Assembly and maintenance

Assembly profiles

Roof pitch

The standard minimum roof pitch is 5° or 8,7°.
If the slope is shallower than that, the following points should be borne in mind:

• 1 monolithic roof panel = no traverse overlap
• an additional seal in the longitudinal overlapping, with a neoprene seal or a pre-formed bead of butyl mastic seam joint + a mechanical fastening every 0,40m
• the panel should, in the through, at the highest point, be bent upright
• a mousse strip should be laid under the double ridge course, running down both sides of the ridge (see sealing strips)

Overlapping and watertightness

On a roof pitched at 5° to 10°, a side lap of 200mm, with 2 beads of mastic (silicone or butyl), is prescribed as the sealant.

On pitches of 10° and over, use an overlap of 200mm and a single bead of mastic at the end of the upper sheet.

Laying the roofing according to the prevailing wind direction

The longitudinal overlap is positioned according to the prevailing wind direction. The side of the sheet with the short ribs must always, in a longitudinal overlap, be on top.

Conversion tables

Formula to obtain length C:

Attachment

Saddle in pre-painted steel sheet

We can recommend a saddle under the screw. This prevents water infiltration and transformation of the sheet. (see fasteners)

Laying a roof on timber purlins

When laying a roof, the metal sheet is fixed along the top of the corrugation. if laying it onto wood, you don't need top predrill. Make a small hole with a sharp pin punch and screw it down with self-drilling screws type A22, A32, A50, A80, A110, A130, A150, A170, A200, A250. At the beginning, the end and the lap joint of the sheet it is fixed at every ridge in the corrugation. For the rest the screws are distributed evenly over the sheet.

Laying a roof on steel purlins

When laying a roof onto steel, you don't need to pre-drill, provided self-drilling screws are used; type BZB25, BZB32, BZB65, BZB80, BZB100, BZB125, BZB145, BZB165, BZB200, BZB235 and BZB255. (see fasteners)

Laying a roof using hook bolts and matching nuts

Types: HB130/47, HB160/57, HB220/67 (see fasteners)

Cladding a wall with steel or timber purlins

When cladding a wall, it's best to pre-position each sheet perpendicularly using a plumb line or a spirit-level. Fix each sheet securely at the lap joint and in the valley. Only then should the previous sheet be bolted down all over. In that way you preclude the risk of any deformation or damage. The cladding is fixed to each and every profile.

Fixing rooflights to roofs and walls

• The sheets on the building sites have to be fully protected against solar radiation so as to preclude the risk of deformation due to the accumulation of heat. the risk disappears once the're installed.
• So as to obtain a saw cut free from burrs, the sawing should be done as follows: 
      by hand: saw the sheet using a thin saw blade and thin saw teeth
      mechanically: a circular saw with a max. sawing speed of 2,500 revs/minute
• Depending on the spacing of the attachment points, the diameter of the drilled holes in the polyester will, in each case, be 2mm larger than the diameter of the fastening bolts. Consequently, any damage to the sheets is precluded should they expand due to differences in temperature. This linear expansion usually occurs in the direction that the water flows off thee profiled sheets.
• The spacing between the purlins must not exceed 1,20m in normal environment and 1m in exposed areas (the coast, mountainous areas).
• To stop the polyester sheet from deforming, screws or bolts may, on no account, be fixed directly onto it. Alu-saddles are used instead. Screw down, through the saddle, to bring it into contact with the hollow ridge underneath. Don't over tighten as this may deform the ridge.
• The longitudinal overlap is 1 corrugation (1 ridge). The transverse overlap is 200m for a roof pitch of 8° thru'15° with beads of mastic of 100 to 200mm on pitches of 15° and over.

Important: rooflights should not be walked on!

Assembly composite panels

Machining and shortening of composite panels

For the machining or shortening of the panels, use a circular saw (see accessories). To get a clean cut you'll need to saw along a guide strip. All snot should be dislodged and cleared away afterwards.

Fixing of composite panels

The panels are to be fixed at the top and bottom of each corrugation. Don't skip more than 1 corrugation at the intermediate structural rails. Try to fasten these lock rails in a staggered pattern. Particular attention, the case of the composite panels, must be paid to the damp proof butt-ending of panels so as to preclude the risk of condensation. To form a hermetic seal, the composite panels have a wedge of polyethylene foam running in the longitudinal direction. The panels should be pressed firmly against one another. It's advisable to apply some sealing tape to all connections on the sides, roof ridges, cross-joints, on interior gutters, etc. Above all it is recommended to apply a butyl sealing strip between purlin and panel.
A few examples thereof are given below:

Assembly roof-tile profiles

Roof pitch

The minimum roof pitch for the roof-tile panels is 8°

Instructions for handling and machining

Storage

The roof-tile profiles can be stockpiled outdoors temporarily (max. one month). The sheets are, preferably, covered, provided there's adequate ventilation between the sheets and the covering material. the sheets should be supported at spacings of 1m.

Machining

the roofing is supplied to order, based on the client's plan. If it has to be cut to size (or cut to fit), use a fretsaw or a metal saw with thin saw teeth. You are discouraged from using grinding wheels or other devices with a high grinding speed because the grinding edges will start to glow, destroying the zinc plating and the coating of the sheet in the process. Red-hot particles of metal would fly about everywhere and burn holes in the protective coatings of the sheet.

Relacquering

Every instance of damage to the surface layer must be relacquered at once using touch-up paint.

Cleaning

All drilling fillings and drilling residues should be scrupulously cleaned off using a softbristled brush.

Tips

• It is best to carry the panel vertically so that the sheet doesn't bend.
• You can lay 2 beams from ground level up to the wall sheet as so as to support the sheet when hoisting it onto the roof.
• Always step on the hollow part of the corrugation when walking over the roofing.

Determining the key dimensions

The roof-tile panels are supplied to order, based on the client's plan; the maximum length is 8,40m

Length

Measure the distance between the top and bottom eaves and, to that, add the requisite no. of centimeters so that the panel will extend beyond the lower eave, to just over the gutter.

Width

The useful width of the sheet is 1,100m. To determine the number of sheets, divide the width to be covered by 1,100m. The sheet is cut lengthwise if necessary. For roof pitches longer than 8,40m, 2 sheets are laid in a single bay with the requisite overlapping.
To do that, proceed as follows: take, as the bottom sheet, a multiple of 350mm + 200mm for the overlap. The length of the overlying sheet is given by the overall length of the bottom sheet plus 200mm.

e.g.:
L = 10m or 10000mm. Take, as the bottom sheet, an arbitrary length to be fixed by you in practice) as follows: 15 tiles x 350mm (the length of one tile) + 200mm for the overlap = 5450mm
Hence, the length of the overlying sheet is: 10000mm - 5450mm + 200mm = 4750mm

Hipped roof

In the case of a hipped roof first draw a plan to scale of every roof bay in order to determine their number (how many sheets) and the sizes.

Roof with 2 different lengths in one and the same roof plane

First take the dimension L of the widest roof bay (bay A). The size of the longest sheets is the length of the shortest sheet + a multiple of 350mm, until these sheets extend beyond the lower eave, to just over the gutter. These sheets in bay B are then, at the lower eave, shortened with tailor-made tools. Using this technique, the number of sheets to be shortened is confined to the narrowest roof bay.

Underroof

In the case of certain applications, it's necessary to layan underroof. As an underroof, we can warmly recommend our anti condensation film which lets through all the vapours from inside but whitch is 100% waterproof so that the condensation that forms on the underside of the panel can be drained away into the gutter. For this purpose a small gap has to be left between the underroof and the tile laths. Counterlaths, therefore, have to be laid in the longitudinal direction of the underroof.

Counterlaths and tile laths

Begin, on the underroof, by laying the counterlaths. The tile laths are then fixed to these counterlaths at a c/c spacing of 350mm. Important: underneath the first row of tiles on the gutter side, 2 tile laths are laid the bottom one of which is 1cm thicker than the other. The other tile laths are fixed in place to coincide with the end of each tile.
Important: it's advisable to use a wider type of lath for your tile laths.

Means of attachment

The tiles are attached by means of self-drilling screws (4,8 x 35mm), galvanised and prepainted in the same colour as the sheets, which come complete with a washer (i.e a neoprene sealing ring). the screws are screwed down in the valley part and just below the kink of the tile. the roofing sheets are secured along the top bottom rows and at the lap joints of each tile. The other screws per m. At the overlap, in order to get a neater joint, you can screw one sheet to the next in the optimal place, on top of the corrugation, just before the kink in the sheet.

Assembly of roof-tile panels

These are laid working from right to left and from bottom to top (see sketch). Check that the roof is at right angles. Measure the diagonals from corner to corner. If these differ the roof isn't exactly square. In that case the sheet should be laid so that the bottom of the sheet hugs the line of the lower eave. Small differences can be compensated for by the bargeboards and ridge tiles. You would do best to lay a few panels on the roof so that the bottom edges run parallel with the eave. On wider roof bays lay the first sheet, in from the corner, at an angle to the right and then connect the others to it.

Assembly of accessories

Gutter flashing or wall sheet trim

To hide the eave or gutter, a wall sheet trim is used. Sealing profiles (i.e. sealing strips) are used between the gutter and the sheets.

Flat sheets and angles sections

Flat sheets of 1250mm by 2000mm, as well as several kinds of bent-to-measure angle sections, are available in the same colours as the sheets.

Ridge tile

Aech ridge tile is screwed to the top of corrugation by means of self-drilling screws. If necessary, a watertight sealing profile is fitted beneath the ridge tile. When using Permapan it is important to look after the vapourdensity of the ridge in order to avoid condensation. Therefore an underridge is used and insulation is put between the two panels.

Sealing profiles

Positive profile: sealing between wall sheet and roof-tile panel

Flat profile: sealing between verge flashing and sheet

Negative profile: sealing between ridge tile and roof-tile panel

Terminal tiles

A terminal tile is put at each end of the ridge and screwed down. The seams are sealed with a silicone mastic.

Verge flashing (verge board)

To hide the side walls and protect them from rain, verge flashings are available in lengths of 2,10m. If desired, a profile filler can be inserted between the tile and the bargeboard. On the left-hand side you can, if desired, bend the far end of the cut-off sheet a little.

Valley gutters

Valley gutters come in lengths of 2,10m.
The minimum overlapping is 15cm.

Pipe feed-throughs

Pipe feed-throughs ensure a watertight joint in places where pipes have to pass through the roof surface. They are made from EPDM (Ethylene propylene diene rubber). In the pipe feed-through a hole is made which is smaller than the outside diameter of the pipe. The pipe sleeve is pulled over the pipe and sealed using a silicone mastic. After the silicone mastic has been applied, the pipe feed-through is screwed down using self-drilling screws that pass through the deformable aluminium wall.

Mansard roof

On a mansard roof, the bottom part of the roof-tile panel fits exactly on top of the leading part of the next sheet.

Instructions for use

Treatment

• Get someone to help you carry the sheets, one at time, wherever possible.
• Extra support is advisable for longer panels.
• Sheets of up to 6m length can be unloaded with a forklift truck.
• If lifting the sheets with a crane, the sides should be protected to stop them from deforming.
• A yoke must be used, to which a sufficient number of hoisting belts can be attached for distributing the load, for sheets greater than 10m.

Storage and safety precautions, precautions against white rust

• Store your sheets in the dry. Under a lean-to roof is a good temporary solution.
• If stored in the open air, take the following precautions: ensure there's a slope so that no water can be pond up between the sheets.
• Store preferably under a tarpaulin and ensure adequate ventilation.
• Never stack rooflights where they're exposed to strong sunlight. Always store them under a tarpaulin!

 

Longer term storage (a month or more) must be undertaken in an enclosed and moisture-free space!

Machining

• Profiled sheet steel can be cut to size using an electric nibbler. Never use a grinding wheel. If you did, the grinding edges would start to glow, destroying the zinc plating and the coating of the sheet in the process. Red-hot particles of metal would fly about everywhere and burn holes in the protective coatings of your sheet.
• Any metal residues (bore chips) should, during assembly, be dislodged from the sheets as quickly and as thoroughly as possible. If not, they will cause permanent damage.

Cleaning

If the profiled sheets have got dirt during assembly, clean them. Use pure water with nothing added and a soft-bristled brush.

Transport

Our point of sale is, without exception, ex-works. As an extra service to our customers, we can deliver to your door after making an appointment woth ou sales department. Complaints relating to hidden defects or to any damage must be reported to us no later than 7 days after delivery and prior to the assembly thereof.