Page 25. Page 26. Page 27. Page 18. Page 39. Page 30 Curving for Rigidal Ziplok 300 & 400. Page 31. Page 32. Page 36. Page 41. Page 42.

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2 Contents Page 3 Page 4 Introduction / Properties ZL 100 Dimensions Page 5 Liner Sheets - 20/100/1000 Page 6 Page 7 ZL 101 Thermohalter ZL 102 Halter Bracket & Thermal Break Pad Page 25 Page 26 Page 27 Page 28 Page 29 Thermal Capacity of Rigidal Ziplok Systems Acoustics Vapour Control Fire Expansion Page 8 ZL 103 Available Bracket Heights Page 30 Curving for Rigidal Ziplok 300 & 400 Page 9 ZL 104 Fixing Sequence Page 31 Production Tolerances Page Page 14 Page 15 Page 16 Components for Illustrated Constructions ZL 105 General Construction Thermohalter ZL 106 General Construction Bar & Bracket ZL 107 Acoustic Construction Detail Thermohalter Page 32 Page 33 Page 34 Page 35 Page 36 Rooflights ZL 113 Corolyte Single Skin Rooflight to Suit Rigidal Ziplok 400 ZL 114 Translucent Sheet Interface Details ZL 115 Rooflight End Lap Details Miscellaneous Page 17 ZL 108 Acoustic Construction Detail Bar & Bracket Page 37 ZL 116 Translucent Sheet Interface Details Page 18 ZL 109 Structural Deck Construction Thermohalter Page 38 Page 39 Zl 117 Bar & Bracket with Rivetted Lap Zl 118 Bar & Bracket with Welded Lap Page 19 Page 20 ZL 110 Structural Deck Construction Bar & Bracket ZL111 Structural Deck Acoustic Construction - Thermohalter Page 40 Page 41 Page 42 ZL 119 Roof Apertures Durability of Aluminium Aluminium Paint Systems Page 21 ZL112 Structural Deck Acoustic Construction - Bar & Bracket Page Aluminium - Inspection & Maintenance Recommendations Page 22 Page 23 Ultimate Fixing Capacities Load Span Tables - Rigidal Ziplok 300 & 400 systems Page Page 49 Aluminium - Health & Safety Data Sheet Aluminium - Site Safety Page 24 Load Span Tables - 20/100/1000 Liner Sheet Page 50 Aluminium - Site Safety, Handling & Storage Contents continued overleaf

3 Contents Page Page Page 56 Page 57 Page 58 Page 59 Page 60 Page 61 Page 62 Page 63 Page 64 Page 65 Page 66 Steel - Inspection & Maintenance Recommendations Steel - Health & Safety Data Sheet Steel - Site Safety Steel - Site Safety, Handling & Storage ZL 120 Ridge & Eaves Accessories ZL 121 Verge Accessories ZL 122 Ridge Detail - Thermohalter ZL 123 Ridge Detail - Bar & Bracket ZL 124 Eaves Detail - Thermohalter ZL 125 Eaves Detail - Bar & Bracket ZL 126 Eaves Detail - Cantilever with Socket - Thermohalter ZL 127 Eaves Detail - Cantilever with Socket - Bar & Bracket ZL 128 Eaves Detail - Boundary Wall Gutter - Thermohalter Page 76 ZL 138 Roof window - Upslope - Thermohalter Page 77 ZL 139 Roof window - Upslope - Bar & Bracket Page 78 ZL 140 Ridge Abutment Detail - Thermohalter Page 79 ZL 141 Ridge Abutment Detail - Bar & Bracket Page 80 ZL 142 Opening Through Roof Detail - Thermohalter Page 81 ZL 143 Opening Through Roof Detail - Bar & Bracket Page 82 ZL 144 Typical Lightning Detail - Thermohalter Page 83 ZL 145 Typical Lightning Detail - Bar & Bracket Page 84 Page 85 ZL /100/1000 Convex Curving Sketch ZL 147 Ziplok Convex Curving Sketch Page 67 Page 68 ZL 129 Eaves Detail - Boundary Wall Gutter - Bar & Bracket ZL 130 Eaves Detail - With Internal Parapet - Thermohalter Page 86 Page 87 ZL 148 Ziplok Concave Curving Sketch ZL 149 Ziplok Waveform Curving Sketch Page 69 ZL 131 Eaves Detail - With Internal Parapet - Bar & Bracket Installation Page 88 Measurement and Setting Out Page 70 ZL 132 Insulated Verge - Thermohalter Page 89 Forming the Seams Page 71 ZL 133 Insulated Verge - Bar & Bracket Page 72 ZL 134 Insulated Verge - With Overhang Flat Fascia - Thermohalter Page 91 Page 92 Page 93 Ridge Detail / Eaves Detail Verge Detail ZL 150 Halter Tolerance on Plan Page 73 ZL 135 Insulated Verge - With Overhang Flat Fascia - Bar & Bracket Page 94 ZL 151 Halter Tolerance in Vertical Plane Page 74 ZL 136 Roof window - Thermohalter Page 95 ZL 152 Halter Tolerance for Curved Roofs Page 75 ZL 137 Roof window - Bar & Bracket RIGIDAL ZIPLOK - Zip-up standing seam roof system

4 Introduction Rigidal Ziplok is a zip-up standing seam roofing system, which is manufactured on one of three state-of-the-art roll former s either in our factory or on site. Only site restrictions and the ability to handle them limit the lengths produced by site rolling. Rollforming is possible also at eaves height on site. The Rigidal Ziplok system is available in 0.7mm gauge colour coated steel or 0.9mm / 1.2mm gauge aluminium. Besides supplying the latter in plain mill finish or stucco embossed, other finishes and colours are available to add to the overall aesthetic appeal of the roof application as well as prolonging the life of the sheet. Rigidal Ziplok is also available in aluzinc, stainless steel,zinc or copper. For further information on these substrates please contact our Technical Department. The sheets are pushed onto the aluminium halter brackets and then zipped-up using a special tool. This design eliminates through fix fasteners and the need for end laps by incorporating full-length sheets to run from ridge to eaves (eaves to eaves on curved roofs), therefore making water penetration virtually impossible even when laid at extremely shallow pitches. Halters The halter brackets are available in two different materials. 1) A unique pultrusion with an extruded aluminium base. This Thermohalter can be used in the traditional Rigidal Ziplok System without cold bridging through the system. 2) Traditional aluminium extrusion for use with the Corogrid bar and bracket system. Whilst Bar & Bracket systems used with traditional halters meet full compliance with current regulations they only do so because the current regulations allow widespread brackets to be omitted from calculations. The Ziplok Thermohalter is the next generation of halter to ensure continued compliance when the regulations change as undoubtedly they will. Profiles The Rigidal Ziplok system is available in 65mm deep sheets of three cover widths: Ziplok 300 Ziplok 400 Ziplok 500 Offers an exceptional load carrying capacity due to the narrow pan width, and is particularly suited to tight curves Most popular and cost effective system Due to the wide pan, full support is required by incorporating a more dense slab type of mineral wool insulation to prevent bowing of this pan. Roof Pitch Because of the true standing seam concept of the Rigidal Ziplok system the following pitches may be maintained: Continuous sheet ridge to eaves 1.5 Welded end lap joint 1.5 Welded roof penetrations 1.5 Laid in rooflights ridge to eaves 1.5 Rooflights lapped onto Ziplok >4.0 End lap joints with sealants and fixings 3.0 NB. Above falls must be achieved after consideration of loadings and deflection. Ensure gutter straps and edge flashing details at the eaves do not reduce the above roof pitches to avoid ponding of water at the sheet edge Properties Aluminium Rigidal Ziplok Rigidal Ziplok sheets are manufactured from aluminium alloy of the 3000 series containing magnesium and manganese for increased strength and durability. The alloy is designated as: EN AW (Al Mn1 Mg1) or EN AW H28 (Al Mn 1 Mg 0.5): to BS EN : Minimum 0.2% proof stress being 200N/mm 2. Steel Rigidal Ziplok The substrate used is hot dipped galvanised steel with a coating mass of 275g/m 2 and a minimum yield strength of 220 N / mm 2 to BS EN The Table below Shows Comparison of Basic Properties of Both Metals Density Modulus of Thermal Thermal Expansion Melting Point Material (kg/m 3 ) Elasticity (kn/cm 2 ) Conductivity (W/m C) in mm per C ( C) Aluminium x Steel x For properties of Aluzinc, Stainless Steel, Zinc and Copper contact Rigidal Technical Department 3

5 RIGIDAL ZIPLOK DIMENSIONS ZL 100 Indicates rollformed section prior to assembly Rigidal Ziplok 300 Rigidal Ziplok 400 Rigidal Ziplok 500 4

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7 RIGIDAL ZIPLOK THERMOHALTER ZL 101 Resin Based Halter Installation direction marker Aluminium Base EPDM Vapour Seal Direction of lay 6

8 Thermal break pad with factory applied 7x5 EPDM foam strip (section on Y-Y) Halter base (plan on X-X) Halter RIGIDAL ZIPLOK HALTER BRACKET AND THERMAL BREAK PAD - BAR & BRACKET SYSTEM ZL

9 RIGIDAL ZIPLOK COROGRID BAR & BRACKET SYSTEM ZL Available bracket heights

10 ZL 104 Head of halter Fixing direction FIXING SEQUENCE - GENERAL PRINCIPLE 9

11 Components for Illustrated Constructions Sheet Product Available materials Finishes Top Sheets Ziplok 300mm 0.9 aluminium ARS Ziplok 400mm 1.2 aluminium PVDF Ziplok 500mm 0.7 steel Plain mill stucco 0.9 steel Polyester Copper* Weathered* Zinc* Aluzinc* Liner Sheets 20 / 100 / steel Polyester 0.7 steel PVDF* 0.9 aluminium Structural Decks RD 65/ steel and 0.9 steel Internal Polyester RD 70/ steel Exterior polyester RD 85/ steel Plain Galvanised RD 89/ steel Plastisol RD 100/ steel PVDF RD 101/ steel RD 106/750 RD 110/1000 RD 135/930 RD 153/840 RD 158/750 RD 200/750 * Non standard items - may require longer lead times, please contact Rigidal Systems 10

12 Components for Illustrated Constructions Component Location Description Code/ref Thermohalter Height - 225mm HALT/TH/225 Aluminium halter bracket Height - 85mm HALT/AL/85 135mm HALT/AL/ mm HALT/AL/ mm HALT/AL/ mm HALT/AL/ mm HALT/AL/245 Thermal break pad Under each aluminium halter Extruded rigid PVC HALT/PL/THPAD Verge/cap support Continuous at verge (straight verge) 2mm aluminium, 3m long ZSEC/AL/VCAPS Curved verge/cap support - notched for site curving Continuous at verge (curved verge) 2mm aluminium, 3m long ZSEC/AL/CVCAP Pressed verge clip At verge at each purlin 3mm aluminium pressed section, 60mm long ZSEC/AL/VERGE Verge flashing clip Continuous for securing verge flashing 105mm girth x 2 bends - 2mm plain mill, in 3m lengths ZSEC/AL/VCLIP Pan support zed in 3m lengths Continuous on top of ridge/eaves Corogrid bar to support pans 60 x 26 x 60 galvanised steel ZSEC/OG/PANZD Ridge retainer Continuous to position filler under edge of ridge flashing 1.6mm aluminium, in 3m lengths ZSEC/AL/RIDRT Ridge support zed To support large girth ridge flashings 1.2mm aluminium, in 3m lengths ZSEC/AL/RIDZD 2mm drip angle Continuous at eaves 60 x 30mm in 3m lengths ZSEC/AL/DRIPA Rooflight clamping section in 5m lengths Over rooflight seams Extruded aluminium omega section ZSEC/AL/RCLMP Zipclip Attachment for walkways and snowguards Stainless steel two part clamp - with bolts, nuts and washers ZCLP/SS/ mm high performance glass fibre insulation For use with Thermohalter compressed to 140mm Glass fibre based insulation, density 16.5kg/m 3, Lambda INS/HPGF/080 80mm rock fibre insulation, for increased acoustic performance For use with Thermohalter compressed to 140mm Rock fibre based insulation, density 45kg/m 3, Lambda INS/HPRF/080 80mm glass fibre insulation For use with standard halter/corogrid system Glass fibre based insulation, density 10.5kg/m 3, Lambda INS/GF/ mm glass fibre insulation For use with standard halter/corogrid system Glass fibre based insulation, density 10.5kg/m 3, Lambda INS/GF/ mm glass fibre insulation For use with standard halter/corogrid system Glass fibre based insulation, density 10.5kg/m 3, Lambda INS/GF/ mm glass fibre insulation For use with standard halter/corogrid system Glass fibre based insulation, density 10.5kg/m 3, Lambda INS/GF/180 80mm rock fibre insulation For use with standard halter/corogrid system Rock fibre based insulation, density 23kg/m 3, Lambda INS/RF/ mm rock fibre insulation For use with standard halter/corogrid system Rock fibre based insulation, density 23kg/m 3, Lambda INS/RF/ mm rock fibre insulation For use with standard halter/corogrid system Rock fibre based insulation, density 23kg/m 3, Lambda INS/RF/ mm rock fibre insulation For use with standard halter/corogrid system Rock fibre based insulation, density 23kg/m 3, Lambda INS/RF/180 11

13 Components for Illustrated Constructions Component Location Description Code/ref 30mm tissue faced rock fibre acoustic slab Above perforated liner/deck in acoustic systems Density 60kg/m 3, Lambda INS/ACO/030 40mm tissue faced rock fibre acoustic slab Above perforated liner/deck in acoustic systems Density 60kg/m 3, Lambda INS/ACO/040 30mm hardrock insulation Local support for welded features and seams Rock.fibre based insulation, density 100kg.m 3, Lambda INS/HR/ mm galvanised top hat section for decks up to 158mm To bridge adjacent crowns of structural deck under halters 350mm long top hat, 30mm deep ZSEC/OGCHANS 1.6mm galvanised top hat section for 200mm deck To bridge adjacent crowns of structural deck under halters 400mm long top hat, 30mm deep ZSEC/OG/CHANL Continuous top hat section for acoustic system For continuously supported acoustic insulation slab 3000mm long top hat, 30mm deep ZSEC/OG/AC030 Powder coated continuous top hat section As above in corrosive environments 3000mm long top hat, 30mm deep ZSEC/PC/CHANL Supporting bracket For attaching continuous top hat to structure, acoustic system Galvanised bracket to suit 20/1000 liner, 50mm overall depth ZSEC/OG/AC050 Powder coated supporting bracket As above in corrosive environments Powder coated bracket to suit 20/1000 liner, 50mm overall depth ZSEC/PC/AC050 Vapour barrier - Ultra 2000 For use with perforated liner or separation 2m wide x 50m long roll polyethylene VBAR/01/02050 Aluminium encapsulated vapour barrier For use with perforated liner or separation High performance vapour barrier, 2m wide x 50m VBAR/02/02050 Talshield breather membrane Below top sheet in cold roof applications Microperforated clear LDPE membrane BM/04/02050 Jointing tape for membranes (if required) Side/end laps and perimeters of breather membranes/vbs 12mm x 2mm x 22.5mm VBAR/03/12222 Sealant tape for liner side laps Liner side laps Polyband, 50mm wide x 1mm thick POLB/ST/50X01 End lap sealant for steel/aluminium liner Liner end laps Butyl mastic tape, 6mm wide x 2mm thick TAPE/BM/06X02 High performance sealant Ziplok steel / aluminium end laps and for general use Gun applied structural sealant adhesive type IIFC SEAL/IIFC/310ML Isolation tape between Corogrid and Ziplok Areas at risk of bi-metallic contact Flexible tape 75mm wide x 33mm long TAPE/FX/75X33 Eaves fillers For use with Ziplok 300 Profiled EPDM FILL/EP/E0300 Eaves fillers For use with Ziplok 400 Profiled EPDM FILL/EP/E0400 Ridge fillers For use with Ziplok 300 Profiled EPDM FILL/EP/R0300 Plain aluminium shroud To protect ridge filler Pressed aluminium channel FILL/AL/SD300 Coloured shroud To protect ridge filler Colour coated to match Ziplok FILL/AL/CSD300 Ridge fillers For use with Ziplok 400 Profiled EPDM FILL/EP/R0400 Plain aluminium shroud To protect ridge filler Pressed aluminium channel FILL/AL/SD400 Coloured shroud To protect ridge filler colour matched to sheet Colour coated to match Ziplok FILL/AL/CSD400 Profiled filler strip to fit 20/100/1000 liner Small flute - black FILL/EP/SFBLK Small flute - white FILL/EP/SFWHT Small flute - black and white FILL/EP/SFBAW Large flute - black FILL/EP/LFBLK Large flute - white FILL/EP/LFWHT Large flute - black and white FILL/EP/LFBAW 12

14 Components for Illustrated Constructions Fixings Description Code/Ref Fixing steel liner to thin gauge purlins (1.4mm 3.6mm thick) No 2 point. self drilling screws, carbon steel, 5.5mm x 25mm long with 16mm washer FIX/LCS/55025 Fixing aluminium liner to thin gauge purlins (1.4mm 3.6mm thick) No 2 point. self drilling screws, stainless steel, 5.5mm x 25mm long with 16mm washer FIX/LSS/55025 Fixing halter bracket to steel / aluminium liner + purlin (1.4mm 3.6mm thick) No 2 point. self drilling screws, stainless steel, 6.3mm x 35mm long with 16mm washer FIX/LSS/63035 Fixing halter bracket to top hat section (1.6mm Thick) No 2 point. self drilling screws, stainless steel, 6.3mm x 35mm long with 16mm washer FIX/LSS/63035 Fixing top hats to 1.6mm galv. support brackets No 2 point. self drilling screws, carbon steel, 5.5mm x 25mm long with 16mm washer FIX/LCS/55025 Fixing galv. support bracket to steel liner + purlin (1.4mm 3.6mm thick) No 2 point. self drilling screws, carbon steel, 5.5mm x 25mm long with 16mm washer FIX/LCS/55025 Fixing galv. support bracket to aluminium liner + purlin (1.4mm 3.6mm thick) No 2 point. self drilling screws, stainless steel, 5.5mm x 25mm long with 16mm washer FIX/LSS/55025 Fixing Top Hat Section to Structural Deck (0.70mm 1.25mm thick) Steel rivets, 4.9mm, grip range 0.5mm mm FIX/MG/49105 Stitching steel liner sheet Self drilling stitcher screws, carbon steel, 6.3mm x 25mm long with 16mm washer FIX/SCS/63025 Stitching aluminium liner sheet Self drilling stitcher screws, stainless steel, 4.8mm x 20mm long with 16mm washer FIX/SSS/48020 Fixing halter bracket into timber (at least 40mm penetration is required) No 2 point. self drilling screws, stainless steel, 6.35mm x 65mm long with 16mm washer FIX/TSS/63065 End lap rivets in Ziplok top sheet Aluminium rivets, 5.2mm x 11.5m, grip range FIX/RAL/52019 End lap rivets in Structural Decks Steel truss head rivets 4.8 dia, grip range FIX/MG/48111 For further information please contact Rigidal Systems, telephone

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17 RIGIDAL ZIPLOK ACOUSTIC GENERAL CONSTRUCTION - THERMOHALTER SYSTEM ZL 107 Rigidal Ziplok sheet Rock fibre insulation Vapour control layer Acoustic insulation slab tissue faced Section X Perforated steel liner profile See section X Galvanised support bracket Thermohalter Top hat section Top hat sections to be butt jointed over supporting bracket 16

18 Ziplok halter with thermal break pad Rigidal Ziplok sheet Compressed insulation Corogrid spacer bar and bracket Acoustic insulation tissue faced Intermediate liner - side and end laps sealed to create vapour check Section X Top hat section Pan perforated liner Galvanised support bracket Top hat sections to be butt jointed over supporting bracket See section X RIGIDAL ZIPLOK ACOUSTIC GENERAL CONSTRUCTION - BAR & BRACKET SYSTEM ZL

19 RIGIDAL ZIPLOK STRUCTURAL DECK GENERAL CONSTRUCTION - THERMOHALTER SYSTEM ZL 109 Rigidal Ziplok sheet Rock fibre insulation Vapour control layer Decking profile Top hat section spanning over two crowns Thermohalter 18

20 Ziplok halter with thermal break pad Rigidal Ziplok sheet Compressed insulation Vapour control layer Deckin profile Corogrid spacer supported on top hat section spanning over two crowns RIGIDAL ZIPLOK STRUCTURAL DECK GENERAL CONSTRUCTION - BAR & BRACKET SYSTEM ZL

21 RIGIDAL ZIPLOK STRUCTURAL DECK ACOUSTIC GENERAL CONSTRUCTION - THERMOHALTER SYSTEM ZL 111 Rigidal Ziplok sheet Rock fibre insulation Vapour control layer Acoustic insulation slab tissue faced Perforated decking profile Thermohalter Top hat section spanning over two crownc 20

22 ZL 112 Ziplok halter with thermal break pad Rigidal Ziplok sheet Perforated decking profile Compressed rock fibre insulation Vapour control layer Acoustic insulation tissue faced Corogrid spacer supported on top hat section spanning over two crowns RIGIDAL ZIPLOK STRUCTURAL DECK ACOUSTIC GENERAL CONSTRUCTION - BAR & BRACKET SYSTEM 21

23 Ultimate Fixings Capacities Pull Out Strength (kn) Steel Thickness (mm) Z35 Material Screw 1.6mm 2.0mm 2.5mm 2.8mm 3.2mm 5.5mm Diameter No 2pt mm Diameter No 3pt Washer Pull Over Values (kn) Sheet 16GB* 19GB* 29GB* 0.7mm Steel mm Aluminium mm Aluminium mm Aluminium * 16, 19, 29 = washer diameter (mm) Stitcher Pull Out Values Sheet Double Sheets (kn) 0.7mm Steel 2 x 0.7mm Steel mm Aluminium 2 x 0.7mm Aluminium mm Aluminium 2 x 0.9mm Aluminium mm Aluminium 2 x 1.2mm Aluminium 2.69 Pull Out Values for Bulbtite Rivets Type 6604/6/3W Sheet (kn) Failure Mode 2 x 0.7mm Aluminium x 0.9mm Aluminium 1.53 Rivet pulled through 2 x 1.2mm Aluminium 1.60 aluminium sheet Top Hat to 0.70mm Steel Deck 1.53 Top Hat to 0.90mm Steel Deck 2.20 Top Hat to 1.10mm Steel Deck 2.20 Rivet failure Top Hat to 1.25mm Steel Deck 2.24 We recommend a safety factor of 2.0 be applied to the above ultimate capacities to bring them into line with characteristic working loads. Materials yield steel 220 N/mm 2 aluminium 200 N/mm 2 22 RIGIDAL ZIPLOK - Zip-up standing seam roof system

24 Load Span Tables Rigidal Ziplok 300 & 400 Systems Rigidal Ziplok mm Aluminium (self weight 3.87 kg/m 2 ) Span (m) Download Wind Uplift Rigidal Ziplok mm Aluminium (self weight 5.13 kg/m 2 ) Span (m) Download Wind Uplift Rigidal Ziplok mm Aluminium (self weight 3.53 kg/m 2 ) Span (m) Download Wind Uplift Rigidal Ziplok mm Aluminium (self weight 4.70 kg/m 2 ) Span (m) Download Wind Uplift Rigidal Ziplok mm Steel (self weight 7.98 kg/m 2 ) Span (m) Download Wind Uplift All loads are characteristic working loads in kn/m 2 based on 4 or more spans Download figures based on a deflection limit of span / 200 Wind uplift figures based on a deflection limit of span / 90 Loadings take account of Rigidal Ziplok sheet pulling out of the halter bracket under wind uplift using the formula: C = cover width of sheet (m) L = spacing of the brackets along the sheet (m) W = wind uplift loading (kn/m 2 ) Safe load on bracket (P) = 2.80kN (0.7mm steel / 0.9mm aluminium sheet) Safe load on bracket (P) = 3.10kN (1.2mm aluminium sheet) P (max) = 1.15 x C x L x W 23

25 Load Span Tables 20/100/1000 Liner Sheet To comply with HSE Regulations regarding Non - Fragility status of roofing products, we do not advocate the use of single spanning liner sheets and therefore do not show performance figures for this condition. 0.7mm gauge Aluminium (self-weight 2.27 kg/m 2 ) Double Span (m) Span Download Wind Uplift Triple Span (m) Span Download Wind Uplift mm gauge Aluminium (self-weight 2.92 kg/m 2 ) Double Span (m) Span Download Wind Uplift Triple Span (m) Span Download Wind Uplift mm gauge Steel (self-weight 6.6 kg/m 2 ) Double Span (m) Span Download Wind Uplift Triple Span (m) Span Download Wind Uplift All loads are characteristic working loads in kn/m 2 Download figures based on a deflection limit of span / 200. Wind uplift figures based on a deflection limit of span / RIGIDAL ZIPLOK - Zip-up standing seam roof system

26 Thermal Capacity of Rigidal Ziplok Systems A selection of halter heights to accommodate varying thickness of insulation will achieve different U-values. Compressed insulation will ensure the zone between liner and top sheet is filled completely. By using the Thermohalters system, less insulation thickness is required. THERMAL CONSTRUCTION THERMOHALTER Liner Spacer Grid Halter Acoustic Ins Thermal Quilt Thermal Compressed U-Value Conductivity Conductivity N/A N/A 225 N/A N/A W/m 2 K N/A 225 N/A N/A W/m 2 K N/A N/A N/A W/m 2 K COROGRID Liner Spacer Grid Halter Acoustic Ins Thermal Quilt Thermal Compressed U-Value Conductivity Conductivity N/A N/A N/A W/m 2 K N/A N/A N/A W/m 2 K ACOUSTIC CONSTRUCTION THERMOHALTER Liner Spacer Grid Halter Acoustic Ins Thermal Quilt Thermal Compressed U-Value Conductivity Conductivity N/A W/m 2 K N/A W/m 2 K N/A W/m 2 K COROGRID Liner Spacer Grid Halter Acoustic Ins Thermal Quilt Thermal Compressed U-Value Conductivity Conductivity W/m 2 K W/m 2 K 25

27 Acoustics Unwanted noise is a form of pollution and whether it is to be kept out of buildings or retained inside, the cladding must provide an adequate level of acoustic insulation. The Rigidal Ziplok roof system has the flexibility of being able to be tailored to meet the acoustic requirements of most buildings. The standard system is based on 0.7mm steel liner and 0.9mm aluminium top sheet. For actual values the construction needs to be tested for the application proposed. The acoustic performance of the system is considered over a frequency range of 100Hz Hz. The test data is then reduced to a single number, referred to as the Weighted Sound Reduction Index (SRIw). To achieve 0.25 thermal performance, a typical system will achieve a weighted sound reduction of 40 db Acoustic Absorption Inside a building, noise can echo off walls, floors and ceilings, this effect is known as reverberation. Incorporating perforated liners and dense acoustic slabs within the Rigidal Ziplok system may help to absorb some of this sound. The Reverberation Time (RT) of a room, or building is defined as the time taken for a sound to decay by 60dB. This is a function of the size of a room and the nature of its various surfaces (and varies with sound frequency). Its approximate value can be calculated from the formula: RT = 0.16 V / S A V = volume of the room. A = area of the surface x its absorption coefficient. As guidance, the RT values in 630Hz for various constructions are: 0.55mm trapezoidal steel sheet = 6.62 seconds 0.7mm steel outer sheet & 0.4mm steel inner sheet with 80mm insulation (23kg/m 3 ) = 2.72 seconds Above system with 15% pan perforations = 1.20 seconds System (2) but with 30% pan perforations and tissue faced acoustic slabs (100kg/m 3 ) = 0.91 seconds When a sound wave strikes a surface, some energy is absorbed and the rest is reflected. The Coefficient of Absorption expresses this surface property as a number between 0 & means that all the energy is reflected and 1 means that all the energy is absorbed. 26 RIGIDAL ZIPLOK - Zip-up standing seam roof system

28 Vapour Control Relative humidity is the ratio of water held in a given volume of air to the maximum amount that could be held at that temperature. If the temperature of the air is raised, the amount of water held is unchanged, but the amount required to saturate the air is increased. So, an increase in temperature causes a decrease in the relative humidity for this given volume of air. Conversely, a reduction in temperature reduces the amount of water required to saturate the air and so the relative humidity increases. As the temperature continues to fall, the relative humidity will eventually rise to 100% and become fully saturated - this is known as the dew point. The surplus water in the air cannot be held as a vapour and is expelled as water droplets leading to condensation. When moist air comes into contact with a cold surface the above cycle deposits water droplets on the surface causing surface condensation. This can occur in a cold roof construction where vented flutes are incorporated to the underside of the top sheets. The Rigidal Ziplok system greatly reduces this risk by incorporating a high level of insulation, which is compressed tightly to the underside of the top sheet. This reduces the risk of air pockets and prevents the top sheet from becoming too cold. Furthermore, the seamed joints allow a natural venting of the roof system. Humid air exerts a greater pressure than dry air, and will attempt to enter the roof construction through any available apertures. When condensate is formed in the cool zones of the roof this is known as interstitial condensation. Here, there is a local drop in pressure due to the removal of water vapour from the air. A minute distance away the air is warmer and contains a large quantity of water vapour and is therefore under higher pressure. The high-pressure air will migrate to where the pressure is lower, and more condensate is formed. This process is continuous as long as the temperature and relative humidity is maintained. To combat this, a vapour barrier is required on the warm side of the insulation in the roof build-up to prevent humid air from gaining access to the cool zones of the roof. In standard standing seam roof constructions a sealed liner will act as a vapour control layer (see P5 Liner Sheets). However in high humidity applications or acoustic applications where a perforated liner is used an additional vapour barrier will be required. Before installing a separate vapour control layer, any water must be removed and the surface kept clean, dry, smooth and free of any dirt and swarf. The vapour control layer is spread loose, flat and without wrinkles in the same direction as the liner sheet. End and side laps should be sealed with two continuous runs of 12mm x 2mm crosslinked butyl rubber tape. The minimum width of lap should not be less than 150mm. Where puncture damage has occurred, good-sized patches must be applied over the area ensuring a continuous double bead of sealant all around the hole. Our BBA Agrément Certificate No.99/3605 proposes a choice of three VCL products: TALCHECK 0.3mm thick lightweight polyethylene with a Water Vapour Resistance of 272MNs/g, or ULTRA mm thick reinforced polyethylene with a Water Vapour Resistance of 522MNs/g, or TALFOIL Reinforced foil vapour barrier with a Water Vapour Resistance of 25,000MNs/g. Vapour Control Lap Detail 27

29 Fire Buildings should provide a safe environment and building materials should not increase the risk of fire, or increase hazards resulting from fire. If a fire breaks out in a building there is a rapid build up of heat, smoke and fumes. An aluminium roof is weakened by the heat and the sheets will collapse inwards allowing the heat and fumes to escape because of its low melting point (650 C). This reduces the heat damage of the building structure, increases the chances of occupants to locate the exits, and assists fire fighters in gaining access to the source of the blaze. By contrast, a steel roof remains intact by virtue of its meting point (1900 C). The resulting increase in temperature and toxic fumes can increase the loss of life and the extent of damage. AA Classification The external skin is tested in accordance with BS476: Part 3 and is given a designation in the range AA to DD. The first letter refers to fire penetration performance should there be a fire on the roof deposited from adjoining burning premises. The second letter refers to the resistance of surface spread of flame resulting from the fire on the roof. Aluminium achieves the designation AA, the highest possible rating. Class O Classification If there is a fire in a building, the wall or ceiling lining material must not help to spread the fire. The statutory requirements of the Building Regulations approved document B define the highest product performance classification for a lining material as class O. To attain this class, a material has to achieve the highest index performance when tested in accordance with BS476: Part 6 (for coated aluminium I = 3 & i = 1.5), and a class 1 rating when tested in accordance with BS476: Part 7. Aluminium satisfies this class O rating. Ignitability BS476: Part 5 is a test for ignitability. Materials are classified as easily ignitable - X or not easily ignitable P. Aluminium receives the better rating, P. 28 RIGIDAL ZIPLOK - Zip-up standing seam roof system

30 Expansion Coefficient of Expansion Typical Temperature Overall Movement Movement about ambient Material x 10-6 per C Range ( C) (mm/m) Temperature (mm/m) Aluminium Mill or Light Aluminium Dark Colour Steel Light Colour Steel Dark Colour For other metals please contact Rigidal Technical Department The table above shows the expansion of sheets that can be expected in the UK due to temperature changes. The ambient temperature during sheet installation has been assumed to be 5 C. When sheeting during very cold weather the temperature range base should be decreased to -20 C to assess tolerances for sheet movement. By inspection a Rigidal Ziplok sheet 30m long with a mill finish could experience an expansion of 30 x 1.08 = +32.4mm in hot weather and a contraction of 30 x 0.36 = -10.8mm in wintry conditions. It is important, therefore, that all roof details take account of all such possible changes in length, especially where the sheets meet abutments or gutters. Although the halter brackets anchor the sheets to the roof structure they do not restrict thermal movement and the sheets are free to slide on the halters. To control this movement a Fixed Point should be created and it is usually best to locate it near the ridge so that the flashing is mounted on a static base allowing the sheet to expand into the eaves. Consequently, the drip angle needs to be positioned carefully with adequate clearance to allow for downslope movement due to summer expansion and upslope movement due to winter contraction. On shallow roof pitches of up to 3 and sheets up to 25m long the Fixed Point can be achieved by drilling through the small roll edge of the sheet and the head of the halter bracket and inserting a blind rivet to create a locking mechanism. On steeper pitches and longer sheets a stronger Fixed Point is required by bolting through the upstand of the sheets and the web of the halter bracket which is then hidden by the ridge foam filler block and aluminium shroud. 29

31 Curving for Rigidal Ziplok 300 & 400 The Rigidal Ziplok profiles are available in various curved options to suit the required application. The profile can be concave, convex or wave shaped incorporating both curves in one sheet. The sheets will self curve to a certain degree, otherwise they can be mechanically smooth or crimp curved as detailed below. When straight sheets are sprung down to match the curve, the halter brackets need to be set out by approximately an extra 5mm of the cover width of the sheet, dependant on the radius. This relieves the stress from the pan by allowing the upstands to open out. For maximum sheet lengths refer to page 31 which takes into account transport logistics. Convex Curve Gauge Recommended Radius (m) Support Spacing (m) Site Sprung 0.9mm Aluminium /45.0 Curved 1.2mm Aluminium /60.0 Sheets 0.7mm Steel /60.0 Smooth Rolled 0.9mm Aluminium Curved 1.2mm Aluminium Sheets 0.7mm Steel Factory Crimp 0.9mm Aluminium mm Curved 1.2mm Aluminium mm Sheets 0.7mm Steel mm Concave Curve Gauge Recommended Radius (m) Support Spacing (m) Site Sprung 0.9mm Aluminium Curved 1.2mm Aluminium Sheets 0.7mm Steel Smooth Rolled 0.9mm Aluminium Curved 1.2mm Aluminium Sheets 0.7mm Steel For other metals and radii outside the above parameters consult our Technical Department. 30 RIGIDAL ZIPLOK - Zip-up standing seam roof system

32 Production Tolerances - Ziplok Sheet Minimum Sheet Length = 1m Maximum sheet Length = 27m (for longer lengths we recommend site rolling Cover Width +/- 2mm Edge Squareness 1% of sheet cover width Upto 10m long +10mm / -5mm Over 10m long +10mm +(1mm per metre length over 10m) / -5mm The Relationship Between Rigidal Ziplok Sheet Length & Radius To Meet Transportation Criteria Maximum Maximum Maximum Maximum Radius Sheet Length Radius Sheet Length Radius Sheet Length Radius Sheet Length (m) for Transport (m) for Transport (m) for Transport (m) for Transport (m) (m) (m) (m) to Note: It may be more cost effective to deliver straight sheets and curve on site. 31

33 Rooflights There are two types of rooflights available which can be used in conjunction with the Rigidal Ziplok system: Lay - in Rooflights This rooflight can be manufactured in GRP to match the Rigidal Ziplok as a single or double width module in either 1.83kg/m 2 or 2.44kg/m 2 weight (as shown on drawings ZP24 ZP26). Due to its profile this rooflight is unsuitable to lap under the Rigidal Ziplok sheet and is therefore more suited to run from under the ridge flashing down the roof slope to finish at the eaves, or if required, lapped onto a Ziplok sheet. Special aluminium batten caps are fitted over the top of all rooflight seams, which are then compressed using a special set of rollers on the Rigidal Ziplok seaming machine. Barrel Rooflights These translucent panels can run longitudinally along the ridge or transversely from the ridge to the eaves of the roof. The interface between the roof system and this rooflight is minimised and the purlin spacing is not compromised by any structural inadequacy of the rooflight. The level of illumination may be controlled by selection of the width of the rooflight without being influenced by the roof sheet module. GRP multi-vaults lap at the sides to form units of unlimited length, the double skin construction is formed on site from identical inner and outer sheets separated by metal spacers and foam fillers. The rooflight is closed by insulated, opaque, white GRP end panels, which lap on to the end of the translucent sheets. Downslope daylighting units should be mounted on their own kerbs with their sides flashed using standard verge components. David Lloyd Racquet & Fitness Club 32 RIGIDAL ZIPLOK - Zip-up standing seam roof system

34 Female Header Female Header Single skin roof light to suit Rigidal Ziplok 400 Female Header Male Header Female Header Single skin, double width roof light to suit Rigidal Ziplok 400 RIGIDAL SINGLE SKIN ROOFLIGHT TO SUIT RIGIDAL ZIPLOK 400 ZL

35 TRANSLUCENT SHEET INTERFACE DETAILS ZL 114 ROOFLIGHT GOES UNDER METAL AT BTH SIDE LAPS 34

36 Sealant RIGIDAL ZIPLOK ROOFLIGHT END LAP DETAIL ZL

37 Miscellaneous End Laps Where sheets are required to be end lapped then the sheets will need to be notched as shown in the drawing, for a pitch greater than 3 the overlap joint must be fixed with Rigidal end lap rivets (6604/6/3W) and sealed with Rigidal end lap sealant (TAPE/BM/06). For a more secure overlap and any pitch below 3 site welding will ensure that there are no penetrations of the external weathering skin. Tapered Sheets The standard Rigidal Ziplok sheet can be fabricated to achieve a taper to form a radial roof on plan. The sheet is rolled as normal to the required length and the pan is then marked out with two inclined lines. The surplus triangular material is cut out and the remaining upstand & pan pieces of the sheet are tacked together and eventually fully welded to create the tapered Rigidal Ziplok ready for installation. When matching painted surfaces, aluminium tapered sheets are powder-coated after fabrication and the customer must be made aware that a shade variation may occur as the post applied colour may not match the pre-coated coil used to roll the Rigidal Ziplok. Roof Openings Small penetrations such as vent pipes and flues can be accommodated within the width of a Rigidal Ziplok sheet, openings can be created by means of a welded collar or a flexible Dek-Tite soaker. In such cases it is important to ensure that the drainage of the sheet is not blocked and therefore a channel at least 50mm should be left at each side of the penetration. For large openings, the seams will need to be cut and welded and the complete soaker system supported on a framework as shown on the drawing. Drumming The impact of rain or hail on a roof will always produce a noise, this sound energy (vibration) is then transmitted through the construction to the inside of the building. BS 5427: Part 1: 1996 states that this noise can be reduced by the introduction of a flexible insulation layer directly under the outer sheets. The insulated Rigidal Ziplok system deadens such sounds with absorption by virtue of the soft insulation being compressed to the underside of the roof sheet. Lightning Protection A close liaison should be ensured between the architect, the builder, the lightning protection system engineer and the appropriate authorities throughout the design stages to meet or exceed the requirements of BS 6651: Modern buildings use metal extensively in their structure and there is considerable benefit in utilising such metal parts to maximise the number of parallel conducting paths. The Rigidal Ziplok roof system combined with the steel frame of the building can be used to provide a principal lightning protection system. Fall Arrest Systems There are companies that specialise in safe access systems for the Rigidal Ziplok system. For further advice Rigidal Technical Department may be contacted. Rigidal can recommend approved suppliers for compatible systems in instances where Rigidal do not supply direct. Please contact Rigidal Technical or Sales Team for further information or specialist systems. 36 RIGIDAL ZIPLOK - Zip-up standing seam roof system

38 IIFC sealant TRANSLUCENT SHEET INTERFACE DETAILS ZL

39 BAR & BRACKET SYSTEM WITH RIVETTED LAP ZL aluminium rivet with neopreen sealing washer Insulation quilt compressed under hardrock slab Continuous lines of IIFC sealant positioned between sheets thus 38

40 BAR & BRACKET SYSTEM WITH WELDED LAP ZL

41 40 RIGIDAL ZIPLOK ROOF APERTURES ZL 119

42 Durability of Aluminium The oxide layer When fresh aluminium is exposed to the atmosphere, it combines with oxygen to form a thin inert protective layer of oxide, this layer isolates the metal from the air and inhibits further reaction. The layer thickens very slowly with age and causes the initial highly reflective surface to change with a natural dulling effect. If a piece of aluminium is scratched or abraded, the oxide layer is removed, exposing the aluminium to the atmosphere. This causes the formation of a new oxide layer, self-repairing the damage without further assistance. This behaviour is in direct contrast with mild steel, which requires artificial layers of zinc and plastic and corrodes rapidly when these layers are penetrated. Marine Atmosphere Aluminium is an ideal cladding element in marine and coastal environments. Here the pollution is mainly caused by sodium chloride and is much less aggressive to aluminium than the common industrial pollutants. Rural Atmosphere The level of pollution is usually very low and aluminium can have an exceptionally long life of 40 years or more. The naturally formed layer of aluminium oxide also ensures that corrosion does not creep under colour coated systems helping ensure maximum lifespan. Industrial Atmosphere The most frequently encountered industrial pollutants are sulphur dioxide and hydrogen chloride. These gases mixed with moisture can form acids that may dissolve the oxide layer and attack the aluminium at a weak spot resulting in a small pit. The consumed metal combines with the pollutant to create a far greater volume of corrosive product, which fills the pit and inhibits further attack. The rate of pitting reduces with time and becomes negligible after a few years. This pitting attack occurs in a random manner and is termed as weathering. These rarely cause problems to areas that are washed by the rain as the pollution is diluted and carried away. Areas that are sheltered, e.g. soffits at overhanging eaves, often display more pitting and staining. Occasional washing of such areas is therefore beneficial. Other common industrial pollutants include ammonia, carbon monoxide and carbon dioxide, all of which has little effect on aluminium. 41

43 Aluminium Paint Systems Although aluminium is both stable and durable in most environments, there may be the desire to apply a colour coating for aesthetic reasons. These coatings are applied by world class specialist companies by the reverse-roller coating method. They are applied prior to the product (with the exception of Colourbond) being rollformed by Rigidal and are stored in gas fired ovens to ensure excellent life span. Below are listed a few paint coat options: ARS (Abrasion Resistant Surface) ARS is the standard and preferred Rigidal paint finish. The main benefit of this system is the highly stippled and extremely hard surface which has excellent scratch resistance without the need for a protective film. The system is a primer with a polyamide modified polyurethane paint to a coating thickness of 28 microns, which has very good durability and weatherability. Its ultra violet performance is superior to that of plain polyester. PVF 2 This product is a primer with a Class1 polyvinylidene fluoride/acrylic paint system applied to a total coating thickness of 25 microns. It is an extremely durable system, giving excellent flexibility and chemical resistance, combined with the highest possible performance with respect to gloss retention, chalking and colour change. However, it is more easily scratched than ARS and must be handled with care. It can be supplied with a strippable plastic film as additional protection for site use. Strippable film must be removed within 48 hours of the product being installed as UV exposure can cause the film to bond irreversibly with the coating finish. Colourbond This is an alkyd-amino based coating of 40mic thickness applied by spray with electro-static attraction to the metal and finally stove cured. This results in some wrap around at the edges which ensures that there are no exposed cut edges and is therefore useful in aggressive environments. Due to the nature of the process, sheets are limited to a maximum length of 6m. Backing Coat This is normally a 2 microns lacquer coating with 6 microns chromated epoxy coating providing limited protection and preventing damage to the top coat when in the coil or in stacks of flats / sheets. It is not intended for external exposure. The Decorative Life is the time period when a decision to repaint may be required. The figures are based on marine or industrial environments and may be extended by 5 years for suburban or rural environments. The Ultimate Life is based on marine or severe industrial environments and may be extended to 40 years for suburban or rural environments. Special finishes/effects Available on application. Minimum quantities may apply - please consult our technical department. Decorative Life Ultimate Life Scratch Stain Colour Weathering Chalking System (years) (years) Resistance Resistance Fastness Aluminium Resistance ARS Excellent Good Good Good Good PVF Good Excellent Excellent Excellent Excellent Colourbond Good Good Good Good Moderate 42 RIGIDAL ZIPLOK - Zip-up standing seam roof system

44 Aluminium Inspection & Maintenance Recommendations Maintenance Mill finish aluminium does not require maintenance to restore its appearance, it is normally accepted in its weathered condition. Coated finishes should be regularly maintained to ensure maximum life and continued good appearance. Rigidal Technical department can give specific maintenance advice for the various finishes in specific environments. Washing with clean water or a sugar soap solution is especially advantageous in dusty or industrial areas. Roofs should be given periodic inspections and the accumulation of debris, falling leaves, etc. should be removed before it can block drainage and promote corrosion. Damaged sheets or flashings should be removed and replaced at the earliest opportunity, to minimise damage due to ingress of storm water. Maintenance and cleaning personnel must use scaffold boards on all roofs. Always provide load-spreading measures at the ridge and at the eaves in order to avoid local deformations from excessive foot traffic especially at the point of access to the roof. Aluminium sheets must be isolated from any other materials that may cause galvanic corrosion. Any contamination or exposure to corrosive materials must be removed. Any moisture trapped in the construction must be removed. Cleaning Upon completion of each section of the roof it should be thoroughly cleaned to remove all swarf, rivet mandrels, screws, washers, rivets etc. Any of these items could cause unsightly rust stains. Cement or mortar droppings should be removed immediately or they will leave permanent stains. Marks from oil, grease etc should be removed by washing with a mild detergent, remembering to rinse thoroughly with clean water. Sometimes coated sheets are protected by a thin plastic film, which must be removed immediately after fixing. Long exposure to ultra violet light can harden the film and make it difficult to remove, leaving sticky deposits which collect dirt and spoil the appearance of the roof. Should adhesive marks remain, these can be removed by using a specialist thinners available from Rigidal Systems. It is recommended that periodical inspections should be made for damage. Should debris be causing obstructions, it should be removed and the area washed down with a mild detergent and rinsed thoroughly with clean water. In some areas (particularly industrial ones and where cladding is sheltered directly below a soffit) it may be necessary to clean the installation periodically to restore its appearance to remove corrosive deposits. This can be carried out by hosing with water using a neutral detergent. Colour-Coated Surfaces Use special non-abrasive, biologically degradable cleaner compatible with the coating system and rinse thoroughly after cleaning. It is often worthwhile waiting, since weathering and dirt accumulation will reduce colour differences. This process will be faster on a natural finish surface than on coloured material. Removing Dirt Use an abrasive agent with a ph value of between 5 and 8.When using special cleaning agents, make sure that they are ecologically compatible. Always rinse off with water. Repairs to Painted Surfaces In the case of aluminium, minor scratches and abrasions do not require repairs, except where the scratches become visually unacceptable. However, it should be noted that site repairs on scratches can not always be justified on aesthetic grounds as the repaint is usually more prominent than the scratch. A good guide for this is if the defect cannot be seen in good lighting from more than 6 metres viewing distance it should be deemed acceptable. Air drying paints will never be a perfect match for factory stoved paints, the gloss levels will probably differ and they will certainly age differently. Larger areas of damage must be site painted to disguise unsightly patches or exposed metal. In these cases the damaged areas should be cleaned and painted with an approved touch up paint to match the sheet finish. In all cases, small areas should be painted using a small soft artists brush. Daubing with a decorator s brush will never be successful. When painting over coated areas, preparatory measures and type of coating must be coordinated with the existing paint system on the advice of a paint specialist. PVF2 coated sheets should only be touched up with air drying PVF2 paint such as Duranar ADS. Trained specialists can only apply this paint system. Use the standard air drying touch up paint provided. For minor scratches and small repairs apply the paint provided sparingly using a pencil brush in two coats, allowing 15 minutes between coats. The paint should be touch dry in 30 minutes. Do not paint in damp conditions or when rainfall or condensation is expected within 2 hours. Only paint when the temperature range is within 5-30 C. Care must be taken to comply with Health & Safety Regulations as recommended by the paint and solvent manufacturers. Colour matched touch up paints are available from Rigidal Systems in both brush applied and aerosol formats. 43