True Beauty - solarspan.com.au · Outer Beauty Steel Roof & Ceiling Your next generation corrugated...

SupaCore® Insulation

Superior Thermal Performance

Patios with Comfort and StyleLeaders in Thermal & Architectural Building Solutions

Outer Beauty Steel Roof & Ceiling

Your next generation corrugated roof• Longer spans

• Outstanding thermal performance

• Smooth ceiling underside

• Australian made Steel

• Wider coverage 1000mm

• Higher water carrying capacity

True Beauty

2 InsulRoof® - Design & Install Guide

InsulRoof® - Design & Install Guide solarspan®

Contents

Panel Overview ..................................................................................3

Insulation Layer ............................................................................... 3

Ceiling Layer ................................................................................... 3

Roof Colour Range ......................................................................... 3

Ceiling Finishes .............................................................................. 3

Roofing Layer .................................................................................. 3

Dimensions ..................................................................................... 3

Ceiling Colours ................................................................................ 3

Required Tools & Equipment .............................................................4

Required Tools & Equipment ............................................................ 4

General Tools .................................................................................. 4

Components .................................................................................... 4

Clean Up ......................................................................................... 4

Packing for Shipment ........................................................................4

Delivery to Site ................................................................................ 4

Design Considerations ......................................................................5

UltraSlim Extra Bright 9W LED Downlight Kit ................................... 5

InsulRoof® Span Table - Domestic Patios Single Spans (mm).........6

Domestic Patio Applications: Wind Classification .............................. 7

Patio Designs .................................................................................. 7

Fixing Recommendations ..................................................................8

InsulRoof® Flashing Details...............................................................8

Patio Construction Overview - Attached Flat/Skillion Patio ............9

InsulRoof® Installation Instructions ...............................................10

Step 1: Structure Preparation ........................................................ 10

Step 2: Panel Preparation .............................................................. 10

Step 3: Turn Up Roof Pans House Fascia End ................................. 10

Step 4: Trim Panel Overlap of House Fascia End ............................ 10

Step 6: Turn Panel Over ................................................................. 11

Step 7: Remove Rib at Fascia Gutter End ....................................... 11

Step 8: Electrical Preparation ........................................................ 11

Step 9: Peel Back Protective Plastic ............................................... 11

Step 10: Installing Panel ................................................................ 11

Step 11: Screw Ribs As Per Engineering ........................................ 11

Step 12: Insert Infill Strips ............................................................. 11

Step 13: Clean Down Roof ............................................................. 11

Step 14: Flashings ......................................................................... 11

Step 15: Overlap stitching screws ................................................. 11

Clean up and Maintenance ..............................................................12

Installation Checklist .......................................................................12

Core EPS-FR (Expanded Polystyrene with fire retardant additive) PUR (Polyurethane Foam)

Width (cover mm) 1000

Thickness (mm) 50, 75, 100, 125, 150, 200mm

Length Up to 12m (check for availability)

External Material 0.42mm G550 Colorbond® pre-painted steel

External Finshes Corrugated

Exterior Colour Options Classic Cream™, Surmist®, Paperbark®, Shale Grey™, Dune®, Pale Eucalypt®, Headland®**, Jasper®^, Basalt®^, Woodland Grey®^**, Zincalume™

Internal Material 0.6mm G300 Colorbond® pre-painted steel.

Internal Finshes Smooth, Elegance

Interior Colour Options Classic Cream™, Surmist®

Pitch 5 degree minimum 1:12 for roofing

BCA C1.10 as Group 2

Paint System AS 2728 & AS 1397-2011

Fire Hazard Properties AS 1530.3

Ignitability Index 0

Spread of Flame Index 0

Heat Evolved Index 0

Smoke Index 2-3

NOTES:1. Extended span tables including Region B, single span and multi-span wind pressure acting

inwards are also available. Refer Bondor®.2. Fixing with 14g tek screws (or equivalent) at 4 ribs per panel per support are required.3. Pressures specified are for wind gusts only per AS 1170.4. Deflection limit of span/150 applies, and in accordance with Serviceability Limit State

criteria per AS1170.0 - TABLE C1.5. Self weight of the panel has been allowed for, plus an allowance of up to 10kg/m2 for light

duty fittings (lights, etc.). No other dead loads permitted.6. Non-trafficable maintenance access (concentrated load) of 140kg (exceeding min.

requirements of AS/NZS 1170.1:2002) on any one panel has been allowed for. 7. Distributed live load of 0.25kPa (as per AS/NZS 1170.1:2001) has been allowed for.** Limited availability.^ Darker colours warranted for use in limited regions. Check with your local InsulRoof® dealer

for more information.

Panel Properties

Panel Thickness (mm) 50 75 100 125 150 200

Mass (kg/m2) 11.58 11.94 12.30 12.64 12.98 13.65

Thermal Performance at 15°C

‘R’ Value (m2K/W) 1.63 2.26 2.90 3.53 4.16 5.43

Thermal Performance at 30°C

‘R’ Value (m2K/W) 1.60 2.19 2.79 3.39 3.99 5.18

3InsulRoof® - Design & Install Guide

Insulroof® - Design & Install Guide solarspan®solarspan®

Ceiling Finishes Select from two popular ceiling underside finishes in either Smooth or Elegance that complement the home and offer stylish design options for your outdoor area.

Panel Overview

DimensionsRoof Colour Range InsulRoof’s colour range has been rigorously tested and hand picked with the support of BlueScope® Steel to offer roofing colours with the best thermal performance, made tough for Australian conditions.

Surfmist® Paperbark® Classic Cream® Pale Eucalypt® Manor Red®

Dune® Shale Grey® Basalt™^ Woodland Grey®^ Zincalume™

^ Darker colours warranted for use in limited regions. Check with your local InsulRoof® dealer for more information.

Smooth Elegance

Ceiling Colours

Surfmist® Classic Cream®

Insulation Layer• Outstanding thermal performance

• Choose from 50, 75, 100, 125, 150 & 200mm core thicknesses

• Service cabling ducts for ceiling lights and fans

Roofing Layer• Low pitch of 5° minimum

• Available in thermally efficient and modern colours

• Australian made and proven steel

Ceiling Layer• Ceiling underside pre-finished in choice of two colours

• Two ceiling finish options in Smooth or Elegance

• Low maintenance and durable steel

1000mm cover width

Thickness

19mm Nominal77mm Nominal 20mm

20mm



Required Tools & Equipment

Required Tools & Equipment• Personal Protective Equipment

• Long sleeves & pants

• Cut resistance level 5 gloves

• Eye protection

• Hearing Protection

• Enclosed footwear

General Tools• Saw Horse Stools (Padded)

• Rivet gun

• Multi-purpose step ladders

• Socket set (metric) for post bolts

• RH & LH Hand Tin snips

• Shifting spanner for roof pan turn ups

• Spirit Level

• Chalk Line

• Roof Screw Gun with Hex Head Adapters 5/32” R 14g Tek Adaptor

• Measuring Tape

• Towels or blankets to cover patio beams

• Shears to remove overlap (first panel only)

Components• Patio Structure

• InsulRoof® Roofing Panel

• Receiver Channel (for attached patios)

• Barge and Fascia Gutter Flashings

• Blind rivets (sealed)

• 14g class 4 metal/timber roof screws with Multiseal Cyclone Washer for Insulated Panel, as per engineering

• 8-15x15mm needle point screws with neoprene washer for overlap

• Profiled vermin protection and EPS-FR rib infill strip

Clean Up• Broom for cleaning swarf from roof

• Blower/Vacuum

Packing for Shipment

InsulRoof® sheets are packed to a maximum pack height of 1.2m with the number of panels per pack dependant on panel thickness, length and overall pack weight.

InsulRoof® panels are manufactured with a protective film applied to the ceiling skin. InsulRoof® panels can be marked externally on the insulated core with the panel number and/or length, on request.

Delivery to SitePanel packs should be secured using cargo straps spaced approximately every 2m with 600mm plastic cargo angles under the straps (refer to Figure 1a). Long 600mm angles must be place on top and bottom of panel pack to protect from straps. Do not overtighten straps, no depression in panel should be seen, back off on strap tension, panel skin should be flat (refer to Figure 1b). Unloading remains the client’s responsibility. For lifting panels >8.0m use of a spreader bar is recommended (refer to Figures 1c & d). Refer to Figures 1e & f and 4 for recommended steps to unload panels of less than and greater than 8m in length. Panels should always be kept dry and if placed on site, stored off the ground, slightly inclined, allowing adequate drainage and ventilation of the panel pack.

2m Max

Figure 1a Figure 1b

Figure 1c Figure 1d

Figure 1e Figure 1f



Design Considerations

InsulRoof® should be installed at a minimum pitch of 5° (or 85mm fall over 1 metre) to allow for adequate rainfall runoff and the roof lap facing away from prevailing wind to prevent flooding of side laps.

To maintain the minimum clearance height below the fascia beam and a suitable roof pitch, it may be necessary to design the structure as a ‘fly over’ as opposed to attaching the patio to the house fascia.

Gutter size (capacity), downpipe size and quantity should be considered carefully, taking into account local rainfall intensity and any additional rainwater runoff from other roof structures to eliminate overflow back in to the building structure or InsulRoof® panel.

InsulRoof® combines roofing, insulation and ceiling in one durable, functional and attractive panel. This all-in-one roofing solution offers the potential to create the ideal indoor or outdoor living environment in any climate. InsulRoof® features a high tensile COLORBOND® steel roof sheet with an attractive corrugated profile, a world first and patented SupaCore® dual insulating core, ranging from 50mm to 200mm thick, for insulation in all seasons and a flat or lightly profiled pre-painted COLORBOND® Surfmist® or Classic Cream® finish underside.

InsulRoof® roof panels have a 1000mm cover width and come in lengths up to 12m. The panel edge interlocks using a slip joint and has a pre-routed services duct to accommodate electrical services i.e. conduit for lighting.

While InsulRoof® is simple to install, there are a few considerations before you begin. To ensure InsulRoof® is installed correctly and performs to its maximum potential, review the following information. We have provided a checklist that can be used to verify InsulRoof® has been installed correctly.

UltraSlim Extra Bright 9W LED Downlight Kit

InsulRoof’s low heat ultraslim 9W LED downlight has been custom designed for Bondor® insulated roof products and outdoor use in patios and pergola applications. Our 9W LED Downlight provides an energy efficient lighting solution with up to 50,000 hours of operational use and covered by a 3 year manufacturer’s return to base warranty.

KIT INCLUDES

• 1 x UltraSlim Bright 9W Downlight

• 2 x Flush Trims (1 x White & 1 x Silver)

• 1 x 12m light extender lead

• AS Compliant for InsulRoof®

White Flush Trim

SILVER Flush Trim



Span (backspan)

HousePatio

Overhang

InsulRoof® Span Table - Domestic Patios Single Spans (mm)

Case A

3 Open Sides Freestanding

Case B

2 Open Sides

Case C

1 Open Side

Case D

Fully Enclosed

Case E

Free Standing

Wind Category

Panel Thickness

(mm)

A Max. Span

B Max.

Overhang

A Max. Span

B Max.

Overhang

A Max. Span

B Max.

Overhang

A Max. Span

B Max.

Overhang

A Max. Span

B Max.

Overhang

N1/N2

50 5400 1100 5260 1100 4950 1100 4350 1100 5400 1100

75 6900 1200 6450 1200 5600 1200 5150 1200 6900 1200

100 7500 1300 6900 1300 6300 1300 5490 1300 7500 1300

125 8100 1350 7700 1350 7200 1350 6200 1350 8300 1350

150 8900 1350 8400 1350 7950 1350 6700 1350 8900 1350

200 9900 1500 9900 1500 9200 1500 7600 1500 9900 1500

N3

50 5110 1100 4000 1100 3600 1100 3580 1100 5180 1100

75 6200 1200 5220 1200 4300 1200 3970 1200 6300 1200

100 6600 1300 5560 1300 4600 1300 4450 1300 6730 1300

125 7600 1350 6300 1350 5300 1350 4700 1350 7800 1350

150 8400 1350 6800 1350 5800 1350 4950 1350 8550 1350

200 9700 1400 7750 1400 6750 1400 5300 1400 9900 1400

N4

50 4330 1100 3300 1100 3000 1100 2730 1100 4570 1100

75 5120 1200 4160 1200 3680 1200 3250 1200 5420 1200

100 5450 1300 4500 1300 4000 1300 3700 1300 5760 1300

125 6150 1350 4850 1350 4200 1350 3850 1350 6700 1350

150 6600 1350 5170 1350 4400 1350 4000 1350 7250 1350

200 7500 1400 5650 1400 4700 1400 4200 1400 8350 1400

C1

50 4500 1100 4000 1100 3600 1100 3300 1100 4500 1100

75 5600 1100 4300 1100 4200 1100 3800 1100 5600 1100

100 6000 1100 4600 1100 4500 1100 4400 1100 6000 1100

125 6250 1100 5300 1100 4800 1100 4800 1100 6200 1100

C2

50 3800 900 3000 900 3100 900 2700 900 3800 900

75 4700 900 3600 900 3200 900 3100 900 4700 900

100 5100 900 3900 900 3500 900 3400 900 5100 900

125 5300 900 4200 900 3800 900 3600 900 5300 900

C3

50 2900 700 2000 700 2000 700 1400 700 2900 700

75 3600 700 2200 700 2150 700 1500 700 3600 700

100 4000 700 2500 700 2400 700 1800 700 4000 700

125 4250 700 2800 700 2700 700 2000 700 4200 700

Note: Longer spans are now available with InsulRoof 150mm & 200mm, now included with InsulRoof patio engineering. Speak to your local representative for more information.

* Overhangs shall not be greater than 25% of the immediate backspan. The above InsulRoof® span table is for use as a guide only for domestic patio covers attached to one-storey & two-storey homes. For full analysis please ask your builder, installer or engineer to use the InsulRoof® patio engineering available from your local dealer in reference to AS1170.2.

** Limited availability.

^ Darker colours warranted for use in limited regions. Check with your local InsulRoof® dealer for more information.



Cairns (C)Atherton (B)

Darwin (C)

Broome (C)

Port Headland (D)

Karratha (D)

Exmouth (D)

Carnarvon (D)

Townsville (C)

Bundaberg (C)

Rockhampton (C)

Toowoomba (A) Brisbane (B)

Sydney (A)

Wollongong (A)

Newcastle (A)

Launceston (A)

Hobart (A)

Melbourne (A)

Canberra (A)

Adelaide (A)

Mount Gambier (A)

Geelong (A)

Perth (A)

Albany (A)

Kalgoorlie (A)Geraldton (B)

Domestic Patio Applications: Wind ClassificationThis is an approximate method for estimating wind speeds for domestic structures. Refer to Australian Standard AS/NZS1170.2:2011 for a full analysis.

Determine your Wind Region A, B, C, D

Domestic Patio Applications: Wind Speed Examples

Location Classification

Region A

Region B

Region C

Region D

Flat Suburbs REGION A - N1(W34), REGION B - N2 (W40)

and REGION C - C1 (W50)

<< Prevailing Wind

<< Prevailing Wind

Structures built adjacent to an oval or open area with prevailing winds. REGION A - N2 (W40), REGION B - N3

(W50) and REGION C - C2 (W61)

Structures on undulating terrain in suburbs REGION A - N2 (W40), REGION B - N3 (W50) and

REGION C - C2 (W61)

Structures on undulating open terrain REGION A - N3 (W50), REGION B - N4 (W61)


The first row of buildings adjacent to the sea front REGION A - N3 (W50), REGION B - N4 (W61)


Extremely severe - isolated building on the crest of a hill REGION A - N4 (W61)

Patio Designs

Flyover Attached Skillion Free Standing

Gable Two Storey Carport

Granny Flat Enclosed Boat Port



Hex Slot Head with seal 8-15x15mm needle point

screws @ 1m centres

Slip Joint

Services Duct

Side Lap

Fixing Recommendations

The InsulRoof® side lap should be laid away from the prevailing wind and sit neatly on the preceding roof sheet. Use Bondor® recommended insulated roofing fasteners along with cyclone caps with multi-seal neoprene washers fixed as specified in the InsulRoof® patio engineering. Fix side laps at approximately 1000mm centres using a 8-15x15mm needle point screw with a neoprene washer (available from Bondor®). Fascia gutter flashings should be fixed using sealed rivets in the valley.

Non Cyclonic Fixing - through every 3rd rib (5)*

Fastener Size Selection

Fixing to Steel (minimum 1.0 BMT) Fixing to Timber

InsulRoof® crest fixing only. One fixing required

per crest.

Panel Thickness

(mm)

Panel Thickness

(mm)

50 14-14x125 hex head screw with cyclone washer 50 14-10x125 type 17 screw with cyclone washer






* Refer to patio engineering for fixing details in various wind categories. ** Series 500 screws are also available for fixing to thicker steel. Check with Bondor® for availability.

Cyclonic Fixing - through every 2nd rib (7)*

* Refer to patio engineering for fixing details in specific wind categories.

InsulRoof® Flashing Details

For residential housing and commercial applications, other detail drawings are available. Please contact Bondor® in your state to request a copy.

Suits 50mm Suits 75-200mm Suits 50-200mm

Fascia Gutter End Flashing

Side Barge Flashing Top Barge Flashing Fascia Gutter End

Flashing Side Barge Flashing Top Barge Flashing

1.0mm Receiver Channel

& 0.55mm Apron

Panel Thickness + 25mm




Apron Flashing

Lapping



Patio Construction Overview - Attached Flat/Skillion Patio

The below overview is conceptual only. Contact Bondor® or your reseller, for InsulRoof® Patio Engineering certified construction details.

Detail D - Side Barge Detail

COLORBOND® side barge flashing

COLORBOND® side barge flashing

Steel post by others

14g Hex head screw with multiseal cyclone washer

Tek screw fixing

Fascia/Rafter strengthener by others

House fascia (timber)

Silicone seal between receiver and fascia

InsulRoof® insulated panel roof

InsulRoof® insulated panel

ceiling

Turn up roof pans to full rib height

Rivet fixing at each pan 600mm centres

Rib infill strip

Receiver Channel

Apron flashing

Profiled pan infill stripRivet fixing

Rivet fixing at 300mm centres

Gutter bracket by others

Gutter by others

COLORBOND® fascia flashing by others

Rivet fixing at 600mm centres

Self-drilling screw fixing by others

Post foot by othersMasonry anchor fixing by others

InsulRoof® panel roof

Rivet fixing at 600mm centresRivet fixing at 600mm centres

Rivet/Tek screw fixing

Detail C - Fixing Post to Ground

Detail A - Fixing to Posts

Detail B - Fixing to House



Handy Tips

Prepare your carpenter’s trestles (or similar work platform) by taping soft material or foam to the top of the trestles.

InsulRoof® Installation Instructions

InsulRoof® Installation Instructions - This example shows a typical installation to an existing house timber fascia. For other examples, visit www.insulroof.com.au

✓✗

Step 1: Structure PreparationFix the InsulRoof® receiver channel to the house fascia using appropriate fasteners as per InsulRoof® Patio Engineering. Apply to the receiver channel a thick continuous bead of silicone to the top of the back face of the receiver channel for protection against water ingress retained behind the receiver or to the patio floor below.

Install patio structure, including posts and beams to manufacturer’s specifications, ensuring the frame is square, checking diagonals.

Step 2: Panel Preparation Carefully lift panels directly from the pack without dragging panels and place roof side up on padded trestles.

Trim side overlap (first panel only)

FIRST PANEL ONLY, trim the side overlap using shears to prevent obstruction during the side barge installation.

Trim Overlap

Tin snips

Step 3: Turn Up Roof Pans House Fascia End At the house fascia end (receiver channel end) of the panel, cut out a small ‘V’ in the foam below each pan with the boot knife. Use the shifting spanner to turn up roof pans to the full rib height, being careful not to over bend and tear the steel skin.

Figure 1a Figure 1b

Step 4: Trim Panel Overlap of House Fascia EndTrim the overlay rib corner at the house fascia end (receiver channel) to prevent fouling with the turned up pan of the adjacent panel.

Figure 2a



Step 6: Turn Panel OverCarefully lift panel off trestles without dragging and place ceiling side up.

Step 7: Remove Rib at Fascia Gutter EndRemove the SupaCore® insulation material from ribs using a boot knife or multi-tool with wire brush without damaging/scratching the paint protected steel underside.

Step 8: Electrical PreparationMark the location of each downlight/fan, cut appropriate size hole in the ceiling of InsulRoof® panel. The ceiling core-strip protective film should be left on while any marking, drilling and cutting is carried out. Additional service ducts can be routed using an auger or spade extended drill bit.

Step 9: Peel Back Protective PlasticPeel back the plastic core-strip coating from all four edges of the panel, 50-100mm depending on beam & receiver channel location on the panel. Remove completely at project completion.

Figure 3a

Step 10: Installing PanelPlace a towel or blanket over the beams to protect InsulRoof®’ pre-painted ceiling. Place the roof panel cutback end (gutter or low end) on to the covered beam and then push the panel back into the receiver channel. Ensure panel is square with beam and fascia and pin with a screw fixing through a middle rib and a single rivet underneath the receiver channel to hold square in place. Continue to move the blanket down the beam.

Install the second and subsequent panels by placing the roof overlap over the previously fitted panel and with the panel at approx. 20* pull it down and engage the male interlock into the female interlock. Be sure to undertake (Step 4 – trim overlap & Step 5 – trim underlay rib) for each panel and check the ceiling joint is a neat ‘v’ with a 0-2mm gap.

Step 11: Screw Ribs As Per EngineeringScrew fix the InsulRoof® to the beam as per patio engineering fixing details and rivet the bottom of the receiver channel ensuring your line is square. Most non-cyclonic regions require (5) fixings each overlap and every 3rd rib and cyclonic regions every 2nd rib.

Fixings Every 3rd Rib (5)

Fixings Every 2nd Rib (7) for Cyclonic and as noted.

Step 12: Insert Infill StripsInsert foam infill strips into the last rib at the gutter end and profiled foam into receiver channel.

Step 13: Clean Down RoofOnce roof fixings are installed use a soft broom to sweep swarf and debris off roof surface before installing flashings. Once flashings and gutter are installed, clean the flashings and roof using the same method.

Figure 4a

Step 14: FlashingsInstall flashings for receiver, fascia and barge, gutters and downpipes as per AS HB 39. Ensure gutters are clear from swarf and debris to prevent corrosion. A wet microfiber cloth can be used on COLORBOND® to clean down any marks.

Step 15: Overlap stitching screwsStitch InsulRoof® roof overlap at 1000mm centres with 15mm stitching screws with neoprene washer.

www.insulroof.com.au1800 763 707

*InsulRoof® Standard Warranty and BlueScope Steel conditions apply. Metecno Pty Limited. ABN 44 096 402 934. The manufacturer reserves the right to change the specification without notice. Bondor® and InsulRoof® are trademarks of Metecno Pty Limited. BlueScope, COLORBOND®, Permagard® and colour names are trademarks of BlueScope Steel Limited. The colours shown in this publication have been reproduced to represent actual product colours as accurately as possible. However, given printing limitations, we recommend checking your chosen colour against an actual sample before placing orders. This advice is of a general nature only. Designers must provide for adequate structural performance and other Building Code requirements. This information is subject to change. Refer to Bondor® website for latest version. Consult Bondor® for your application. BON0301 InsulRoof Install Guide v18 - 28/08/2017

Clean up and Maintenance

Ensure all metal filings (swarf) are swept off and disposed of into bins as you install each sheet. These filings can leave unsightly stains on the surface of the sheet and also on floor tiles/pavers, etc, in the near vicinity.

Intermittent cleaning of all surfaces not washed by regular rainfall will prolong the life of the products and keep them looking their best. A mild detergent solution is recommended ensuring the surfaces are always wiped off with clean water afterwards. Hosing of the ceiling is to be avoided as it will cause water to sit inside panel joins and flashings leading to possible corrosion.

Installation Checklist

Description Completed (tick) Name/Signed

Pitch equal to or greater than 5 degrees

All roof pans turn up at roof high point (house fascia end)

Trimming of underlay

Downpipe selection suitable

Clean down of roof and gutter (removing any swarf)

Any incorrectly drilled holes are sealed

Electrical completed by Licensed Professional

True Beauty - solarspan.com.au · Outer Beauty Steel Roof & Ceiling Your next generation corrugated...

Documents

Transcript of True Beauty - solarspan.com.au · Outer Beauty Steel Roof & Ceiling Your next generation corrugated...