Using Lysaght Roofi ng & Walling

Using Lysaght®
Roofi ng & Walling
2007 2nd Edition

www.lysaght.com
Using
LYSAGHT®

roofing
and walling

2007 2nd Edition

Disclaimer, warranties and limitation of liability
This publication is intended to be an aid for professional
engineers and is not a substitute for professional judgement.
Terms and conditions of sale are available at local BlueScope
Lysaght sales offices.
Except to the extent to which liability may not lawfully be
excluded or limited, BlueScope Steel Limited will not be under or
incur any liability to you for any direct or indirect loss or damage
(including, without limitation, consequential loss or damage
such as loss of profit or anticipated profit, loss of use, damage
to goodwill and loss due to delay) however caused (including,
without limitation, breach of contract, negligence and/or breach
of statute), which you may suffer or incur in connection with this
publication.

Published by BlueScope Lysaght Limited

© BlueScope Lysaght Limited 2007

Using Lysaght Roofing and Walling

Previously published as
Steel Roofing and Walling: Installation Manual.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 Contents

Introduction 1

PART A: DESIGN 2 PART B: INSTALLATION 27

Design preliminaries 2 General care, safety and handling 27
2.1 Product selection 2 7.1 Safety 27
2.2 Materials and finishes 2 7.2 Care and storage before installation 27
2.3 Support spacings 3 7.3 Handling cladding on site 27
2.4 Maximum lengths of roofing 3 7.4 Walking on roofs 27
2.5 Low roof pitches 3 7.5 Marking out, cutting and drilling 27
2.6 Wind forces on roofs 3 7.6 Clean up 28
2.8 Codes and performance tests 3 7.7 Warn other contractors 28
2.9 Environmental conditions 4 7.8 Strippable coatings 28
2.10 Metal and timber compatibility 4 7.9 Sealants 28
2.11 Transportation 4 7.10 Maintenance 29

Fasteners 9 Installing pierce-fixed cladding 31

3.1 Materials for screws 9 8.1 General installation procedure 31
3.3 Materials for blind rivets 9 8.2 Side-lapping & positioning pierce-fixed sheets 33
3.4 Materials for sealing washers 9 8.3 Pierce-fixing on crests 33
3.5 Identification of screws 10 8.4 Pierce-fixing on valleys (for walling only) 34
3.6 Setting of screws 10 8.5 Pierce-fixing on side-laps 34
3.7 Quantity of fasteners and clips 11 8.6 Installing MINI ORB 34
3.8 Recommended fasteners and locations 11
Installing concealed-fixed cladding 35
Curved, bent & tapered cladding 16 9.1 Installing KLIP-LOK roofs 35
4.1 Spring-curved-ridge roof 16 9.2 Installing KLIP-LOK walls 39
4.2 Spring-arched roof 17 9.3 Installing EASYCLAD HI-TEN 40
4.3 Spring-curved concave roofs 18 9.4 Installing LONGLINE 305 roofs 42
4.4 Pre-curved roofs 18 9.5 Installing LONGLINE 305 walls 43
4.5 Capped bent ribbed roofs 19
4.6 Tapered roofing 19 Ends of sheets 44
10.1 Turn-ups 44
Insulation & skylights 20 10.2 Turning-down 46
5.1 Heat control 20 10.3 Blocking off rib cavities 47
5.2 Condensation 21 10.4 End-lapping 48
5.3 Noise reduction 22 10.5 Expansion 50
5.4 Insulation materials 22 10.6 Roof overhang with edge stiffener 51
5.5 Insulation thickness 23
5.6 Skylighting 23 Flashings 52
11.1 Materials 52
Roof drainage 24 11.2 Longitudinal flashings 52
6.1 Introduction 24 11.3 Transverse flashings 53
6.2 Design of drainage (eaves-gutter system) 24 11.4 Flashing at change of pitch 55
6.3 Gutter fall 25 11.5 Flashing large roof penetrations 56
11.6 Flashing small roof penetrations 58
11.7 Flashing walls 59
11.8 Bushfire protection 61

References 62

Index 63

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 Contemporary and traditional –both are
accomplished with ease using LYSAGHT building
products.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INTRODUCTION 1

1 Introduction
Introduction

Scope Conditions of use

This book is a guide to the installation of steel roofing and Where we recommend use of third party materials, ensure
walling manufactured by BlueScope Lysaght®. We intend you the qualities and capabilities of those products wirh the
that it be used by all trades and professions involved with relevant manufacturer before use..
specifying and applying the wide range of our products.

We refer only to genuine steel roofing and walling Your suggestions

manufactured by us and marketed under our brand names. Please send your suggestions for improvements to this
Our recommendations should only be used for our products manual to BlueScope Lysaght Technology Department
because they are based on comprehensive testing of our PO Box 504, Chester Hill, NSW 2162.
profiles, base-metal-thicknesses (BMT) and material finishes.
Further information on products and services
s 9OUR SUPPLIER OF LYSAGHT products
Specific product information
We also have specific publications for all of our products, and s "LUE3COPE ,YSAGHT )NFORMATION 3ERVICE
you should use them in conjunction with this manual. on 1800-641-417

s WWWLYSAGHTCOM
Cyclonic conditions
)N GENERAL THIS BOOK REFERS TO NON CYCLONIC CONDITIONS $ESIGN
information for cyclonic areas is in our Cyclonic Area Design
Manual.

Warranties
For well over 100 years we have consistently manufactured
the highest quality building products. The LYSAGHT® brand is
synonymous with Australian building.

Our continuing confidence in our products is shown in the

warranties we offer.

Our products are engineered to perform according to our

specifications only if they are used in the appropriate
conditions and installed to the recommendations in this
manual and our other publications.

Naturally, the warranties require specifiers and installers

to exercise due care in how the products are applied and
installed and are subject to final use and installation. And,
owners need to maintain the finished work.

We invite you to ask about the warranties applicable to your

proposed purchase, at your supplier of LYSAGHT products.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

2 DESIGN—DESIGN PRELIMINARIES

PART A: DESIGN

2
Design preliminaries
2.1 Product selection 2.2 Materials and finishes
When you design steel cladding into your building you have Our most widely used cladding profiles are listed in Tables
a wide range of profiles from which to choose. Whilst roofing 2.3.1 and 2.3.2. They are available in COLORBOND® prepainted
and walling obviously have to keep out the weather, they also steel complying with AS/NZS-2728:1997, or in unpainted
have significant effects on the looks, cost and durability of a ZINCALUME® aluminium/zinc alloy-coated steel complying with
building. AS-1397—2001.

)F YOU ARE UNSURE ABOUT ANY PRODUCT FEATURE ASK US ON OUR COLORBOND® steel has either a ZINCALUME® or stainless steel
information line or get advice from the relevant specialist. base metal, with a range of organic coatings to cope with
exposure to a range of environments.
Other factors that affect selection are treated in Chapters
2 to 6. s COLORBOND® is prepainted steel for exterior roofing and
WALLING )T IS THE MOST WIDELY USED

Walls s COLORBOND® METALLIC is prepainted steel for superior

The design of walling from a steel perspective is fairly aesthetic qualities displaying a metallic sheen.
straightforward. Once you have made the aesthetic decision
of which profile to use, the main considerations are the s COLORBOND® ULTRA is prepainted steel for severe coastal or
support spacings (Section 2.3), fixing details (Chapter 3) and industrial environments (generally within about 100-to 200
the details of flashing (Chapter 11). metres of the source).

s COLORBOND® STAINLESS is prepainted stainless steel for very

Roofs severe coastal or industrial environments (generally within

There are many factors in designing roofs including: about 100-metres of the source).

s THE SHAPE IS THE ROOF TO BE @FLAT OR PITCHED Check with your local BlueScope Lysaght office for availability
or curved? of profiles, colours, accessories; and for suitability of the
product.
s THE SUPPORTING STRUCTURE AND SUPPORT SPACING
Tables 2.3.1 and 2.3.2 list general information for profile
s THE WIND FORCES THAT THE ROOF MUST SUSTAIN selection. Refer to our publications on specific products
for detailed specifications. There are also publications on
s THE PITCH WHICH AFFECTS THE LOOKS THE PROFILES ABILITY TO
ZINCALUME® steel and COLORBOND® prepainted steel from our
efficiently carry rain to the gutters, and fixing details;
information line (Page 1).
s THERMAL EXPANSION OF LONG SHEETS #HAPTER  

s THE ATTRIBUTES OF OTHER MATERIALS USED IN THE ROOF Material specifications

design. s ZINCALUME® aluminium/zinc alloy-coated steel complying
with AS 1397—2001. Minimum yield strengths are G550
4HIS BOOK DOESNT ATTEMPT TO COVER THE STRUCTURAL DESIGN (550 MPa), or G300 (300 MPa) depending on profile.
details of supports or aesthetics: there are many other texts Minimum coating mass is AZ150 (150 g/m2 ), or AZ200
and Australian Standards that cover them. (200 g/m2 ) depending on the product.

This chapter gives tables of recommended support spacings, s 3TAINLESS STEEL COMPLYING WITH !)3)!34- 4YPE  5.3
and the maximum roof length for pitch and rainfall intensity for No. S43000.
steel roofing products.

The appropriate design will depend on your particular needs

AND CIRCUMSTANCES 9OU SHOULD GET ADVICE FROM THE RELEVANT
specialists where required.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 DESIGN—DESIGN PRELIMINARIES 3

2.3 Support spacings 2.5 Low roof pitches

The maximum recommended support spacings are shown Unless there is adequate positive fall in a roof, there is
in Tables 2.3.1 and 2.3.2. They are based on testing in danger of ponding, which can lead to a reduced service life,
accordance with AS 1562.1—1992 Design and installation particularly in coastal areas.
of sheet roof and wall cladding: Metal, and AS 4040.1—1992
Methods of testing sheet roof and wall cladding—Resistance At low slopes, say around 1 in 50 (1°) slope, all roof supports
to concentrated loads. must be in the one plane because slight variations can result
in zero or negative fall. This may occur even after completion

2 Design preliminaries
The spacings in the tables for roofs are recommended to of the building as the result of settlement, timber warping or
produce adequate performance of roof claddings under foot shrinking, or extra loadings (like air conditioners).
traffic loading (incidental for maintenance). For walls, the
following conditions apply: Wherever possible, you should design for a minimum slope of
1 in 30 (2°). Minimum recommended slopes are listed in Table
s BUILDINGS UP TO  M HIGH IN 2EGION " 4ERRAIN #ATEGORY 2.3.1 at the end of this chapter).
3 conditions (Vs = 38 m/s and Vu=60 m/s);

s #p, e = -0.65 (for walls), Cp, i = 0.2 and Kl up to 2.0, in 2.6 Wind forces on roofs
accordance with AS 1170.2—1989 SAA Loading Code:
Winds create considerable forces on both the topside and
Wind loads.
the underside of roof cladding, and you must consider these
)N ALL CASES CLADDING IS FIXED TO A SUPPORT OF  MM MINIMUM forces in the design and fixing of any roof. The forces are:
base metal thickness (BMT) and minimum yield stress of G550.
s inward forces tending to collapse the roof cladding
)F YOU WANT TO USE METAL BATTENS THINNER THAN  MM SEEK
inwards, caused by wind acting directly on the windward
advice from our information line.
side; and
For support spacings in wind conditions other than those
s outward forces tending to lift the roof cladding from its
shown, refer to our publications on specific products for wind
framing, and the entire roof structure from the rest of the
pressure data or other standards which may apply.
building. Outward forces can be caused both by uplift
from negative wind pressures, outside the building; and by
positive wind pressure inside the building.
2.4 Maximum lengths of roofing
The valleys (or pans) of roofing have to carry water Generally the greatest wind forces imposed on roofs are due
TO THE GUTTERS )F IN HEAVY RAIN THE VALLEYS OVERFILL to the outward forces. Because the dead weight of roofing
water can flow into the roof through the side-laps materials is relatively small, the outward forces must be
and flashings. resisted by the roof fasteners.

Factors affecting drainage capacity and waterproof-ness of )T IS VERY IMPORTANT THAT THE BATTENS AND ROOF FRAMING
the laps of a profile include: are adequately fixed to the rafters and walls, and that
under extreme conditions the wall framing is anchored to
s THE WIDTH AND DEPTH OF THE VALLEYS OR PANS the footings. Special anchoring provisions may apply in
s THE PITCH OF THE ROOFˆRAIN FLOWS FASTER ON A STEEPER cyclonic areas. Specialist advice should be sought in these
pitch; circumstances.

s RAINFALL INTENSITY FOR THE GEOGRAPHICAL AREA

2.8 Codes and performance tests
s THE LENGTH OF THE ROOF FROM RIDGE TO GUTTER AND AS 1562.1—1992 specifies the design and installation of sheet
s PENETRATIONS THAT CAUSE NEARBY VALLEYS TO CARRY metal roof and wall cladding. Our roofing profiles satisfy all the
extra rain diverted from valleys obstructed by the requirements of this standard, including the ability of the roof
penetration (Figure 2.4.1). to resist outward forces and concentrated loads. The testing
is performed according to AS-4040.
The maximum recommended roof lengths for drainage for
each profile are given in Table 2.4.1 at the end of this chapter.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

4 DESIGN—DESIGN PRELIMINARIES

Metal roofing products must comply with the performance s MATERIALS SUBJECT TO CYCLES OF DRYNESS AND WETNESS
specifications, and be checked by stringent tests, in or which have excessive moisture content (such as
accordance with the standard. Such tests have been carried improperly-seasoned timber)
out on all our claddings and the results have been used in the s WET AND DRY CONCRETE
preparation of the fixing and installation recommendations in s SOILS
this manual. s VEGETABLE MATTER
s ANY MATERIAL WHICH WILL INHIBIT NORMAL EXPOSURE TO THE
atmosphere
2.9 Environmental conditions
Paint and COLORBOND® finishes
Coated steel products can be damaged by some environmental
COLORBOND® finishes can be damaged by some types of
conditions including industrial, agricultural, marine, intensive
paint. There can also be problems of colour matching due to
animal farming, swimming pools or other aggressive
different weathering characteristics.
conditions.
)F ANY OF OUR PRODUCTS ARE TO BE USED IN THESE CONDITIONS Cladding with severely damaged COLORBOND® paint are best
or unusually corrosive environments, seek advice from our replaced rather than patched up. We recommend that you
information line (Page 1). DONT TOUCH UP MINOR SCRATCHES WITH PAINT

9OU MAY OVERPAINT WHOLE ROOFS AND PAINT ACCESSORIES TO

2.10 Metal and timber compatibility match specific colours. The particular paints and methods
Contact with, or runoff from, some materials can damage recommended are discussed in Technical Bulletin TB-2,
coated steel products. Buildings can also be susceptible to published by BlueScope Lysaght.
condensation on inside sufaces.

The materials include certain metals, treated timbers and 2.11 Transportation
chemicals. Because our roofing and walling is manufactured by
continuous processes, sheet lengths can be supplied up to
s $ONT ALLOW ANY CONTACT OF COATED STEEL PRODUCTS WITH
the limits of transport regulations, which vary from state to
incompatible materials.
state.
s $ONT ALLOW DISCHARGE OF RAINWATER FROM INCOMPATIBLE
KL-700HS is available in extra long lengths via an on-site
materials onto coated steel products (Table-2.10.1).
mobile rollformer. This service is available nationally, subject
s %NSURE THAT SUPPORTING MEMBERS ARE COMPATIBLE WITH to enquiry.
the coated steel products or, alternatively, appropriately
coated.

)F THERE ARE DOUBTS ABOUT THE COMPATIBILITY OF OTHER PRODUCTS

being used, seek advice from our information line.

Incompatible materials include:

s LEAD
s COPPER
s MONEL METAL
s BARE STEEL
s STAINLESS STEEL EXCEPT WITH COLORBOND®
stainless cladding)
s CARBON IN PENCILS AND SOME RUBBERS
s GREEN OR SOME CHEMICALLY TREATED TIMBER
(like CCA or tanalith treatments)

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 DESIGN—DESIGN PRELIMINARIES 5

Table 2.10.1
Acceptability of drainage from one surface onto another

2 Design preliminaries
CUSTOM BLUE ORB lends itself to the
smooth curves of large arched
roofs. This roof has both convex and
concave curves.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

6 DESIGN—DESIGN PRELIMINARIES

Table 2.3.1
Specifications of roofing & walling profiles
Maximum recommended spacing of supports
ROOFS WALLS
Overhang3

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 DESIGN—DESIGN PRELIMINARIES 7

Table 2.3.2
Specifications of profiles for walling only

EASY-CLAD 2PF 300

2 Design preliminaries
EASY-CLAD 4P 300

MINI ORB 7

MULTICLAD

MULTILINE 900

PANELRIB 6

TRIMWALL

WALLCLAD

O
ES IS IS ES

Spacing definitions
ES = End span
Single
span

IS = Internal span
O O = Overhang

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

8 DESIGN—DESIGN PRELIMINARIES

Table 2.4.1
Maximum roof lengths for drainage measured from ridge to gutter (m)
Penetrations alter the flow of water on a roof. Thus, for design, you need to use
an effective roof length (Figure 2.4.1).

Figure 2.4.1
Example of calculating effective roof
lengths where penetrations alter the
flow of water on a roof.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 DESIGN—FASTENERS 9

3
Fasteners
When you select fasteners, you should consider the design life of the
structure, because the fasteners and the cladding material should have
similar life expectancies.

3.1 Materials for screws

Screws are available in a variety of materials, finishes, colour to match
COLORBOND® PREPAINTED STEEL AND DESIGN 9OU SHOULD USE SCREWS TO !3
3566—2002 Class 3 (or better). Additional information on fastener finishes
is in the technical bulletin TB-16.

Table 3.1.1
Materials for screws

3 Fasteners
3.2 Materials for nails
Nails should be of galvanised steel. They are only used to fix the clips of
some concealed-fixed cladding to timber supports.

3.3 Materials for blind rivets

For COLORBOND® STAINLESS use stainless steel blind rivets with stainless
steel mandrels; for GALVABOND®, ZINCALUME® and COLORBOND® steels, use
aluminium blind rivets. Blind rivets are used for fixing flashings,
accessories and side-laps.

3.4 Materials for sealing washers

Sealing washers used under the heads of screws on COLORBOND® finishes
MUST BE MADE FROM MATERIALS THAT DONT HAVE SIGNIFICANT LEVELS OF
conductive carbon black, particularly in marine environments. Use EPDM
washers, not neoprene.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

10 DESIGN—FASTENERS

3.5 Identification of screws

The format of the number code is:

14 – 20 x 45
Screw gauge Thread pitch Overall length of the
(Thread outside (threads per screw measured from
diameter) inch) under the head (mm)

Fasteners must have a coating system to meet AS 3566 Class 3.

or
Fasteners must have a coating system to meet AS 3566 Class 4.
2IPPLE 4EKS AND 2OOFZIPS ARE REGISTERED TRADEMARKS OF )47 "UILDEX

Figure 3.5.1
Typical hexagon-headed screws

Table 3.5.1
Features of recommended screws
Screw type Head Seal Shank protection Drill point
Metal - Hex head, self drilling, Hexagon washer, EPDM Depends on screw length &
Self drilling for metal
self tapping screw with seal or wafer or none u se
Timber - Hex head, self drilling, Hexagon washer, EPDM Depends on screw length &
Self drilling for timber
self tapping screw with seal or wafer or none use
Hex head, self drilling, self tapping Hexagon washer, EPDM
screw with seal and extended drill or wafer or none Self drilling for metal

Metal - Hex head, self drilling, EPDM

Hexagon washer Al ways Self drilling for metal
self tapping screw for thin battens or none
Slotted hexagon with thin
EPDM
Stitching screws washer. Needle
or none
Serrated also available.
Ripple Teks® Special self-sealing head Self drilling for metal

3.6 Setting of screws

Fasteners with sealing washers should be tightened only until the washer
is gripped firmly enough to provide a weathertight seal. The fasteners
should not be over-tightened because this may split the sealing washer
or deform the sheet, either of which could lead to water penetration. Take
particular care when valley fixing because there is no flexibility with the
sheet hard against its support.

Figure 3.6.1
)T IS IMPORTANT THAT YOU SET SCREWS CORRECTLY

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 DESIGN—FASTENERS 11

3.7 Quantity of fasteners and clips Number of clips per job =

KLIP-LOK 406, KLIP-LOK 700HS and LONGLINE 305 (Number of purlins) x (Number of sheets +1)
For number of clips, see equation at right.
For KLIP-LOK 406, there are 2 fasteners per clip.
For KLIP-LOK 700, there are 3 fasteners per clip.
For LONGLINE 305, there is 1 fastener per clip.

Pierce-fixed profiles
For number of fasteners, see equation at right (n is the number Number of fasteners per job (for pierced fixing) =
n x (Number of sheets) x (Number of supports)
of fasteners per support, as shown in the diagrams in Table 3.8.1).

Side-laps
Side-lap fasteners are often placed at about 900-mm centres,
see equation at right. Number of side-lap fasteners per sheet =
Support spacing (in mm) x Number of supports
900

3.8 Recommended fasteners and locations

Recommended fasteners and their locations are in Table 3.8.1.

Fastener length with insulation

Where insulation is installed under cladding, you may need to increase
the length of screws given in Table 3.8.1, depending on the density and

3 Fasteners
thickness of the insulation. When the screw is properly tightened
(Section 3.6):

s INTO METAL:there should be at least three threads protruding past the

support you are fixing to—but the shank protection must not reach
that support;

s INTO TIMBER: the screw must penetrate the timber by the same amount
that the recommended screw would do if there were no insulation.

Fixing to steel thicker than 3 mm

s 5SE (EX HEAD SELF DRILLING SELF TAPPING SCREWS WITH SEAL WITH AN
extended drill point; or

s IN A PRE DRILLED HOLE USE (EX HEAD SELF DRILLING SELF TAPPING SCREWS
with seal, of 12 gauge–14 pitch, with the length as specified in
Table 3.8.1.

Side-lap and accessory fastenings

For MINI ORB and PANELRIB use 3.2 mm diameter aluminium sealed blind
rivets. For all other products use:

s 3TITCHING SCREWS WITH SEAL   X  OR

s (EX HEAD SELF DRILLING SELF TAPPING SCREWS

with seal: 10 16 x 16; or

s 3EALED BLIND RIVETS  MM DIAMETER ALUMINIUM

(not MINI ORB and PANELRIB—see above).

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12 DESIGN—FASTENERS

Table 3.8.1
Guide to fasteners without insulation

CUSTOM ORB AND CUSTOM BLUE ORB

Fixing to steel Fixing to steel
Fixing to timber
up to 0.75 mm BMT >0.75 to 3 mm BMT
Hex head self drilling self tapping screw Hex head self drilling screw
with EPDM seal for thin metal battens for timber with hex. washer
13-13 x 41 Hex head self drilling self tapping screw head & EPDM seal
Crest Fixing to timber with EPDM seal and hex. washer head SOFTWOOD: 12-11 x 50
fixed Hex head self drilling self tapping and shank protection with Higrip & Shank protection
screw for timber
12-14 x 35
EP DM seal & s hank protection HARDWOOD: 12-11 X 40
12-11 x 40 with Shank protection
Hex head self drilling self tapping screw
with EPDM seal and hex. washer head Hex head self drilling screw
10-16 x 16 for timber with hex. washer
Valley Hex head self drilling self tapping screw head & EPDM seal
fixed Hex head self drilling self tapping
with EPDM seal and hex. washer head SOFTWOOD: 10-12 x 30
screw with hex. washer head for timber
& EPDM seal 10-16 x 16 HARDWOOD: 10-12 x 20
10-12 x 20

Do not fix screws

less than 25mm
from the end of sheet.

EASYCLAD

Hex head self drilling self tapping Hex head self drilling self tapping Hex head self drilling self tapping
screws with seal screws with seal screws for timber with seal
and hex. washer head and hex. washer head and hex. washer head
10-16x16 10-16x16

EASYCLAD 4P 1 fastener† Do not fix screws

less than 25mm
from the end of sheet.
EASYCLAD 2P 1 fastener†

KEY
† Fasteners per sheet per support
S = Side-lap

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 DESIGN—FASTENERS 13

Table 3.8.1 continued

Guide to fasteners without insulation

Crest: 4 fasteners†

3 Fasteners

KLIP-LOK 406

Clip Clip
Clip
LONGLINE 305
Do not fix KL406 less than 75mm Clip
from end of sheet,
do not fix Longline 305
sheets less than 75mm from
the end of the sheet.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

14 DESIGN—FASTENERS

Table 3.8.1 continued

Guide to fasteners without insulation

®
®

Number of fasteners depends on

Valley: 6 fasteners† wind pressure (see brochure on
this product).
Do not fix screws
Valley: 11 fasteners† less than 25mm
from the end of sheet.

Valley: 4 fasteners†

Number of fasteners depends on

Valley: 3 fasteners† wind pressure (see brochure on
this product).
Do not fix screws
Valley: 6 fasteners† less than 25mm
from the end of sheet.

Number of fasteners depends on

wind pressure (see brochure on
Valley: 4 fasteners† this product).
Do not fix screws
Valley: 8 fasteners† less than 25mm
from the end of sheet.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 DESIGN—FASTENERS 15

Table 3.8.1 continued

Guide to fasteners without insulation

Crest: 3 fasteners†
S

3 Fasteners
Valley: 3 fasteners†
Number of fasteners depends on
SPANDEK wind pressure (see brochure on
this product).
Crest: 4 fasteners† Do not place fasteners less than 25mm
from the end of sheets.
S
Valley: 4 fasteners†

Crest: 4 fasteners†
TRIMDEK S
Valley: 4 fasteners†

KEY
† Fasteners per sheet per support
S = Side-lap

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 16 DESIGN—CURVED, BENT AND TAPERED ROOFING

4
Curved, bent & tapered cladding

Spring curved-ridge roof An excellent method of cladding low-slope gable roofs is

Sheets straight except for
a curve near the ridge to run continuous lengths of roofing from eave to eave,
across the full width of the roof. This gives a particularly neat
Spring-arched roof AND ATTRACTIVE ROOF )T IS ALSO POSSIBLE TO SPRING CURVE SHEETS
Sheets curved in a radius
from eave to eave into a concave shape.

Spring-curved concave roof With the exception of KLIP-LOK, the ridge capping is eliminated
Sheets curved concavely in a radius
in these roofs, thus avoiding any possibility of leakage along
Pre-curved roofing
the ridge. KLIP-LOK can be used similarly, but the ribs are cut
Sheets curved by machine before at the ridge and a metal cap is fitted over the cut.
installation

Capped bent ribbed roofs

(for example KLIP-LOK)

Figure 4.1 4.1 Spring-curved-ridge roof

Typical curved and bent applications
Sheets in a spring-curved-ridge roof remain straight except
for a curve near the ridge.

The pans of KLIP-LOK, INTEGRITY, LONGLINE 305 and TRIMDEK tend to oilcan
(minor waviness in the pan) when spring curved.
Apart from not looking good, an oilcanned pan may retain water which
could lead to discolouration and/or deterioration of the sheet coating and
ALSO CONTRIBUTES TO THERMALLY INDUCED ROOF NOISE )F SOME OILCANNING IN THE
pans is acceptable, these profiles can be spring-curved up to a maximum
slope of 1 in 30 (2°); with the spacing between the purlins at the ridge
being slightly less than the internal span recommended for the profile
in Table 2.3.1.

Over the supports at the ridge, very slight crease marks may appear in the
PANS OR VALLEYS WHEN SUBJECTED TO FOOT TRAFFIC 4HEY DONT AFFECT STRENGTH
and will usually not be seen from the ground.

Only the sheet profiles recommended for spring-curving are shown in

Table 4.1.1.
NS
NS
Each sheet is first fixed to one side of the roof, and then pulled down to
Spacing from be fixed to the other side. To minimise small laying errors, lay alternate
NS
Table 4.1.1
sheets from opposite sides of the roof.
NS = Normal spacing NS
given in Table 2.3.1
Side laps should be sealed with silicone sealant for the length
Figure 4.1.1 of the curve.
Spring-curved-ridge roof

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 DESIGN—CURVED, BENT AND TAPERED ROOFING 17

Table 4.1.1
Minimum spacing of purlins at ridge for spring curved-ridge roof (mm)

4.2 Spring-arched roof

Sheets in a spring-arched (convex) roof are curved in a radius from eave Rise
to eave. SPANDEK, CUSTOM ORB and CUSTOM BLUE ORB can be spring-curved for Width
an arched roof. Table 4.2.1 shows the acceptable radii.
Radius

The top face of all purlins must accurately follow and be tangential to the 2
Radius = Width + 4(Rise)
2

radius of the arch. The radius of curvature can be calculated from the 8 x Rise
formula in Figure 4.2.1.
Figure 4.2.1
Calculation of radius

Table 4.2.1
Recommended radii for convex spring curving

4 Curved, bent & tapered

Seal length
measured on roof

At the crest of an arch the roof is flat, which is obviously below the
specified minimum roof pitch. Therefore side laps should be sealed
over the crest of the arch until there is sufficient pitch to give adequate
ius
drainage (see Table 2.3.1). The length of seal is shown in Figure 4.2.2. Rad

Over the supports very slight crease marks may appear in the pans or
VALLEYS WHEN SUBJECTED TO FOOT TRAFFIC 4HEY DONT AFFECT STRENGTH AND WILL
usually not be seen from the ground.

)F END LAPS ARE NECESSARY THEY SHOULD NOT BE LOCATED AT OR NEAR THE
crest of the arch and each sheet length must span at least three purlin
spacings.
Figure 4.2.2
Seal length for side laps on spring-
arched roof
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 18 DESIGN—CURVED, BENT AND TAPERED ROOFING

Profiles with wide pans manufactured from high tensile steel (such as
KLIP-LOK and INTEGRITY 820) are susceptible to local buckling of the pans and
are therefore not recommended for spring-arched roofs. These products
can be made specially from soft steel (G300) to overcome the problem.

Each sheet is first fixed to one side of the roof, and then pulled down to
be fixed to the other side. Alternate sheets are laid from opposite sides of
the roof.

4.3 Spring-curved concave roofs

Roofing can be spring-curved into concave shapes.
Table 4.3.1 shows the acceptable radii.

Table 4.3.1
Radii for spring curved concave roofs

Figure 4.3.1
Spring-curved concave roof

4.4 Pre-curved roofs

Pre-curved corrugated roofing is popular for aesthetics (such as a
bullnosed verandah roof), or for function (such as a gutterless eave
design). CUSTOM BLUE ORB can be curved to a radius as small as 300-mm.
7E DONT RECOMMEND PRE CURVING FOR OTHER PROFILES

MINI ORB CAN BE CURVED TO A RADIUS TO AS SMALL AS  MM THOUGH IT ISNT

recommended for roofing.

Because of the spacing of curving rolls, there is usually a straight portion

at the end of the sheet beyond the curve (often 50 to 110 mm for CUSTOM
BLUE ORB , and about 50-mm for MINI ORB) !LLOW FOR THIS IN YOUR DESIGN )T
can be trimmed off if necessary.

)F A PRE CURVED SECTION OF CLADDING IS TO BE JOINED TO A STRAIGHT SECTION

you should order the curved and straight sheets at the same time, asking
for them to be matched in production.
End-lap the sheets as described in Section 11.4 (End-lapping).

Our CUSTOM BLUE ORB brochure gives more details.

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 DESIGN—CURVED, BENT AND TAPERED ROOFING 19

4.5 Capped bent ribbed roofs

Tray cladding can be used in continuous lengths from eave to eave by
cutting the ribs and bending the pans at the ridgeline. The same process
is used on Mansard roofs. Caps are fitted over the cut ribs, which open up
when the pans are bent. Fitting the rib caps can be time-consuming and
care must be taken with sealing to avoid any possibility of leakage.

The ribs must be cut squarely, with a metal cutting blade in a power saw,
set to the depth of the rib minus 2 mm.

)N SOME STATES PRESSED STEEL CAPS CAN BE OBTAINED TO SUIT KLIP-LOK ribs,
though the range of angles is limited. Caps can be handmade to suit any
angle from flat sheet.

KLIP-LOK is most frequently used for capped bent ribbed roofs, but
LONGLINE 305, TRIMDEK or even SPANDEK can be used. For these two profiles Figure 4.5.1
the rib caps can be made from pieces of rib profile cut from a short length Capped bent ribbed roof
of cladding.

4.6 Tapered roofing

We can taper LONGLINE 305 in its width, at either end, to produce a sheet
that lends itself to a wide range of roof designs. The maximum reduction
in width is 50%. The taper can be left-hand or right-hand (Figure 4.6.1).
Get our advice for long spans or high loadings.

4 Curved, bent & tapered

Figure 4.6.1
Tapered LONGLINE 305

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 20 DESIGN—INSULATION AND SKYLIGHTING

5
Insulation & skylights
9OU OFTEN CONSIDER INSULATING A BUILDING TO REDUCE

s HEATING FROM THE SUN IN SUMMER

s LOSS OF HEAT FROM INSIDE IN WINTER

s CONDENSATION ON THE INSIDE OF THE ROOFING AND WALLING AND

s NOISE FROM RAIN THERMAL EXPANSION AND CONTRACTION AND OTHER

sources.

Usually, when one of these four is treated, there is also a beneficial effect
on the others.

9OU NEED TO COMPARE THE INITIAL COST OF INSTALLING INSULATION WITH THE
savings in costs of heating and cooling. There are also gains for the
environment when you save energy.

AS 2627.1—1993 Thermal insulation of dwellings, thoroughly treats

the subject, including comprehensive tables of recommended thermal
resistance (R values) for over 1000 towns throughout Australia.

5.1 Heat control

)N SUMMER BUILDINGS GET HOT FROM THE SUN AND WE WANT TO COOL THE INSIDE
in winter we often heat the inside and want to avoid losing that heat.

Factors in controlling heat include:

s THE ORIENTATION OF THE BUILDING RELATIVE TO THE SUN

s EXTERNAL SHADING FROM TREES OR OTHER BUILDINGS

s DESIGN OF THE BUILDING ESPECIALLY VENTILATION AND SEALING

at doors and windows;

s THE COLOURS AND SURFACE GLOSS OF THE CLADDING

The first three factors are outside the scope of this book. Heat is
absorbed into a sheet on one side, and some of that absorbed heat is re-
radiated from the other side (Figure 5.1.1).

s ,IGHT COLOURED OR SHINY SURFACES DONT ABSORB MUCH HEAT

and they radiate little.

s $ARK COLOURED OR DULL SURFACES ABSORB A LOT OF HEAT

AND THEY RADIATE A LOT 4HIS DOESNT STOP YOU USING DARKER CLADDINGS
because you can use reflective foil laminate
under the cladding.

Figure 5.1.1
Heat transmitted into a building

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 DESIGN—INSULATION AND SKYLIGHTING 21

Table 5.1.1
Approximate thermal transmission (for comparisons only)

Surfmist
Wilderness
Woodland Grey
Night Sky

Comparison of thermal performance

Table 5.1.1 shows thermal performances of different insulation systems by
showing the heat that may be expected through roofs of new materials.

Heat control methods

)N ROOFS A SIMPLE INEXPENSIVE AND VERY EFFECTIVE METHOD IS TO DRAPE A
membrane of reflective foil laminate over the supports before laying the
cladding. The laminate can also provide a vapour barrier to minimise
CONDENSATION )F THE MEMBRANE IS ALLOWED TO DRAPE  TO  MM BETWEEN
the supports the air space between the membrane and the roof cladding
will further improve heat insulation (Figure 5.1.2).

Additional heat insulation is often achieved by using bulk insulation Figure 5.1.2
blankets or batts (Figure 5.1.3). Reflective foil laminate is simple, cheap and very
effective
The same principles apply to walls, though the foil is not draped.

5.2 Condensation
When the air in a building in contact with metal cladding is warmer than
the cladding, water vapour (moisture) in the air can condense on the
inside of the cladding.

Water vapour passes fairly freely through most building linings into the

5 Insulation & skylighting

ceiling and wall spaces where it may directly contact the cladding.

Condensation can lead to deterioration of building components and

STAINING OF CEILING AND WALLS )F INSULATION BLANKETS OR BATTS ARE WET
or even slightly dampened by condensation, its efficiency is reduced
markedly.

The amount of condensation depends upon the amount of water vapour

in the air and this varies with climatic conditions. Activities within a
building can add substantially to the amount of water vapour, and typical
domestic situations include bathing, showering, cooking, washing
AND DRYING CLOTHES AND DISHES AND BREATHING )T IS ESSENTIAL TO VENT
substantial amounts of water vapour to outside the building.

To minimise the risk of condensation on the underside of roofing, a vapour

barrier is often used to prevent contact of warm moist air with the roofing Figure 5.1.3
– reflective foil laminate is commonly used. Typical roof insulation with foil and blanket

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 22 DESIGN—INSULATION AND SKYLIGHTING

To minimise the risk of condensation on the underside of the 5.4 Insulation materials
laminate, the laminate must be draped between roof supports Typical insulation materials are reflective foil laminates,
so that the cold cladding is not in contact with the laminate insulation blankets or batts made from fibreglass, and boards
(except at the supports). made from polystyrene. Remember that the colour of cladding
also has a marked effect (Section 5.1).

5.3 Noise reduction Foil laminates

Rain noise Foil laminates reflect heat and can double-up as a vapour
To reduce rain noise on metal roofing, an insulation blanket barrier to control condensation. Where they are used as
can be placed over the foil laminate described above, before a vapour barrier the joints between successive strips are
LAYING THE ROOFING )T IS IMPORTANT THAT THE LAMINATE IS PULLED overlapped about 100 mm, and sealed with a tape impervious
tight enough to hold the blanket hard against the underside of to moisture.
the roofing so as to dampen the rain-induced vibration at the
Blankets and batts
POINT OF IMPACT )F THE BLANKET IS NOT HARD AGAINST THE ROOFING
Blankets and batts minimise heat convection and are available
the noise reduction will not be as good.
with the laminate bonded to the fibreglass. They are also
For purlin spacings over 1200 mm: first lay wire mesh over the effective in reducing noise.
purlins, tighten and fix it, before laying the membrane.
)NSULATION BLANKETS MUST BE PROTECTED FROM MOISTURE
Thermally-induced noise particularly around the edges of the roof and even more
Roofing expands and contracts due to temperature changes in particularly at the bottom end of the cladding where rainwater
the cladding, and particularly rapid changes can be caused by RUN OFF CAN BE BLOWN BACK UNDER A LOW PITCHED ROOF )F THE
passing clouds or a strong breeze. For example: if a passing blanket overhangs the bottom support, it may even come into
cloud suddenly shades the roof from the sun, the cladding contact with water in the gutter, where the insulation will
temperature could drop about 3°C after 30 seconds in shade absorb moisture and remain damp for extended periods, thus
and about 10°C after 2 minutes in shade. leading to deterioration of the coating on the underside of the
roofing and reducing the effectiveness of the insulation.
Thermally-induced noise is caused by slipping at fasteners
where the roof expands relative to its supports. The slipping )NSULATION BLANKETS UP TO A NOMINAL THICKNESS OF UP TO  MM
is controlled by the friction between the roof and its supports. for pierce-fixed cladding and KLIP-LOK 700; and up to 50 mm for
When the static friction is overcome impulsively, sounds are KLIP-LOK 406 and all other concealed-fixed profiles will compress
produced — sometimes as loud as a pistol-shot — the higher sufficiently over the roof supports to allow normal procedures
the friction, the louder the sound. to be used for fixing. However, you may need to increase the
length of fasteners slightly to allow for the thickness of the
The noise can be reduced by: compressed blanket between the cladding and support, see
Table 3.8.1.
s PLACING A MATERIAL WITH LOW COEFFICIENT OF FRICTION BETWEEN
the roofing and its supports (for example PVC tape or Polystyrene boards
strips of foil laminate); Expanded and extruded polystyrene is also used for the same
purposes as blankets and batts. The boards are more rigid
s CHOOSING STEEL SUPPORTS RATHER THAN TIMBER LOWER
and relatively less compressible which demand different fixing
coefficient of friction);
to that mentioned above. Seek advice from manufacturers of
s CHOOSING LIGHT COLOURED ROOFING polystyrene insulation.

s VENTING THE ROOF SPACE

s INCLUDING AN EXPANSION JOINT 3ECTION  

s BEING CAREFUL ABOUT DESIGN DETAILS IN VALLEYS

(where heat tends to be retained); and/or

s INSULATING THE ROOF SPACE TO REDUCE THE THERMAL DIFFERENTIAL

)N TROPICAL AREAS IT MAY BE BETTER TO INSULATE THE CEILING
rather than the roofing (which can also reduce noise).

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 DESIGN—INSULATION AND SKYLIGHTING 23

5.5 Insulation thickness

)NSULATION BLANKETS AND BATTS CAN CAUSE CLADDING TO BOW OUT
between the fasteners. To minimise this problem, the maximum
thickness of blankets and batts should be 100-mm for pierce-
fixed cladding and KLIP-LOK 700; and 50 mm for KLIP-LOK 406 and all
other concealed-fixed cladding.

5.6 Skylighting
One of the simplest methods of getting natural light through a
steel roof is the inclusion of translucent sheets which match
the steel profiles.

)T IS PREFERABLE TO USE PROFILED TRANSLUCENT CLADDING IN SINGLE

widths so that they can overlap, and be supported by, the steel Figure 5.6.1
CLADDING ON BOTH SIDES )T IS ALSO PREFERABLE TO POSITION THE Placement of translucent sheets -
lengths of translucent cladding at the top of a roof run so the pierce fixed decks
high end can lap under the capping or flashing and the low
end can overlap a steel sheet. This is because the translucent
cladding will readily overlap a steel sheet but the reverse is
difficult.

Building regulations require a safety mesh to be fitted under

translucent cladding. Figure 5.6.2
Placement of translucent sheets -
Because of its greater thermal expansion, translucent concealed fixed decks
cladding should be fixed using oversized holes and sealing
washers recommended by the cladding manufacturer. When
used with concealed fixed claddings, ensure the fasteners
do not penetrate the steel cladding. There are translucent
PRODUCTS AVAILABLE THAT EASILY ACCOMMODATE THIS $ONT EXCEED
the maximum support spacing specified by the translucent
cladding manufacturer.

Skylighting increases the transmission of solar heat.

Generally speaking, heat transmission is proportional to light
transmission, so the more sunlight that enters a building the
hotter it will be. Clear, uncoloured fibreglass has good light

5 Insulation & skylighting

transmission of about 65% but this means on a typical summer
day, with peak solar radiation of 850 W/m2, transmission
through a clear fibreglass skylight would be about 550 W/m2.

Translucent fibreglass cladding is available to match CUSTOM

ORB, INTEGRITY 820, KLIP-LOK 406 and 700, LONGLINE-305, SPANDEK and
TRIMDEK. Polycarbonate cladding is also available for CUSTOM
ORB and TRIMDEK.

On KLIP-LOK roofs the translucent cladding should be pierce-

fixed.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

24 DESIGN—ROOF DRAINAGE

6
Roof drainage
6.1 Introduction
The design of roof drainage aims to protect people, property and the
building. A thorough design includes:

s 4HE ROOFING MATERIAL AND ITS PROFILE

s 4HE PITCH OF THE ROOF AND ANY PENETRATIONS THAT

reduce the capacity of the profile to carry rain
efficiently to the gutters

s 4HE CATCHMENT AREA OF THE ROOF INCLUDING GUTTERS

Adjacent roofs and walls can affect the catchment,

but are not considered in this book.

s 4HE GUTTERS THEIR LOCATION AT EAVES OR ELSEWHERE

Figure 6.1.1), cross-sectional area, and gradient

s 4HE DOWNPIPES THEIR CROSS SECTIONAL AREA QUANTITY

and location relative to the gradient

s $ISPOSAL OF WATER FROM THE DOWNPIPES

s /VERFLOW PRECAUTIONS

6.2 Design of drainage (eaves-gutter system)

This section outlines a procedure for designing the drainage of a roof
USING AN EAVES GUTTER SYSTEM )T IS ASSUMED THAT THE GUTTERS WILL HAVE A
gradient steeper than 1:500. Box gutter systems can be more complex
and are thoroughly treated in AS/NZS-3500.3.2:1998.

 $ECIDE ON THE AVERAGE RECURRENCE INTERVAL !2)  7HERE SIGNIFICANT

inconvenience or injury to people, or damage to property (including
contents of a building), is unlikely (typical of an eaves-gutter system)
A MINIMUM !2) CAN BE  YEARS
)F THESE CONDITIONS ARE LIKELY TYPICAL OF BOX GUTTERS  YEARS
is recommended.

2. Determine rainfall intensity for the site from Table 6.2.1.

More data are in AS/NZS 3500.3.2:1998.

3. Sketch a roof plan showing dimensions in plan view, pitch of roof,

layout of ridges and valleys.

 #HECK THAT THE EFFECTIVE ROOF LENGTHS DONT EXCEED THE CAPACITY OF THE
roofing profile (Section 2.4).

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 DESIGN—ROOF DRAINAGE 25

5. Calculate the catchment area of the roof from the plan. Table 6.2.1
To allow for the slope of the roof, increase the plan area by 1% for Design rainfall intensities
every degree of pitch up to 40°. For pitches over 40° refer to
AS 3500.3: 2003.

6. Get the effective cross-sectional area of the gutter you intend to use
from Table 6.2.2.

7. Using the cross-sectional area of the gutter on the graph in Figure

6.2.2, determine the catchment area per downpipe.

8. Calculate (as a first test) the minimum number of downpipes required

for the selected gutter using the equation:

Number of Total catchment area of the roof


downpipes (min.) Catchment area determined in (7)

Round the number of downpipes up to the next whole number.

9. On the plan, select locations for the downpipes and the

high points in the gutters. Where practical, the catchments
for each downpipe should be about equal in area; and a
high point should be located at the bottom of any valleys
(Figure 6.2.3).

Calculate the area of each catchment for each downpipe.

10. Returning to the graph in Figure 6.2.2, with the area of your eaves
gutter, check that the catchment area for each downpipe, calculated
in Step 9, is equal to or less than the catchment area shown by the
graph.

)F A CATCHMENT AREA IS TOO BIG THEN YOU CAN

s INCREASE THE NUMBER OF DOWNPIPES

s REPOSITION THE DOWNPIPES ANDOR THE HIGH POINTS

s CHOOSE A GUTTER WITH BIGGER EFFECTIVE CROSS SECTIONAL AREA THEN

repeat the above from Step 7.

11. Decide on the downpipe size. Recommendations in

AS/NZS 3500.3.2:1998 suggest that the area of round pipes should
be equal to the area of the gutter, whilst the area of square or
rectangular pipes may be 20% smaller (Table 6.2.2).

12. Consider measures to counter overflow of gutters into

the building.

6.3 Gutter fall

)NSTALL GUTTERS WITH A GENEROUS FALL TO AVOID PONDING WHICH REDUCES
gutter life), but the fall should not be so steep as to be obvious to the
casual observer. Typical fall on house guttering is often about 1:250
6 Roof drainage

(12 mm in 3000 mm), though a steeper fall of 1:100 should give the gutter a
longer life.
Figure 6.1.1
Typical gutters

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 26 DESIGN—ROOF DRAINAGE

Figure 6.2.2
Cross-sectional area of eaves gutters required for various
roof catchment areas (where gradient of gutter is flatter than
1:500). (Adapted from AS 3500.3:2003)
Table 6.2.2
Gutter areas and downpipes

Figure 6.2.3
Gutter
Locating high points and downpipes

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 CARE AND HANDLING 27
0!24 " ).34!,,!4)/.

7
General care, safety and

7 Care & handling

handling
7.1 Safety When you walk parallel to the ribs:
)T IS COMMONSENSE TO WORK SAFELY PROTECTING YOURSELF AND
s FOR RIBBED ROOFING WALK ON AT LEAST TWO RIBS OR
workmates from accidents on the site. Safety includes the
corrugations (CUSTOM ORB, CUSTOM BLUE ORB
practices you use; as well as personal protection of eyes and
and SPANDEK);
skin from sunburn, and hearing from noise.
s FOR PAN TYPE ROOFING walk in the pans
Occupational health and safety laws enforce safe working
(LONGLINE 305, KLIP-LOK 406, KLIP-LOK 700,
conditions in most locations. Laws in every state require you
KLIP-LOK 700, TRIMDEK, INTEGRITY 820).
to have fall protection which includes safety mesh, personal
harnesses and perimeter guardrails. We recommend that you When you walk across the ribs, walk over or close to the
acquaint yourself with all local codes of safe practice and you roofing supports.
adhere strictly to all laws that apply to your site.
Be careful when moving between supports. Do not walk in the
pan immediately adjacent to flashings or translucent sheeting.
7.2 Care and storage before installation Walk at least one pan away.
Rain or condensation is easily drawn between the surfaces of Always take particular care when walking on wet or newly
stacked sheets by capillary action, or they can be driven in by laid sheets — particularly on steeply pitched roofs.
wind. This trapped moisture cannot evaporate easily, so it can
cause deterioration of the coating which may lead to reduced )F THERE WILL BE HEAVY FOOT TRAFFIC ON A ROOF PROVIDE A TEMPORARY
life-expectancy or poor appearance. walkway or working platform to minimise damage.

)F MATERIALS ARE NOT REQUIRED FOR IMMEDIATE USE STACK THEM

NEATLY AND CLEAR OF THE GROUND )F LEFT IN THE OPEN PROTECT THEM 7.5 Marking out, cutting and drilling
with waterproof covers.
Marking out
)F STACKED OR BUNDLED PRODUCT BECOMES WET SEPARATE IT A pencil of any colour may be used except black or so-called
without delay, wipe it with a clean cloth and stack it to dry LEAD PENCILS $ONT USE BLACK PENCILS TO MARK ROOFING OR WALLING
thoroughly. because the graphite content can create an electric cell when
WET AND THUS CAUSE DETERIORATION OF THE FINISH 9OU CAN ALSO
use a string line with chalk dust, or a fine, felt-tipped marker.
7.3 Handling cladding on site Cutting
On large building projects you can reduce handling time by Where possible, you should minimise site-work by using
lifting bundles with a crane direct from the delivery truck sheets cut to length in the factory.
onto the roof frame. Use a spreader bar for long sheets. For
small to medium size projects, without mechanical handling For cutting thin metal on site, we recommend
facilities, you can unload sheets by hand and pass them up to that you use a power saw with a metal-cutting blade because
the roof one at a time. it produces fewer damaging hot metal particles and leaves
less resultant burr than does a carborundum disc.
For personal safety, and to protect the surface finish, wear
CLEAN DRY GLOVES $ONT SLIDE SHEETS OVER ROUGH SURFACES OR Cut materials over the ground and not over other materials
OVER EACH OTHER !LWAYS CARRY TOOLS DONT DRAG THEM where hot particles can fall and cause damage to finishes—
especially COLORBOND® PREPAINTED FINISHES )T IS BEST TO HAVE
the exterior colour finish of a COLORBOND® prepainted sheet
7.4 Walking on roofs facing down, however you must then protect the paint finish
)T IS IMPORTANT THAT YOU WALK ON ROOFING CAREFULLY TO AVOID from scratching by your work supports.
damage to either the roofing or yourself.
)F YOU HAVE TO CUT MATERIALS NEAR SHEETS ALREADY INSTALLED
Generally, keep your weight evenly distributed over the soles mask them or direct the stream of hot particles away.
of both feet to avoid concentrating your weight on either heels
or toes. Always wear smooth soft-soled shoes; avoid ribbed
soles that pick up and hold small stones, swarf and other
objects.
Using LYSAGHT Roofing and Walling 2nd Edition, 2007
 28 CARE AND HANDLING

Reciprocating nibblers are also widely used in the roofing 7.9 Sealants
trade, and they produce an excellent cut. Recommended sealants
The resulting small, sharp scraps can rust and damage Neutral-cure silicone sealants have been successfully used
finishes; and they can cause personal injury. Take special care with the range of steel finishes on our roofing and walling;
to collect these scraps. and on flashings, cappings, and gutters made from the same
materials as the cladding.
Making holes
Holes are often made by drilling or cutting by hole saw or Neutral-cure silicone sealants:
jig saw. Mask the area around the hole to protect paint from
damage by swarf. s HAVE GOOD ADHESION TO THE CLEAN SURFACE OF ALL OUR ROOFING
and walling;

7.6 Clean up s ARE WATER RESISTANT AND NON CORROSIVE

Swarf (metal scraps and/or abrasive particles resulting from s ARE RESISTANT TO EXTREMES OF HEAT AND COLD WHILE RETAINING
cutting and drilling) left on the surfaces of materials will cause good flexibility;
rust stains which can lead to reduced life of the material.
s PROVIDE HIGH RESISTANCE TO ULTRA VIOLET RAYS SUNLIGHT  AND
s 3WEEP OR HOSE ALL METALLIC SWARF AND OTHER DEBRIS FROM
roof areas and gutters at the end of each day and at the s HAVE A LONG SERVICE LIFE
completion of the installation.
)T IS IMPORTANT THAT ONLY NEUTRAL CURE SILICONE BE USED WITH
s )F SWARF HAS BECOME STUCK ON A FINISH IT CAN BE REMOVED sheet steel. Other silicone sealants, often have a vinegar or
Take great care not to remove the paint or the metal ammonia smell, and give off aggressive by-products during
coatings. curing which are detrimental to sheet steel.

s &OR CRITICAL APPLICATIONS INSPECT THE JOB TWO WEEKS AFTER )F IN DOUBT LOOK FOR A MESSAGE ON THE SEALANT PACKAGE
completion, when rain or condensation will have caused like: Suitable for use with galvanised and ZINCALUME® steel
any remaining swarf to rust, and thus highlight affected products.
areas.
Cleaning surfaces
For effective bonding, all surfaces must be clean, dry and free
from contaminants such as old sealant or oil.
7.7 Warn other contractors
Many stains arising from swarf do so, not from the work Mineral turpentine is suitable for cleaning the surfaces but
of roofing-installers, but from other contractors working care must be taken to completely remove all residual solvent
on the job. Similarly, problems can arise from contact with with a clean dry cloth. White spirits is an alternative.
incompatible materials, like copper piping or chemically
treated timber. Acid cleaning of bricks can also be a problem. Sealant must be applied on the same day as the surface is
Architects and builders need to be aware of this, and warn cleaned.
contractors accordingly.
Joint strength
Seams sealed with sealant should be mechanically fixed for
7.8 Strippable coatings strength. Fasteners in joints should generally be no further
To provide temporary protection during production, handling apart than 50 mm.
and transport, some COLORBOND® products are coated with a
plastic. This coating peels off easily when new, but it has a The sealant does not require significant adhesive strength in
RELATIVELY SHORT LIFE ESPECIALLY IN SUNLIGHT )F YOU DONT REMOVE itself, but it must bond positively to all the surfaces it is to seal.
this coating at the time of installation, you may find it very hard To ensure complete sealant cure, the width of sealant in a lap
to remove later on. should not exceed 25 mm when compressed (Figure 7.8.1).

Please dispose of the plastic in an environmentally

responsible manner.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 CARE AND HANDLING 29

Applying sealant Sealant clean up

7 Care & handling

Always apply the bead of sealant in a continuous line along With practice you will be able to judge the size of beads thus
the centreline of the fastener holes. This ensures that, when avoiding squeeze-out and the subsequent need to clean up.
compressed, the sealant positively seals the fastener.
Uncured sealant can be removed with a clean, dry rag and
Be careful not to entrap air when applying sealant. Especially, any excess then removed with a cloth lightly dampened with
DONT PLACE A RING OF SEALANT AROUND FASTENER HOLES BECAUSE mineral turpentine or white spirits. Excess cured sealant is
entrapped air compresses during tightening of fasteners, and best removed with a plastic spatula to avoid damage to the
may blow a channel through the sealant, which could prevent surface finish of the metal.
the fastener from being sealed.
Avoid any unnecessary smearing of sealant on surfaces
Fasteners intended for painting as silicone can affect adhesion of paint.
Use solid or sealed fasteners, otherwise you have to apply Smeared sealant may be treated by lightly abrading the area
sealant to the hollow centre of open blind rivets. with a non-metallic scouring medium.

To preserve the life of your cladding, is very important that

fastener materials are compatible with the cladding 7.10 Maintenance
(Section 2.10).
Factors that most affect the long life of a roof (or wall) are
Procedure original design, the environment of the installation, and the
The preferred procedure for lap fabrication is: maintenance of the installation. Maintenance is probably the
biggest factor.
1. Assemble, clamp and drill;
Maintenance includes:
2. Separate components and remove drilling debris;
s 2EGULAR INSPECTION FOR PROBLEMS BEFORE THEY BECOME MAJOR
3. Clean joint surfaces as recommended above; corrosion sites;

4. Apply bead(s) of sealant; s 2EGULAR WASHING DOWN ESPECIALLY NEAR COASTAL OR

industrial influences;
5. Relocate components and fix;
s 2EMOVAL OF LEAVES AND OTHER DEBRIS FROM GUTTERS
6. Externally seal each fastener if hollow blind rivets are
used. s +EEP WALLS FREE OF SOIL CONCRETE AND DEBRIS NEAR
the ground;
To prevent premature curing (which causes poor bonding),
finish the joint as soon as practical after applying the beads s $ONT OVERSPRAY PESTICIDE
OF SEALANT 4HE MANUFACTURERS SPECIFIED SEALANT OPEN TIMES
should be followed.

Figure 7.8.1
Typical joints with sealant
Using LYSAGHT Roofing and Walling 2nd Edition, 2007
 30 CARE AND HANDLING

Maintenance of COLORBOND® prepainted steel

The paint system on COLORBOND® steel sheet is very durable.
Simple maintenance of the finish enhances its life and
maintains attractiveness for longer periods.

Where the paint finish is naturally washed by rainwater

(roofs, for example) there is usually no additional maintenance
needed. However areas to be washed include soffits, wall
cladding under eaves, garage doors, and the underside of
eave gutters.

Washing should be done at least every six months and more

frequently in coastal areas where sea spray is prevalent, and
in areas where high levels of industrial fallout occur. Avoid
accumulation of salty deposits or industrial dirt.

Establish a regular routine for washing COLORBOND® prepainted

steel products. Often garage doors can be washed with clean
water at the same time as your car is being washed. Guttering
and eaves can be hosed down when windows are being
cleaned. Walls can be hosed down while watering the garden.

7HERE REGULAR MAINTENANCE DOESNT REMOVE ALL THE DIRT WASH

the surface with a mild solution of pure soap or non-abrasive
non-ionic kitchen detergent in warm water. Use a sponge, soft
cloth or soft bristle nylon brush; be gentle to prevent shiny
spots. Thoroughly rinse off the detergent with clean water.

Never use abrasive or solvent cleaners (like turps, petrol,

kerosene and paint thinners) on COLORBOND® steel surfaces.
For advice on grease, oil or deposits not removed by soap or
DETERGENT CONTACT OUR )NFORMATION 3ERVICE

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—PIERCE-FIXING 31

8
Installing pierce-fixed
cladding

Pierce-fixing is the method of fixing sheets using fasteners which pass

through the sheet. This is different from the alternative method called

8 Pierce-fixing
concealed-fixing (Chapter 9). The method of fixing you use is determined
by the cladding profile you are using.

9OU CAN PLACE SCREWS THROUGH THE CRESTS OR IN THE VALLEYS HOWEVER TO
maximise watertightness, always place roof screws through the crests.
For walling, you may fix through either the crest or valley (Figure 8.1).
Figure 8.1
Always drive the screws perpendicular to the cladding, and in the centre Crest and valley fixing
of the corrugation or rib.

The following procedures are described for roofs, but the same general
principles apply to walls.

8.1 General installation procedure

Check flatness, slope and overhang
Before starting work ensure that:

s THE SUPPORTS FOR YOUR CLADDING ARE TRULY IN THE SAME PLANE

s THE MINIMUM ROOF SLOPES CONFORM TO 3ECTION 

(Low-roof-pitches); and

s THE OVERHANGS OF SHEETS FROM THE TOP AND BOTTOM SUPPORTS DONT
exceed those in Table 2.3.1, whilst also overhanging at least
50 mm into gutters.

Make any necessary adjustments before you start laying sheets, because
they will be difficult or impossible to rectify later.

Orient sheets before lifting

For maximum weather-tightness, start laying sheets from the end of
the building that will be in the lee of the worst-anticipated or prevailing
weather (Figure 8.1.1).
Figure 8.1.1
)T IS MUCH EASIER AND SAFER TO TURN SHEETS ON THE GROUND THAN UP ON THE Lay sheets towards prevailing weather
roof. Before lifting sheets on to the roof, check that they are the correct
way up and the overlapping side is towards the edge of the roof from
which installation will start.

Place bundles of sheets over or near firm supports, not at mid span of
roof members.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 32 INSTALLATION—PIERCE-FIXING

Position first sheet

With particular care, position the first sheet before fixing to ensure that it
is correctly located in relation to other parts of the building.
Check that the sheet:

s IS ALIGNED WITH THE END WALL OR ITS BARGE OR FASCIA

bearing in mind the type of flashing or capping
treatment to be used; and

s ALIGNS CORRECTLY AT ITS ENDS IN RELATION TO THE GUTTER

and ridge (or parapet or transverse wall). Roof sheets
should overhang at least 50 mm into gutters.

Fix the sheet as described later in this chapter.

Position other sheets

After fixing the first sheet in position, align the following sheets using:

s THE LONG EDGE OF THE PREVIOUS SHEET AND

s A MEASUREMENT FROM THE END OF THE SHEET TO THE FASCIA OR PURLIN AT

THE GUTTER )T IS IMPORTANT THAT YOU KEEP THE GUTTER END OF ALL SHEETS
in a straight line.

Fix the sheet by either:

s FIXING EACH SHEET COMPLETELY BEFORE LAYING THE NEXT OR

s FIX THE SHEET SUFFICIENTLY TO ENSURE IT CANT MOVE COMPLETE LAYING

all sheets, then return to place all the intermediate fasteners later.

Check alignment occasionally

Occasionally check that the sheets are still parallel with the first sheet, by
taking two measurements across the width of the fixed cladding (Figure
8.1.2).

At about half way through the job, perform a similar check but take
the measurements from the finishing line to aim for the final sheet to
BE PARALLEL WITH THE END OF THE ROOF )F THE MEASUREMENTS ARE NOT CLOSE
enough, lay subsequent sheets very slightly out of parallel to gradually
correct the error by:

s PROPERLY ALIGN AND FIX A LAP THEN

Figure 8.1.2
Check alignment occasionally s FIX THE OTHER EDGE OF THE SHEET PLACING THE FASTENERS SLIGHTLY
closer or further from where they would normally be if there was
no error.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—PIERCE-FIXING 33

8.2 Side-lapping & positioning pierce-fixed sheets

To prevent moisture being drawn into laps by capillary action, the edges
of sheets are slightly modified. CUSTOM ORB and CUSTOM-BLUE ORB have the
edges of the sheet over-curved, other products like SPANDEK, TRIMDEK,
INTEGRITY 820 ALL HAVE FLUTES FORMED INTO THE UNDERLAPPING RIB )T IS IMPORTANT
that sheets be lapped correctly (Figure 8.2.1).

After fixing the first sheet, place the next (and subsequent) sheet with its
side lap snugly over the previous sheet (Figure 8.2.1). Secure the sheet
firmly in place until each end of the sheet has been fixed.

9OU CAN DO THIS EASILY BY

8 Pierce-fixing
s ALIGN THE BOTTOM EDGE ACCURATELY BY A MEASUREMENT FROM THE END
of the sheet to the fascia or purlin at the gutter;

s CLAMP THE LAP WITH A PAIR OF VICE GRIPS &IGURE  

s AT THE TOP OF THE SHEET NESTLE THE SIDE LAP SNUGLY CHECK
alignment, and fix the sheet with a fastener.

Figure 8.2.1
Crest fixing

8.3 Pierce-fixing on crests

Crest fixing is recommended for roofs made from: Figure 8.2.2
Clamp one end of the sheet whilst fixing the other
s #534/- /2" end.
s #534/- ",5% /2"
s 30!.$%+
s 42)-$%+
s ).4%'2)49 820

Crest fixing may also be used for these products when they are used as
walling.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

34 INSTALLATION—PIERCE-FIXING

8.4 Pierce-fixing on valleys (for walling only)

Wall fasteners may be placed on the crests, but they are usually placed
in the valley of wall cladding because:

s THEY ARE LESS CONSPICUOUS AND DONT BREAK THE AESTHETIC LINES OF
the steel cladding;

s THERE IS NO RISK OF THE PROFILE BEING DEFORMED

because the fastener is placed through the cladding
where it rests flat against its support (Figure 8.4.1); and
Figure 8.4.1 s WATER PENETRATION IS NOT A PROBLEM
Typical valley fixing (for walls only)
However, when valley-fixed, the cladding needs a side-lap fastener in all
LAPS AT EACH SUPPORT 9OU WILL FIND IT MORE ECONOMICAL IN LABOUR TIME AND
cost of fasteners to use a crest fastener at each side lap in place of the
lap fastener and adjacent valley fastener (Figure 8.4.2).

8.5 Pierce-fixing on side-laps

Where roofing and walling are installed according to the support
spacings shown in Tables 2.3.1 and 2.3.2, side-lap fasteners are generally
not required.

9OU MAY NEED TO USE SIDE LAP FASTENERS WHERE THE CLADDING IS LAID A LITTLE
out of alignment and the weather resistance of a joint is questionable.
Decide on the number of side-lap fasteners by what looks effective in
each individual case.
Figure 8.4.2
Alternative valley fixing with crest fixing at side Where valley fasteners are used, you need side-lap fasteners along each
laps (for walls only) lap at each support. Alternatively a crest fastener may be used at each
side-lap, in place of the side-lap fastener and adjacent valley fastener (as
mentioned above in Section 8.4).

Side-lap fasteners are located in the centre of the crest of the

overlapping corrugation (Figures 8.4.1 and 8.4.2).

8.6 Installing -).) /2"

A little extra care is needed with MINI ORB to get the best appearance.
Detailed notes are in our brochure on MINI ORB.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—CONCEALED-FIXING 35

9
Installing concealed-fixed
cladding

Concealed-fixing is the method of fixing sheets using fasteners which do

NOT PASS THROUGH THE SHEET )NSTEAD THE CLADDING IS HELD IN PLACE WITH
clips. This is different from the alternative method called pierce-fixing
(Chapter 8). The method of fixing you use is determined by the cladding
profile you are using.

Concealed-fixing is used for:

s +,)0 ,/+
s +,)0 ,/+

9 Concealed-fixing
s ,/.',).% 
s %!39#,!$

Very steep pitches

To prevent concealed-fixed cladding from sliding downward in the fixing
clips, on very steep pitches, you should pierce-fix through each sheet
under the flashing or capping, along the top of the sheets.

9.1 Installing KLIP-LOK roofs

Use the same general procedure described in Section 8.1 (General
installation procedure). However, at the start of installing KLIP-LOK 406,
KLIP-LOK 700 a row of clips is fixed to the supports before the first sheet is
located over them and locked in position.

Clips
For KLIP-LOK 700 use 700 clips.
For KLIP-LOK 406 use KL65 clips.

The orientation of the clips is important because they are not symmetrical
(Figure-9.1.1).

The fixing holes are pre-punched. On KL65 and KL75 clips you can use
the dimples to locate other fasteners where a fastener breaks or a timber
support splits.

Figure 9.1.1
KLIP-LOK clips
Using LYSAGHT Roofing and Walling 2nd Edition, 2007
36 INSTALLATION—CONCEALED-FIXING

Preparation
As described in General installation procedure (Section 8.1):

s CHECK FLATNESS SLOPE AND OVERHANG

s ORIENT THE SHEETS BEFORE LIFTING .OTE THE OVERLAPPING RIB

is towards the end of the building where you start
(Figure 9.1.3);

s #HECK THAT THE OVERHANG OF THE SHEETS FROM THE CLIPS

at both eaves and ridge, is not less than the minimum
in Table 2.3.1.

s 4HE FIRST AND THE LAST SUPPORTS AND CLIPS SHOULD BE AT

least 75mm from each end of the sheet to keep
maximum holding power.

Position the first sheet

With particular care, position the first sheet before fixing,
to ensure that it will correctly locate in relation to other parts
of the building. Check that the sheet:

s IS ALIGNED WITH THE END WALL OR ITS BARGE OR FASCIA

bearing in mind the type of flashing or capping
treatment to be used; and

s ALIGNS CORRECTLY AT ITS ENDS IN RELATION TO THE GUTTER

and ridge (or parapet or transverse wall). Roof sheets
should overhang at least 50 mm into gutters.

Fix the first clips

KLIP-LOK 700
Starting method 1. Cut the 1st clip 25 mm from the centre of the second
tower (as shown). The first tower on the cut clip locates in the 1st rib of
THE FIRST SHEET &IGURE   4HIS METHOD IS PREFERRED BECAUSE YOU DONT
have to reach so far to fix the remote end of the clip.

Starting method 2. The first tower on the first clip locates in the first rib of
the first sheet (Figure 9.1.2). The clip fixes the edge of the first sheet, but
you must fix two clips at the start, and thus reach out further for the first
and all subsequent sheets.

The following description is for Method 1.

!,, +,)0 ,/+ 02/&),%3

Fix the first clip on the purlin nearest the gutter, with the clip pointing
correctly in the direction of laying (Figures 9.1.1 and 9.1.2). Be sure the
clip is 90-degrees to the edge of the sheet.

Using a string line (or the first sheet as a straight edge) to align the clips
as you fix a clip to each purlin working towards the high end of the roof.

Figure 9.1.2
Fix the first row of clips

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—CONCEALED-FIXING 37

Place the first sheet

1. Locate the first sheet over the fixed clips (Figure 9.1.3).

2. Using a measurement from the gutter-end of the sheet to the fascia

or purlin, position the sheet so that it overhangs the desired amount
INTO THE GUTTER USUALLY ABOUT  MM  )T IS IMPORTANT THAT YOU KEEP THE
gutter-end of all sheets in a straight line.

3. KLIP-LOK 406:)F A SPUR ON THE EDGE OF A KLIP-LOK 406 sheet fouls a clip,
flatten the spur with a rubber mallet to allow the clip to sit down over
the rib (Figure 9.1.4).

!,, +,)0 ,/+ 02/&),%3 Fully engage the sheet with the clips, using
vertical foot pressure on all the ribs over each clip.

9 Concealed-fixing
Figure 9.1.3
Placing the first sheet

Fix the next (and subsequent) clips and sheets

1. Fix the next row of clips, one to each support. Be sure the clip is
90 degrees to the edge of the sheet, and the embossed arrow on the
Figure 9.1.4
clip points in the correct direction (Figure 9.1.1). Flatten spurs in way of clips
KLIP-LOK 700: Engage the slots and tabs on the clips.

KLIP-LOK 406 & 700: Engage the clips over the rib of the installed sheet
&IGURE   )F A SPUR ON THE EDGE OF THE SHEET FOULS A CLIP FLATTEN
the spur with a rubber mallet to allow the clip to sit down over the rib
(Figure 9.1.4).

KL65

2. As before, place the next sheet over its clips also engaging the edge
of the preceding sheet.
Figure 9.1.5
Clip engaged over rib of installed sheet
3. Accurately position the sheet so that it overhangs the desired amount
INTO THE GUTTER )T IS IMPORTANT THAT YOU KEEP THE GUTTER END OF ALL
sheets in a straight line.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

38 INSTALLATION—CONCEALED-FIXING

4. Fully engage the two sheets along the overlapping rib.

9OU CAN DO THIS BY WALKING ALONG THE FULL LENGTH OF THE SHEET WITH ONE
foot in the centre pan of the previous sheet and the other foot applying
vertical pressure to the top of the interlocking ribs at regular intervals.
)T IS IMPORTANT THAT YOU DONT WALK IN THE UNSUPPORTED PAN BESIDE THE
overlap (Figure 9.1.7). A rubber mallet may help engagement of laps on
long spans.

5. Similarly, engage all the clips by applying vertical foot pressure to the
top of the other ribs over each clip.

)T IS ESSENTIAL THAT THE SHEETS INTERLOCK COMPLETELY )T IS IMPORTANT THAT YOUR

Don't step in this pan
until ribs are engaged weight is fully on the sheet you are installing.
KLIP-LOK 700 KLIP-LOK 406 & 700:
The spurs on the free edge of the underlapping rib must
BE FULLY ENGAGED IN THE SHOULDER OF THE OVERLAPPING RIB &IGURE   9OU
will hear a distinct click as the spurs snap in.
Spurs on edge of bottom
sheet must be fully engaged
in shoulder of top sheet.

KLIP-LOK 406

Figure 9.1.7
Engaging edges of sheets

Check alignment occasionally

Occasionally check that the sheets are still parallel with the first sheet, by
taking two measurements across the width of the fixed cladding (Figure
Fixed sheets Purlin 9.1.8).
Early checks = Later checks =
At about half way through the job, perform a similar check but take
Finish
Start

the measurements from the finishing line to aim for the final sheet to
BE PARALLEL WITH THE END OF THE ROOF )F THE MEASUREMENTS ARE NOT CLOSE
Early checks = Later checks =
enough, lay subsequent sheets very slightly out of parallel to gradually
correct the error. To allow this to happen, flatten the tabs on the base of
Figure 9.1.8 subsequent clips—the slot in the clip will allow the clips to be fixed out of
Check alignment occasionally
standard pitch.

Place the last sheet

KLIP-LOK 700: )F THE FINAL SPACE IS LESS THAN THE FULL WIDTH
of a sheet, you can cut a sheet along its length and shorten
the clips as appropriate.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—CONCEALED-FIXING 39

KLIP-LOK 406 & 700 )F THE FINAL SPACE IS MORE THAN HALF THE WIDTH OF A SHEET
you can cut a sheet along its length leaving the centre rib complete
(Figure 9.1.9). Place the cut sheet onto a row of clips, as for a full sheet.

)F THE FINAL SPACE IS LESS THAN HALF THE WIDTH OF A SHEET FIX THE EDGE OF THE KL65

sheet at each purlin, with a clip that has been cut in half (Figure 9.1.10).
Cover the gap with the capping or flashing.

Sheet cut longitudinally

leaving full centre rib intact

Figure 9.1.9
KLIP-LOK 406
Placing last sheet where half a sheet will fit

9 Concealed-fixing
9.2 Installing KLIP-LOK walls
KL65

The installation procedure for walls is similar to that described for roofs
(Section 9.1). To engage clips, use a rubber mallet (instead of foot Sheet cut longitudinally
pressure). leaving full centre rib intact

To prevent KLIP-LOK from sliding downward in the fixing clips, you should Figure 9.1.10
pierce-fix through each sheet under the flashing or capping, along the top KLIP-LOK 406
of the sheets. 0LACING LAST SHEET WHERE HALF A SHEET WONT FIT

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40 INSTALLATION—CONCEALED-FIXING

9.3 Installing Easyclad

9OU CAN USE EASYCLAD for walls, soffit linings or ceilings. Use a similar
installation procedure for all.

EASYCLAD 2PF300 (2 pans per sheet) and 4P300 (4 pans per sheet) are
pierce-fixed through the underlapping edge of each sheet. The fasteners
in one sheet are concealed by the leading edge of the next. For the last
sheet, a trim channel is used.

)F YOU ARE USING EASYCLAD with the ribs horizontal, start installing from the
bottom of the wall so that the joints between panels tend to shed water
(Figure 9.3.6).

9OU CAN USE EITHER OF TWO METHODS TO FIX THE FIRST PANEL A #$ TRIM
channel or CD40 starting clips.

Start method 1 – Using a trim channel

Support With particular care, fix a trim channel at each support.
Be careful to locate it correctly in relation to other parts of the building
(see Section 8.1 Position first sheet).

Trim channel Easyclad panel s 5SE TRIM CHANNEL #$ WITH EASYCLAD 4P300.

s 5SE TRIM CHANNEL #$ WITH EASYCLAD 2PF300.

Support The first EASYCLAD panel is held in place by fitting it into the fixed trim
channel

channel (Figure 9.3.1).

Trim

Recommended
fastening
Figure 9.3.1
Using a trim channel to start

Start method 2 – Using clips

With particular care, fix starting clips at each support. Be careful to
locate them correctly in relation to other parts of the building (see
Support
Section 8.1 Position first sheet).

Hook the lip of an EASYCLAD sheet under these clips (Figure 9.3.2).

CD40 Starting clip Easyclad panel

Figure 9.3.2
Using a clip to start

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—CONCEALED-FIXING 41

Fixing Easyclad panels

Locate the first panel either in its trim channel or under the clips
(depending on the start method you used). Indentations to
locate screws
Fix the underlapping side of the panel, to each support,
through the flat edge, with the recommended fastener
(Chapter 3). The indentations along the edge help you locate
the fasteners (Figure 9.3.3).

Figure 9.3.3
)NDENTS ON EDGE OF SHEET HELP TO LOCATE
screws

9 Concealed-fixing
Fit subsequent panels by hooking the lip of your next sheet under the
folded-back edge of the previous panel before fixing in the same way as
before (Figure 9.3.4).
Figure 9.3.4
Starting for subsequent sheets

Support Panel Pierce fixing

fastening in valley
Usually the last EASYCLAD panel will have to be cut in width to suit the
BUILDING 4HE PANEL MAY REQUIRE EXPOSED PIERCE FIXING )F YOU USE A TRIM
channel at the end of the EASYCLAD walling, position it and pierce-fix with
the last panel (Figure 9.3.5). Last panel cut to width Trim channel

Figure: 9.3.5
Using trim channel to finish

Support

Weather side Inside

Figure 9.3.6
Start external walls from the bottom

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

42 INSTALLATION—CONCEALED-FIXING

9.4 Installing LONGLINE 305 roofs

Cut clip across big hole For LONGLINE 305 (standard width, fluted or tapered) use the same general
and discard section shown
with dashed line procedure described in Section 8.1 (General installation procedure).
However, at the start of installing LONGLINE 305, a row of clips is fixed to the
supports before the first sheet is located over them and locked in position.

Clips
The 2 clips are shown in Figure 9.4.1.
Starting/finishing clip Top fixing clip

Figure 9.4.1
LONGLINE 305 clips Preparation
Cut all starting/finishing clips and discard the unwanted pieces
(Figure 9.4.1).

As described in General installation procedure (Section 8.1):

Bend tab down
over rib
s CHECK FLATNESS SLOPE AND OVERHANG AND

s ORIENT THE SHEETS BEFORE LIFTING .OTE THE OVERLAPPING

rib is towards the end of the building where you start
(Figure 9.4.2).

Fix the first row of clips

Overlapping With particular care, determine the location of the first sheet and mark
rib
ing
the edge of the sheet on the purlins (see Section 8.1 Position first sheet).
y
f la
iono
ect Fix the first clip on the purlin. Using a string line (or the first sheet as a
Dir straight edge) fix the other starting clips for the first sheet.
Underlapping
rib
Figure 9.4.2
Place the first sheet
Placing first sheet
1. Locate the first sheet over the fixed clips (Figure 9.4.2).

2. Using a measurement from the gutter-end of the sheet to the fascia or

purlin, position the sheet so that it overhangs the desired amount into
the gutter. When setting the first sheet, remember that it is important
you keep the gutter-end of all sheets at a constant distance from the
edge of the gutter or fascia.

3. Bend the tab of all clips over the rib (Figure 10.4.3).

Figure 9.4.3
Place top fixing clips
Using LYSAGHT Roofing and Walling 2nd Edition, 2007
 INSTALLATION—CONCEALED-FIXING 43

Fix the next (and subsequent) clips and sheets

1. Using the rib closing tool, flatten the rib of the first (previous) sheet at
each purlin where the top fixing clips will fit (Figure 9.4.4).

2. Place top fixing clips over each flattened rib and fix to the purlins
(Figure 9.4.5). With a felt-tipped pen, make a small mark in the pan to
enable you to locate the clips in the later locking operation with the
button punch (Figure 9.4.6).

3. Place the next sheet over the edge of the preceding sheet, (Figure
9.4.5). Accurately position the sheet so that it overhangs the desired
AMOUNT INTO THE GUTTER )T IS IMPORTANT THAT YOU KEEP THE GUTTER END OF
all sheets at a constant distance from the edge of the gutter or fascia.

4. Fully engage the sheet with the clips, using foot pressure on the
RIBS OVER EACH CLIP 9OU CAN DO THIS BY WALKING ALONG THE FULL LENGTH
of the sheet with one foot in the tray next to the overlapping rib and Figure 9.4.4
the other foot applying pressure to the top of the interlocking ribs at Flatten rib for top fixing clips
regular intervals.

For walling applications use a rubber mallet instead of the weight on your

9 Concealed-fixing
feet.

Check alignment periodically

Check alignment as described in Section 8.1 (General procedure).

Place the last sheet

Assess how the last sheet will fit as described for installation of KLIP-LOK
(Figures 9.1.8 and 9.1.9).

Fix a cut starting/finishing clip to the purlins.

Place the last sheet over the starting/finishing clips, flatten the rib at each
purlin, and bend the tab of all clips over the rib.

Lock all ribs

All lapped ribs must be locked along their length, by button punching at
no greater than 900 mm centres (Figure 9.4.6). Figure 9.4.5
9OU MUST BUTTON PUNCH THROUGH THE HOLE IN EACH TOP FIXING CLIP ˆYOU Placing subsequent sheets
locate the clip with the pen mark made previously. When operating the
punching tool, stand on the pan of the overlapping sheet to ensure that
the sheets are fully engaged.

9.5 Installing LONGLINE  walls

The installation procedure for walls is similar to that described for roofs
(Section 9.4).
Rib
To prevent LONGLINE 305 from sliding downward in the fixing clips, you must touch
should pierce-fix through each sheet under the flashing or capping, along
30 mm

the top of the sheets.

Figure 9.4.6
Lock all ribs with button punch

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 44 INSTALLATION—ENDS OF SHEETS

10
Ends of sheets

This chapter describes how you can treat the ends of sheets to maximise
waterproofing, or to stop vermin entering.

CUSTOM ORB 10.1 Turn-ups

At the high end of roofing, wind can drive water uphill, under the flashing
or capping, into a building. To minimise this problem, you turn up the
valleys (or pans) at the high end of roofing.
The process is called turning-up (or stop-ending).

All roofing on slopes below 1 in 2 (25°) should be turned-up.

Turn-up tools are available for all our roofing profiles except CUSTOM ORB
Figure 10.1.2 and LONGLINE 305 when it is tapered (Figure 10.1.1 on the next page).
Turning-up CUSTOM ORB
9OU CAN TURN UP SHEETS BEFORE OR AFTER THEY ARE FIXED ON THE ROOF )F YOU DO
the latter, you must have sufficient clearance for the turn-up tool at the
top end of the sheets (about 50 mm).

Turning-up #534/- /2"

With pliers, multi-grips or a shifting spanner closed down to approximately
2 mm, grip the valley corrugations 20 mm in from the end of the sheet
and turn up as far as possible (Figure 10.1.2). Be careful not to tear the
sheet.

Turning-up 42)-$%+ and 30!.$%+

Slide the turn-up tool onto the end of the sheet as far as it will go. Holding
Figure 10.1.3 the tool against the end of the sheet, pull the handle to turn up the tray
Turning-up (TRIMDEK shown) about 80° (Figure 10.1.3).

Turning-up KLIP-LOK
9OU GET THE BEST RESULTS BY FIRST CUTTING OFF THE CORNER OF THE DOWN POINTING
leg of each female rib. Do this before you place the sheets on the roof.

s 7ITH THE HINGED TURN UP TOOL OPEN POSITION THE TOOL ON THE SHEET WITH
the locating pins hard against the end of the sheet.

s (OLD THE HANDLES TOGETHER TO CLAMP THE TOOL ONTO THE TRAY AND PULL
them to turn-up the tray 90° (Figure 10.1.4).

-ups
ted turn
Comple

Figure 10.1.4
KLIP-LOK tool ready for turn-up

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—ENDS OF SHEETS 45

Turn
up

TRIMDEK Turn
down Backing
tool

KLIP-LOK 406

LONGLINE 305
Turn-up &
turn-down
INTEGRITY 820
Turn-up &
turn-down

SPANDEK

Turn
up

Figure 10.1.1
Turn-up and turn-down tools

10 Ends of sheets
Flush turning-up KLIP-LOK
)N NORMAL TURNING UP OF KLIP-LOK, the tops of the ribs protrude past the
turned up tray. Consequently the turn-ups cannot be positioned hard mm
against a fascia or wall, or the ends of the sheets on either side of the 40

ridge cannot be butted together. This is usually of no consequence

because the turn-up is completely covered by a flashing or capping.
However, if you want the ribs not to protrude past the turn-up, you can
MAKE A FLUSH TURN UP 9OU NEED AN EXTRA  MM IN SHEET LENGTH FOR FLUSH
turn-ups.

1. Cut the top of each rib before turning-up the pans (Figure 10.1.5).
Turn-up the pans as described before.

2. Position the backing tool in the tray and hold it hard against the turn-
up with a foot. 'Ear' flattened
'Ear' awaiting
 7ITH A RUBBER MALLET FOLD THE PROTRUDING @EARS FLUSH AGAINST THE flattening
backing tool. Figure 10.1.5
Using the backing tool for flush turn-up on
KLIP-LOK

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 46 INSTALLATION—ENDS OF SHEETS

Turning-up LONGLINE 305

50
Flush turn-ups are usually used on LONGLINE 305. Cut off a portion of the
mm
female rib for at least 50 mm. For a flush turn-up, you also need to cut the
50
crown of the centre rib for at least 50 mm.
mm
Holding the end of the tool against the end of the sheet, pull the handle up
— )F TURNING UP FLUSH FOLD THE PROTRUDING @EARS FLUSH AGAINST THE TURN UP
Part of rib
removed tool with a rubber mallet (Figure 10.1.6).

90¯

Fold 'ears' against tool

for a flush turn-up

Figure 10.1.6
Turning up LONGLINE 305

10.2 Turning-down
At the low end of roofing, wind or capillary action can cause water to run
et
she back up the underside of the cladding. To minimise this problem, you turn
d g e of -down
E ned down the valleys (or pans) at the low end of roofing. The process is called
tur
turning-down (or lipping).

All roofing on slopes below 1 in 5 (10°) must be turned-down.

Figure 10.2.1 Turn-down tools are available for all our roofing profiles except
Turning-down the gutter end
CUSTOM ORB, SPANDEK and tapered LONGLINE 305. The valleys of CUSTOM ORB
(TRIMDEK shown)
corrugated cladding can be turned down with multigrips, pliers or a
shifting spanner (Figure 10.1.2).

Turning-down is usually done after the cladding is fixed on the roof,

provided there is no obstruction to the operation of the turn-down tool.
20¯
s 0USH THE TURN DOWN TOOL OVER THE END OF THE TRAY AS FAR AS IT WILL GO

s (OLD THE TOOL HARD AGAINST THE END OF THE TRAY AND PUSH THE HANDLE TO
form a turn-down about 20°.

Figure 10.2.2
Turning-down the gutter end
(LONGLINE 305 shown)
Using LYSAGHT Roofing and Walling 2nd Edition, 2007
 INSTALLATION—ENDS OF SHEETS 47

30!.$%+ overlaps
When SPANDEK is laid on slopes of 5 degrees or less, cut back the corner
of the under-sheet, at the downhill end of the sheet, to block capilliary
action (Figure 10.2.3).
Approx. Approx.
5 mm 5 mm
Cut back corner

Figure 10.2.3
Cut SPANDEK on low slopes.

10.3 Blocking off rib cavities

Dust, insects, birds, rodents and wind-driven rain can enter a building s n
top tte
through the cavities under ribs. To minimise these problems the cavities n d s to ba
E d
can be blocked off. Rib end-stops are available for KLIP-LOK; strips of ten
e
fas
plastic foam can be used for other profiles.
Figure 10.3.1
Fitting rib end-stops during installation of
Fitting KLIP-LOK rib end-stops during sheet installation sheets
Fix the rib end-stops to the side of the eaves support after the KLIP-LOK clip
has been secured in position. Align the rib end-stops with the upstands of
the fixing clips (Figure 10.3.1).

2
Fitting KLIP-LOK rib end-stops after sheet installation
Bend the flat of the end-stops 90°. Push an end-stop into the space under

10 Ends of sheets
each rib until the flat is wedged firmly between the underside of the
cladding and support (Figure 10.3.2).
1
Infill strips
Closed-cell, foam-plastic infill strips are available to match the top or
bottom profile of our roof claddings. Figure 10.3.2
Fitting rib end-stops after installation of
At the lower end of cladding, the strip is sandwiched under the roof sheets
cladding. Similarly, at the upper end, the strip is sandwiched between
topside of the roofing and the underside of the flashing or capping
(Figure 10.3.3).

$ONT USE INFILL STRIPS THAT CAN ABSORB WATER BECAUSE RETAINED MOISTURE
can lead to deterioration of the sheet coating. Avoid using infill strips
made from, or treated with, flammable materials, particularly in areas
prone to bushfire (Section 11.8).

Where roof pitches are below 1 in 5 (10°), you should incorporate infill
strips to maximise waterproofness.

Figure 10.3.3
Profiled closed-cell infill at eaves

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 48 INSTALLATION—ENDS OF SHEETS

10.4 End-lapping
Because our roofing and walling is manufactured by continuous
processes, sheet lengths can be supplied up to the limits of transport
regulations which are frequently long enough to cover roofs without end-
lapping the sheets.

)F YOU CONTEMPLATE USING SHEETS THAT ARE SHORTER THAN THE FULL SPAN AND
overlap them, you need to consider:

s THE ROOF SLOPE BECAUSE IT AFFECTS THE AMOUNT OF OVERLAP

(see Table 10.4.1);

s THE METHOD OF FIXING OF THE CLADDING TO ITS SUPPORTS BECAUSE IT

affects the maximum length of sheet
(see Section 10.5 (Expansion joints) and Table 10.5.2).

Table 10.4.1
End-laps

See Table 10.4.1

Fixing methods for end laps

There are three methods of fixing cladding at end laps.

See text for (a) s 0IERCE FIXED THROUGH CRESTS

spacing of fasteners Pierce-fixed Position the lap centrally over the support; and the fastening secures
through crest
both the lap and the cladding. Space the fasteners as for an end span
See Table 10.4 (layout in Figure 10.4.1.a, terminology and spacing in Table 2.3.1). The
.1
thermal expansion is away from the fastener and towards the outer ends
of the sheet run.

2 fasteners per tray

s 0IERCE FIXED THROUGH VALLEYS
self-drilling screws (b) Position the lap centrally on the support, and the fastening secures both
with EPDM sealing washer Pierce-fixed the lap and the cladding (Figure 10.4.1.b). The thermal expansion is away
through valley
from the fastener and towards the outer ends of the sheet run.
See Table 10.4.1 s #ONCEALED FIXED SHEETS
Fastened clip 9OU CAN EITHER PIERCE FIX THROUGH THE CRESTS OR THE VALLEYS
on purlin
(Figures 10.4.1.a and 10.4.1.b), or use clips near the lap (Figure 10.4.1.c).

KLIP-LOK 406 SHEETS DEFORM AT THE CLIPS SO THAT SHEETS WONT NEST TOGETHER
2 fasteners per tray (c) )F YOU USE CLIPS THE LAP IS PLACED JUST CLEAR OF AND ON THE HIGH SIDE OF THE
self-drilling screws
with EPDM
Concealed-fixed clip (Figure 10.4.1.c). The lap is secured with pierce-fixing through the
sealing washer with valleys. The clips allow the sheets to slip when they expand with heat.
pierce-fixing
through valley
Figure 10.4.1
Fixing at end laps

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—ENDS OF SHEETS 49

To make the end-lapping of KLIP-LOK 406 easier: remove, for the length of
the lap, the down-turn of the underlapping ribs of the top and bottom
sheets in each sheet run (Figure 10.4.2). The cut-back ribs are covered by 2 4
*
the sheets of the next sheet run.
*
LONGLINE 305,
can be fixed using any of the three methods.
*
The underlapping ribs have to be slightly squashed at the lap to allow *
them to nest. An end-lap tool is available. *
4
2
KLIP-LOK 700HSSHOULD NOT BE END LAPPED )NSTEAD AN EXPANSION JOINT MUST 1 3
1 3
BE USED 2EFER TO 3ECTION  BELOW )DEALLY LONG LENGTH SHEETS FROM A
mobile rollformer should be used where possible as this eliminates the
* Downturn of male rib removed
need for joining. for length of lap
Figure 10.4.2
Order of laying Remove down-turn of male rib when end-lapping
For profiles other than LONGLINE 305, lay each run of sheets in turn from KLIP-LOK 406
bottom to top before moving on to the next run. For LONGLINE 305, lay all
lower run of sheets first, then lay the upper sheets (Figure 10.4.3).

Spacing of supports at end-laps 2 4

For the maximum spacing between purlins, either side of an end lap in a
roof, use the spacing given for end spans (terminology and spacing in 1 3 5
Table 2.3.1). Profiles other than LONGLINE 305

4 5
End laps in pitches less than 15 degrees
1 2 3
End laps in roofs of less than 1 in 4 (15°) slope should be sealed with a
sealant. LONGLINE 305

Use two runs of sealant (Figure 10.4.4): Figure 10.4.3

10 Ends of sheets
Laying sequence for end-lapped sheets
s ONE RUN OF SEALANT AT THE LOW END OF THE LAP TO PREVENT MOISTURE
being drawn in by capillary action);

s THE OTHER RUN AT THE HIGH END TO PREVENT CONDENSATION FROM
running down the underside of the top sheet and entering the lap).
1
When the sheets are lapped together and fixed, the compressed sealant Apply 3 mm bead of sealant to
should just appear at the end of the lap. underside of overlapping sheet,
25 mm from end of sheet
1. With the top sheet upside down, extrude a 3 mm bead
of sealant across the underside of this sheet about 25 mm from the
end.

2. Position the bottom sheet, then extrude a 3 mm bead of sealant

across the top of the sheet to encapsulate the cut end of the
3
underlapping sheet. Turn sheet
over
3. Turn the top sheet over and fit it in place.

The side-lap between sheets of roofing has a cavity to prevent capillary 2

action between adjacent sheet runs (Section 8.2). Apply 3 mm bead of sealant
)T IS IMPORTANT THAT EXCESS SEALANT EXTRUDED FROM AN END LAP DOES NOT to encapsulate the cut end
of the underlapping sheet
enter this cavity because, if it does, moisture that may have entered the
side lap will not be able to drain unimpeded down the roof slope. Figure 10.4.4
Sealing end-laps on very low pitched roofs
Using LYSAGHT Roofing and Walling 2nd Edition, 2007
 50 INSTALLATION—ENDS OF SHEETS

10.5 Expansion
Background on thermal expansion
All metals expand and contract with changes in temperature. Although
steel is by far the least affected of all the metals commonly used for roof
and wall cladding, the changes in length experienced in very long runs of
roofing are significant.

On a clear hot summer day, with no wind, the steel temperature in roof
cladding can reach approximately 50°C in COLORBOND® SURFMIST®, 60°C in
plain ZINCALUME® and more than 80°C in COLORBOND® NIGHT SKY®.

Examples of the thermal changes in lengths of steel cladding that would

result from various temperature changes in the steel are shown in Table
10.5.1.

The actual expansion or contraction between the end of a sheet and the
last support would only be a fraction of the figures shown because the
movement in the length of fixed cladding would normally take place from
the centre towards each end of the sheet. The movement at each end is
thus only half the total expansion or contraction.

Transverse thermal expansion poses no problems in ribbed cladding

because each rib absorbs some transverse movement.

Expansion joints
Thermal expansion effects are mitigated by slight bending of fastener
shanks, thermal movement of the building structure, and slight flexing of
the purlins (where they are not restrained by cleats or bridging). However,
for very long runs of roofing, you should include an expansion joint to
overcome linear thermal expansion.
Table 10.5.1
Thermal expansion and contraction of steel Table 10.5.2 shows the maximum distance between the top and bottom
cladding ROWS OF FASTENERS ON A SHEET )F THE TOTAL LENGTH OF TWO SHEETS PIERCE
fixed through the lap, or a single sheet exceeds this distance, then an
expansion joint is needed. There should be no more than one pierce-fixed
end-lap between expansion joints.

An expansion joint involves overlapping the ends of the upper sheets

over the ends of the lower sheets—but with a clearance between them
(about 15 mm). A typical overlap is 250 mm (this overlap is not the same
as the overhang in Table 2.3.1 which does not apply to expansion joints).
The clearance is usually created by having all the purlins for the roofing
on the high side of the joint, higher than the roofing on the low side of
the joint. An extra purlin is needed at the joint. A baffle flashing provides
weatherproofing. See Figure 10.5.1.
Table 10.5.2
Maximum distance between top & bottom rows Where there is a risk of high winds, or the ribs are big, you may need
of fasteners on a sheet, before expansion joint is extra flashing, including closed-cell foam plastic infill strips.
needed

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 INSTALLATION—ENDS OF SHEETS 51

10.6 Roof overhang with edge stiffener Sheeting

turned down
Foam infill
commonly used
For the stiffened overhangs listed in Table 2.3.1, you need to stiffen the with INTEGRITY
Baffle flashing. Depth of
gutter ends of the roofing. Notch over sheeting
250 mm plus
ribs & fasten to
underlapping minimum overlap 15 mm
Our SHEERLINE gutter, fixed through the return lip to the underside of roofing sheet
at 200 mm centres will provide the required stiffening.

Alternatively, you can use a 50 x 50 x 1.2 mm steel angle fixed at 200 mm

centres to the underside of the roofing about 50 mm from the end.
Trays turned up

25 mm min.
clearance

300 mm

Figure 10.5.1
Expansion joint detail

Overhang

Sheerline gutter fixed to underside of roofing

(200 mm centres)

g
rhan
Ove

10 Ends of sheets
Steel angle 50 x 50 x 1.2 mm
fixed to underside of roofing
(200 mm centres).
Gutter may be fixed to angle.

Figure 10.6.1
Methods of stiffening roof overhangs

Flashings provide the essential weatherproofing

at the edges, and they sharpen the image of the
finished job.
Using LYSAGHT Roofing and Walling 2nd Edition, 2007
 52 INSTALLATION—FLASHINGS

Flashings and cappings are strips of metal formed to weatherproof the

11 edges of roofing and walling.
For the purposes of this chapter, only the term flashing is used.
The following sections should be considered as a guide only.
Flashings For a comprehensive account of flashing guidelines, refer to HB39-1997.

3IMILAR METHODS OF FLASHING ARE USED FOR DIFFERENT CLADDING PROFILES 9OU
can adapt the principles to suit your application.
)N ALL CASES IT IS IMPORTANT TO HAVE AMPLE COVER PROVIDED BY THE FLASHING
and proper turn-up of the cladding underneath.

Be careful when moving between supports. Do not walk in the pan

immediately adjacent to flashings or translucent sheeting. Walk at least
one pan away.

BlueScope Lysaght has a range of standard flashings. We can also

supply custom flashings to your requirements – ask your local service
centre for details.

11.1 Materials
)T IS VERY IMPORTANT THAT FLASHINGS BE MADE FROM MATERIALS THAT ARE
compatible with the cladding (Section 2.10).

Lead flashing is not recommended, however it will usually be retained

WHEN RE ROOFING BECAUSE IT IS USUALLY CEMENTED INTO THE STRUCTURE )N
these cases:

s THE TOP SURFACE OF THE LEAD FLASHING MUST BE PAINTED WITH A GOOD
quality exterior paint system (to limit contamination with lead
compounds in water running off the flashing); and

s THERE MUST BE A BARRIER BETWEEN THE LEAD FLASHING AND THE

cladding: either a plastic strip (such as polythene dampcourse), or
paint.

Flashings should conform to AS/NZS 2179.1:1994, and be compatible with

the cladding (Section 2.10).

Materials for flashings are available in ZINCALUME® or COLORBOND® finishes.

11.2 Longitudinal flashings

Longitudinal flashings run parallel to the pans or valleys, and are made to
suit the cladding profile (Figure-11.2.1). They should have an edge turned-
down to dip into the pan or valley.

Flashing Cover
The minimum recommended cover of longitudinal flashings over cladding
(as taken from HB39-1997) should be as follows:

Pierce fixed roof sheet 150mm min.

#ONCEALED FIXED ROOF SHEET )NTO FULL PAN
(2/3 pan covered)

Fixing of Flashings
Figure 11.2.1 Longitudinal flashings shall be fastened at maximum 500mm centres.
Typical longitudinal flashings

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—FLASHINGS 53

Every 4th rib

11.3 Transverse flashings
Transverse flashings run across the pans or valleys (Figure 11.3.1). They
usually have a stiffening lip, along the lower edge, which is turned-down
to dip into the pan or valley. To maximise weather proofing, the bent lip is
fashioned to fit the profile.

The turn-down for transverse flashings for CUSTOM ORB and CUSTOM BLUE
ORB can be fashioned to fit the profile by either notching or scribing to
match the corrugations, or lightly dressed into the valleys. The type of
fashioning (if any) depends upon profile shape and the type of material Every 3rd rib
used to flash. Fashioning is preferred for low-slope roofs.

The turn-down for transverse flashings for wide panned cladding is

always notched or scribed to fit over the ribs.

Flashing Cover
Lysaght produces a range of standard flashings (hip, barge, apron). To
increase weathertightness, BlueScope Lysaght recommends you maximise
the overlap between flashings and claddings.

Fixing of Flashings
Transverse flashings shall be fastened in accordance with HB39-1997, as
detailed below.

Profile Recommended Fixing Spacing

CUSTOM ORB/CUSTOM BLUE ORB Every 4th rib
).4%'2)49  Every rib
Every rib
+,)0 ,/+  Every rib
+,)0 ,/+  ()'( 342%.'4( Every rib
,/.',).% 05 Every rib
SPANDEK Every 3rd rib
42)-$%+ Every rib
4HE ABOVE FASTENER SPACING RELATES TO THE STITCHING OF FLASHINGS TO SHEETING )T DOES
not constitute the minimum number of fasteners required to fix the sheeting to purlins. Figure 11.3.1
Typical transverse flashings

Notching tools
Hand-operated notching tools cut one notch at a time. Each tool matches
only one cladding profile. There are two types of tool; their use depends
on whether or not the edge of the flashing has first been bent down
(Figure 11.3.2). 11 Flashings

Table 11.3.1
Notching tools

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 54 INSTALLATION—FLASHINGS

Using notching tools

After the cladding is fixed and the turn-ups finished, proceed
as follows.

s 0LACE A FLASHING WITH THE NOTCH EDGE RESTING ON THE RIBS

s ,OCATE YOUR NOTCHING TOOL OVER A RIB WITH THE NOTCHING HEAD AGAINST
the flashing.

VERTICAL TOOL: The body locates along the rib.

HORIZONTAL TOOL: the lugs on the underside locates on top of the rib.

s 2AISE THE HANDLE TO OPEN THE TOOL AND

VERTICAL TOOL: lift the flashing into the mouth of the tool;

HORIZONTAL TOOL: slide the mouth of the tool over the edge of the
flashing as far as it will go.

s 0USH DOWN ON THE HANDLE TO PERFORM THE NOTCHING

s 2EPEAT FOR ALL RIBS CHECKING IN EACH CASE THAT THE FLASHING IS CORRECTLY
positioned.

s )F YOU ARE USING A HORIZONTAL TOOL BEND DOWN THE TONGUES BETWEEN THE
notches over a suitable straight edge (such as a piece of timber).

Notching with tinsnips

)F NOTCHING TOOLS ARE NOT AVAILABLE FLASHINGS CAN BE NOTCHED TO THE RIB
profile with tinsnips (Figure 11.3.3). The procedure is sometimes known as
scribing. After the cladding is fixed and the turn-ups finished, proceed as
follows.

s 0LACE THE FLASHING WITH THE TURNED DOWN EDGE RESTING

on the ribs.

s -ARK OUT THE NOTCHING USING A TEMPLATE POSITIONED OVER

each rib.

s #UT THE NOTCHES WITH TINSNIPS

This procedure is also used for hip cappings.

Fasteners for transverse flashings

9OU MUST PROPERLY FIX BOTH FLASHINGS AND THE ENDS OF ALL SHEETS

Where the cladding is pierce-fixed through crests, and the position of

the purlin allows it, the fasteners used to fix the sheets, may also fix the
flashings.

On all other installations, pierce-fix your flashing to the ribs or crests of

the sheets.

Figure 11.3.2
Using notching tools

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—FLASHINGS 55

Table 3.8.1 shows the fasteners and their locations for the ends of sheets
(Figure 11.3.1).

Joining flashings
The overlaps of transverse flashings should be sealed with a
recommended sealant and fastened. Before finally positioning and fixing
the lap, turn over the top piece and apply a 3 mm bead of sealant across
the flashing, about 12 mm from the end.

Figure 11.3.3
Using a template to mark out for notching with
tinsnips

11.4 Flashing at change of pitch

11 Flashings

Figure 11.4.1
Typical flashing at changes of pitch

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 56 INSTALLATION—FLASHINGS

11.5 Flashing large roof penetrations

Penetrations through ribbed cladding block the valleys (or pans), and
thus affect the free flow of rainwater down a roof. All flashings have to
weatherproof the cladding – but on the uphill side of large penetrations,
they also have to channel rainwater sideways into valleys that run
unobstructed to the eaves.

&OUR METHODS ARE DESCRIBED HERE )N ALL METHODS THE ENDS OF CUT RIBS MAY
be closed off with caps on the outside of the rib, or with plugs inside the
ribs. Plugs must be used on side-laps to allow the anti-capillary cavity to
drain.

Note: For masonry construction, Building Code Australia (BCA) requires

the use of Damp Proof Course (DPC) to ensure weatherproofing. For
acceptable methods see BCA section on weatherproofing masonry.

Support framing
Wherever one or more of the sheet ribs are cut, you must provide framing
to support the cut ends of the roof cladding each side of the penetration.

Existing flashing
)F YOU HAVE TO RE USE LEAD FLASHINGS THAT ARE BUILT INTO THE STRUCTURE
special protection is needed (Section 11.1).

Method 1: Head gutter and apron flashings

Figure 11.5.1 This is often the simplest method, and commonly used for existing
Flashing method 1: Head gutter protrusions (Figure 11.5.1).

Method 2: Flat tray and sleeve

To avoid fitting and sealing end caps to all the sheet ribs on the low
side of the penetration, an apron flashing can be fitted to the sleeve and
sealed to the tray each side.

Figure 11.5.2
Flashing method 2: Flat tray and sleeve

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—FLASHINGS 57

Method 3: Tray gutter for steeper roofs

)F THE ROOF PITCH IS MORE THAN SAY  IN  — YOU CUT THE ROOF CLADDING
sufficiently high above the penetration to allow a tray gutter to raise
rainwater over the top of the sheet ribs and divert it around the
penetration (Figure 11.5.3).

Figure 11.5.3
Flashing method 3:
Tray gutter for steeper roofs

Method 4: Penetration close to ridge capping

)F A ROOF PENETRATION IS CLOSE TO A RIDGE CAPPING OR FLASHING ABOVE THE
penetration), you can fit a simple flat tray, on top of the roofing, so that it
extends from under the capping down to a sleeve around the penetration.
A similar installation is shown in Figure 11.6.3).

11 Flashings

Figure 11.5.4
Penetrations close to ridge capping

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 58 INSTALLATION—FLASHINGS

11.6 Flashing small roof penetrations

A flanged cylindrical sleeve is a fairly simple method of flashing around
small penetrations (such as pipe penetrations) which fit between the ribs
of a roof sheet, or penetrate only a single rib.

Three methods are described here. Wherever roofing is cut, you must
consider providing extra support for the roofing above and below the
penetration.

Method 1: Tapered metal skirt and sleeve

This method uses parts custom-fabricated from metal. There is no positive
seal between inside the building and the outside atmosphere (Figure 11.6.1).

Method 2: Sleeve
This is often the simplest method (Figure 11.6.2). Flexible flanged sleeves
can be bought for flashing around penetrations of at least 350 mm
diameter. They overcome the problem of capping and sealing the open
ends of cut ribs. A sleeve is commonly used, though silicone sealant has
a wider operating temperature range and is available in a wider range of
colours.

The flange around the base of the sleeve can be contoured by hand to
Figure 11.6.1 match the cladding profile before it is sealed and fixed to the cladding.
Small penetration with metal skirt and sleeve
Be careful not to dam any valleys or pans so that rainwater can drain
freely from the high side of the roof penetration. Moisture held in
such areas can cause deterioration of the sheet coating, reduced life
expectancy or poor appearance.

Where damming of any valley or tray is unavoidable, due to the size of the
pipe penetration, treat the installation as a large penetration
(Section 11.5).

Copper penetrations
All copper pipe penetrations through ZINCALUME® or COLORBOND® cladding
must be physically and electrically isolated from the cladding. This can
be done by using a sleeve of PVC polythene or similar plastic that is also
ultra-violet stable.
Figure 11.6.2
Small penetration with sleeve

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 INSTALLATION—FLASHINGS 59

11.7 Flashing walls

Cladding is usually installed with the profile running vertically or
horizontally, though sheets have been laid diagonally—the choice is
aesthetic.

Wind can drive rain hard against wall flashings, so it is important that you
pay attention to the detailing of flashings around windows, doors,
re-entrant and external corners, to ensure you get a watertight building.
9OU ALSO WANT A NEAT APPEARANCE

We make wall flashings for some wall claddings (like EASYCLAD

and MINI ORB) which are sometimes called trims. Where these are not
suitable, custom-made flashings can be easily produced following the
general principles described in this section.

Walling profile running horizontally

s )T IS USUAL TO LAY THE FIRST SHEET AT THE BOTTOM OF A WALL AND WORK
UPWARDS TOWARDS THE EAVES 9OU WANT THE WINDOW AND DOOR FLASHINGS
to fit properly into the valleys, so you should locate the first sheet
relative to the heads and sills of doors and windows. Thus, you first
have to decide where the cladding will eventually be located at the
heads of doorways and at the heads and sills of windows before you
place the first sheet.

s 7HERE POSSIBLE SELECT THE VERTICAL SIZE OF WINDOWS SO THAT THE

flashings at both heads and sills will coincide neatly with the pitch of
your profile (Figure 11.7.1).

s "E SURE THAT THE CRESTS OF THE PROFILE ALIGN WITH EACH OTHER ON
adjacent walls, either side of a corner—this ensures that horizontal
fashings fit properly into all valleys.

s 7HERE VALLEYS CREATE A VOID AT FLASHINGS USE CLOSED CELL FOAM PLASTIC
infill (Figure 10.3.3).

s 7HERE WIND DRIVEN RAIN CAN BE EXPECTED TURN BACK THE EDGES OF
flashing to restrict water movement past the flashing.

11 Flashings

Figure 11.7.1
Typical header and sill flashing: profile running
horizontally (elevation)
Using LYSAGHT Roofing and Walling 2nd Edition, 2007
 60 INSTALLATION—FLASHINGS

Figure 11.7.3
Typical flashing at window and door jambs: profile
running horizontally

Figure 11.7.2
Typical corner flashings: profile running
horizontally (plan view)

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INSTALLATION—FLASHINGS 61

Walling profile running vertically

Flashings are generally easier on jobs where the profile runs vertically
(Figures 11.7.4 and 11.7.5).

Figure 11.7.4
Typical header and sill flashing: profile running
vertically (elevation)

Figure 11.7.5
Typical corner flashings: profile running
vertically (plan). Jamb flashings follow same
principle.

11.8 Bushfire protection

11 Flashings

AS-3959—1999 sets out requirements for the design and construction of

BUILDINGS IN BUSHFIRE PRONE AREAS )T CALLS FOR FLASHINGS TO BE BEDDED ON
fire resistant insulation material.
Be sure that flashings fit closely. Transverse flashings should be notched
or scribed (Figures 11.3.1 and 11.8.1)

Figure 11.8.1
Typical protection from sparks at ridge

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 62 INSTALLATION—FLASHINGS

References

Australian standards BlueScope Lysaght

AS 1170.1 SAA Loading Code: Dead and live loads and load Amongst the publications of BlueScope Lysaght,
combinations the following are particularly appropriate.
AS 1170.2—1989 SAA Loading Code: Wind loads

AS 1170.3—1989 SAA Loading Code: Snow loads (and the Technical bulletins (General)
Supplement) TB-1 Steel roofing and walling products: Selection guide
AS 1170.4—1989 SAA Loading Code: Earthquake loads (and TB-2 Overpainting and restoration of COLORBOND® prepainted
the Supplement) steel sheet
AS 1397—2001 Steel sheet and strip—Hot-dipped zinc-coated TB-4 Maintenance of COLORBOND® prepainted steel roofing
or aluminium/zinc-coated
TB-5 Swarf staining of steel roofing and walling profiles
AS 1562.1—1992 Design and installation of sheet roof and wall
cladding: Metal TB-8 Flashing materials for ZINCALUME® & COLORBOND® steel
sheet
AS/NZS 2179.1:1994 Specification for rainwater goods,
accessories and fasteners: Metal shape or sheet TB-13 General guide to good practice in the use of steel
rainwater goods, and metal accessories and fasteners roofing and walling products
AS 2334—1980 Steel nails—Metric series TB-15 Recommended steel gutter systems
AS 2627.1—1993 Thermal insulation of dwellings TB-16 Fasteners for roofing and walling product: Selection
guide
AS/NZS 2728: 1997 Prefinished/prepainted sheet metal
products for interior/exterior building applications— TB-17 Selection guide for galvanised steel purlin products
Performance requirements

AS 3500.3—1990 National plumbing and drainage code—Part

3: Stormwater drainage Technical bulletins (Corrosion)

AS 3566—1988 Screws—Self-drilling—For the building and CTB-1 General introduction

construction industries
CTB-8 Building applications
AS 3959—1999 Construction of buildings in bushfire-prone
areas CTB-10 Roof penetrations

AS 4040.1—1992 Methods of testing sheet roof and wall CTB-11 Condensation

cladding—Resistance to concentrated loads
CTB-12 Dissimilar metals
AS 4040.2—1992 Resistance to wind pressures for non-
CTB-13 Contact with timber
cyclone regions
CTB-15 Acid cleaning brickwork
AS 4055—1992 Wind loads for housing
#4"  )MMERSION
AS/NZS 4256—1994 Glass fibre reinforced polyester
CTB-17 Following trades
3!! ("ˆ )NSTALLATION CODE FOR METAL ROOF AND WALL
cladding CTB-18 Painting lead flashing
SAA HB106—1998 Guidelines for the design of structures in
snow areas.

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 INDEX 63

Index

A E at change of roof pitch 55

alignment of roofing effective roof lengths for drainage 8 at copper penetrations 58
KLIP-LOK 700HS 38 end-lapping 48 at large penetrations 56
pierced-fixed 32 expansion 50 at small penetrations 58
Australian Standards 62 fixing methods 48 sleeve 58
low pitches 49 longitudinal 52
order of laying sheets 49 materials 52
B spacing of supports 49 notching 55
blocking rib cavities 47 ends of sheets 44 notching tools 53
bullnosed (see pre-curved roofs) 18 blocking rib cavities 47 notching with tinsnips 54
bushfire protection 61 end-lapping 48 transverse 53
overhang, stiffened 51 walls 59
C turn downs 46
cappings. See flashings turn ups 44
environmental conditions 4 G
care of products 27
expansion 50 gutters
clean up 28
expansion joints 50 areas 26
clips
typical types 25
for EASYCLAD 40
for KLIP-LOK 35 F
for LONGLINE 305 42 fasteners 9 H
required quantities 11 features table 10 handling products 27
coatings, stripable 28 for accessories 11 heat control 20
COLORBOND® 2 for CUSTOM BLUE ORB 12 holes 27
and painting 4 for CUSTOM ORB 12
avoiding rust stains 28 for EASYCLAD 12 I
compatibility of materials 4 for insulation 11 incompatibility. See compatibility of
drainage table 5 for INTEGRITY 820 13 materials
concealed-fixing. See installation for KLIP-LOK 13 infill strips 47
condensation 21 for LONGLINE 13 information 1
crest fixing 33 for MINI ORB 13 installation
curving. See roof: curved for MULTICLAD 14 alignment of roofing 32
cutting cladding 27 for MULTILINE 900 14 concealed-fixing 35
cyclonic for PANELRIB 14 EASYCLAD HI-TEN 40
anchoring footings 3 for side-laps 11 KLIP-LOKon walls 39
conditions 1 for SPANDEK HI-TEN 15 KLIP-LOK 35
for thicker steels 11 LONGLINE 305 42

D for transverse flashings 54 pierce-fixed 31

Dektite flashings 58 for TRIMDEK HI-TEN 15 crest fixing 33
for TRIMWALL 15 MINI ORB 34
design 2
for WALLCLAD 15 procedure 31
roof drainage 24
identification 10 side-laps 33, 34
roofs 2
materials 9 valley fixing 34
walls 2
quantity required 11 insulation
dissimilar metals. See compatibility of
rivets, sealing 29 fastener length 11
materials
screws, setting tightness 10 heat 20
downpipe size. See roof: drainage:
sealing washers 9 materials 22
downpipe size
washers, sealing 9 noise 22
drainage of roofs. See roof: drainage:
finishes 2 thickness limitations 23
design
References & Index

flashings 52

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

 64 INDEX

L lengths 3
roofing drainage 8
lengths
transportation 4
roofing 3
pitches 3
roofing drainage 8
tapered 19
transportation 4
walking on 27
lifting roofing 31
wind forces 3
rust stains
M avoiding 28
maintenance 29 warn other contractors 28
marking out 27 S
materials safety 27
cladding specifications 2 guardrails 27
for fasteners 9 lifting roofing 31
for flashings 52 walking on roofs 27
for insulation 22 screws. See also fasteners
MINI ORB 34 setting tightness 10
sealant use 29
N sealants 28
nails. See fasteners sealing washers 9
noise reduction 22 selection of products 2
notching. See flashings silicone sealant. See sealants
skylighting 23
solvents 30
P spacing definitions 6
pencils for marking out 27 SPANDEK overlaps 47
performance tests 3 specifications
pierce-fixing. See installation for profiles (tables) 6
pitches of roofs 3 materials 2
products storage of products 27
profiles 6 stripable coatings 28
selection 2 support spacings 3
profiles of claddings 6

T
Q tapered roofing 19
quantities of clips & fasteners 11 technical bulletins 62
testing performance 3
R thermal transmission (see heat control)
rainfall intensities table 25 20
references 62 translucent cladding. See skylighting
rivets. See fasteners transportation 4
roof trims (see flashings, walls) 59
alignment of sheets 32 turn downs 46
curved 16 turn-ups 44
bullnosed (see pre-curved roofs)
18 V
capped bent ribed 19
valley fixing 34
pre-curved 18
spring-arched 17
spring-curved 18 W
spring-curved-ridge 16 walking on roofs 27
design 2 wall flashings 59
drainage walls, design 2
design 24 warranties 1
downpipe locating 26 washers, sealing 9
downpipe size 25, 26 wind forces 3
gutter areas & downpipes 26
gutter types 25
maximum roof lengths 8 Z
rainfall intensities 25 ZINCALUME® 2

Using LYSAGHT Roofing and Walling 2nd Edition, 2007

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