Profiles & Installation of Stone Coated Steel Roofing

Featuring Both Gerard Roofing Technologies Allmet Roofing Products 955 Columbia Street Brea CA, 92821-2923 714-529-0407 Main Number 714-529-6643 Fax 1-800-23ROOFS WWW.GERARDUSA.COM WWW.ALLMET.COM Profiles & Installation of Stone Coated Steel Roofing You must complete the quiz online to receive credit for this course. Course Sponsor: Headwaters Roofing Course Number: met07a An AIA Continuing Education Program Credit for this course is 1 AIA HSW CE Hour

Course Description Stone coated steel roofing systems are a sloped roof application used for both commercial and residential buildings. These roofing systems give the aesthetic resemblance of tile, shake, slate, or asphalt, but with the strength and durability of steel.

Course Objectives By completing this course, the design professional will be able to: 1. Briefly discuss issues with traditional roofing systems 2. Describe the manufacturing process for stone coated steel roofing 3. List several benefits of utilizing stone coated steel roofing 4. Explain why energy efficiency is critical & what roofing qualities might meet Energy Star s criteria 5. Discuss how specifying stone coated steel roofing systems may contribute towards a project earning LEED certification 6. Illustrate 3 installation methods and several application types for stone coated steel roofing systems

Introduction to Stone Coated Steel Stone coated steel roofing systems are a sloped roof application used for both commercial and residential buildings (check manufacturer s specifications on pitch requirements). These roofing systems give the aesthetic resemblance of tile, shake, slate, or asphalt, but with the strength and durability of steel. The next slide will show how closely stone coated steel resembles the material it is designed to look like.

Why Stone Coated Steel? There are numerous applications for stone coated steel. It is the perfect alternative when needing the strength of steel while seeking the traditional look of tile, shake, or asphalt.

Before After

Learning Objectives Upon completion of this course, the design professional will be able to: 1. Briefly discuss issues with traditional roofing systems 2. Describe the manufacturing process for stone coated steel roofing 3. List several benefits of utilizing stone coated steel roofing 4. Explain why energy efficiency is critical & what roofing qualities might meet Energy Star s criteria 5. Discuss how specifying stone coated steel roofing systems may contribute towards a project earning LEED certification 6. Illustrate 3 installation methods and several application types for stone coated steel roofing systems

Problems with Concrete Roofing Systems 1. Expansion and contraction (rips the underlayment) 2. Becomes more brittle with age (cracks and breaks) 3. Fastens at the neck (susceptible to wind uplift)

Problems with Asphalt Roofing Systems 1. UV rays break down material stability 2. Foot traffic or hail impact creates internal deterioration 3. Fastens at the neck (susceptible to wind uplift) 4. Not environmentally friendly 5. Low aesthetic appeal

Problems with Wood Shake Roofing Systems 1. UV rays break down material stability 2. Foot traffic or hail impact creates internal deterioration 3. Fastens at the neck (susceptible to wind uplift) 4. Fire hazard

Problems with Painted Metal Roofing Systems 1. UV rays break down paint, causing peeling and fading 2. Hail impact shows every dent. 3. Repairs do not match because of fade 4. Oil Canning (ripples in the metal) 5. Industrial appearance

Why Stone Coated Steel over Other Roofing Systems 1. Expansion and contraction: When the stone coated steel roofing system is installed correctly, the roof is virtually water tight. The underlayment is the secondary protector. 2. It will not crack, break, or curl: Stone coated steel does not become more brittle with age. 3. It fastens at the neck and nose: This contributes to the high wind ratings.

How Stone Coated Steel is Manufactured Integrated system sandwiched between 26 gauge formed steel with rock solid components

How Stone Coated Steel is Manufactured Steel Coil Cutting the Panel Forming the Panels Stamping the Steel Shingle

How Stone Coated Steel is Manufactured Applying Acrylic Resin Basecoat Applying Variegated Stone Flashing Applying Stone Coating Heat Cured

How Stone Coated Steel is Installed Most manufacturers require their panels installed from left to right and from the top down (Ridge to Eave) unless installed battenless; then the installation is still left to right but from the bottom up. Neck Nose How the panel fastens The interlocking system allows the panels to over lap. When the fastener is applied at the nose, it also anchors down the neck giving it superb strength against Mother Nature.

Features and Benefits of Stone Coated Steel Light Weight Fire Class A rating Wind High wind warranties Hail Class 4 impact Snow & Ice Earthquake Insurance Discounts Energy Efficient Environmentally Friendly Attractive Presentation

Stone Coated Steel Roofing is Light Weight A stone coated steel roofing system is extremely light weight. It is an excellent choice when considering weight load or in roof-over applications. Because of its light weight, stone coated steel does not require additional support; in fact, its interlocking panels lower the amount of stress placed on framing and trusses. This product is ideal for any structure requiring the look of tile but does not have the proper support to hold the weight of clay or cement roofing.

Stone Coated Steel Roofing is Light Weight Added weight means more stress on framing and trusses which contribute to settling and eventual cracks in walls and ceilings. To limit the chances of roof collapse, all national building codes require additional support for any roofing system that exceeds 6 pounds per square foot. Stone coated steel is well under that weight.

Stone Coated Steel Roofing is Light Weight Per Sq Foot Per Sq Foot Per Sq Foot Per Sq Foot Per Sq Foot Protection/ Benefits Stone Coated Steel Concrete Tile & Shake Fiber-Cement Tile & Shake Architectural Composition Shingles Wood Shake Lightweight 1.4 lbs 9-15 lbs 6 lbs 3-4 lbs 3-5 lbs

Stone Coated Steel Roofing is Light Weight In building projects where concrete roofing is specified a substitution of stone coated steel roofing can create the following benefits: 1. Reduction to standard dead load framing 2. Reduction in material cost 3. Reduction in labor cost

Stone Coated Steel Roofing is Light Weight Case Study In 2007, a historical church in downtown Atlanta, Georgia needed a new roof. Engineers told the church that the structure could not safely hold the original clay tile. Because the original aesthetics and the structural integrity could not be compromised, they turned to stone coated steel for their solution.

Because of the resilience of stone coated steel roofing, less damaged/removed roofing materials are sent to the landfills. Other roofing materials require replacement and repair much more frequently, thus resulting in an increased volume contribution to landfills. Throughout the following section, we will explore the properties that allow for this resilience in stone coated steel roofing LONG LIFE

Stone Coated Steel Protects Against Fire Stone coated steel is non-combustible and safe from exposure to airborne burning cinders. The patented interlocking fastening system prevents the panels from lifting and allowing blowing embers to ignite the roof deck. Where a Class A assembly is required, stone coated steel should be installed with specified underlayments, as tested ASTM E-108, U.B.C-15-2 and U.L. 790 Class A fire tests.

Stone Coated Steel Protects Against Fire Fire Case Study In California, firemen tested the stability of the stone coated steel roofing system against concrete tile. The interlocking installation methods and the rugged steel panels of the stone coated steel did not collapse; concrete did. It is easy to see why stone coated steel is much safer in fires than other roofing products.

Stone Coated Steel Protects Against Fire

Stone Coated Steel Protects Against Fire I ve seen too many homes burned to the ground, a tragedy that could ve been prevented, says Jim McMullen, former California State Fire Marshall. A metal roof is one of the best steps a homeowner can take to prevent the spread of residential fires and save their own homes.

Stone Coated Steel Protects Against Wind The stone coated steel interlocking panels offer an extraordinary resistance to wind uplift. Stone coated steel roofing systems can carry warranties protecting against wind storms with winds up to 120 mph. (warranties vary depending on manufacturer). Some manufacturers have preformed controlled testing at the Hurricane Testing Center in Miami, Florida with winds exceeding 170 m.p.h... NO DAMAGE.

Stone Coated Steel Protects Against Wind Testing In Miami

Stone Coated Steel Protects Against Wind

Concrete Tile Roof... TOTAL LOSS

Stone Coated Steel Protects Against Wind Stone coated steel...no DAMAGE The Roof is Perfect There is damage to the soffit & fascia but no damage to the roof.

Stone Coated Steel Protects Against Wind

Stone Coated Steel Protects Against Hail Class 4 Impact Rating When considering the design of your building and how to protect it from the forces of nature...

Stone Coated Steel Protects Against Hail Independent testing by Underwriters Laboratories rated certain stone coated steel roof systems an industry best, U.L. 2218 Class 4 hail resistant product. Most of all the other tested materials (fiber cement, concrete tile, composition shingles, and medium cedar shakes) suffered severe damage under the same conditions.

Stone Coated Steel Protects Against Hail Stone Coated Steel Protects Against Hail

Stone Coated Steel Protects Against Hail This customer has replaced his roof three times in eight years. His home has been hit by three major hail storms. The 2007 hail storm hit his home 1 month after his new stone coated steel roof was installed... NO DAMAGE. No dented panels, No stone loss.

Stone Coated Steel Protects Against Snow & Ice 1. Does not absorb moisture and therefore has excellent compatibility with snow and ice. 2. Strong, stone-coated steel panels have been tested in weights in excess of 224 lb. per sq. ft. before panel deformation occurs (ice damming). 3. Freeze/ thaw cycles do not cause the panels to rise because of their interlocking design and unique fastening system. 4. Helps keep snow on the roof. In contrast to painted metal roofing, which is smooth and allows snow to fall dangerously to the ground below; stone coated steel s stone coating works as an abrasion to the snow, helping to hold it in place. 5. Can withstand large snow loads without weight issues.

Stone Coated Steel Protects Against Snow & Ice In extreme cold climates ice damming is a serious problem. When a stone coated steel roofing system is installed with a counter batten the ventilation from the eave to the ridge allows free air movement between the deck and the panel. This helps air temperature stabilize; thus, reducing ice issues on the roof.

Stone Coated Steel Protects Against Snow & Ice Asphalt Ice Damming

Stone Coated Steel Protects Against Snow & Ice Stone Coated Steel Very Little Ice Damming

Stone Coated Steel Protects Against Earthquakes Stone Coated Steel interlocking roof systems add structural strength to the roof. Many other roofing materials can not offer this. Instead they rely upon the underlying deck for structural integrity. Additionally, the light weight provides safety by reducing the threat of roof collapse. The death of several thousand people during the Kobe, Japan earthquake was attributed to the collapse of buildings roofed with heavy roof tiles. In its survey of roofs after the Northridge, California earthquake (January 17, 1994), the McMullen Company found only minor damage to about 1% of the homes protected by stone-coated steel roofing. In contrast, more than 50% of the concrete and clay roofs observed had significant damage.

Stone Coated Steel Protects Against Earthquakes Heavy Roofing can be Dangerous

Stone Coated Steel Qualifies for Insurance Discounts Insurance Discounts Up To 36% Discounts are offered by most insurance companies in most areas

Stone Coated Steel Qualifies for Insurance Discounts TRUE STORIES In early 2006, we paid $849 for our Homeowners insurance. For 2007, it went down to $573. It actually comes out better at 32.5% savings. Chris Potter has State Farm and switched from asphalt to Stone Coated Steel. The Curries, a USAA customer, said she is saving around 50%. She was paying around $2200/yr and now only $1200/yr. She s excited about the discount. It s a very big difference in dollars! Colorado Springs, CO

Energy Efficiency is becoming an increasing concern in the world we live in. There are some simple steps any design professional can take to address these concerns on almost any project. During this section we will briefly examine the design decisions that are critical to your contribution in sustainable design and how these design decisions will have a positive impact, both for the owner and globally. SUSTAINABLE DESIGN

Stone Coated Steel is Energy Efficient The roof can have the greatest impact on the energy use of a building. Buildings consume one-third of all energy and twothirds of all electricity generated. Cool Roofs can help reduce energy consumption by lowering cooling loads. Reflective Roofs directly save up to 40% in heating and cooling costs, as reported by Oak Ridge National Laboratory. Highly Emissive Roofs can lower urban air temperatures, thereby benefiting the environment by reducing fog formation. COOL ROOF REFLECTIVE ROOF HIGHLY EMMISIVE ROOF = STONE COATED STEEL ROOFING

Stone Coated Steel is Energy Efficient Reflective roof product lower roof surface temperature by up to 100 F, thereby decreasing the amount of heat transferred into a building's interior. ENERGY STAR qualified roof products save money and energy by reducing the amount of air conditioning needed to keep a building comfortable. http://www.energystar.gov/index. This information is taken directly from the energy star website.

Stone Coated Steel is Energy Efficient The ENERGY STAR energyefficiency criteria do not include a specification for roof insulation. However, in addition to reflectivity, roof insulation (measured by the R-value) plays an important role in building energy consumption for heating and cooling. The colder the climate, the greater the need for a higher R-value to ensure that less heat is lost from the building envelope. To determine the minimum R- value for a given location, refer to the International Energy Conservation Code. Americans spend about $40 billion annually to air condition buildings- one-sixth of all electricity generated in this country. http://www.energystar.gov/index. This information is taken directly from the energy star website.

Stone Coated Steel is Energy Efficient The Florida Solar Energy Center found that metal roofing, saves the most energy as a result of its high reflectance and superior ability to cool quickly at night. Metal roofing was reported to save a Florida homeowner about 23% annually in cooling costs, compared to a dark gray asphalt shingle roof. For reflectance results on our Energy Star qualified finishes please visit www.energystar.gov Energy Efficient

Stone Coated Steel is Energy Efficient A building s heating and cooling costs can be effectively reduced by insulation under the roof surface. Adding increasing amounts of insulation is not always the best way to save energy. As part of total system design, a cool metal roof can be an economical method for better energy efficiency. Cool metal roofing is available in granular or stone coated surfaces. This family of roofing can achieve solar reflectance of over 70 percent. Reflected solar energy allows the roof surface to remain cooler, which means less heat is transferred into the building.

Stone Coated Steel is Energy Efficient According to the Environmental Protection Agency (EPA), building owners with an Energy Star roof can expect a reduction in the amount of air conditioning needed, thus reducing peak cooling demand by as much as 10-15%. Energy Star qualified stone coated steel roofing systems reflect more of the sun s rays when compared to other roofing products. Stone Coated Steel brands have been tested to current methods and it has been concluded that their Energy Star qualified roof products can lower a roof s temperature substantially, thus decreasing the amount of heat transferred into the building. Homeowners in warmer climates will experience a reduction in their annual cooling costs, ultimately saving them money. Ventilation, attic insulation, geographical location, color of finish and number of degree/days all are important factors when calculating how much money you will save on your cooling bills.

Stone Coated Steel is Energy Efficient DRIFTWOOD CARIBBEAN PEARL AUTUMN GOLD SEGURA TSR 36% TE 95% TSR 56% TE 95% TSR 31% TE 95% TSR 28% TE 95% ENERGY STAR COLORS SOME COLORS ARE ONLY AVAILABLE BY A SPECIFIC MANUFACTURER TSR (Total Solar Reflectance) TE (Total Emissivity) Values are average expected values based on average yield of granular used, recognizing that the variegated colors have tow differing, randomly applied components. Additionally, it should be noted that as the granules are ceramic colored, the TSR value should not vary more than 1% with age and generally increases in reflectivity value.

Stone Coated Steel and LEED Leadership in Energy and Environmental Design (LEED ) and Energy Star use ASTM standards to test the following characteristics of stone coated steel roofing systems: 1. Emittance: ASTM E408 2. Absorptions, Reflectance & transmittance: ASTM E903 3. Solar Reflectance: ASTM E1980

Stone Coated Steel and LEED Specifying stone coated steel roofing systems may contribute towards a project earning LEED certification through the following credits: Sustainable Sites Credit 7.2 Heat Island I Point: stone coated steel roofing systems that comply with Energy Star label requirements and help reduce the Heat Island effect. The Heat Island effect is the term used to describe the phenomenon of urban regions that experience warmer temperatures compared to adjacent rural areas. As well, these products meet the minimum thermal emittance value of.9 under American Society for Testing and Materials (ASTM) E408. The emittance of a surface or material refers to its ability to release absorbed heat; the higher the number, the better the performance of the material.

Stone Coated Steel and LEED Sustainable Sites Credit 7.2 Heat Island I Point:, cont d Products with Solar Reflectance Index greater than or equal to 29 meet SRI requirements. The Solar Reflectance Index measures the ability of a material to reject solar heat and is calculated using both the reflectance value and emissivity value of a product. Energy and Atmospheric Credits 1.1 and 1.2-1-10 Points: Most colors and profiles of stone coated steel roofs could contribute to Energy and Atmospheric credits that address optimizing energy performance through the design of the building envelope. Certain products may contribute when using Option 1 Whole Building Energy Simulation. Results of a noteworthy study, conducted by Oak Ridge National Labs, suggest increased energy efficiency can be obtained with batten-installed roofing systems.

Stone Coated Steel and LEED Material and Resources Credits 4.1 and 4.2 1 Point Each: According to the Steel Recycling Institute, products that are manufactured using the Basic Oxygen Furnace (BOF) have a total recycled content between 25-30%. Check with the manufacturer to ensure their product can contribute to this category. Material and Resources Credit 5.1 1 Point Each: Stone coated steel roofing systems that are manufactured, then shipped within 500 miles of the manufacturing facility may quality for this credit, providing the granules are extracted locally. LEED-EB, LEED-CI, and LEED-CS have similar credits.

In this section we will address the three different types of installation methods for roofing and describe the advantages and disadvantages of each type. We will take a closer look at some of these methods through an exploration of case studies. Upon completion of this section you should be able to describe these methods and define the terminology associated with the installation process. INSTALLATION OF STONE COATED STEEL

Installation of Stone Coated Steel 3 Different Types of Installation Direct-to-Deck Batten (2x2 only) Counter Batten Be sure and check with the manufacturer. Installation procedures may differ. Some profiles can only be installed direct-to-deck or only on battens while others can be installed either way. Stone coated steel is installed with either screws or ring shank nails. It is important to check with local building codes and manufacturer specifications when determining the types of fasteners needed. High wind areas may require more fasteners per panel.

Installation of Stone Coated Steel Advantages of Direct-To-Deck 1.Ease of installation. 2.Cost of installation; there are substantial savings on material and labor. *Must be installed on solid decking

Installation of Stone Coated Steel Advantages of Battens 1. System can be used as a ladder during installation giving added security and safety on the job. 2. System creates greater air space between the deck and panel giving higher energy savings. 3. System requires less fasteners per panel 4. System is nose fastened which allows for greater wind resistance and strength. *This system can be installed with screws or ring shank nails. Check with manufacturer and city codes for specified fasteners. **This system can be installed on space sheeting, solid sheeting, or tongue and grove.

Installation of Stone Coated Steel Advantages of Counter Battens 1. System can be used as a ladder during installation giving added security and safety on the job. 2. System MAXIMIZES air flow between the deck and panel giving higher energy savings. 3. System requires less fasteners per panel 4. System is nose fastened which allows for greater wind resistance and strength. 5. System strengthens roof structure. 6. System is needed when doing most roof-over applications. This helps avoid expensive tear-offs and unnecessary land fill disposal.

Batten/Counter Batten Case Study Benefits of Over-the-Deck Venting Oak Ridge National Labs conducted a study (commissioned by the Department of Energy s Buildings Technologies Program) on infrared-blocking color pigments. The DOE was interested in the possible benefits of using cool pigment in roofing materials, especially stone coated steel roofs since IR-blocking granules are highly emissive and reflective. Ten decks were tested for one year to include both summer and winter conditions: Control deck was covered in dark grey asphalt shingles applied direct to deck. One deck was painted metal and fastened direct to deck. Two decks were stone coated steel with dark grey conventional (no IR-blocking granules) on counter batten and/or batten systems. Six decks were stone coated steel with light grey IR-pigment granules and applied on batten or counter batten systems. Venting was achieved with meshcovered openings at the eave and at the ridge.

Batten/Counter Batten Case Study Continued Here are the results of the study: IR-pigments returned expected results. Heat transfer was reduced by approximately 45% when compared to the control deck (asphalt shingles); however, only 15% could be attributed to the IR-pigment granules 30% was attributed to batten/counter batten installation (over the deck venting). When the decks coated with conventional dark grey granules (similar in reflectance and emittance to the asphalt shingles) were compared to the control deck (asphalt shingles) heat transfer was still reduced by the venting created with the batten/counter batten installation. continued

Batten/Counter Batten Case Study Continued When the light grey IR-pigment stone coated panels were compared to the dark grey conventional stone coated panels (both installed on a counter batten and batten system), it was noted that the panels with the dark grey conventional granules swept away more than twice the amount of heat flow than the IRpigment granular coated panels: the heat produced by the darker pigment granules increased the amount of hot air swept away from the deck, preventing it from entering the attic.

Installation of Stone Coated Steel Core Vent being installed at the ridge

Installation of Stone Coated Steel Advantages of Counter Battens Venting attic space with soffit and ridge ventilation

Installation of Stone Coated Steel Advantages of Counter Battens Stone coated steel is ideal in roof-over applications. Installing over existing roofing material, wood shake or asphalt shingles, saves expensive tear-off charges and unnecessary landfill disposal.

Installation of Stone Coated Steel Advantages of Counter Battens CREATES FREE AIRFLOW & GREATER EFFICENCY Venting of the stone coated metal roofs is just as important as the boost in solar reflectance for reducing the heat gain into the attic and conditioned space.

Installation of Stone Coated Steel Underlayments Stone coated steel is non-combustible and a Class A material. If Class A assemblage is required, certain underlayments may be necessitated. See manufacturer's ICC Report for specific information. Screws or nails can be used to fasten panels. In high wind areas, additional fasteners might be needed to meet local building codes. Less expensive underlayments are adequate due to stone coated steels dry below nature.

Installation of Stone Coated Steel Side Wall Flashing Sidewall panels are bent up at the edge Z-bar trim is placed over the panel and attached to the sidewall. providing superb water protection

Installation of Stone Coated Steel Pipe Flashing Step 1 Step 2 Step 3 Step 4 Step 5 Finished Look

Installation of Stone Coated Steel Solar Panels Solar panels are easily installed using J brackets

Installation of Stone Coated Steel Valley Installation Direct-To-Deck

Installation of Stone Coated Steel Shake, Mission, or Rakeless Trim The Shake or Mission trim is always used on hip and ridge areas. The rake can be installed with any of the three choices.

Installation of Stone Coated Steel Recommended Uses for Open Valley: 1. Extreme Weather Area 2. High Foliage Area 3. Ease of Application

Installation of Stone Coated Steel Closed Valley Installation

In this section we will briefly run through a series of images of projects utilizing 4 styles of stone coated steel roofing. While advancing through the images please note the different application examples provided and the multiple project typologies stone coated steel roofing may be appropriate for. PROJECT TYPOLOGIES

Stone Coated Steel Photo Gallery

Shake Style

Tile Style

Barrel Style

Commercial Installations

Churches

Commercial

Commercial Spruce Goose Hanger

Commercial Long Island University

Hotels

La Quinta Inn Hotels

Hotels

Professional

Condominiums & Apartments

Condominiums & Apartments BEFORE AFTER

Condominiums & Apartments

Course Summary By now the design professional should be able to: 1. Briefly discuss issues with traditional roofing systems 2. Describe the manufacturing process for stone coated steel roofing 3. List several benefits of utilizing stone coated steel roofing 4. Explain why energy efficiency is critical & what roofing qualities might meet Energy Star s criteria 5. Discuss how specifying stone coated steel roofing systems may contribute towards a project earning LEED certification 6. Illustrate 3 installation methods and several application types for stone coated steel roofing systems

Thank you for taking the course! Please proceed to the short test Featuring Both Gerard Roofing Technologies Allmet Roofing Products 955 Columbia Street Brea CA, 92821-2923 714-529-0407 Main Number 714-529-6643 Fax 1-800-23ROOFS WWW.GERARDUSA.COM WWW.ALLMET.COM Profiles & Installation of Stone Coated Steel Roofing You must complete the quiz online to receive credit for this course. Course Sponsor: Headwaters Roofing Course Number: met07a An AIA Continuing Education Program Credit for this course is 1 AIA HSW CE Hour