ALUMINIUM ROOFING.pdf
- 2. INTRODUCTION A metal roof is a roofing system made from metal pieces or tiles. It is a component of the building envelope. It makes noise when its raining . Sheet metal is available in flat pieces or coiled strips. The coils are formed by running a continuous sheet of metal through a roll slitter. There are many different metals that can be made into sheet metal, such as aluminum, brass, copper, steel, tin, nickel and titanium. For decorative uses, important sheet metals include silver, gold, and platinum (platinum sheet metal is als utilized as a catalyst.) Sheet metal is used for roofs of buildings (architecture) and many other applications . Sheet metal workers are also known as "tin bashers" (or "tin knockers"), a name derived from the hammering of panel seams when installing tin roofs.
- 4. Aluminum is also a popular metal used in sheet metal due to its flexibility, wide range of options, cost effectiveness, and other properties. Its properties include: Lightweight Corrosion- resistant Nonmagnetic Has a low melting point Has a good thermal and electrical conductivity Malleable Ductile ALUMINIUM as a roofing material
- 6. FEATURES: Durability: Aluminium roofing sheet is exceptionally durable. It builds its own resistance to atmospheric attacks in the form of an inert oxide film that is always present on its surface. Wind Resistance: Aluminium Roofing Sheets are strong enough to resist wind forces. However, because of lesser dead weight, cladding should be adequately fixed to the roof supporting structure. It is recommended to use wind ties for aluminium roofs in high wind zone areas. Appearance: Aluminium Roofing Sheets stay bright and reflective for many decades. These sheets can take a variety of finishes, colours and textures, which add further to its beauty, protection and, in turn, improve the aesthetics of the building structure. Staining, discoloring, rusting or rotting does not take place throughout the life span of Aluminium roofing sheets. Low Weight: Lightness has been epitomized as one aluminium’s outstanding properties.Aluminium is about one-third as light as corrugated galvanized steel sheet of the same section and about one-seventh the weight of standard sheet of the same profile. Working with light and easy-to-handle material leads to substantial reductions in time spent on and cost of labour, transportation, handling and construction.
- 8. ADVANTAGES Corrosion Protection: Avoidance of galvanic corrosion which can be a problem when aluminium is in contact with certain other metal in a corrosive atmosphere. 2.Design Versatility:. *Can be curved *Outstanding durability *High performance *Simple and fast installation by trained personnel *Wide selection of colours *A range of gauges, shapes and profile options *Fully recyclable *Environmentally friendly *A complete range of components and accessories. OF ALLUMINIUM ROOFING
- 9. 3.Efficiency: *Aluminium corrugated sheet has a built-in corrosion resistance *It can stand unprotected where it is subject to the aggressive elements *Aluminium roofing sheet is age resistance and non-sensitive to UV rails *Little or no maintenance required *High residual value *Recyclability 4. Environmental Friendly: *Only 5% of original energy used to produce Aluminium corrugated sheet is needed for recycling *Aluminium can be recycled for generations without limitations *Aluminium corrugated sheet is the third most commonly occurring elements in the earth’s crust. *Smooth curving and on site tapering, extreme resistance to wind uplift and excellent thermal properties are few key benefits of the superior weatherproof roofing solutions.
- 11. DISADVANTAGES Aluminum roofing has disadvantages to keep in mind when choosing this material: Cost: Aluminum roof is more expensive than roof shingles. Pay attention to the price of aluminum roofing. Dents on the roof: If you hit the metal, especially aluminum, it formed dents. However, metal roofs with anemone are stronger, so the problem disappears. Detachment and damage of the paint: As is colored material, there is a possibility of exfoliation of the paint, the formation of cracks and destruction of the coating. Change the size of the roof: By its nature the metal tends to expand and contract. This can lead to loosening of fasteners so the installation process of aluminum roofing should be approached with the utmost seriousness. OF ALLUMINIUM ROOFING
- 12. Corrosion Resistance: Aluminium continues to set the benchmarking standards for corrosion resistance. Aluminium Roofing Sheets have excellent corrosion resistance in desert and normal environments, and are also highly corrosion resistant in coastal and industrial environments. Aluminum normally needs no protective painting, which is an additional cost factor for steel roofs. However, protective paint is recommended to be used in severely corrosive atmospheres to enhance the life span of the roofing sheets. Finishes: All products have the same finish that is: *Mill finish in its natural sense *Aluminium corrugated sheet can be surface treated in a range of colour . Formability : *Aluminium corrugated sheet has excellent formability *It can be rolled, bent, pressed, die cast, roll formed, anodized etc.
- 13. MANUFACTURING PROCESS Roll-forming Standing Seam Panels All standing seam metal roofs go through a roll-former – a machine that turns a metal coil into actual metal roofing panels. The roll former machines can be outfitted with different panel profiles, mechanized or manual shears, computer controller unit, portable or stationary platform / trailer, uncoilers, built-in 10000 watts generator, and other upgrades, depending on the purposes of its use and how much you want to spend. The basic process of making standing seam panels involves feeding metal coil into a roll-former. – Once inside a roll- former, the metal coil goes through a series of rolls, which make bends and curves. – Each successive roll makes more of a bend than a previous one. These rolls are made of hardened stainless steel for increased lifespan and durability The bottom line is that running a metal roofing panels manufacturing facility is quite costly, and all work must be coordinated between the guys that make the panels and the sheet metal shop. Most of the time, to simplify things, the roll-forming machine is located in the shop, on the transportable trailer, and is only taken to a job-site when the job is far from the shop, and panels are too long to be transported by conventional means. Often, metal roofing contractors who own a roll-forming machine, and manufacture their own standing seam panels, employ an independent sheet metal shop to produce their flashing and accessories, as running a fully equipped shop can be afforded only by bigger, commercial size roofing contractors.
- 14. ROLL FORMING MACHINE SHEET METAL COIL
- 15. ACTUAL PROCESS First of all, metal roofs can be made from steel, aluminum, zinc, copper, and even stainless steel. However, galvanized steel and aluminum are the most popular metals, and we will concentrate on these two. There are about four or five large suppliers of metal roofing coil in steel, and two or three in aluminum, with smaller players picking up the slack. Sheet metal coil: All of these guys basically take a thick metal coil, and run it through rolling machines, to reduce the thickness to a required grade – usually 29, 26, 24 and 22 gauge in galvanized steel, and .032? / .040? in aluminum. The steel coil also undergoes a hot-dip galvanization process, where the coil runs through a pool of boiling galvanic mix of molten zinc (G-90 galvanization) or a mixture of zinc and aluminum (Galvalume). Once the coil is dipped in the hot galvanic metal, a thin galvanization layer is formed all around an otherwise highly corrosive steel. Then the coil is run through an annealing machine, which is basically a hot furnace with cooling tubes and ammonia gas inside the chambers. Annealing softens the metal, which can then be easily rolled down to the required thickness. Aluminum coils do not require galvanization and just go through an annealer machines and then get rolled down.
- 16. Applying Solar Reflective Paint (Kynar 500) is done once a metal coil has been galvanized and cleaned. The coil is then fed into a special “painting machine”, which is a series of separate units, each responsible for its own operation. First, the coil is thoroughly cleaned and dried. Then it goes through a primer application chamber, where primer is applied to both sides of the coil. Then it goes through a baking chamber where the coil is dried at a high temperature, and primer is baked on. Then another primer and bake-on drying process happens for better, more even primer application. Once the coil has been primed, and primer has cured in the “baking” chamber, it goes through the painting cycle, which is essentially the same as priming, only the main color is added to the coil in two layers on top. Usually a white coat is added to the underside of the coil, which once again goes through the baking / drying cycle. Then the coil is run through an annealing machine, which is basically a hot furnace with cooling tubes and ammonia gas inside the chambers. Annealing softens the metal, which can then be easily rolled down to the required thickness. Aluminum coils do not require galvanization and just go through an annealer machines and then get rolled down. Applying Solar Reflective Paint (Kynar 500) is done once a metal coil has been galvanized and cleaned. The coil is then fed into a special “painting machine”, which is a series of separate units, each responsible for its own operation. First, the coil is thoroughly cleaned and dried. Then it goes through a primer application chamber, where primer is applied to both sides of the coil. Then it goes through a baking chamber where the coil is dried at a high temperature, and primer is baked on. Then another primer and bake-on drying process happens for better, more even primer application. Once the coil has been primed, and primer has cured in the “baking” chamber, it goes through the painting cycle, which is essentially the same as priming, only the main color is added to the coil in two layers on top. Usually a white coat is added to the underside of the coil, which once again goes through the baking / drying cycle.
- 18. MANUFACTURERS Once the coil is painted, it gets shipped to various metal roofing manufacturers .These guys slit the coils to their standard widths and cut them into smaller coils instead of huge coils, which come from coil manufacturers. These smaller coils are then either formed into different types of metal roofing panels or sold off to smaller sheet metal shops or contractors with roll-forming machines, who either install them, or resell them to metal roofing contractors. The bottom line here is that most standing seam metal roofs are virtually the same product, as most of them use standard Snap-Lock or Mechanical Lock profiles (under different names of course), and the coil usually comes from the same three or four places. The difference is in price, warranty and manufacturer-specific custom panel profiles.
- 20. INSTALLATION:- 1) Measure the area. Before you can begin to update your roof, you will have to get an accurate measurement and order your materials. Always try to measure from the ground first in order to keep yourself safe. If you must climb onto the roof to measure the space, be sure to use caution. Find out the slope of your roof. The slope is given as rise-over-run, meaning the distance up over the distance over. This measurement will typically be a measurement over 12 inches (30.5 cm), something like 4/12 or 8/12. Convert this to the equivalent in degrees and as a decimal. Use the slope factor to determine the area of the roof. Measure the area (length x width) on the ground, and then multiply this by the slope (in decimal form). This means the slope factor form is: length x width x slope. This will give you the number of square feet that need to be covered. For example, if your roof measures 10 feet (3.0 m) x 10 feet (3.0 m) and the slope of the roof is 12/12 (45 degrees, which converts to 1.414 in decimal form), you would multiply 10 x 10 x 1.414, to get the total of 141 square feet of roofing. Find the square footage for the entirety of your roof, and add up the total to find out how much metal roofing you need to order. Allow for a minimum of 10% waste (extra roofing).
- 21. 2) Get your materials. You will most likely have to order the roofing metal in the amount and color specific to your house. You will also need a large garbage can, a jigsaw or power metal shear, a staple gun, a drill and assorted drill bits, 1¼ inch roofing nails, metal roofing screws, and self drilling, self- sealing wood screws. Image titled Install Metal Roofing Step 3 3) Prepare a work site. In order to make your installation as easy as possible, it is important to have a well- organized work area. You will need a large bin for trash (old roofing and debris), a place for tools, and your scaffolding or ladder set up. Make sure that if you are using electric tools that none of the chords are in the way. Store the material in a readily accessible area, protected from the weather. The panels are weather-proof but staining can occur if left open to moisture 4) Remove the old roofing. Although you can install corrugated metal roofing over shingles, for the best foundation it is recommended that all the old roofing be removed. Work at a slow and steady pace, not trying to rip-up or carry-off too much old roofing at once. Start from the highest, furthest point and take up all the old shingles, flashing, vents, and boots. You should be replacing all these with the new metal roofing.
- 23. If you come across any large nails that are sticking out, either remove them and put them in your debris container or hammer them in deep so that they aren’t a danger to anyone working. If you need to reposition your gutters, do so at this point. Always remove the old roofing on a day (or set of days) when the weather is expected to be dry and sunny, as you don’t want any rain or moisture to seep into your building. 5) Repair any damage. With the old materials removed, the bare bones of the roof frame or plywood sheathing will be exposed. If there is any damage to the sheathing (the wood under the shingles), insulation, or ventilation, fix it now. 6) Add your insulation layer. This helps to block out moisture from getting trapped between the metal roof and the sheathing. Use roofing felt to cover the entirety of the roof and secure it with a staple gun or nails
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