Installation Instructions for Standing Seam Profiles INTERFALZ ALUDECK. flexible building. sustainable thinking.

Transcription

1 Installation Instructions for Standing Seam Profiles INTERFALZ ALUDECK flexible building. sustainable thinking.

2 INSTALLATION INSTRUCTIONS Table of contents General information Flashings Ridge INTERFALZ Eaves Verge Introduction to INTERFALZ Transverse joint Product range and warranty Roof fittings Curbs for light domes and SHE Transport and storage (smoke and heat exhaust) incoming goods inspection Ventilators Roof anchors/fall protection Quality Access grids/step grids Seam clamp Possible fields of application Snow guard Roof light panels Installation General information Miscellaneous Holder installation Roof overhangs General information Roof overhang Holder spacing with purlin roofs 24 without clip bar Holder spacing with truss roofs Roof overhang Holder spacing with with clip bar 56 Prodach roofs Curved profiled panels Mechanically curved panels Installing the INTERFALZ panels Naturally curved panels Verge Conical profiled panels Fixed point Prodach INTERFALZ with claw strip INTERFALZ with thermal bolts Flanging 32 2

3 Table of contents 2.0. ALUDECK Miscellaneous Introduction to ALUDECK Roof overhangs Curved profiled panels Product range and warranty Working Transport and storage 3.1. Bending 67 incoming goods inspection Cutting Quality Drilling and screwing Possible fields of application Welding Installation General information Removing dirt Holder installation General information Required tools Installing the ALUDECK panels Standard accessories and tools Verge Fixed point Flanging Flashings Ridge Eaves Verge Transverse joint Roof fittings Curbs for light domes and SHE Ventilators Roof anchors/fall protection Access grids/step grids Seam clamp Snow guard 66 3

4 INSTALLATION INSTRUCTIONS General information General information Economic aspects are increasingly in the focus of the building industry. The ALUFORM INTERFALZ and ALUFORM ALUDECK roofing systems documented herein contribute to cost-conscious planning and building. Based on the realisation of scientific findings, they ideally combine the excellent corrosion resistance and low weight of aluminium with a non-penetrative joining technique and a high load-bearing capacity of the profiles. The nonpenetrative joining technique, combined with the profiles gliding on the holders, enables the installation of long profiled panels with slight roof pitches of up to 1.5 (2.6 %). When a seam seal is additionally applied to the INTERFALZ flange, the roof pitch can be reduced to 0.6 (1.0 %). version is available for download on the Internet at Aluform System GmbH & Co. KG assumes no liability for any errors contained in these installation instructions. Claims for damages cannot be asserted based on their application. These installation instructions primarily deal with the installation of INTERFALZ profiles. The ALUDECK installation instructions merely contain those information which are different from part one. Thus, the INTERFALZ installation instructions must be observed as well when installing ALUDECK profiles. The two systems ALUFORM INTERFALZ and ALUFORM ALUDECK vary mainly in the geometry of the profiled panels and in the way they are installed. These installation instructions are to serve as a guideline and support for the fitter installing the Aluform systems. They take into account the currently applicable rules and standards. It is assumed that the respective applicable accident prevention rules are known. Hence, they will not be detailed here. The installation instructions do not constitute any exemption from the responsibility for one s own actions. Moreover, they are not subject to revision service. Since new technical developments and information to improve the installation processes are incorporated continuously, an updated 4

5 ALUFORM INTERFALZ and ALUFORM ALUDECK Introduction 1.0. INTERFALZ 1.1. Introduction to INTERFALZ In accordance with the provision in certification Z (for aluminium profiles), the profiled panels may be fitted only by those companies which have been trained and authorised by the manufacturer accordingly. The designer or installer has to prepare a design instruction for the installation of the profiled panels. The general technical approval must be available at the site. It can be requested from the manufacturer or downloaded on the Internet at as well. In addition, the documents required at the building site include an installation plan showing the positions of the profiled panels, the positions of the holders and their connection with the substructure as well as the connection details to be realised (ridge, eaves, verges and the like). The stipulation in part 9 of DIN may be used as a guideline concerning its scope. Basis of the installation plan is the proof of stability and fitness for use which must be furnished at any rate. Prior to the beginning of the installation work, the work performed by the preceding trades is to be examined for adherence to the geometric dimensions stated in the approved plans. In case of any deviations, the customer must be informed. 5

6 INSTALLATION INSTRUCTIONS Product range and warranty 1.2. Product range and warranty Aluform INTERFALZ 50/333 Sheet thickness t N (mm) Weight (kg/m 2 ) 333 0,8 3,1 4 0,9 3, ,0 3, Cover width 333 Aluform INTERFALZ 50/429 Sheet thickness t N (mm) Weight (kg/m 2 ) 429 0,8 2,95 0,9 3, ,0 3, Cover width 429 Aluform INTERFALZ 65/305 Sheet thickness t N (mm) Weight (kg/m 2 ) 305 0,8 3, ,9 3, Cover width 305 1,0 4,29 65 Aluform INTERFALZ 65/333 Sheet thickness t N (mm) Weight (kg/m 2 ) 333 0,8 3,35 0,9 3, ,0 4, Cover width 333 Aluform INTERFALZ 65/400 Sheet thickness t N (mm) Weight (kg/m 2 ) 400 0,8 3, 1 7 0,9 3, ,0 3, Cover width 400 The weights apply to aluminium profiles. Other cover widths and materials are available upon request. 6

7 Product range and warranty Aluform INTERFALZ 65/500 Sheet thickness t N (mm) Weight (kg/m 2 ) ,8 0,9 1,0 2,97 3,34 3, Cover width 500 Aluform INTERFALZ 65/305 DF Sheet thickness t N (mm) Weight (kg/m 2 ) , ,5 300 Cover width ,8 0,9 1,0 3,43 3,86 4,29 65 Aluform INTERFALZ 65/333 DF Sheet thickness t N (mm) Weight (kg/m 2 ) ,8 0,9 1,0 3,34 3,76 4, , ,5 328 Cover width 333 Aluform INTERFALZ 65/434 DF without corrugations Sheet thickness t N (mm) Weight (kg/m 2 ) ,8 0,9 1,0 3,07 3,46 3, Cover width 434 Aluform INTERFALZ 65/434 DF Sheet thickness t N (mm) Weight (kg/m 2 ) ,8 0,9 1,0 3,07 3,46 3, Cover width 434 The weights apply to aluminium profiles. Other cover widths and materials are available upon request. 7

8 INSTALLATION INSTRUCTIONS Product range and warranty Aluform INTERFALZ 65/400 DF Sheet thickness t N (mm) Weight (kg/m 2 ) ,8 0,9 1,0 3,16 3,56 3, Cover width 400 Aluform INTERFALZ 65/500 DF Sheet thickness t N (mm) Weight (kg/m 2 ) , ,5 496 Cover width ,8 0,9 1,0 2,97 3,34 3,7 1 The weights apply to aluminium profiles. Other cover widths and materials are available upon request. The INTERFALZ element is a trough-shaped standing seam profile which is normally made of AlMn1Mg0.5 alloy aluminium (mill finish or coated) by means of roll formers. Profiled panels made of: steel, stainless steel, copper and zinc have also been manufactured before and continue to be available in sheet thicknesses which are different from the ones stated in the product range above. When using profiled panels made of copper or zinc, please turn to the factory for advice concerning their special properties. The profiled panels can be finished both at the factory and on site with the help of mobile roll formers. When they are finished at the factory, the panel length is limited to 30 m for transport-related reasons. Moreover, the profiled panels can be finished so that they are straight, convex or concave or with convex/concave curving in one panel. Bending (curving) can be done on site using a mobile machine as well. It is also possible to manufacture conical profiled panels and to round them by way of curving. Crimp-curved profiled panels are available only upon request at the factory. 8

9 Holder system The INTERFALZ profiles are fixed by means of holders (clips) comprised by the flanges of the INTERFALZ panels. These seams are flanged mechanically in the course of installation, ensuring the construction of a non-penetrative and rainproof roof. When exposed to temperature-related changes in length, the roof panels can slide along the holders free of constraint forces. The sliding movement must not be impeded by other structural components. Normal holder made of aluminium Holder made of aluminium with deburred head Plastic holder made of Ultramid Thermal bolts in combination with plastic holders Aluminium holder Thermal holder Due to the extensive range of cover widths, profile heights and curvings as well as surface finishes, optimal design possibilities and adaptations to the building geometry can be realised. The profiled panels can be coated with an anti-condensation or anti-drumming coating in order to improve the properties in terms of building physics. Anti-condensation coatings are available in dependence on the panel length either in the form of fleece or a Grafotherm coating. Thermal bolt Panels with paint coats come with a protective film on the large flange. Panels made of the above-mentioned alloy are fit for seawater as per DIN INTERFALZ and ALUDECK systems can be used as lightning absorption and conducting devices in accordance with DIN EN Holders in various heights and in the designs below are available for fixing the profiled panels on various substructures: 9

10 INSTALLATION INSTRUCTIONS Holder system, warranty Holder Holder Use type height (mm) for profiles /65DF /65/50DF/65DF /65/50DF/65DF /65/50DF/65DF /65/50DF/65DF /65/50DF/65DF /65/50DF/65DF /65/50DF/65DF /65/50DF/65DF 240 * 240 * 50/65/50DF/65DF * Thermal holder only Plastic holders which can be turned in thermal bolts are available in the heights 65, 120, 160 and 240 mm. With panel lengths exceeding 18 m, the use of plastic holders or holders with deburred heads is generally recommended (holders with deburred heads only up to a panel length of 30.0 m). Profiled panels made of copper may only be installed in combination with plastic holders as a rule. Warranty is excluded where: Buyer/fitter has violated the valid rules and regulations and/or the generally accepted rules of the specialised trade. The damage happened at the building site and the surface coating has been damaged. The handling and processing guidelines and particularly the transport and storage instructions have not been observed. Consequential damage occurred due to inadequate construction in terms of building physics. The components have not been used in accordance with the application intended by the manufacturer or the certification respectively. The technical documents (execution planning) have not been observed. In addition to the profiled panels, an extensive range of accessories (fasteners, profile fillers, ridge filler plates and the like) is available to the fitter. See section 6 Accessories. Fitting tools such as flanging machines, upward and downward folding tools, as well as manual flanging pliers can be borrowed from the factory. Delivery and warranty are based on the General Terms and Conditions of Delivery and Payment of Aluform System GmbH & Co. KG. 10

11 Transport, storage and incoming goods inspection 1.3. Transport, storage and incoming goods inspection The delivery time of the profiles depends on profile shape, sheet thickness and coating and must be arranged with the factory. The delivery time of profiled panels that are longer than m and finished at the factory may be extended due to the transport authorisations which need to be obtained and due to route surveys which may be necessary. The profiled panels are transported to the building site using vehicles suitable for the respective panel length where they are packed on wooden pallets. The number of profiled panels per pallet and vehicle depends on the cover width of the profile. Normally, 2-3 panels are placed next to each other on one pallet, up to each 44 panels being stacked. In that process, every other panel is turned. Accessories and flashings are delivered in cartons, in boxes or on pallets. <6m >6m >8m Pallets holding panels in a length of up to 6 m can be unloaded and handled using a forklift truck with maximum fork spread. The services performed by Aluform end at the building site, unloading being excluded. When a delivery arrives, it must be ensured that the delivery vehicle can both access the building site and drive within the building site area itself. Unloading is done by the customer who has to provide suitable equipment to ensure smooth unloading. The weights of the packages can be found in the delivery note or on the package sticker or enquired in advance by contacting the factory. For packages containing very long profiled panels, the customary maximum gross weight of 3.0 t/ package may be exceeded for reasons related to the capacity utilisation of the trucks. Profiled panels of up to 8 m in length can be handled by means of a hoisting machine (crane) and belts. The belts must be spread so as to prevent damage above the pallet. For profiled panels in a length of more than 8 m a traverse with belts is to be used as sling gear. The belts must be spread as well. The required traverse length and number of belts depends on the panel length. The maximum load per suspension point must not exceed 0.8 t. Overhangs of more than 4.5 m with aluminium and 2.5 m with zinc and copper must be avoided. 11

12 INSTALLATION INSTRUCTIONS Transport, storage and incoming goods inspection In cases where the goods are picked up by the customer, the services provided by Aluform System GmbH & Co. KG end as soon as the customer s vehicle is being loaded. Suitable vehicles and load straps must be provided by the customer. The same details as given above apply to unloading in this case as well. When the profiles are roll-formed at the building site, the roll former and the coils needed for roll forming are delivered to the building site. In this case, the leaflet Guidelines for Using the Mobile Roll forming Machine on Site must be observed. The services provided by Aluform System GmbH & Co. KG end upon the handover of the roll-formed profiles at the building site. Where the profiled panels are to be deposited directly on the roof, the load-bearing capacity of the existing roof structure needs to be taken into account. In order to avoid having to rotate them on the roof later on, the profiled panels should be deposited such that the small flange faces the intended direction of installation. The INTERFALZ pallets are to be stored at an angle. The packages must be covered with a material that protects them from the weather and is permeable to air (also during interruptions of the installation work). The formation of condensate inside the stack is to be prevented. Profiled panels with uncoated surfaces which are not installed immediately upon their delivery should be stored in a roofed and ventilated place if possible. Accessories are to be stored in locked area where they are protected from the weather. When storing profiled panels with an anticondensation or anti-drumming coating, the following additional issues are to be taken into account: Direct contact of the coating with soiled surfaces must be avoided. The coatings must not be soaked - neither by direct rain nor by contact with other wet surfaces. Profiled panels with a Grafotherm anticondensation coating or an anti-drumming coating must not be pushed across other structural parts or across each other. The profiled panel packages are identified as follows when delivered: Packing slip showing content and package weight Ü-sign certificate of conformity CE label Information on the protective film Information on unloading and storage The mentioned documents are to be observed accordingly or handed over to the builder respectively. 12

13 Quality Possible fields of application Where visible defects in the material are found on receipt, a corresponding confirmation by the forwarder must be obtained, and the supplier is to be notified immediately. The number of packages is to be checked for completeness and correspondence of the content with the purchase order and/or shipping documents. This applies to the number of items as well as profile, delivered lengths, sheet thicknesses, and surfaces. The supplier is to be notified of any deviations without delay. Transport damage which cannot be found at the time of delivery is considered to be direct damage as well but must also be reported prior to the installation by all means. The same applies to the delivered accessories Quality INTERFALZ is a quality product of Aluform System GmbH & Co. KG. Its properties are monitored at the manufacturing site by the internal quality control department. Regular external monitoring is conducted in accordance with the certification. The insulating material used is an insulation felt made of mineral wool which is compressed during the installation of the INTERFALZ panels such that there is no cavity between the bottom of the INTERFALZ panel and the insulating material. This is normally done by fitting an insulating layer which is approx. 2 cm thicker than the intended final dimension. Exceptions to this are the Prodach roof, the roof with claw strip, the roof variant involving thermal bolts where non-compressible insulation (also in combination with compressible insulation) is used, and the couple roof where there is a rear ventilation between insulation and INTERFALZ panel. A functional vapour/convection barrier that is properly connected to adjacent structural parts is to be ensured with all insulated roofs. Several customary roof structures where INTERFALZ panels can be applied are described below. The descriptions do not include all possible applications Possible fields of application INTERFALZ profiled panels are proper for both non-insulated and insulated roofs. They are suitable for all customary substructures and roof shapes. Owing to the range of various holder heights, it is possible to work with any insulating material thickness, as required for the respective object. 13

14 INSTALLATION INSTRUCTIONS Structural variants of a roof structure Non-insulated purlin roof Non-insulated purlin roofs are usually built on non-insulated buildings or buildings with an aerated attic. Purlin and thus holder spacing (span) depends on the existing load and on the load-bearing capacity of the profile. Applying an anti-condensation coating to the profiled panels is normally recommendable. Purlin roof as a non-ventilated roof In insulated purlin roofs, the inner shell is parallel to the INTERFALZ panel. The load is transferred through holders fixed on spacing profiles that are set at a right angle to the profiling of the upper shell. If the division of holder and purlin spacing is equal, the load is transferred directly to the purlins through the spacing profiles. In this case, the inner shell only supports the thermal insulation. If the purlin spacing is greater or if the holder spacing is halved within the edge areas, the inner shell is also used to transfer the load. Truss roof as a non-ventilated roof This roof structure is often used in industrial and non-residential construction. The loadbearing element is a supporting shell made of trapezoidal (steel) profiles spanned across the trusses. In order to ensure even load distribution, the holders are positioned in an offset pattern on the supporting shell. 14

15 Structural variants of a roof structure Insulated couple roof structure This type of roof is predominantly used on residential construction. In this roof structure, an air space remains between insulation and roof shell. Hence, the roof needs to be designed as a ventilated roof. Any condensate must be dissipated through sufficient ventilation (also where INTERFALZ panels with an anticondensate coating are used). An underlay membrane is recommendable where drift snow is likely to occur. Thermally insulated roof on visible planking and spacing structure This is mainly used in residential construction. The planking is designed as visible planking. A wooden spacing structure spanning the rafters is anchored in the rafters so that the holders can be fixed. The roof structure with vapour barrier and compressed insulation is the same as that of the insulated purlin roof. INTERFALZ DF as a Prodach roofing system This system comprises an upper shell made of INTERFALZ DF profiles which are attached by means of holders to a U-shaped rail which is embedded in a non-compressible insulation layer. This rail is fastened to the supporting shell only in specific places. Thus, this structure is nearly free of thermal bridges. With roof structures designed as truss roofs, the rails are installed diagonally as well. 15

16 INSTALLATION INTERFALZ Structural variants of a roof structure INTERFALZ DF panels on planking This is used either as a non-insulated roof or as a roof above an aerated attic. The holders are positioned in an offset pattern for load distribution in the same way as with the truss roof. The planking must be at least 26 mm thick. The screw is visible from below. INTERFALZ on foam glass In this roof structure the insulation consists of foam glass. The INTERFALZ profiles are attached using holders which are fixed to claw plates pressed into the insulation. The claw plates must be bonded with a cover sheet. The further roof construction can be done directly on top of the cover sheet with DF profiles or by fitting another layer of compressible insulation and normal profiles. This roof system has its own certification Z INTERFALZ on non-compressible insulation with claw strip In this roof structure, a claw strip is pressed into non-compressible insulation and attached to the supporting shell. The INTERFALZ panels are fixed using holders attached to the claw strip. The further roof construction can be done directly on top of the non-compressible insulation with DF profiles or by fitting another layer of compressible insulation and normal profiles. 16

17 Structural variants of a roof structure INTERFALZ on thermal bolts This fastening system enables the fastening of an INTERFALZ thermal holder without installing customary fitting rails on non-yielding insulating materials. The thermal bolt is pressed into the non-yielding insulation and fixed using special screws. Then the corresponding thermal holder with an eccentric socket is placed on the upper part of the thermal bolt and attached by turning it. Once it is attached to the bolt, the position of the holder can still be slightly adjusted. The further roof construction can be done directly on top of the noncompressible insulation with DF profiles or by fitting another layer of compressible insulation and normal profiles. 17

18 INSTALLATION INTERFALZ Installation General information 1.6. Installation General information When installing INTERFALZ panels, the following principles must be observed: Each panel must be flanged and anchored immediately after installation. In this way, it is prevented both from being lifted by the wind and from slipping. The fitting work is to be interrupted in case of strong wind. INTERFALZ profiles have a large surface for the wind to act upon. Thus, great wind forces can develop. Open packages are to be secured. When the installation work is interrupted, the last profile and open packages must be protected from the wind. Contact corrosion in case of combination with other materials must be prevented. Profiled panels with anti-drumming or Grafotherm coating must never be pulled across the substructure. The area at the eaves is to be removed or disabled where profiled panels with anticondensate fleece are used. INTERFALZ panels can be accessed during the fitting work when flanged on one side or after the fitting work (flanged on both sides) without taking any load distribution measures as long as the spans stated in the table below are adhered to (limit span). When the spans stated in the table are exceeded, load distribution measures must be taken (normally by using timber planks, grade S10, with a cross section of 4 x 24 cm and in a length of more than 3.0 m). They can be placed in the trough of the profiled panel or across the flanges. The planks must be secured against slipping. Profile 50/333 50/429 65/305 65/333 65/400 65/500 DF Profile Limit spans (m) of accessibility for the sheet thickness (mm) Accessibility during the fitting work Accessibility after the fitting work 0,8 0,9 1,0 0,8 0,9 1,0 1,90 1,95 2,00 2,44 2,62 2,80 1,81 1,86 1,91 2,44 2,62 2,80 2,10 2,20 2,30 3,70 3,80 3,90 2,10 2,20 2,30 3,70 3,80 3,90 1,70 1,80 1,90 3,10 3,20 3, , ,00 Installation on non-compressible substrate only; hence, no limit spans. 18

19 Holder fitting General information Holder fitting General information The arrangement of the holders, their number and spacing can be found in the installation plan. In order to ensure the respective insulation thicknesses, holders in various heights are available. Moreover, height adjustments can be made by way of additional spacing structures or by placing thermal caps or height compensation elements. The actual purpose of the thermal caps is however the avoidance of thermal bridges in insulated structures. Thermal caps are available in heights of 5, 10 and 15 mm. The use of height compensation elements is permissible only in combination with thermal holders. Small flange Large flange Direction of installation Prior to screwing down the holders, the respective roof area must be measured. In this process, the location of planned roof fittings such as light domes or roof hatches must be taken into account. Holder spacing is determined based on the width of the INTERFALZ profiles using a piece of string. First, the holders on ridge and eaves are placed. By spanning a piece of string between the two holders, the holders to be placed in between can be fitted such that they are flush. In order to compensate structural tolerances, the spaces can be made up to 3 mm wider. The distance between holders must never be shorter than the cover width of the INTERFALZ panel. The holders must be flush. When fitting the holders, the intended direction of installation is to be observed. 19

20 INSTALLATION INTERFALZ Holder fitting General information Note concerning the special screws Only approved joining elements may be used to fasten the holders on the substructure. Those include: Sealing screws for timber or steel substructures 2 mm, Sealing screws for steel substructures 2 mm or aluminium 3 mm Drilling screws Bulb tite rivets Special screws Note concerning the special screws The fasteners Ejot JT3-X-2 as well as SFS SDK2 and SFS SDK3 were developed specifically for being screwed to thin steel and/or aluminium substructures. They prevent the screw from being overtightened during holder fitting as the conical part of the shank grinds into the hole (SFS) or the teeth underneath the screw head grind into the holder (Ejot). Tightening the SFS SDK screws requires a specific screwdriver attachment. Number and type of the connections can be found in the details described in the installation plan as well. The foot of the aluminium holder has two different bore holes serving for the following fasteners: Ø 7.0 mm for fasteners with a diameter of 6.3 or 6.5 mm respectively Ø 6.1 mm for special screws, drilling screws or bulb tite rivets As a minimum, each 2 screws per holder are to be fastened centrally opposite to each other or diagonally. There must not be any bore chips between the holder and the substructure. Jamming the holders due to uneven tightening torques or distorting them is to be avoided. 20

21 Note concerning the special screws The foot of the thermal holder has 4 holes with a diameter of 6.1 mm. As a minimum, each 2 screws are to be fastened diagonally. The connection can be made using drilling screws or bulb tite rivets. The mentioned special screws are not permitted or not suitable for fixing plastic holders. Special system fasteners are supplied to fix the thermal bolt. Aluminium holder foot ,1 7, ,1 7,0 60 For easier holder fitting, it is recommendable to make some installation jigs. 6,1 6,1 Examples: Spacer made of hardwood or metal the length of which equals the distance between the holders Holder for profile 65/ = 245 mm = jig length Where the holder spacing is to exceed the system dimension, that difference is to be added. Longer metal rail with punched out holes for the holder feet. The first hole is placed on the first holder, and all other holders can be inserted in the other holes and fastened without making any measurements. Another option with insulated roofs (e.g. purlin roof) is fitting the holders to the distance profiles in advance at a workshop. Thermal holder foot , right way wrong way wrong way 21

22 INSTALLATION INTERFALZ Installation Holders on various substructures Holder on timber purlin or wooden spacers (Normally without thermal cap) Sealing screw Drilling screw for wood Recommended screw-in depth 50 mm Holder on steel purling With or without thermal cap Sealing screw Drilling screw Holder on steel supporting shell (Normally with thermal cap) Ejot JT3-X x L SFS SDK3-S x L Bulb tite rivet 5.2 x L Drilling screw Holder on steel distance profile (Normally with thermal cap) Ejot JT3-X x L SFS SDK3-S x L Bulb tite rivet 5.2 x L Drilling screw 22

23 Installation Holder on Prodach roof rail (Normally without thermal cap) Ejot JT3-X x L SFS SDK3-S x L Bulb tite rivet 5.2 x L Drilling screw Holder with thermal bolt Drilling screw IF2-S-SQ3-6,0 x L With regard to the fasteners used, it is to be made sure that their drilling performance and clamping zone are in correspondence. (See section 6 Accessories ) Where self tapping screws* are used, primary drilling is to be done as follows: Substructure Material Material thickness (mm) Drill diameter (mm) Steel 2,0 4,9 5,3 5,0 6,9 5,5 7,0 5,7 Aluminium 3,0 4,9 5,0 5,0 5,3 Wood 0.7x screw ø, normally 4.5 mm *The information applie to fasteners sold by Aluform. If screws from other manufacturers are used, the values may vary slightly. 23

24 INSTALLATION INTERFALZ Holder spacing with purlin roofs Holder spacing with purlin roofs In non-insulated purlin roof structures, one row of holders is placed on every purlin. In areas exposed to increased suction loads, shorter purlin distances may be arranged. In insulated purlin roof structures, an intermediate structure normally has to be incorporated as the partition of the supporting shell is not in correspondence with the cover width of the INTERFALZ panel. In special cases, profiles can be manufactured in cover widths that are in correspondence with the grid of the supporting shell. It makes sense to place the intermediate structure on top of the purlin underneath and connect it to the same to make sure that loads are transferred directly into the purlin. If the structure cannot be placed on top of the purlin, or if the holder spacing must be shortened in the edge areas, it must be proofed that the supporting shell can bear the resulting loads see specification in the installation plan. Ridge Verge a a Holder a INTERFALZ + Supporting shell Cover width INTERFALZ Eaves Truss spacing Truss spacing a = Holder spacing = Purlin spacing 24

25 Holder spacing with truss roofs Holder spacing with truss roofs The truss roof has a supporting structure made of trapezoidal steel profiles which is spanned across the trusses. In a distance equalling the cover width, a continuous row of holders is placed on the eaves and on the ridge. Where holders are screwed to an eaves board, it is to be made sure that their height is the same as that of the following holders. In the following holder rows the holder is offset by each one supporting shell rib spacing in relation to the eaves. In this way, a diagonal holder pattern is created, and the supporting shell is loaded evenly. Due to the increased suction loads the edge and corner areas are exposed to, it may be necessary to shorten the holder spacing there compared to the normal area. Holders with truss roofs with normal spacing Rib spacing Supporting shell Supporting shell Ridge Holder Holder spacing Verge INTERFALZ Cover width INTERFALZ Truss spacing Truss spacing Eaves 25

26 INSTALLATION INTERFALZ Holder spacing with Prodach roofs Holders with truss roofs with shortened holder spacing in the edge and corner areas using the example of a single pitch roof Rib spacing Supporting shell Ridge Holder Verge Supporting shell INTERFALZ Holder spacing Cover width INTERFALZ Eaves Truss spacing Truss spacing Areas exposed to increased suction loads Holder spacing with Prodach roofs The installation workflow for Prodach roofs is described in chapter Holder fitting is described there as well. 26

27 Installing the INTERFALZ panels Verge 1.7. Installing the INTERFALZ panels Verge After the holders have been placed, the installation of the INTERFALZ panels begins at the verge. The panel packages have been deposited on the roof before or are lifted onto the roof in the course of the installation work such that the small flange faces the direction of installation. At this point, two verge designs are possible: a.) Verge with extruded verge profile The large flange is seamed prior to installation, and the panel with the small flange is pressed into the holder. After that, the extruded verge profile is twisted in over the large flange and joined with the supporting structure. Another option is to seam the large flange prior to installation and then twisting it in the verge profile that has been attached to the supporting structure and selected to suit the respective INTERFALZ profile height. The small flange covers the next holder. 27

28 INSTALLATION INTERFALZ Installing the INTERFALZ panels Verge b.)verge with verge cap, U-shaped verge profile and verge strip The first INTERFALZ panel covers the holders, the small flange facing the direction of installation again. Then the large flange is seamed (Operate machine!). After that, the U-shaped verge profile is placed on the large flange and riveted to the same with a spacing of approx. 500 mm (distance to holders: at least 100 mm). The connection with the holder is made by screwing (at least 2 drilling screws or self tapping screws) the verge cap to the holder. The verge strip is clipped on over the U-shaped profile and the verge cap by hooking it into the long flank of the U-shaped profile and twisting it. 28

29 Fixed point Fixed point Based on the predefined fixed point design, the fixed point is made now (to prevent the panel from slipping), or the second panel is installed and immediately flanged to the preceding panel. Where the fixed point can be made after the installation of the second panel only (variant involving screwing through the web), the first panel needs to be secured so it will not slip. Fixed points are subject to static verification. The intended design and locations within the roof structure can be found in the installation plan. For information on flanging and possible machine settings, see section 1.8. Possible fixed point designs are shown in the following pictures: ca. 45 Rivet Riveted fixed point A hole is drilled into the holder head through the small flange at an angle of approx. 45 to 1. Drilling a rivet hole accommodate one (or several) blind rivets. The rivet head is covered by the large flange of the next panel. To make sure that the forces acting upon the roof pitch are absorbed, it may be necessary to place a longer holder. 2. Putting the rivet in place and hooking in the seam profile 3. Ready for flanging 29

30 INSTALLATION INTERFALZ Fixed point M8 screw with sealing washers and nut Fixed point made by screwing the panels down through the webs An M8 threaded screw with a locknut is driven through both profile webs and the holder. Sealing washers have to be added on both sides (screw head and nut). External ridge flashing Distance compensation Fixed point INTERFALZ Fixed point made by screwing the panels in the trough bottom to the substructure Self-tapping screws or drilling screws are screwed into the supporting structure through the trough bottom. Height compensation may be necessary. Holder arrangement can be omitted in this area. When completing the roof by installing the roof flashings (ridge, verge, eaves), it is to be observed that temperature-related changes in the INTERFALZ panel length always propagate away from the fixed point. Thus, the fixed point is usually made on the ridge, and the change in length is allowed for at the gutter overhang. The coefficient of linear expansion t of various materials is shown in the table below. Material Coefficient of linear expansion t (mm/mk) Aluminium 0,024 Copper 0,017 Stainless steel 0,016 Zinc 0,029 The anticipated temperature-related change in length is calculated as follows: 0 * t * t When fixed points are made by screwing the panels through the webs and/or the trough bottom, the screwed connection should be located between upward fold and profile filler and covered by the ridge flashing. When further installing the INTERFALZ panels until the entire roof is completed, the panels are placed on the preceding panel with the large flange on top of the small flange at a slight angle. Now the panel is aligned (flush with the eaves), and then its small flange is pushed into the next row of holders. 30

31 Fixed point Prodach roof Length tolerances of the INTERFALZ panels are accommodated at the ridge. Where folding the panels upward at the ridge end is no longer possible after the installation for structural reasons, this needs to be done before the panels are fitted (see section 1.9.1). Furthermore, it is to be taken into account that certain roof fittings can constitute fixed points as well. Heat insulation Vapour barrier Step 1 Milling out the portions for the rail Mill out a portion of the insulation for the fixing rail Prodach roof The installation workflow for the erection of a Prodach roof system is similar to that of a truss roof. The company Rockwool provides a system for the Prodach roof construction consisting of a non-compressible and waterrepellent mineral wool insulating slab and a U-shaped fixing rail which has to be milled into the insulation. Push the fixing rails into the milled-out portion. Step 2 Installing the rails Fix screws to make a connection with the substructure. The rail is fixed to the supporting shell using a system fastener only in certain places which minimises heat losses due to existing thermal bridges. INTERFALZ DF panels are used as roof cladding. Their trough bottoms rest directly on the insulation. Finally, the panels are installed and flanged as described in section 1.8. Step 3 Installing the holder Install the holders to the rails. Hook in and flange the INTERFALZ profiles. Step 4 Installing the panels 31

32 INSTALLATION INTERFALZ INTERFALZ with claw strip INTERFALZ with thermal bolts Flanging INTERFALZ with claw strip In this system, a claw strip is pressed into a non-compressible insulation, similarly to the Prodach roof. Milling is not necessary here. The claw strip is fixed to the supporting shell using a system fastener only in certain places. Claw strips are available with and without punched spacing holes. The claw strip is positioned either parallel to the eaves or diagonally depending on the existing supporting structure. The INTERFALZ holders are screwed to the claw strip. In the course of further roof construction, the INTERFALZ DF panels can either be placed directly on the non-compressible insulation, or another layer of compressible insulation in combination with INTERFALZ in a height of 50 or 65 mm is applied INTERFALZ with thermal bolts The holders are positioned with the help of string in the same manner as described for the truss and/or purlin roof above. Then the bolts are pressed into the non-compressible insulation using a special tool. In order to be able to bring the bolt into the correct position, it is marked with a groove accordingly. Where bolt height and insulation thickness do not match, either the bit must be shortened or an additional spacing structure must be in place. The bolt is fixed to the supporting shell using at least 2 system fasteners. Afterwards, the holder with the 14 mm foot thickness and corresponding height is twisted onto the bolt. If the holder is fixed centrally, it can still be adjusted by 9 mm to both sides later on. The further roof construction can be done directly on top of the non-compressible insulation with DF profiles or in combination with compressible insulation and normal profiles. A special tool is available for fitting the thermal bolts Flanging Each INTERFALZ panel must be flanged as soon as it has been installed. This is done by means of a flanging machine which can be borrowed from the factory or purchased. The direction of travel is arbitrary with panels that are not abutted. The machine can move from the eaves to the ridge and back. Prior to flanging, it must be checked if the flanges are properly seated in the holders so as to avoid faulty flanging. Flanging is to be done such that the panels can still slide across the holders properly. When the flanging work is executed correctly, the flange has the following external dimensions: Sheet thickness Flange width (mm) (mm) 0,8 1, The flanging machine has to be set accordingly. The machine is positioned at the open flange before flanging, then brought together when the front pair of rollers grips, and then it can independently run along the flange. 32

33 Flanging Sheet thicknesses from 0.9 mm require preflanging of the area where the machine is positioned to begin flanging using manual flanging pliers. The INTERFALZ panel and especially the flange must be free from dirt in order to be flanged. Paint-coated INTERFALZ panels must be flanged using plastic rollers as a rule. The protective film on the profiled panel (normally on the large flange only with coloured material) is removed only after flanging. In case of faulty flanging or if any INTERFALZ panels need to be exchanged, the flange can be opened again using a flange opening tool which is attached to the rear end of the machine. spring tension via the lateral knurled nuts. The knurled nuts are secured against being turned out of position by means of threaded pins. Setting the rollers to the web height of 50 mm or 65 mm profiled panels This is normally done at the factory. The setting is to be checked prior to flanging. Replacing the roller sets Knurled wheel for adjusting the number of revolutions and thus the flanging speed The technical data of the machine are as follows: Input voltage Power consumption Weight V 1200 W 15,0 kg ~50/60 Hz (Continuous operation) The flanging machine comes with the following setting options: Setting of the flanging width using a contrivance for gap setting at the front and rear openings in the machine. Contrivance outward = smaller flange; contrivance toward the centre = larger flange Where setting by means of the gap contrivances is not sufficient, the flange width can also be adjusted by modifying the 33

34 INSTALLATION INTERFALZ Flanging Flange width setting options Shifting the gap setting Additional option by adjusting the spring tension Setting options for the height of the guide rollers Loosening the hexagonal socket head screw Shifting the roller holder up or down 34

35 Flanging Switching options Flanging rollers Switching on and off Machine with a set of steel rollers Adjusting the number of revolutions and thus the speed of operation Plastic rollers 35

36 INSTALLATION INTERFALZ Flanging Flanging 1. Manual flanging of the area where the machine is positioned to begin flanging 3. Machine closed 2. Positioning the open machine 4. Flanging 36

37 Flanging Opening flanges Groove for attaching the flange opening tool Machines with a flange opening tool 37

38 INSTALLATION INTERFALZ Flashings Ridge 1.9. Flashings Ridge Upward folds at the ridge end and the ridge filler plate in combination with filler block P serve for sealing the profiled panel at the ridge against drift snow and water. For making upward folds, a special upward folding tool is available for each profile. Using that tool, the end of the profiled panel is folded up by approx. 45 make sure that the profiled panel does not crack laterally at the upturn. Then the ridge filler plate is twisted into the profile and fastened to the flanges by means of blind rivets. 1. Positioning the upward folding tool 3. Upward folding complete 2. Making an upward folding 4. Finished upward folding 38

39 Ridge The distance of the ridge filler plate to the profiled panel end depends on the intended ridge design. It should however measure 120 mm. The filler block is shoved underneath the rear fold of the ridge filler plate, a surface pressure having to be applied on all sides in order to achieve proper tightness. In order to prevent the profiled panels from getting jammed under the ridge filler plate, incorporating non-compressible insulation in the ridge area is recommendable. An additional distance profile can be riveted on the flanges to support the ridge sheeting. Thermal insulation Vapour barrier Holder with thermal cap Ridge filler plate Filler block Upward folding Trapezoidal profile Truss 39

40 INSTALLATION INTERFALZ Ridge Upward folding External ridge flashing Ridge filler plate Filler block Distance profile Spacing structure Internal ridge flashing Depending on the cover width of the profiled panel, the ridge flashings are riveted to the ridge filler plates centrally or at the third points (no riveting in the flange area). Sheets must overlap by at least 100 mm and sealed in addition or by making a butt joint with a splice plate. The sheets must not be joined at the overlap. Fix splice plates on one side only, the distance between the fastening points being maximally 333 mm. In case that the fixed point is not located on the ridge and it needs to be movable, appropriate sliding elements are available. Hips can be made by welding to a split INTERFALZ panel which is aligned with the hip as well. A prefabricated ventilated ridge is available for ventilated roofs. Hips are designed and built like gabled roof ridges. Since the profiled panels have to be cut at the ridge at an angle, profile filler blocks in a length of 1.0 m and variable ridge filler plates without punched out areas for the corrugation are available for sealing. They must both be adapted to the respective bevel on site. 40

41 Ridge Hip Ventilated ridge Prefabricated ventilated ridge Ridge filler plate Filler block Distance profile Hip 41

42 INSTALLATION INTERFALZ Eaves Eaves The edges of the profiled panels at the eaves end include a downward folding at the eaves end, flange filler, an eaves angle and sealing tape to be fitted between the eaves angle and the INTERFALZ panel. So as to avoid restraints between eaves gutter and eaves angle as a result of temperature-related changes in the profiled panel length, a certain excess length (gutter overhang) of the profiled panel beyond the plug-in gutter outlet is necessary. When determining the measure A as shown in the drawing below, a freedom of movement of 1.0 mm/m of the profiled panel must be included in the design in Central Europe. INTERFALZ Gutter overhang -1/3 A 20-2/3 A = freedom of movement 1.0 mm/m of the profiled panel If the temperature differs from the values stated above, the required gutter overhang can be calculated based on the formula in section For making the downward folding at the eaves end, appropriate downward folding tools are available as well. After downward folding and applying the flange filler at the eaves end (apply the flange filler prior to flanging and/or in the course of panel fitting), the eaves angle is to be installed. The eaves angle is attached approx. 20 mm (with the opening facing forward) from the panel front edge. Depending on the eaves design, sealing tape is to be fitted between the eaves angle and the INTERFALZ panel. For easier installation, it is clamped to the profiled panel by means of locking pliers or a screw clamp and then riveted. The flange filler is normally fixed together with the eaves angle. As the eaves angle also has a static function (load distribution), the eaves angle has to be riveted at each rib of the trough bottom in case of overhangs projecting more than 25 cm over the holder. Where the fixed point is located on the ridge and the profiled panels are installed at C, the required gutter overhangs are as follows: Panel length Up to 20 m Up to 30 m Up to 40 m Up to 50 m More than 50 m Gutter overhang 60 mm 70 mm 80 mm 90 mm 50 mm + 0,5 x L (m) L = panel length 42

43 Eaves Only profiled panels of equal length are joined with an eaves angle. Where it is located between two profiled panels of different lengths, the eaves angle has to be abutted. 2. Folding down 1. Positioning the downward folding tool 3. Finished downward folding Holder with thermal cap Downward folding Vapour barrier Thermal insulation Gutter sheet Curtain gutter Eaves angle Flange filler Gutter bracket 43

44 INSTALLATION INTERFALZ Verge Verge The way to begin the installation work at the verge has been described based on two optional variants already in section Installing the opposite verge side is to be started in the same way. The verge may have to be executed either as an upward or downward verge (connection to higher building and/or attic). When using the one-piece verge profile, either the small flange is hooked into the verge profile first and then the large flange of the INTERFALZ profile is pressed onto the small flange of the preceding panel in the same way as it is done at the beginning of the installation work, or the panel is installed normally with the verge profile being twisted into the large flange. The cover sheets are to be fixed to the verge profile or to the verge strip. Joints have to overlap by 10 cm (with additional sealing where necessary). Overlaps must not be connected with each other. For forming transitions, fitted panels with a flange are made profiled on one side and, if requested, additional bends are available as well. However, they are maximally 6.0 m long so that they have to be joined and sealed to make longer panels. With roof pitches of less than 5 the joints should be welded. 44

45 Verge Holding profile as bracket Verge flashing Verge profile Thermal insulation Vapour barrier Bracket Attic covering Two-piece spacing structure Cleat Supporting shell Vapour barrier Thermal insulation Verge profile Distance plate 45

46 INSTALLATION INTERFALZ Transverse joint Transverse joint INTERFALZ panels finished at the factory can be delivered in lengths of up to 30 m. If finished at the building site, virtually infinite fabrication is possible as long as there are appropriate conditions at the building site. Transverse joints in the profiled panels are thus avoidable and should be executed only when absolutely necessary (e.g. in case of restricted installation options). During flanging it is to be observed that the flanging machine may be operated in the direction of the roof pitch only. Joints must be sealed. Transverse joints with roof pitches of less than 5 should be welded, and transverse joints with roof pitches of less than 2.9 must be welded. 46

47 Transverse joint The following pictures show the recess areas needed to make the joint and the joint forming options. Joint as a fixed point Panel 2 Panel 1 a Direction of installation Moveable joint Panels 1 and 2 flanged Panel 4 a recess area Panel 3 Notching of the large flange only with a sheet thickness of 1.2 mm 47

48 INSTALLATION INTERFALZ Roof fittings Curbs for light domes and SHE Roof fittings Welded-in curb Curbs for light domes and SHE When it comes to the installation of curbs, Aluform System GmbH & Co. KG cooperates with renowned manufacturers and can provide both insulated and non-insulated curbs in various dimensions. Curbs can be sealed or welded in. Curbs should be welded in with roof pitches of less than 5 and must be welded in with roof pitches of less than 2.9. Since the equipment installed on the curbs must be accessible for regular maintenance and thus people must be able to walk on the profiled panels, it is recommendable with insulated roofs to fit non-compressible insulation in the area around the curb in addition to installing appropriate access grids. Detailed fitting instructions will be delivered to you along with the curbs. The replacement of parts of the substructure which may be necessary to install the roof fittings must be taken into account already at the time of planning. Weld up the profiles at the front. 48

49 Roof fittings Curbs for light domes and SHE Sealed curb Curb welded to panels on both sides Position the curb on the existing substructure and seal. The flashing design is the same as that of the ridge. Joint formation is the same as that of transverse joints. Flange the panels and rivet the joints. Fitting a light dome with a profiled flange Vapour barrier Flange filler Light dome Curb Cover sheet Filler block Filler plate INTERFALZ INTERFALZ holder with thermal cap Non-compressible insulation Detailed fitting instructions See installation instructions of the light dome manufacturer Supporting shell Insulation 49

50 INSTALLATION INTERFALZ Ventilators Ventilators There are 2 options to make pipe penetrations through the INTERFALZ panel: Welding the pipe penetration into the roof cladding Sealing a pipe fed through the roof cladding by means of a pipe collar. The relevant installation instructions will be delivered together with the pipe collars. In insulated roofs the pipes must be connected to the vapour/air barrier. 50

51 Roof anchors and fall protection Roof anchors and fall protection Fall protection for INTERFALZ systems is available both as single attachment points and in the form of rope systems. Both systems are fastened to the flanges of the INTERFALZ panels without penetrating them. All systems have been tested for use with the INTERFALZ system. Single attachment points as well as the rope system can be used with cover widths of 305 to 500 mm. Installation instructions are included in every delivery of single attachment points. Rope systems may be installed only by certified companies or under the supervision of an Aluform employee. The sheet thickness of the profiled panels must be at least 0.8 mm for all systems, and the distance between holders may be max m. Consulting and sale of the systems is provided by Aluform Bernsdorf. 51

52 INSTALLATION INTERFALZ Access grids and step grids Access grids and step grids Access grids and step grids are used where people need to access the roof regularly, e.g. to maintain roof fittings or superstructures. The short grids, platforms and continuous access grids supplied by Aluform System GmbH & Co. KG have been tested for their fitness as per DIN EN 516. The grids are used as follows: Short grid (460 x 250 mm) as single step grids in the direction of walking and roof pitch. Platform (800 x 250 mm) as single step grids in the direction of walking and roof pitch or step grids in front of individual equipment Access grids (1,500 x 250 mm) as footbridges running parallel to ridge or eaves. The access grids and platforms are fastened to holders made of cast aluminium which are attached to the flanges of the INTERFALZ panels by way of screwed connections without penetrating the roof cladding. Access grids may also be fastened using seam clamp made of aluminium. Perforations in the access grids holders enable the alignment of the grid pitch with the roof pitch. With continuous access grids, the individual grids are to be joined by forming butt joints. The longitudinal expansion of the INTERFALZ panels must not be impeded by the clamping forces. It is to be taken into account already at the time of detailed planning that the spacing of the holders for the INTERFALZ panels (span) must not exceed the limit span after installation. 52

53 Seam clamp Seam clamp Seam clamps made of stainless steel or aluminium serve for the non-penetrative fastening of accessories or supports of solar collectors on the INTERFALZ panels. They are fixed to the flanges of the INTERFALZ panels using clamping screws. For that purpose, the clamping screw is opened, and then the seam clamp is spread and put over the flange. The tightening of the clamping screw must not prevent the profiled panel from sliding. Hence, the clamping screw is to be fastened with a tightening torque of 8 Nm. The elements to be attached to the seam clamp can be connected using the bore holes in the ascending lug. Provided bore hole = ø 7.0 mm. 53

54 INSTALLATION INTERFALZ Snow guard The long flank of the stopper points at the ridge Snow guard Snow guards must be installed where people or goods are endangered by masses of snow falling down or where the load-bearing capacity of lower roofs would be insufficient to bear that snow. If snow guards need to be installed on the roof, their number and positioning can be found in the execution plan. Snow guards consist of: Snow guard fishplates Snow stoppers (in 2 different designs) Circular tubes All parts are made of aluminium. The following table shows the usual arrangement of individual parts when installing snow guards. The number of rows required depends on the existing snow load, on the roof pitch and on the panel length. You can find more detailed information in the installation plan or obtain them from our application consultants. Profile Usual arrangement of snow guard fishplate and snow stopper Snow guard fishplate Snow stopper 50/333 Every other web 1 piece/trough 50/429 Every web 2 pieces/trough 65/305 Every other web 1 piece/trough 65/333 Every other web 1 piece/trough 65/400 Every web 2 pieces/trough 65/434 Every web 2 pieces/trough 65/500 Every web 2 pieces/trough The stated figures are based on experience and must be verified to be used for a specific object. They apply to DF profiles as well. 54

55 Snow guard Roof light panels Installing the snow guard is done in accordance with the following sequence: Attach the fishplates. Feed through the tube(s) and connect the tubes using tube connectors. Adjust and align the snow guard system. Tighten all screws. The required tightening torque for the screw connections of the snow guard fishplates is 25 Nm. Install the stoppers Roof light panels Roof light panels are available measuring 65/305, both insulated and non-insulated. Minimum quantities must however be purchased. More over, only every fourth panel may be a roof light panel. They are fitted as follows: Install INTERFALZ panels to both sides of a roof light panel. (Observe holder spacing of 305 mm.) Flange the large seam adjoining the roof light panel. Lay the roof light panel onto the INTERFALZ panel on both sides. Clip the closing strip (omega profile) on the seams of the roof light panels; flange the closing strip. The closing strips are connected to ridge and eaves by riveting them to the flanges of the INTERFALZ panel so as to prevent shifting. The roof light panels must be recessed in this area in order to prevent damage caused by different length variations. Note: There is a separate set of rollers for flanging the roof light panel closing strips. 55

56 INSTALLATION INTERFALZ Miscellaneous Roof overhangs Miscellaneous Roof overhangs Roof overhangs at the verge are possible only with an appropriate substructure. Roof overhangs at the eaves or ridge end can be executed with or without a clip bar depending on the size of the overhang. A roof overhang at the eaves or ridge end is the distance between the last holder on the eaves or on the ridge and the outer edge of the profiled panel. The certification requires a panel overhang of at least 100 mm to ensure the load-bearing capacity at the end bearings. Roof overhangs cannot be walked on prior to flanging and before the eaves angle has been installed. It is generally recommended to implement load-distribution measures in this area. The expectable profiled panel length variation towards the eaves must be taken into account in the construction of the gutter and/or downpipes Roof overhang with clip bar With a roof overhang design as described in section above, only a limited projection of the roof is possible. It can be increased by fitting clip bars. For that purpose, clip bars with appropriate heights are installed in the profiled panel joints, stretching over at least two spans of the substructure on the building side and end on the eaves side approx. 60 mm before the edge of the profiled panel. Downward folding, eaves angle and flange filler must be fitted at the panel end. a b Clip bar Roof overhang without clip bar Roof overhangs projecting by up to 1/6 of the adjacent span can be realised without verification. Greater roof overhangs are subject to static verification based on the bearing values in the certification. To install gutters, a support bracket can be fitted at the end of the roof overhang to which the gutter brackets can be fastened. The support bracket must be secured against shifting in the flange by riveting or screwing it down (see fixed point options). a Eaves angle as transverse stiffening element b 56

57 Curved profiled panels The gutter brackets can be installed at the end of the clip bar here as well. When installing the clip bars, it is to be made sure that they are flush. Both the clip bar and the way it is fastened to the substructure are subject to static verification. The bearing values of the clip bars can be enquired by contacting the factory. The precise design can be found in the execution plan. curved profiled panels, the specifications in sections and must be observed Curved profiled panels Profiled panels can be curved mechanically both at the factory and at the building site or curved (cambered) naturally. Mechanical curving facilitates smaller radii than natural curving. The maximum possible rise of the panels curved at the factory depends primarily on the maximum transport height and measures approx mm. Curves with larger rises can be carried only by way of special transports or need to be curved at the building site. When they are curved at the building site, it is easier to respond to changed dimensional ratios as well. In this context, the leaflet Guidelines for Using the Mobile Curving Machine on Site must be observed. The flashings are formed in the same way as it is done with straight panels. The verge flashing can however not be formed using continuous verge profiles and/or U-shaped verge profiles due to the curvature. Only short pieces are to be fitted here. When installing 57

58 INSTALLATION INTERFALZ Mechanically curved panels Mechanically curved panels The curving process may cause the webs of the profiled panels to be deformed outward so that the cover width is increased by up to 3 mm and the respective holder spacing (in the transverse direction of the profiled panel) must be adapted accordingly. The actual cover width is to be determined by measuring the profiled panels prior to fitting the holders. When panels are curved, approx mm at both panel ends remain straight for technological reasons. This can be undesirable in case of small radii so that the panel ends have to cut off at the building site. (Please, keep that in mind when placing your purchase order!) When it comes to profiled panels with varying radii (convex and concave) in one and the same profiled panel, transitional areas of similar dimensions as mentioned above are formed as well. There must not be any holders in such areas unless they constitute fixed points. Whenever a holder functions as an fixed point in a transitional area or at the end of a curve, a second fixed point must not be made. The following radii can be achieved by way of curving: Examples of possible curving radii Material Alu; mill finish - stucco Alu; mill finish - smooth Alu; coloured Steel; galvanised, coloured Stainless steel, t = 0.6 mm Titanium zinc; nature Titanium zinc; weathered Copper Convex profile radii in m 65/305 65/305 50/333 65/333 65/333 65/400 65/400 65/500 65/500 DF DF DF DF 1,0 4,0-1,0 4,0 1,0 4,0 1,0 4,0 2,0 6,0 2,0 2,0 6,0 2,0 6,0 2,0 6,0 1,0 4,0-1,0 4,0 1,0 4,0 1,0 4,0 9,0 15,0-9,0 15,0 9,0 15,0 9,0 15,0 9,0 15,0-9,0 15,0 9,0 15,0 9,0 15,0 3,0 10,0-3,0 10,0 3,0 10,0 3,0 10,0 4,0 12,0-4,0 12,0 4,0 12,0 4,0 12,0 5,0 12,5-5,0 12,5 5,0 12,5 5,0 12,5 Material Alu; mill finish - stucco Alu; mill finish - smooth Alu; coloured Steel; galvanised, coloured Stainless steel, t = 0.6 mm Titanium zinc; nature Titanium zinc; weathered Copper Concave profile radii in m 65/305 65/305 50/333 65/333 65/333 65/400 65/400 65/500 65/500 DF DF DF DF 9,0 15,0-9,0 15,0 9,0 15,0 9,0 15,0 10,0 16,0 10,0 10,0 16,0 10,0 16,0 10,0 16,0 9,5 15,5-9,5 15,5 9,5 15,5 9,5 15,5 14,0 18,0-14,0 18,0 14,0 18,0 14,0 18,0 14,0 18,0-14,0 18,0 14,0 18,0 14,0 18,0 15,0 20,0-15,0 20,0 15,0 20,0 15,0 20,0 16,0 21,0-16,0 21,0 16,0 21,0 16,0 21,0 17,0 22,0-17,0 22,0 17,0 22,0 17,0 22,0 When curving INTERFALZ panels made of aluminium, a protective film must be provided over the entire surface with radii of less than 10.0 m. 58

59 l Naturally curved panels Conical profiled panels Naturally curved panels In natural curving the profiled panels are manufactured and delivered to the building site straight (or are roll-formed there) and bent over a specifically curved substructure during the installation. In this context, the information provided in section above has to be observed. The minimum panel length for natural curving is 10.0 m. In order to avoid that the profiled panels are overstrained at the supports (holder area) and to achieve a proper curvature, the holder spacing normally needs to be shortened. More information on this subject can be obtained from the application engineering department at the factory Conical profiled panels All profiled panels (web height of 50 mm; web height of 65 mm and DF profiles) can be manufactured conically and also curved to be conical. The minimum cover width of conicity is 110 mm (200 mm if subsequent curving is intended); the maximum cover width is 600 mm. The minimum panel length is 4500 mm. When the stated dimensions are adhered to, there is no limit to length. Possible radii achievable by way of mechanical or natural curving can be obtained upon request. Min 110 The following table shows examples of achievable radii: Sheet thickness (mm) Profile 0,8 0,9 1,0 Convex Concave Convex Concave Convex Concave 65/305 36,0 40,0 40,0 45,0 48,0 50,0 65/333 65/400 50/333 50/429 37,0 38,0 37,0 40,0 40,0 42,0 Other profiles can be supplied upon request. Max

60 INSTALLATION ALUDECK ALUDECK Introduction Product range and warranty 2.0. ALUDECK 2.1. Introduction to ALUDECK The ALUDECK system is ruled by certification Z In the following sections, only those aspects will be discussed which are different compared to INTERFALZ. For the rest, the INTERFALZ installation instructions are to be observed Product range and warranty Aluform ALUDECK 65/305 Sheet thickness t N (mm) Weight (kg/m 2 ) ,7 0,8 1,0 1,2 2,96 3,38 4,20 5, Aluform ALUDECK 65/400 Sheet thickness t N (mm) Weight (kg/m 2 ) ,7 0,8 1,0 1,2 2,74 3,13 3,91 4,64 65 The ALUDECK element is a trough-shaped standing seam profile which is continuously made of AlMn1Mg0.5 alloy aluminium by means of roll formers. Both profiles, 65/305 and 65/400, can be produced by means of the stationary roll former only. Hence, the panel length is limited to 30 m for transport-related reasons. The profiled panels can be finished so that they are straight, convex or concave or with convex/concave curving in one panel. Bending (curving) can be done on site using a mobile machine as well. In contrast to the way INTERFALZ profiles are installed, ALUDECK panels are turned in into the holders only. 60

61 Product range and warranty Transport and storage Quality Holders in various heights and in the designs below are available for fixing the profiled panels on various substructures: Normal holder Holder with deburred head Slide holder Transport and storage - incoming goods inspection - See section 1.3 Normally, 2 3 panels are placed next to each other on one pallet, up to each 30 panels being stacked. The different holder designs can be used with the following panel lengths: Panels in a length of up to 20 m = normal holder Panels in lengths of m and curved panels = holder with deburred head Panels in a length of more than 30 m = slide holder 2.4. Quality - See section H H Holder designation Height H1 (mm) Height H (mm)

62 INSTALLATION ALUDECK Possible fields of application Installation Holder fitting 2.5. Possible fields of application ALUDECK can be used for all applications mentioned in section 1.5. with regard to the normal INTERFALZ profile as well. They cannot be used for the following applications: Prodach roof Installation on foam glass Installation with thermal bolts Installation on claw strip Holder fitting General information The applicable principles are the same as those applicable to installing the INTERFALZ profiles. Due to the fact that the holder head of the ALUDECK holders has an asymmetrical design, the direction of installation must be taken into account here as well. The lower nose of the holder has to point in the direction of installation when fitted Installation General information When installing ALUDECK panels, the same principles are to be followed as those applicable to INTERFALZ panels. Since the panels are not flanged to the holders, setting a fixed point is required immediately after each panel has been installed. Where slide holders are used, it is to be made sure that their holder support will not move out of the holder foot as a result of temperature-related changes in length. For that purpose, the small flange must be riveted to the holder head similarly to the fixed point execution or pressed in on both sides next to the holder head. If necessary, longer holders are to be used. With a view to being able to walk on the panels, the following limit spans must be adhered to: Profile 65/305 65/400 Limit spans of accessibility (m) with a sheet thickness of (mm) Accessibility during installation Accessibility after installation 0,7 0,8 0,9 1,0 1,2 0,7 0,8 0,9 1,0 1,2 2,00 2,30 2,65 * * * * * * * 1,80 2,20 2,60 3,00 3,20 3,00 3,35 3,70 4,00 4,20 *No span. The span following from the external load can be applied. 62

63 Installing the ALUDECK panels Verge 2.7. Installing the ALUDECK panels Verge The panels are installed in the same way as the INTERFALZ panels. Only the verge profiles It can be used to begin installing at the verge. The large flange does not have to be flanged to be inserted into the verge profile. The ALUDECK panels are installed by turning in the large flange onto the small flange of the preceding panel which already rests on the holder. 63

64 INSTALLATION ALUDECK Fixed point Flanging Flashings Roof fittings Fixed point Fixed points can be executed in the same way as it is done with INTERFALZ panels as follows: Riveted fixed point Fixed point made by screwing the panels in the trough bottom to the substructure Due to the different form of the profile webs compared to INTERFALZ, the fixed point can be formed on the web only by using additional sheet metal plates Flashings Ridge - See section Eaves - See section The edge at the eaves end includes a downward folding at the eaves end, profile filler N and an eaves angle. Fixed point formation through additional sheet metal plates Verge - See section The verge cannot be executed in the variant: Verge cap U-shaped verge profile Verge strip Transverse joint Transverse joints are not possible with ALUDECK Flanging No flanging, except with curved panels see section Roof fittings Curbs for light domes and SHE - See section Due to the fact that ALUDECK panels cannot be abutted, only the variant where the curbs are welded in is permissible as a rule. 64

65 Roof fittings Seam clamp Ventilators In addition to the options of either welding ventilation caps and/or pipe penetrations into the roof cladding or sealing them using a pipe collar, Aluform System GmbH & Co. KG offers a ventilator made of cast aluminium. The ventilator is sealed in the trough bottom of the ALUDECK panel by means of a base plate, a counter plate and an EPDM seal. Fitting is done on top of the roof. The corrugations of the ALUDECK panels are incorporated in the cast plates. With insulated roofs, the ventilator is fitted while installing the roof. In that process, it must be made sure that the flexible hose is connected to the vapour/air barrier properly. Tubes in diameters from 50 to 125 mm can be connected to the flexible hose leading into the attic. Each ventilator is delivered together with corresponding installation instructions. Ventilation cap Screwed connection Base plate EPDM seal Counter plate Flexible hose Roof anchors/fall protection - See section The clamps of the fall protection elements match the ALUDECK flange form Access grids/step grids - See section The clamps of the step grid holders match the ALUDECK flange form Seam clamp - See section The seam clamp is only available in stainless steel design. Due to the asymmetrical geometry of the ALUDECK flanges, this seam clamp is available for left hand side installation and right hand side installation. 65

66 INSTALLATION ALUDECK Snow guard Miscellaneous Snow guard - See section The clamps of the snow guard fishplates match the ALUDECK flange form. The following table shows the usual arrangement of individual parts when installing snow guard equipment. The exact arrangement can be found in the execution plan. Profile Usual arrangement of snow guard fishplate and snow stopper Snow guard fishplate, item 7520 Snow stopper, item /305 Every other web 1 piece/trough 65/400 Every web 2 pieces/trough The ALUDECK panels are flanged using machines with steel rollers only. Thus, it must be made sure that the flanges are absolutely clean during flanging. In case of coloured material, the flange may have to be lubricated a little in order to prevent the varnish coat from being damaged. ALUDECK panels are normally curved by way of smooth curving without any crimps in the profile chords. The profile 65/305 can also be curved by creating uniform impressions in the bottom chords Miscellaneous Roof overhangs - See section Curved profiled panels - See section When installing curved profiled panels, turning them in as it is done with straight panels is not possible. Curved profiled panels (also where natural curving is intended) must be positioned vertically on the holders from above. For that purpose, the ALUDECK profiled panels have to be manufactured at the factory such that they have an appropriate open seam. That seam is then flanged in the same way as it is done with the INTERFALZ panels. If open seams are required, this must be communicated already when ordering the profiled panels! The flanging machines for ALUDECK and INTERFALZ are different. The following radii can be achieved that way: a.) Curving by creating impressions in the bottom chord - ALUDECK 65/305 - convex Sheet thickness (mm) Smallest radius (m) 0,7 5,0 10,0 0,8 5,0 20,0 1,0 5,0 40,0 1,2 6,0 40,0 b.) Curving without impressions - smallest possible radius (m) Largest radius (m) Profile Sheet thickness, convex (mm) 0,7 0,8 1,0 1,2 65/305 Standard 10,0 8,0 3,5 2,5 Limit - - 2,2-65/400 Standard 10,0 8,0 4,0 3,0 Limit - - 3,0 - Profile Sheet thickness, concave (mm) 0,7 0,8 1,0 1,2 65/305 Standard 26,0 18,0 16,0 14,0 Limit /400 Standard 26,0 20,0 17,0 17,0 Limit

67 Working Bending Cutting Naturally curved panels - See section Only profiled panels finished using the stationary roll former at the factory can be supplied. Minimum curving radii (m) applicable to on-site curving convex Sheet thickness (mm) 0,7 0,8 1,0 1,2 Radius for 65/305 or 65/400 profile 40,0 60,0 100,0 120, Working 3.1. Bending Depending on the quality of the material, minimum bending radii need to be adhered to. They are as follows: Material quality Smallest bending radii H44 (half hard) 2.5 x sheet thickness H46 (3/4 hard) 3.5 x sheet thickness H48 (hard) 5.0 x sheet thickness The stated radii apply to working temperatures of approx. 20 C. In case of hart material, bends of 180 (fold-overs) are to be avoided. Coloured material should have a protective film. The material is to be marked with soft pencils, grease pencils or felt tip pens only either on the reverse side of the part or on the protective film. Never use a scribing iron Cutting Straight cuts are made using a hand-held circular saw with a carbide-tipped coarsetooth saw blade (9 20 mm tooth pitch) or with a carbide-tipped toothed blade plus cutting wax. Install a guide rail. In exceptional cases, a hacksaw can be used. Cut out recesses by means of an electric nibbler, making a hole before for the nibbler to start. All cuts made on site must be deburred and covered by flashings as a rule. 67

68 INSTALLATION ALUDECK Drilling and screwing Welding Removing dirt 3.3. Drilling and screwing Use HSS special drill bits for drilling. (Do not regrind special drill bits.) Choose a bore diameter which is appropriate for the thickness of the supporting structure and for the fastening element used. Tighten self-tapping screws which have to be screwed into steel at approx. 600 rpm and drilling screws screwed into steel at rpm. (Do not use an impact screw driver!) Use the depth stop and do not curve against the sealing washers of sealing screws. Drive the screw through all join parts. Place a sealing washer on the drill bit to avoid scratches caused by the drill chuck Welding The process mostly applied to weld aluminium is TIG welding (argon inert gas), requiring a motor generator set or electric power connection. Operate the welding equipment at a no-load voltage of 42 V. A welding cable length of up to 20 m is possible. Perform welding work only where it is dry and windless. Make sure that the welding point is covered by inert gas. Place a shield or tent where necessary. The parts to be welded must be clean, free of grease and dry. In case of coated sheets, the varnish coat must be removed before welding approx. 30 mm around the weld seam area. The joints can be either butt joints or lap joints (better variant). Another option is a butt joint with a narrow strip of the material laid underneath. Fire-sensitive materials must be protected against inflammation or damage Removing dirt Natural dirt should be removed as quickly as possible. This can be done applying warm water and a neutral dishwashing detergent or a soap solution by means of soft brushes or sponges. If pressure washers are used, it is to be made sure that no water enters the joints or connections. 68

69 Removing dirt Required tools Where special cleaning agents are used, the information provided by the cleaning agent manufacturer is to be observed. Prior to applying a special cleaning agent, try it on a spare panel or in a hidden area of the roof. Make sure that the special cleaning agent is environmentally compatible. Always clean in the direction of the roof pitch from the top down. Finally, it is sufficient to rinse with clear, warm water. The following cleaning agents have proven to be suitable: Biochem general purpose cleaner for dirt Biochem special cleaning agent for glue residues from the protective film Uncoated profiled panels can be treated with abrasive cleaning agents (ph value between 5 and 8) in addition to the actions mentioned above using both brushes and special sponges (e.g. Scotch-Brite). Scrub marks will definitely be visible on the profiled panel after cleaning. As the natural patina of the aluminium is roughened in the abrasive cleaning process, those areas will look lighter than the neighbouring areas at first Required tools Flanging machine (INTERFALZ or ALUDECK ) Set of plastic rollers, INTERFALZ Power drill Power screwdriver with depth stop and, if needed, special bit Flange opening device, INTERFALZ Manual flanging pliers (INTERFALZ or ALUDECK ) Upward folding tool depending on the profile shape Downward folding tool depending on the profile shape Seaming pliers Various metal shears Jaw wrench, AF 19 1 set of Allen keys Measuring tools Jigs for holder installation, as necessary Tensioning string Drill bits Rubber mallet Stains caused by corrosion by condensate or precipitation can be removed by way of heavy abrasion only. Abrasive cleaning normally does not cause any reduction in the load-bearing capacity. In case of slight staining it is recommendable to deliberate about whether or not cleaning is even necessary as the surface will gradually blend during the time of use. Drilling chips or other deposits produced during the installation work are to be removed right away. 69

70 ACCESSORIES Accessories INTERFALZ 6.0. Standard accessories and tools Part no. Type/dimensions (mm) Design/material Designation 9001 Type 65 H = 65 mm FALZRIPP holder 9002 Type 80 H = 80 mm 9003 Type 100 H = 100 mm 9004 Type 120 H = 120 mm 9005 Type 140 H = 140 mm Aluminium mill-finished H 9006 Type 160 H = 160 mm 9007 Type 180 H = 180 mm Type 200 H = 200 mm Type 220 H = 220 mm The holders are available in double length as well. Observe different part numbers Type 65 H = 65 mm FALZRIPP thermal holder 9014 Type 80 H = 80 mm 9015 Type 100 H = 100 mm 9021 Type 140 H = 140 mm Ultramid plastic material H 9018 Type 185 H = 185 mm Type 200 H = 200 mm Type 220 H = 220 mm

71 Accessories INTERFALZ Part no. Type/dimensions (mm) Design/material Designation FALZRIPP thermal holder 9190 Type 65 H = 65 mm 9191 Type 120 H = 120 mm Ultramid plastic material with eccentric socket H 9192 Type 160 H = 160 mm Type 240 H = 240 mm 71

72 ACCESSORIES Accessories INTERFALZ Part no. Type/dimensions (mm) Design/material Designation 9053 Type 80 FALZRIPP thermal bolt 9054 Type 100 Ultramid plastic material 9055 Type TK 5 64 x 64 x 5 Thermal cap 9011 TK x 64 x 10 Polyamide 9012 TK x 64 x Type 5 70 x 60 x 5 mm Height compensation element Ultramid plastic material 9052 Type x 60 x 10 mm 9042 Type 65 Clip bar 9043 Type Type Type 120 Type 140 Type 160 Aluminium, mill-finished L = Type Type Type

73 Accessories INTERFALZ Part no. Type/dimensions (mm) Design/material Designation 9056 for profile 50/333 FALZRIPP ridge filler plate 9057 for profile 50/ for profile 65/305 for profile 65/333 for profile 65/400 Aluminium, mill finish Aluminium, stucco Aluminium with coloured coating 9061 for profile 65/ for profile 65/ for profile 65/305 DF FALZRIPP DF ridge filler plate for profile 65/333 DF for profile 65/400 DF for profile 65/434 DF Aluminium, mill finish Aluminium, stucco Aluminium with coloured coating 9067 for profile 65/500 DF mm Variable ridge filler plates 9114 for profile 65/ mm mm mm 9117 for profile 50/ mm mm mm 9120 for profile 65/... DF mm mm for profile 50/333 for profile 50/429 FALZRIPP ridge filler 9072 for profile 65/ for profile 65/333 Cellular polyethylene 9076 for profile 65/ for profile 65/ for profile 65/500 73

74 ACCESSORIES Accessories INTERFALZ Part no. Type/dimensions (mm) Design/material Designation 9085 for profile 65/305 DF FALZRIPP DF ridge filler 9086 for profile 65/333 DF 9087 for profile 65/400 DF Cellular polyethylene 9088 for profile 65/434 DF 9089 for profile 65/500 DF FALZRIPP flange filler 9025 for profile 50/... Cellular polyethylene 9026 for profile 65/... FALZRIPP DF flange filler 9027 for profile 65/... DF Cellular polyethylene 9028 for profile 65/... L = 1000 mm FALZRIPP filler block long Cellular polyethylene 9029 for profile 50/... L = 1000 mm 74

75 Accessories INTERFALZ Part no. Type/dimensions (mm) Design/material Designation Spacing profile 9151 L = 6000 mm Aluminium, mill-finished Sliding element x 60 Aluminium for profile 65/... Fitted panel for profile 50/... Aluminium, mill finish Aluminium, stucco Aluminium with coloured coating for profile 65/... DF Verge cap/verge hook 9082 Type 50 Aluminium 9083 Type 65 U-shaped verge profile x 40 x 20 x 1.5 d = 1.5 mm L = 6000 mm Aluminium 75

76 ACCESSORIES Accessories INTERFALZ Part no. Type/dimensions (mm) Design/material Designation Verge strip 7626 d = 1.5 mm L = 6000 mm Mill-finished Verge profile 8429 L = 6000 mm for profile 65/... Mill-finished 8470 for profile 50/... for profile 65/... DF 84 (69) Universal 40 x 20 x 2 L = 6000 mm Eaves angle Aluminium 9091 Universal 70 x 30 x 2 L = 6000 mm Ventilator with cap 9170 Diameter mm Aluminium, uncoated Aluminium with coloured coating 9171 Diameter mm 76

77 Accessories INTERFALZ Part no. Type/dimensions (mm) Design/material Designation Platform 9172 Tread: 800 x 250 mm Aluminium, uncoated Short grid 9173 Tread: 460 x 250 mm Aluminium, uncoated Continuous access grids 9174 Tread: 1500 x 250 mm Aluminium, uncoated 77

78 ACCESSORIES Accessories INTERFALZ Part no. Type/dimensions (mm) Design/material Designation Access grid bracket x 250 mm Aluminium, uncoated Single attachment point Industry 7651 L = 550 mm W = depending on the cover width Stainless steel, uncoated 78

79 Accessories INTERFALZ Part no. Type/dimensions (mm) Design/material Designation Circular aluminium tube 7522 d = 32/2 L = 6000 mm (3000 mm) Aluminium, uncoated Coloured coating as per RAL Snow guard fishplate incl. fasteners 9180 H = 77 mm L = 185 mm Aluminium, uncoated Coloured coating as per RAL Snow stopper incl. fasteners 9181 Type ES Aluminium, uncoated Coloured coating as per RAL 9182 Type ZS ES ZS Access grid bracket Type KH 9176 Roof pitch of 0 20 Aluminium Adjustable 79

80 ACCESSORIES Accessories INTERFALZ Part no. Type/dimensions (mm) Design/material Designation Seam clamp 9092 Type A Horizontal installation Stainless steel Seam clamp 9093 Type B Vertical installation Stainless steel Seam clamp 9094 Type SKL Installation of solar collectors Aluminium Seam clamp 9095 Type SKK Installation of solar collectors Aluminium Seam clamp 9096 Type S5 Installation of various roof superstructures Cast aluminium 80

81 INTERFALZ tools and machines Part no. Type/dimensions (mm) Designation FALZRIPP flanging machine 7700 For flanging sheet thicknesses mm 220 V Incl. steel box FALZRIPP flange opening device 7714 Compatible with the flanging machine 81

82 ACCESSORIES INTERFALZ tools and machines Part no. Type/dimensions (mm) Designation FALZRIPP manual flanging pliers 7702 for flanging by hand 9200 for profile 50/333 FALZRIPP upward folding tool 9201 for profile 65/ for profile 65/ for profile 65/ for profile 65/333 DF 9205 for profile 65/434 DF 9206 for profile 50/ for profile 65/ for profile 65/305 DF 9209 for profile 65/400 DF 9210 for profile 65/500 DF 82

83 INTERFALZ tools and machines Part no. Type/dimensions (mm) Designation for profile 65/305 for profile 65/333 50/333 for profile 65/400 FALZRIPP downward folding tool 9214 for profile 65/333 DF 9215 for profile 65/434 DF 9216 for profile 50/ for profile 65/ for profile 65/305 DF 9219 for profile 65/400 DF 9220 for profile 65/500 DF 83

84 60 ACCESSORIES Accessories ALUDECK Part no. Type/dimensions (mm) Design/material Designation 7447 Holder 0 H = 80 mm (without thermal insulation) ALUDECK holder Holder 80 H = 144 mm (for 80 mm thermal insulation) Holder 100 H = 164 mm (for 100 mm thermal insulation) Aluminium, mill-finished H H Holder 120 H = 184 mm (for 120 mm thermal insulation) Holder 140 H = 204 mm (for 140 mm thermal insulation) ALUDECK sliding holder 7452 HSLAD H = 80 mm (without thermal insulation) Aluminium, mill-finished Thermal cap x 64 x 5 PE x 64 x 15 84

85 Accessories ALUDECK Part no. Dimensions (mm) Design Designation 7463 Clip bar Holder 0 Clip bar Clip bar Holder 80 Clip bar Holder 100 Aluminium, mill-finished 7466 Clip bar Holder 120 stucco/smooth ALUDECK ridge filler plate 7457 for profile 65/305 SP/smooth PVdF/smooth stucco/smooth 7458 for profile 65/400 SP/smooth PVdF/smooth stucco/smooth Arris filler plate up to a width of 650 mm (Greater widths upon request) 7462 for ALUDECK 65/305 and 65/400 SP/smooth PVdF/smooth 85

86 ACCESSORIES Accessories ALUDECK Part no. Dimensions (mm) Design Designation ALUDECK profile filler N 7431 for profile 65/305 Cellular polyethylene 7456 for profile 65/400 ALUDECK profile filler P 7457 for profile 65/305 Cellular polyethylene 7458 for profile 65/400 Profile filler block 7667 for profile 65/ L = 1000 mm Cellular polyethylene 86

87 Accessories ALUDECK Part no. Dimensions (mm) Design Designation Verge profile 8429 L = 6000 mm mill-finished 84 (69) universal 30 x 40 x 2 L = 6000 mm mill-finished Coloured coating as per RAL Eaves angle mill-finished 8425 universal 25 x 70 x 2.5 L = 6000 mm Coloured coating as per RAL Spacing profile 7460 L = 6000 mm mill-finished Circular aluminium tube Aluminium, uncoated 7522 d = 32/2 L = 6000 mm (3000 mm) Coloured coating as per RAL 87

88 ACCESSORIES Accessories ALUDECK Part no. Dimensions (mm) Design Designation Snow stopper including fasteners Aluminium, uncoated 7519 H = 60 mm L = 120 mm Coloured coating as per RAL Aluminium, uncoated Snow guard fishplate incl. fasteners 7520 H = 60 mm L = 120 mm Coloured coating as per RAL Installation on the left hand side W = 20 mm H = 37 mm L = 38 mm Installation on the right hand side W = 20 mm H = 37 mm L = 38 mm Stainless steel, uncoated Seam clamp including fasteners left hand side right hand side 88

89 Accessories ALUDECK Part no. Dimensions (mm) Design Designation Ventilation system Aluminium, uncoated Incl. flexible hose DN H = 300 mm W = 200 mm L = 300 mm Coloured coating as per RAL Short grid 7467 Tread: 460 x 250 mm Stainless steel Platform 7468 Tread: 800 x 250 mm Aluminium, uncoated 89

90 ACCESSORIES Accessories ALUDECK Part no. Dimensions (mm) Design Designation Access grid bracket x 250 mm Aluminium, uncoated Continuous access gridds 7664 Tread: 1500 x 250 mm Aluminium, uncoated Fall protection 7470 L = 550 mm W = depending on the cover width Stainless steel, uncoated (Schematic illustration only; the actual design may be different.) 90

91 ALUDECK tools and machines Part no. Dimensions (mm) Designation ALUDECK upward folding tool 7715 for profile 65/ for profile 65/400 ALUDECK downward folding tool 7717 for profile 65/ for profile 65/400 ALUDECK flanging machine 7713 For flanging with open seam 220 V Including steel box 91

92 ACCESSORIES ALUDECK tools and machines Part no. Dimensions (mm) Designation ALUDECK manual flanging pliers 7720 For flanging by hand with open seam (Schematic illustration only; the actual design may be different.) 92

93 Fasteners Part no. Type/dimensions (mm) Design/material Designation x 25.4 Clamping zone: Structure with TK 5 mm Bulb-Tite rivet Aluminium/ aluminium x 22.2 Clamping zone: Structure without TK x 25 E16 Sealing screw for connection with metal substructure Stainless steel, e.g. JZ3- For aluminium > 2.5 mm Steel ST 37 > 2.0 mm Stainless steel x 38 E x 32 E16 Sealing screw for connection with metal/timber substructure Stainless steel, e.g. JA3- For aluminium < 3.0 mm Steel ST 37 < 2.0 mm Wood > 60 mm x 64 E16 Stainless steel x 75 E16 93

94 ACCESSORIES Fasteners Part no. Type/dimensions (mm) Design/material Designation x 25 Clamping zone: up to 9 mm Drilling screw for connection with metal substructure* Stainless steel, e.g. Ejot JT3-X-2 For aluminium mm Steel ST mm x 36 Clamping zone: up to 20 mm Stainless steel Carbon steel x 46 Clamping zone: up to 30 mm x 25 Clamping zone: 6 18 mm Drilling screw for connection with metal substructure* Stainless steel, e.g. SFS SDK2 S 377 For aluminium mm Steel ST mm Stainless steel Carbon steel x 25 Clamping zone: 6 13 mm Stainless steel, e.g. SFS SDK3 S 377 For aluminium mm Steel ST mm FALZRIPP fixed point fastener Stainless steel screw M8 x 25 With 2 sealing washers and locknut Stainless steel Clamping zone: 15 mm * Not permitted and/or not suitable for screwing down plastic holders. 94

95 Tools in general Part no. Dimensions (mm) Designation Complete DAM Special two-speed screwdriver with depth stop and additional handle 220 V 600 W 600/1800 rpm 7056 K 3/8 x 65 SW 3/8 Screwdriver bit suitable for DAM M 8 x 65 SW 8 Attachment device DS-K ZA 1/4 for tightening SFS SDK screws K = clamping nut M = magnetic nut SW = width across flats (AF) inch/mm 95

96 ACCESSORIES Tools in general Part no Dimensions (mm) Ø 4.5 x 125 Ø 4.5 x 175 Ø 5.3 x 95 Ø 5.3 x 125 Ø 5.3 x 175 Ø 5.5 x 95 Ø 5.5 x 125 Ø 5.5 x 175 Ø 5.7 x 95 Ø 5.7 x 125 Ø 5.7 x 175 Designation HSS drill bit 96

97 Flat sheets Part no. Dimensions (mm) Design Designation x 1250 x 1.0 *2000 x 1255 x 0.8 st/sm mill finish sm SP coating sm PVdF coating Flat sheet x 1250 x 1.0 *4000 x 1255 x 0.8 st/sm mill finish sm SP coating sm PVdF coating 2000 x 625 x 1.0 cover width 1830 st/sm mill finish Serrated sheet P for ALUDECK 65/ sm SP coating *2000 x 625 x 0.8 cover width 1830 sm PVdF coating Example: = sheet 8085 length: 2000 mm = sheet 8085 length: 4000 mm st = coarse-patterned/stucco sm = smooth SP = two-layer polyester coating/protective paint on reverse side PVdF = PVdF metallic coating/protective paint on reverse side 97

98 Aluform System GmbH & Co. KG Dresdener Straße 15 D Bernsdorf Phone: +49 (0) Fax: +49 (0)