 2 men should be provided to allow for continuous sheet running whilst the previous sheet is walked into position.

For example a 30m sheet on a curved roof

30/6 + 1 + 1 for the ridge= 7men to carry the sheets. Allow for two further operatives to support the following sheet whilst the previous is walked into position. (For Steel sheets allow 1 man every 4m).

35

7 Skip facilities are to be provided by the

roofing contractor for Ash & Lacy Building Systems to use to dispose of packaging and wastage.

8 Unrestricted access to a 4.5 tonne rough

terrain fork truck is to be provided/hired by the roofing contractor.

9 Where sheets are to be run and then

stored on the roof in packs, the project engineer must be informed to ensure that the structure will take the additional loading. It is preferable that the MRU and frame will be positioned above a main rafter.

10 If Ashgrid bar and bracket spacers are

being used to form a cavity, anti-sway brackets must also be used when loading out. This is as follows:-

One at each end of run of bar One at loading out positions Curving on site When curving Ashzip sheets on site at ground level it is important to remember that allowance should be made for the sheet length on both sides of the curving machine and space should also be allowed as the sheet curves around through one end.

11 The roof must be fully lined out prior to

the MRU arriving on site.

The Roll former restraint frame must be fixed into position by the roofing contractor prior the equipment arriving on site. Note: The frame is fixed through the liner into the supporting structure below. In the area where the framework is to be positioned the Ashgrid is to be removed to allow direct connection to the structure.

12 Consultation should be sought from the

crane hire company by the roofing contractor to ensure site access and restrictions are considered. The size of crane must be determined by the roofing contractor in conjunction with the crane hire company.

13 Note: When rolling at eaves the restraint framework must be in position before the mobile roll forming unit can be placed at eaves level. Our operatives are instructed to work on the basis of NO FRAME NO ROLLING.

For example a 40m Ashzip sheet curved to a radius of 30m would have a chord of 76.6m and a chord height of 17.35m as illustrated below. In this case a clear area of 80m X 20m would have to be allowed for curving without before taking into account an area for the storage of the Ashzip packs before lifting. Operatives are to be provided by the roofing contractor for this process as per rolling at eaves level. 76.6m

40m

Curving machine

17.3

5m

36

Rolling At Eaves Level Lifting the MRU into position Lifting Equipment – ID no 20861 S1 The MRU is lifted by 16mm Ø 4 leg Sysma grade 8 chain slings 5m long B to B with each leg terminate with 6.5t alloy bow shackles with a type E pin sling complete with shortening clutches. Tare weight of 160kg. The components stated in this paragraph are inspected and tested as one unit and classed as one working component. The safe working load of this component is 17t @ 45° when the chains are fully loaded from the lifting eyes. Framework around MRU – ID no 2059-9 What the frame is carrying Special purpose lifting frame, constructed from 152mm x152mmn UC having 4 shackle lifting lugs, one welded at each top corner of the frame. Framework general dimensions being 7550mm overall length, 2750mm wide, 2900mm overall height. The members stated in this paragraph are designed and tested as one unit. With a safe working load of 12t. The total weight of the loaded MRU is 9.3t + 2t maximum coil weight.

Restraint weights & chains – ID nos A317417 & A317396 Wherever possible restraint weights are to be used which are tied to the bottom eyes of the container with 6m long chains. This component is not necessary for the safe operation of the MRU and is only incorporated as a matter of good practice. The chains are as stated 6m long but wherever required extensions are available. These chains have a SWL of 1t although as they are positioned on the ground they will not be carrying such a load. Attached are the certificates of inspection for the above mentioned components. Hard copy upto date certificates are available for checking when the container arrives on site.

37

38

What the crane must lift 1. A crane will be provided by the roofing

contractor to lift the 11.2t (MRU + frame) + 2t coil = 13.2t (allow 14.5t weight in total) This takes into account friction caused by Restraint weight blocks and MRU on lifting chains. The crane will then lift the MRU into position over the restraint frame which will have already been fixed into place by the roofing contractor. The MRU is to be lowered into position but not rested on the frame. The MRU must not be moved horizontally into position, it must be lowered from above to allow safe and proper alignment without damaging the restraint frame.

For this the crane must have sufficient reach and jib length. The frame is only to provide restraint against adverse movement caused by strong gusts of wind, also the front bottom eyes of the MRU are tied back to the frame for additional stability. This is shown under Analysis of Side Loading to Suspended Rolling Cab below. Ash & Lacy cannot offer advice on the size of the crane as this will depend on site conditions and where the MRU will have to be lifted to. We do however suggest a Minimum of 80t is used. Confirmation should be sought through the crane supplier and they should do a site visit and be fully conversant with application.

The roofing contractor must also provide or arrange a suitable Banksman who is responsible for all connection of lifting equipment and supervision of lifting operations. 2 Herras, or similar high visibility fencing is

to be provided by the roof contractor in conjunction with the main contractor to form a restricted access area which is only to be used by our site operatives. The scaffold should be adequately closed off and guardrails positioned around the edges of the machine where the scaffold walkway ends.

39

40

Analysis of Side Loading to Suspended MRU Information received from a typical crane hire company gives a maximum wind speed for safe crane operation of 24mph which equates to 11m/s, referring to BS6399: Part 2: 1997, the calculated wind force acting on the rolling cab side elevation is 0.4kN/m2 based on a suspended height of 10m. 2.6m 7.9m Rolling Cab Side Elevations Total wind load acting on the rolling cab side elevation is 0.4 x 7.9 x 2.6 = 8.2kN. The force resisting this wind load is: - F = µR Where R is the reaction, which in this case is the weight of the rolling cab of 10 tonnes. µ is the coefficient of friction; a value of 1.0 is equivalent to the cab sitting on a rough concrete floor and a value of 0 allows continuous movement with no force. Taking a value of say 1% of full friction due to tension of chains, the resistance force becomes F = 0.01 x 1000kN = 10kN > 8.2kN wind force. By inspection, it appears the self weight of the cab will resist the wind force and will remain stable, however, our framing guide when fixed to the purlins over the rafter back will resist side movement due to natural twist of chains and vibration from rolling machinery. In practice roofing operatives will have been brought down from the roof before wind speeds become unsafe for the crane to work.

41

Mobile Rollforming Unit Details Container no: 02 Container ID no: MLCU 01 Manufactured: Originally 05/90 Reinforcements and modifications to take Roll former: 05/03 Next survey due: 11/04 Gross laden Weight: 13.2t Power: The MRU is powered by remote

generator provided by ourselves. This is detailed further on (415 volts). The MRU runs on a compatible voltage to the generator and the details provided further on. All cables are suitable strength and quality and inspected for use on site.

UNDER NO CIRCUMSTANCES MAY A PERSON FROM ANOTHER SITE OPERATION ENTER THE ROLL FORMING CABIN. NOR CAN ANY TOOLS WITHIN THE CABIN CAN BE USED BY A MEMBER OF ANOTHER SITE OPERATION. Notes:

1. The crane is to be provided by the roofing contractor. Advice Should be sought by the roofing contractor from the crane company before a crane is ordered. (See previous notes).

2. The MRU will be will be positioned and

located within the restraint framework provided. The restraint framework which is fixed through the liner profile into the supporting structure. The container is not placed on the framework as the frame is there to prevent lateral movement.

3. When the MRU and restraint framework

is positioned at the eaves it should be positioned over the rafter position for additional stability when ever possible.

4. Where the MRU overhangs or lands onto the leading edge of the roof, a recess in the scaffold handrail must be incorporated to end the footpath when the roll former is in place. The handrail where the MRU is to be positioned must also be removed when the cabin is placed. This should be arranged by the roofing contractor with the main contractor. (On tight radii roofs this may not be required as the container may be above this level.

Any changes to scaffold and positioning of

support rails must be in accordance with relevant safety guidelines and is determined by the roofing contractor. Operating the machine Name of operative Chris Griffiths Dave Galvin Pete Hand Other to be advised…. Programming the MRU Sheet lengths can be programmed into the machine by two means. Either at ground level within the cabin, or alternatively when the cabin is at eaves level using a remote control panel outside of the MRU (up to approximately 10m from machine). Changing and loading coil When the coil runs out or needs to be changed the MRU will be lowered to ground level and the coil will be changed and then the MRU is lifted back into position. The side doors on the machine where the coil is to be loaded will be locked from the outside to prevent an exit point whilst the cabin is at the eaves. The rear doors will also be locked from the outside. Refer to the above mentioned drawings and notes for area required at ground level for loading coil.

42

1

23

4

5

6

7

Access into the MRU during manufacture Operatives in general will not enter the MRU, but in certain circumstances they may need to enter whilst the machine is rolling. This is due to coil manufacturing process and coil delivery, the coil can in some cases birdsmouth or be slightly over width and snag on the de-coiler. In such cases entry into the machine is unavoidable. However, a guard door is in place to ensure that access is restricted to the de-coiler. The roll former will need to be lubricated during manufacture. 99% of the time this is done automatically by a rig inside the machine. In some cases where the coil is ‘dry’ manual lubrication may have to take place but in most cases this is not necessary. Safety Guards within the MRU

1. Door guard to rear of roller 2. Earthing box (HAGAR box) 3. Rear door 4. Sliding roll former guard 5. Coil 6. Remote control panel

onto main panel

7. Side door 8. De-coiler guard door

8

43

Earthing Both the generator and the MRU must be earthed. This is by means of earthing cable and then electronically testing the connection with and earth testing kit. Earthing path The generator is connected to the MRU by plug-in earthing cable which is located below the control panel on the generator. The cable is then connected to the roll forming machine which is in turn connected to the earthing point on the building. Alternatively the machine can be directly earthed into the ground by means of driven spikes. Earth testing Kit Testing via yellow and green cable with copper spike connected to Hager box (descriptive name for connection in roll former cabin – See roll former diagram) Equipment: Earth Tester Manufacturer: METREL Model: SMARTEC MI2124 Serial No: 12118877 Results: Digital readings in accordance with European Standard EN 61557-5 Operative: To be used by a competent person to test earthing as per instruction manual and descriptive method on underside of equipment lid. Notes:

1. To be sent to site with calibration certificate in case

2. To be used in accordance with instruction manual

3. Does not require regular service or calibration

Safe use and handling

1. To ensure operator protection the equipment must be used in accordance with instructions set out in manual.

2. The machine will not be used if damaged.

3. Any calibration or service requirements must be carried out by a competent person as prescribed by the manufacturer.

4. To be used on low voltage machines as per descriptions in instruction manuals.

5. Turn power off by before opening battery cover.

Copies of calibration and declaration of conformity are given on the following pages. Earthing Diagram

Earthing connection point to building

RollformerGenerator

44

45

46

47

Power Generator

Note: This is the specified generator that we use. From time to time we may source from another company or a different generator will be used. In all such cases the Generator will be supplied and operated on the same basis as set out below. Supplier: LCH Generators (or equal

approved) Model: XD27 (or similar)

Specification:-

Noise Levels Fuel tank capacity Consumption Running time (Hrs)

Ltrs/hr (US Gal/hr KVA(K

w) Engin

e Alternato

r LWA dBA @ 7m Litres (US Gal) 50 Hz 60Hz 50Hz 60Hz

27 (21.6) 3.1524 LL1014S 92 61 232 (61.3) 7.6(2.0) 8.6(2.30) 27 24

NOTE: UNDER NO CIRCUMSTANCES MAY AN OPERATIVE FROM ANOTHER SITE OPERATION WHETHER IT BE THE ROOFING OR MAIN CONTRACTOR USE OR BORROW THIS GENERATOR FOR OTHER WORKS. Operational checks Before use the operator must do the following checks and procedures.

1. Check oil levels and replenish using SAE 15/W40 or equivalent

2. Check the fuel level and use water free Diesel/Derv/Gas oil to BS2869

3. Check coolant level 4. Check air filter. In dusty areas this

must be cleaned regularly 5. Visually check drive belts 6. Check all meters and gauges are

functional 7. Check for leaks 8. Check engine oil and pressure are

within limits 9. Ensure generator is not past service

date (refer to next service figure on machine and compare to hour counter – machine serviced on number of hours used).

Fault finding on site procedure Engine does not crank – Check emergency stop buttons on the control panel and on the outside of the canopy are released. Check battery voltage. Check no fault lamps lit.

Engine cranks but does not fire – Check fuel level. check emergency stop push buttons are out. Engine stops due to high temp – Check generator not overloaded and check airflow not restricted. Engine stops due to low pressure – Check and top up engine oil . If fault persists call out LCH generators service dept. – 24 hr call out. No Voltage output – Check voltage with voltmeter. Check that the circuit breaker is in the on position. Check that the cable terminal box is closed and the catch is on (if open the circuit breaker will trip). Check no fault lamps are lit. Black engine smoke or loss of power/speed – Check air filters are clean. Check fuel filters and air level. Check that the generator is not being overloaded. Engine slows down when load is applies – This is normal unless it slows down to less than 49Hz (for 50Hz operation) or 59 (for 60Hz operation). Operation Name of operative Chris Griffiths Dave Galvin Pete Hand

48

1. Before starting the generator check lubrication oil and coolant level. (Do not remove the radiator cap when the engine is hot).

2. Ensure the generator circuit breaker is

switched off. 3. Follow all further start up instructions 4. Check for abnormal noise once

started or for abnormal vibration 5. Check control panel readings at

regular intervals 6. TO STOP GENERATOR – Open

circuit breaker by moving the handle to point downwards to position 0.

7. Allow generator to run for 2 minutes

to cool down and then turn selector switch to off.

Generator Health and safety Notes 1. The generator must be operated by a

competent and experienced person. (See listed above).

2. Use lifting points provided (these are covered by LCH’s inspection and maintenance manuals with regards to LOLER) check before lifting that attachment to the chassis is satisfactory. Inspect connection points

3. for damage that may have occurred

during transportation. 4. Position the generator away from any

flammable liquids. 5. Check all guards are secure.

Generator not to be used if any guards are defective or missing.

6. Exhaust position to be facing away

from any area of work wherever possible.

7. The roofing contractor is to inform the

main contractor that there are hot exhaust pipes from the generator. The roofing contractor and main contractor should inform all operatives of this risk and reference

should be made in any site risk assessment.

8. Earthing as per previous description. 9. Any servicing or electrical repair work

to be carried out by a suitable LCH approved operative.

10. Operatives to wear protective gloves

and clothing when handling fuels. 11. The machine can be operated

remotely and can start up at any time. A warning to this effect is clearly displayed on the control panel of the machine. Reference should be made to this in the roofing contractors method statement and risk assessment.

Generator – other notes The machine is serviced after a set number of operating hours. This is clearly written on the machine and a second counter is incorporated in the machine to prevent the number being changed. Refer to figure or inspection and maintenance certificate to confirm generator adequate for use.

49

a

Ashzip Components list order form Full height halter clips

MAIN ROOF COMPONENTS VERGE COMPONENTS Halter Verge Tolerance clip (3m lengths)

Verge Channel (3m lengths)

RIDGE COMPONENTS Ridge retainer (3m lengths) Ridge support Zed (3m lengths)

Ridge closures (300 & 400mm to suit width of sheet) Ridge filler block (300 & 400mm to suit width of sheet)

EAVES COMPONENTS Drip angle (3m length) Eaves filler profile (1nº per sheet)

VERGE COMPONENTS CONT. Verge Clip Tick appropriate system U value

to clip height

Nº Required

Nº Required

Nº Required

Nº Required

Nº Required

Nº Required

Nº Required

Nº Required

Note: In some cases there may points of contact between dissimilar materials. Such as galv on aluminium, in such locations a barrier tape must be used to prevent electrolytic reaction.

245 295 345

Halter Height (a)

Nº Required

0.25 U Value

0.2 U Value

0.16 U Value

Verge Clip

Nº Required Slotted between halters at verge

Verge tie - used at every verge clip location

Nº Required

Is this a curved roof ? Y N

50

Components list order form VERGE COMPONENTS Verge Clip to be used on halters 120mm deep and above Verge Tolerance clip (3m lengths)

Verge clip to suit 85mm Halter only Verge Channel (3m lengths)

RIDGE COMPONENTS Ridge retainer (3m lengths) Ridge support Zed (3m lengths)

Ridge closures (300 & 400mm to suit width of sheet) Ridge filler block (300 & 400mm to suit width of sheet)

EAVES COMPONENTS Drip angle (3m length) Eaves filler profile (1nº per sheet)

SPECIAL TOOLS REQUIRED Ridge turn up tool Eaves turn down tool Left hand hip turn up Right hand hip turn up Hand seamer Zipping machine and tool kit (steel rollers for Stucco Aluminium and Nylon rollers for painted materials)

Nº Required

Nº Required

Nº Required

Nº Required

Nº Required

Nº Required

Nº Required

Nº Required

Nº Required

Nº Required

Zipping Machine Hand crimping tool Ridge turn up tool Eaves turn down tool

51

Weld detail for tapered sheets

STAINLESS FIXINGS TO BE USED THROUGHOUT

52

Tapered sheets in layered format

Weld location

Weld location

Seams do not line through in this instance

Note- seams can line through, this depends on the curvature of the building and the number of tiers required over the length of the slope. Refer to Ash & Lacy Technical for further details.


53

Typical mono ridge with AJC cleat and fixed point


54

Mono ridge isometric 1


55

Mono ridge isometric 2


56

Typical welded soaker detail with AJC cleat fixed point

Note: In some cases there may points of contact between dissimilar materials. Such as galv on aluminium, in such locations a barrier tape must be used to prevent electrolytic reaction. ALL PENETRATIONS MUST BE FULLY AIRSEALED.


57

Typical Weld Joint Detail



58

Typical Verge Detail



59

Verge isometric 1


60

Verge isometric 2


61

Typical Ridge Detail


Note: AS AN ALTERNATIVE TO THE RIDGE TIE THE AJC CLEAT THAT IS USED TO CREATE THE FIXED POINT ON A MONO RIDGE DETAIL CAN BE USED. REFER TO THE MONO RIDGE DETAIL IN THIS BROCHURE.


62

Ridge isometric 1

Note: AS AN ALTERNATIVE TO THE RIDGE TIE THE AJC CLEAT THAT IS USED TO CREATE THE FIXED POINT ON A MONO RIDGE DETAIL CAN BE USED. REFER TO THE MONO RIDGE DETAIL IN THIS BROCHURE.


63

Ridge isometric 2 Note: AS AN ALTERNATIVE TO THE RIDGE TIE THE AJC CLEAT THAT IS USED TO CREATE THE FIXED POINT ON A MONO RIDGE DETAIL CAN BE USED. REFER TO THE MONO RIDGE DETAIL IN THIS BROCHURE.


64

1000mm Wide GRP liner

400

PIR board

82

1590mm Overall length of rooflight weather sheet at top of crown

Filler block

Standard vergecomponents

Airseal cleat1.6mm Galv

material

135

1200

132

400

Barrel vault section



65

Welded Valley Detail


66 Note: In some cases there may points of contact between dissimilar materials. Such as galv on aluminium, in such locations a barrier tape must be used to prevent electrolytic reaction.

Barrel vault end detail STAINLESS FIXINGS TO BE USED THROUGHOUT

67


Green roof application

68

Typical construction arrangement

69

Typical acoustic arrangement with liner

70

Typical acoustic arrangement with structural deck

71

Typical arrangement with structural deck and support channel

72

ABOVE ASHGRID BRACKETAND BAR AT EAVES ONLY

HALTER POSITONED

3MM GALVd TIE STRAP

THERMALLY EFFICIENT HALTERCLIP SYSTEM

1.6MM THICK GALVdTOP HAT SPACER

RIVETED THROUGH TOSTRUCTURAL DECK

IMPORTANT NOTE - with details that require a combination of full height halters and shallow halters on Ashgrid. The setting out template should only be used for the full height halters and the halters at the eaves (or any other location where this happens) should be set manually. This will avoid any discrepancies caused by tolerances in the different templates and will mean that the halter lines do not creep from component to component

Typical eaves arrangement incorporating Ashgrid gutter support and shallow halter

73

Fixed point hidden behind Ridge filler and shroud

Line of Ashgrid beneath Halter clips

Ridge retainer

Ridge Flashing

Ridge Shroud

Ridge Filler Block

Ridge components isometric

The fixed point at the ridge location will vary depending upon application. The detail shown above shows a fixing through the side of the halter and hidden behind the ridge components. This is the quickest and easiest way of providing a fixed point. The fixing used will depend upon the loading which is being transmitted at this point. Typically a rivet can be used on sheets upto 10m and curved roof applications. Self Drilling self tapping fixings can be used up to 20m. For sheet lengths larger than 20m we recommend using 3 fixings in the pan of the profile fixed directly into an Ashgrid. The Ashgrid will be positioned directly to the underside of the sheet with a deeper than normal bracket. The halter would then be removed in this location.

Ashzip installation Guide 110507

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