SAFEBRIDGE. High performance roof insulation system

SAFEBRIDGE High performance roof insulation system

.0 INTRODUCTION SafeBridge is a unique, patented system that combines roof safety with BCA Section J compliance without the use of roof spacers. SafeBridge utilises the depth of the purlin and the position of the purlin bridge bar to create exactly the right amount of space to comply with Section J of the BCA, which states that, where required, insulation must comply with AS/NZS4859.1 and be installed so that it maintains its position and thickness. SafeBridge is a unique system that is application specific and must be 'designed into the building' with standard purlin spacing; 610/910/1210/1360mm. The SafeBridge system has been jointly developed by Metroll, CSR Bradford, ITW Buildex, Australian Mesh & SafeBridge and is exclusively available when combining all of these system components..0 SAFEBRIDGE SYSTEM OVERVIEW 3 Code compliant with BCA/NCC Section J Uses the purlin space without elevating the overall roof or fascia height Creates a safer roof environment for workers during construction Suitable for cyclonic and non-cyclonic regions Figure 1. Roof sheet Bradford Anticon SB Australian Mesh SafeBridge mesh SafeBridge Bridge Bar Thermal break tape Metroll SafeBridge purlin 2.1 Designing for Green Star and Building Code Compliance Minimum energy efficiency standards for commercial buildings are mandatory in the Building Code of Australia (BCA) and National Construction Code of Australia (NCC). Thermal insulation plays a key role in meeting these requirements and improvements in insulation also contribute to reductions in energy use which is a critical factor in Green Star accreditation. Choosing the right insulation also offers the additional benefits of condensation control, dampening noise and controlling heat flow in and out of the building. To achieve the BCA/NCC Section J thermal insulation values, the roof system must allow sufficient space under the roof sheet for the insulation to recover to its design thickness to provide its rated insulation value. Failure to provide enough space will result in compression of the insulation and reduce its performance. SafeBridge essentially uses the depth of the purlins to provide a cavity for the insulation to recover to its design thickness, rather than create a space above the purlin using a roof spacer. Through the development of a patented bridging system and keyway, SafeBridge allows the purlin bridging to be set at a predetermined height during the design phase. 2.2 Designing for Worker Safety A unique feature of the system is the application of the safety mesh between, rather than over the top of the purlins. This configuration eliminates the need to lap safety mesh and cover the purlins, resulting in immediate wire mesh material cost savings. Additionally, this method of assembly allows the use of the SafeBridge Wire Pulley system which not only saves time in applying the wire mesh, but also removes workers from the exposed edge of the roof during construction, greatly increasing their safety. 2.3 Design Considerations The space created between the SafeBridge bridge bar and the underside of the roof sheet is exactly the right depth to suit the insulation and to ensure control of condensation on the underside of the roof sheet and purlins. As the SafeBridge system is integrated into the purlin and bridge bar assembly, there is little or no change to the roof design. Specified designs primarily need to consider the SafeBridge purlin spacing and bridge bar location relative to other roofing components during the design phase. In summary, SafeBridge: Can achieve high thermal performance in any climate zone (as defined by the BCA/NCC) Requires no additional roof spacers to elevate the roof sheet above the purlin Retains the structural integrity and load points of the roof interior Suits most roof pitches and complex roof designs Is available with either foil, decorative or acoustic finishes on the internal faced insulation material Can be used in cyclonic regions in conjunction with cyclonic rated components. Does not increase the size of the roof cavity space and subsequent capacity of building services. PAGE 2 SafeBridge

Important Purlin Spacing Design Considerations: SafeBridge relies upon specific purlin spacing listed in Table 1. Please ensure that you consult with Bradford and Metroll early in the design phase to understand the relationship of purlin depth and spacing to R-Value and the BMT relative to your ultimate roof design loads. Table 1. Purlin and Bridge Bar Spacing Standard Purlin Spacing Bridge Bar Spacing 610mm, 910mm, 1210mm, 1360mm Maximum 1500mm.0 KEY DESIGN ELEMENTS Anticon SB has centre bonded foil lap to protect purlins from condensation Purlin Keyway - simple roofing screw assembly R0.2 Thermal Break Tape - 10mm thick Bridge Bar Stabiliser - prevents purlin roll SafeBridge PAGE 3

.0 5 THERMAL DESIGN TABLES PERFORMANCE SOLUTIONS FOR ALL APPLICATIONS The flexibility of the SafeBridge system allows a variety of different thermal solutions to be achieved by changing the combination of purlin depth and insulation products. Whilst these combinations are infinite, the two series below and on the next page provide a range of solutions for most applications, ranging from simple code compliance through to high R-Value solutions. If the right solution for your project is not listed, contact Bradford for project specific design support. Roof sheet Thermal break tape Purlin Bulk insulation Foil facing Safety mesh 4.1 BCA/NCC Compliant Series Deemed to Satisfy Solutions The BCA/NCC represents the minimum level of insulation for good energy efficiency and performance of the building envelope. Given the relatively low capital cost of insulation, increasing roofing insulation R-Values during the design phase can decrease the air conditioning load, thus reducing project capital equipment costs as well as future running costs. Table 2 below outlines the minimum SafeBridge system insulation requirements to meet the Deemed to Satisfy provisions of the BCA/NCC. Figure 2. SafeBridge component configuration The BCA/NCC also sets out a requirement for adjustment of minimum R-Value to compensate for loss of ceiling insulation. Please note the following tables do not address solutions where the loss of ceiling insulation exceeds the amount nominated in BCA/NCC table J1.3b. Please refer to the BCA/NCC for further details and contact Bradford for solutions. Table 2. BCA/NCC COMPLIANT SERIES Roof Systems no ceiling - R0900 (reflective) no ceiling - R0900 (non-reflective) suspended ceiling - R1000 (100-600mm cavity) suspended ceiling - R1000 (> 600mm cavity) System Illustrations BCA/NCC Compliant Year Climate Zone Heat Direction Solar Absorbance # Required Total R-Value [R T ] BCA/NCC Compliant Insulation Product Note: Thinner blanket must be on top for dual blanket applications Very Light R3.2 Anticon SB110 R M 2.5 Anticon SB145 R M 3.6 Anticon SB100 R M 2.3 Anticon SB100 R M 2.3 2010 to 2011 Zone 1,2,3 Inwards Light R3.7 Anticon SB130 R M Dark R4.2 Anticon SB145 R M 3.6 3.8 Anticon SB130 + Roof 4.3 Anticon SB100 R M 2.3 Anticon SB110 R M 2.5 Anticon SB100 R M 2.3 Anticon SB130 R M 6 Zone 4,5,6 Inwards All R3.2 Anticon SB110 R M 2.5 Anticon SB145 R M 3.6 Anticon SB100 R M 2.3 Anticon SB100 R M 2.3 2012 to 2014 2010 to 2014 Zone 1,2,3, 4&5 Inwards Very Light R3.2 Anticon SB110 R M 2.5 Anticon SB145 R M 3.6 Anticon SB100 R M 2.3 Anticon SB100 R M 2.3 Light R3.7 Anticon SB130 R M Dark R4.2 Anticon SB145 R M 3.6 3.8 Anticon SB130 + Roof 4.3 Anticon SB100 R M 2.3 Anticon SB110 R M 2.5 Anticon SB100 R M 2.3 Anticon SB130 R M Zone 6 1 Inwards All R3.2 Anticon SB110 R M 2.5 Anticon SB145 R M 3.6 Anticon SB100 R M 2.3 Anticon SB100 R M 2.3 Zone 7 1 Outwards All R3.7 Anticon SB145 R M 3.6 Anticon SB145 R M 3.6 Anticon SB130 R M Anticon SB130 R M Zone 8 1&2 Outwards All R4.8 Anticon SB130 + Roof 4.3 Anticon SB145 + Roof 4.9 3.8 3.8 Temperature gradient Note: Refer to the ICANZ handbook for detailed descriptions of roof constructions and thermal calculation parameters. Note that quoted R-Values are based on reflective Thermofoil facings and are not applicable to decorative facings unless stated please contact Bradford for assistance when calculating R-Values for these materials. Refer to the relevant BCA/NCC Solar Absorbance table for the buildings roof colour. 1. For condensation control, use of roof sarking products such as Enviroseal TM ProctorWrap TM High Tensile Roof (HT-R) is recommended. Whilst all lap joints and penetrations are to be taped using Proctor Plain tape. Excludes high humidity applications (eg. swimming pools) please consult Bradford. 2. Please consult Bradford for zone 8 projects. PAGE 4 SafeBridge

.0 ULTIMATE PERFORMANCE SERIES R-VALUE BY PURLIN SIZE For applications that require R-Values beyond code compliance or simply the flexibility to achieve an R-Value for a non code compliant application, Table 3 below highlights the maximum thermal performance that can be achieved for each Metroll purlin height. By selecting the required R-Value and purlin depth, the base material thickness (BMT) and purlin spacing can then be customised based upon the projects structural requirements. Impressive thermal insulation R-Values up to R M 5.5 (inwards for a roof with no ceiling) can be achieved with the Bradford Anticon SB insulation which has been specifically developed to complement the SafeBridge system. Table 3. ULTIMATE PERFORMANCE SERIES Roof Systems no ceiling - R0900 (reflective) no ceiling - R0900 (non-reflective) suspended ceiling - R1000 (100-600mm cavity) suspended ceiling - R1000 (> 600mm cavity) System Illustrations Metroll Purlin Size Bradford Insulation Material R-Value [R M ] Heat Direction Maximum Total R-Value [R T ] Note: Thinner blanket must be on top for dual blanket applications 150mm Anticon SB100 R2.3 150mm Anticon SB110 R2.5 200mm Anticon SB130 R 200mm Anticon SB145 R3.6 Inwards R R2.4 R4.2 R3.5 Outwards R2.7 R2.6 R3.2 R3.2 Inwards R3.2 R2.6 R4.4 R3.7 Outwards R2.9 R2.8 R3.4 R3.4 Inwards R3.7 R3.1 R4.9 R4.2 Outwards R3.4 R3.3 R3.9 R3.9 Inwards R4.3 R3.6 R5.5 R4.7 Outwards R4.1 R3.9 R4.6 R4.6 250mm blanket 60mm R3.8 Inwards R4.4 R3.8 R5.7 R4.9 Outwards R4.3 R4.2 R4.8 R4.8 300mm Anticon SB130 + Roof blanket 60mm R4.3 Inwards R4.9 R4.3 R6.1 R5.4 Outwards R4.8 R4.7 R6.3 R5.3 300mm Anticon SB145 + Roof blanket 60mm R4.9 Inwards R5.5 R4.9 R6.7 R5.9 Outwards R5.4 R5.3 R6.0 R5.9.0 SYSTEM COMPLIANCE ADVANCED TESTING PROGRAM SafeBridge is an innovative roofing system that has undergone hundreds of hours of development and testing to ensure it performs in accordance to its published specifications and the building code. As part of this program, the SafeBridge system has undergone experimental temperature analysis using a roof section to validate 3 dimensional theoretical modelling of heat transfer calculations. This complex process was used to develop the new generation of Bradford Anticon SB thermal insulation used in the SafeBridge system to ensure effective management of condensation across all climate zones through the purlin and adjacent materials (roof sheet, mesh, screw, insulation and thermal break tape). Modification of this system by the substitution of similar or alternative products cannot be guaranteed to perform in accordance with the stated information provided in this and other documentation. Please note that the design of high humidity applications (such as indoor swimming pools) should always be reviewed with Bradford during the design phase. Figure 3. Complex Thermal Modeling of Temperature Analysis Across Roof Structure SafeBridge PAGE 5

.0 8 INSTALLATION DETAILS Installation details for a typical SafeBridge application, excludes requirements for condensation control or for an aesthetic appearance, where sarking products may be required. Step 1: Install the bridging. Telescopic bridge bars fit all purlin spacing and the punched SafeBridge keyway accepts bridge bars from each side. Step 2: Screw off the bridging. Bridge bar fixing uses a standard Metal-Tek screw through both bars, and final screw in centre of bridge bar secures the system. 9 Step 3: Attach wire to bridging. Safety mesh should be tied to bridge with no side lap joints, this reduces installation time as well as the overall amount of material required as the mesh does not need to cover the purlin and overlap by 150mm. Step 4: Pull wire on wire pulley. Improved safety is achieved by utilising a unique trolley system to lay the safety mesh between the purlins this allows workers to remain safely secured below the roof surface, rather than above it on the open roof. Step 5: Attach wire to bridging (same as step 3). Area is now safe with fall protection installed. Step 6: Roll thermal breath tape along the purlin to prevent thermal bridging. Step 7: Roll out insulation. Safety wire and insulation components are cradled within the purlins, hence leaving the purlins visible as a working surface/footing area. Step 8: Lay roof on purlins and screw off. PAGE 6 SafeBridge

.0 SPECIFYING SAFEBRIDGE When specifying SafeBridge, the following components have been tested and recommended to achieve the performance standards specified in this document: Metroll SafeBridge Purlins and Bridge Bars Bradford SafeBridge Anticon SB[size] RM[value] centrally faced with Bradford Thermofoil Medium Duty [plus optional additional specification - laid on top of Bradford Thermoplast 993 White - laid separately] Bradford Thermal Break Tape 10mm Australian Mesh SB[width] SafeBridge Safety Mesh supplied by Bradford Insulation (installed between the purlins) ITW Buildex Metal Tech Screws Metal roof sheet to suit.0 SAFETY CREDENTIALS The SafeBridge roofing system represents an evolutionary step forward in the construction process of metal framed roofing and has been acknowledged as a safer roofing system by some of the peak safety bodies of Australia. In 2010 SafeBridge won Safety Product of the Year in the Queensland Work Safe Awards and shortly after was a finalist in the 6th Annual National Safe Work Australia Awards. The following year, SafeBridge was recognised by winning the National Safety Council of Australia Awards Best Solution of an OHS&E Specific Workplace Risk Award 2011. 2011 WINNER Best solution of an OHS&E Specific Workplace Risk Award 2010 FINALIST Safe Work Australia Awards FINALIST 2010 WINNER Safety Product Solution of the Year QLD Worksafe Awards Safety is key to the SafeBridge system reduce risk further by utilising the SafeBridge Mesh Trolley which allows installation of the safety mesh from below the roof surface from the safety of a scissor lift. SafeBridge Mesh Trolley needs to be purchased separately and is available from Metroll. SafeBridge PAGE 7

0.0 PRODUCT DETAILS SAFEBRIDGE ROOFING SYSTEM Product Base Blanket R-Value Nominal Thickness Min. Purlin Height Facing Std Size (m)x(mm) Suitable for std purlin spacing Product Code Anticon 100 SB R2.3 100mm 150mm Med Duty 10m x 620mm 610mm 112516 Anticon 100 SB R2.3 100mm 150mm Med Duty 10m x 920mm 910mm 111687 Anticon 100 SB R2.3 100mm 150mm Med Duty 10m x 1220mm 1210mm 105506 Anticon 100 SB R2.3 100mm 150mm Med Duty 10m x 1370mm 1360mm 126662 Anticon 110 SB R2.5 110mm 150mm Med Duty 10m x 620mm 610mm 122533 Anticon 110 SB R2.5 110mm 150mm Med Duty 10m x 920mm 910mm 110172 Anticon 110 SB R2.5 110mm 150mm Med Duty 10m x 1220mm 1210mm 112503 Anticon 110 SB R2.5 110mm 150mm Med Duty 10m x 1370mm 1360mm 112504 Anticon 130 SB R 130mm 200mm Med Duty 10m x 620mm 610mm 112532 Anticon 130 SB R 130mm 200mm Med Duty 10m x 920mm 910mm 111688 Anticon 130 SB R 130mm 200mm Med Duty 10m x 1220mm 1210mm 107982 Anticon 130 SB R 130mm 200mm Med Duty 7.5m x 1370mm 1360mm 126663 Anticon 145 SB R3.6 145mm 200mm Med Duty 7.5m x 620mm 610mm 123385 Anticon 145 SB R3.6 145mm 200mm Med Duty 10m x 920mm 910mm 126753 Anticon 145 SB R3.6 145mm 200mm Med Duty 7.5m x 1220mm 1210mm 126665 Anticon 145 SB R3.6 145mm 200mm Med Duty 6.5m x 1370mm 1360mm 103936 SAFEBRIDGE ROOF INSULATION MESH SafeBridge Safety Mesh SafeBridge Safety Mesh with PVC 50m x 600mm 50m x 900mm 50m x 1200mm 50m x 1350mm 50m x 600mm 50m x 900mm 50m x 1200mm 50m x 1800mm 610mm 105276 910mm 104052 1210mm 104032 1360mm 104048 610mm 116854 910mm 104054 1210mm 104046 1360mm 118289 For more information call 1300 850 305 or visit www.bradfordinsulation.com.au 6871/08/14 Publish date: 08/14 Doc Ref: B00002D CSR Bradford Locked Bag 1345 North Ryde BC NSW 1670 CSR Bradford is a business division of CSR Building Products Limited ABN 55 008 631 356 The contents of this brochure are copyright protected and may not be reproduced in any form without prior written consent of CSR Bradford. Recommendations and advice regarding the use of the products described in this brochure are to be taken as a guide only, and are given without liability on the part of the company or its employees. We reserve the right to change product specifications without prior notification, please refer to the CSR Bradford website for the latest revision of this document. The purchaser should independently determine the suitability of the product for the intended use and application.