SMART ROOFS AFFORDABLE HOUSING LEISURE HOUSING STORAGE BUILDINGS BARNS GARAGES & CARPORTS GARDEN OR WOOD SHEDS.

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1 SMART ROOFS AFFORDABLE HOUSING LEISURE HOUSING STORAGE BUILDINGS BARNS GARAGES & CARPORTS GARDEN OR WOOD SHEDS DURACOR DURACOR

2 AN UNIVERSAL TYPE OF ROOFING AFFORDABLE WATERPROOFING PANELS FOR ROOFING APPLICATIONS DURACOR 10 is a lightweight roofing solution, extremely tough, offering guaranteed protection for buildings, the people inside and their belongings. The DURACOR 10 sheet is ideal for a wide range of roofing applications. Thanks to its unrivalled versatility, DURACOR is suitable for many kind of projects. A UNIQUE ROOFING MATERIAL DURACOR 10-3 MAIN QUALITIES: Lightweight: only 6.1 kg per sheet (3,2 kg/m²), can be fixed on lightweight carpentries or lightweight metallic structures. Flexible, ideal for new building as well as for renovation works. Does not break during transportation and installation. Entirely asbestos-free. Never rusts. Green: environmental friendly production, based on recycled materials. Contains no hazardous chemical. 1 2 AN EFFICIENT SOLUTION FOR EVERY INSTALLER Fast to install. Easy to reach perfect waterproofing. Practical and safe to use: easy to handle, carry on the roof, cut, shape and fix. Easy to stock and to transport. 3 A 10 year waterproofing warranty is provided with DURACOR 10 corrugated bitumen sheets. This warranty is only valid if the following instructions are respected: Installation is made in total respect of the instructions provided in this installation Guide. DURACOR roofing system is installed with specified accessories and fasteners. A CLEVER CHOICE FOR THE USERS Price efficient. Excellent waterproofing characteristics. Safe for the environment: Rainwater collected from an DURACOR 10 sheet is suitable for all cultivation purposes. 3 4

3 DURACOR 10 TECHNICAL SPECIFICATIONS RECOMMENDATIONS DIMENSIONS AND PHYSICAL SPECIFICATIONS WATERPROOFING WARRANTY Length 2000 mm (tolerance -4 ; +20) Width 950 mm (tolerance -20 ; +20) Thickness +/ mm ((tolerance -0.1 ; +0.5) Gross Surface 1,9 m² Corruga ons 10 Corruga on Width 95 mm (tolerance -3 ; +3) Corruga on Height 38 mm (tolerance -2 ; +2) Weight (nominal) Full Weight EN 534 (European norm for Bitumen sheets) 3.2 kg/m² (tolerance 3.2 kg / 3.4 kg) 6.1 kg/sheet (tolerance 6,1 kg / 6,5 kg) Category R SNI :2012 Corrugated bitumen sheets. Product specifica ons and test methods Cer fied Produc on ISO 9001:2008 Thermal Conduc vity (λm) 0,099 W/(m.K) Thermal Resistance (Rm) (corrugated) m² K/W Sound Resistance (R) 28 db Wind upli resistance 3000 Pa (~225 km/h on metal purlins), 4000 Pa (~260 km/h on wooden purlins) Fire reac on Class E (Norm EN ISO ) Length Width Weight Surface RIGDE ELEMENT 1000 mm 485 mm 1.31 kg 0.49 m 2 A 10 year waterproofing warranty is provided with DURACOR 10 corrugated bitumen sheets. This warranty is only valid if the following instructions are respected: Installation is made in total respect of the instructions provided in this installation Guide. DURACOR 10 roofing system is installed with specified accessories and fasteners. TROPICAL CLIMATE DURACOR 10 can withstand severe conditions as long as specifications are followed (notably max spacing between purlins and roof slope). In the case of severe heat conditions, DURACOR 10 must be installed in the morning, at freshest hours. Never walk on the roof when it is hot (never walk directly on the roof in general, always use a plank). HANDLING AND STORAGE For long term storage, stack the crated pallets with single stacked undercover in a warehouse and do Tariff Custom Code HS: not be exposed to the direct. For short term, storage on site cover sheets and store flat on timber bearers. SAFETY ON JOB SITE Lift the sheets without dragging across it to avoid TECHNICAL PARAMETERS the scratch on the surface and can be handled using conventional techniques for corrugated sheeting. IMPACT RESISTANCE Sheets are flexible and should only suffer deformation under soft body impact. Anyhow they might be punctured by hard body impact (such as an hammer falling down) or crushed if heavy loads are placed on it. At all the time, observe standard good safe roofing practices in accordance with local and country regulations. Before starting to work on the roof assess potential risks and organize your job site accordingly. Ensure that tools and equipment are in good condition to perform the job, especially ladders, hand and power tools and safety harness. Make sure electrical equipment is earthed or isolated. Take special care in windy or wet conditions. To prevent accidents, contractors must install planks, ladders or walkways before walking on the roof. Where impossible, project site manager should ensure that workmen walk only over the battens. For walls, ladders required for subsequent wall installation work or maintenance must have a board placed behind the end of the stiles to spread the load over the framing underneath. 5 6

4 DURACOR 10 INSTALLATION REQUIREMENTS APPLICATION PRINCIPLES GENERAL APPLICATION GUIDELINES ROOF PITCH: 5 TO 10 ROOF PITCH: 10 TO 15 AT LENGTHWISE OVERLAPS, A FASTENER SHOULD BE FIXED ONTO EACH CORRUGATION TO FIX TWO SHEETS TOGETHER AT CONSECUTIVE ROWS, STAGGERED APPLICATION IS NECESSARY FOR THIS PURPOSE, THE LAYING OF THE SECOND ROW SHOULD BE STARTED USING A HALF SHEET. USING A BROKEN BOND PATTERN REDUCES THE OVERALL THICKNESS OF THE STRUCTURE. PRECAUTIONS SHOULD BE TAKEN AGAINST WIND AT FACES. Laying direction Prevailing wind direction Full deck Minimum Angle: 10 (18%) Minimum Angle: 5 (9%) ROOF PITCH: >15 AT WISE OVERLAPS, AN ADDITIONAL CORRUGATION SHOULD BE OVERLAPPED AND THE FASTENERS SHOULD BE FIXED SO THAT THEY WOULD FIX THE TWO SHEETS TOGETHER SHEETS SHOULD ALWAYS BE DRILLED ON THE TOP OF THE CORRUGATIONS ALL THE APPLICATION PRINCIPLES VALID FOR EVERY INFRASTRUCTURE SYSTEMS AND PITCHES ARE INCLUDED IN THE INFORMATION BELOW THE OVERHANG AT THE EAVES MUST NOT EXCEED MAXIMUM 7 CM Sheets should always be drilled on the top of the corruga ons. Minimum Angle : 5 (9%) Minimum Angle: 15 (27%) Slope in Degrees >15 Slope in % 9 to 17% 18 to 26% >27% Purlin Spacing Decking or close purlins Overhang at eave 7 cm 7 cm 7 cm Sheet End-lap 32 cm 20 cm Slide lap 2 corruga ons 1 corruga on 1 corruga on Fasteners / sheet

5 ROOFS PITCHES OVER 15 DEGREES (ABOVE 27%) ROOFS PITCHES BETWEEN 10 AND 15 DEGREES (18% TO 26%) ON WOOD FRAMING ON METAL FRAMING ON WOOD FRAMING ON METAL FRAMING 20 cm 20 cm Dessin 08 Dessin 10 Dessin 11 Dessin 06 Dessin 06 APPLICATION WITHOUT HEAT INSULATION Dessin 41 Dessin 42 APPLICATION WITHOUT HEAT INSULATION Dessin 41 SECOND ROW SHEET 1/2 FULL SECOND ROW SHEET 1/2 FULL Purlin distance: 610 mm maximum Purlin distance: 450 mm maximum End lap: 170 mm minimum End lap: 200 mm minimum Side lap: 1 corrugation minimum Side lap: 1 corrugation minimum Overhang: 70 mm maximum FIRST ROW Overhang: 70 mm maximum FIRST ROW Fixings: Net coverage surface: 19 fasteners to fix each sheet 1.59 m² VERGE ALTERNATE CORRUGATION 70 mm max EAVE 1 st FASTENER 2 nd FASTENER AT OVERLAP NOT FIXED UNTIL NEXT SHEET IN PLACE Fixings: Net coverage surface: 18 fasteners to fix each sheet 1.45 m² VERGE ALTERNATE CORRUGATION 70 mm max EAVE 1 st FASTENER 2 nd FASTENER AT OVERLAP NOT FIXED UNTIL NEXT SHEET IN PLACE Dessin 09 Dessi 9 10

6 5-10 MATERIAL ESTIMATION ON DECKING ON METAL FRAMING A. For pitches superior than 15 degrees B. For pitches between 10 and 15 degrees C. For pitches between 5 and 10 degrees 50 cm 30 cm 30 cm With single corrugation side lap (95 mm) and 170 mm end lap. Severe driving rain exposure should have a double corrugation side lap (2x95 mm). With single corrugation side lap (95 mm) and 170 mm end lap. Severe driving rain exposure should have a double corrugation side lap (2x95 mm). With 2 corrugations side-lap and 300 mm end lap. 50 cm 50 cm Dessin 13 From roof plan, measure entire area by marking into squares. From roof plan, measure entire area by marking into squares. From roof plan, measure entire area by marking into squares. Number of sheets: Divide the area by 1.59 Number of sheets: Divide the area by 1.45 Number of sheets: Divide the area by 1.26 SECOND ROW FIRST ROW VERGE SHEET 1/2 FULL ALTERNATE CORRUGATION Dessin mm max EAVE 1 st FASTENER 2 nd FASTENER AT OVERLAP NOT FIXED UNTIL NEXT SHEET IN PLACE SECOND ROW FIRST ROW SHEET 1/2 FULL Other Method: A. Take the measurement from the gutter to the ridge and divide by 1.80: this will give you the number of sheets deep. B. Measure the length of the gutter line and divide by and this figure will be the number of sheets wide. Multiply a x b and this equals the number of sheets required for this area. Other Method: A. Take the measurement from the gutter to the ridge and divide by 1.80: this will give you the number of sheets deep. B. Measure the length of the gutter line and divide by 0.85 and this figure will be the number of sheets wide. Multiply a x b and this equals the number of sheets required for this area. Other Method: A. Take the measurement from the gutter to the ridge and divide by 1.70: this will give you the number of sheets deep. B. Measure the length of the gutter line and divide by 0.76 and this figure will be the number of sheets wide. Multiply a x b and this equals the number of sheets required for this area. Dessin 15 VERGE ALTERNATE CORRUGATION 70 mm max EAVE 1 st FASTENER 2 nd FASTENER AT OVERLAP NOT FIXED UNTIL NEXT SHEET IN PLACE Depending on project size, you may decide to multiply by 1,05 or 1,1 to add 5 or 10% margin in order to compensate the material loss (cut) on jobsite Depending on project size, you may decide to multiply by 1,05 or 1,1 to add 5 or 10% margin in order to compensate the material loss (cut) on jobsite Depending on project size, you may decide to multiply by 1,05 or 1,1 to add 5 or 10% margin in order to compensate the material (cut) loss on jobsite Dessin 16 ROOFS PITCHES BETWEEN 5 AND 10 DEGREES (9% TO 17%) APPLICATION WITHOUT HEAT INSULATION Number of ridges: Measure the length of ridges and hip and divide this figure by 0.78 Number of ridges: Measure the length of ridges and hip and divide this figure by 0.78 Number of ridges: Measure the length of ridges and hip and divide this figure by 0.78 Purlin distance: Fixing on decking or very close purlins ( spacing maximum) Overhang: 70 mm maximum Number of fasteners: Multiply the number of sheets by 19 Number of fasteners: Multiply the number of sheets by 18 Number of fasteners: Multiply the number of sheets by 14 End lap: Side lap: 32 mm (30 mm minimum on full deck) 2 corrugations Fixings: Net coverage surface: 14 fasteners to fix each sheet Effective 1.26 m² 11 12

7 FIXING STEPS SHEET LAY OUT SELECT THE CORRECT TYPE OF DRILL SCREW TO SUIT PURLIN TYPE Start fixing sheets at the opposite end of the roof from prevailing winds. Cut a sheet in half vertically, and use to lay sheet courses in a broken bond pattern. Using a broken bond pattern allows to limit the over thickness of 4 sheets layer at joining corners. This avoids having to cut the sheets at corners. SCREW WITH WASHER METAL PURLIN Dessin 19 SCREW WITH WASHER METAL PURLIN SCREW WITH WASHER Dessin 20 SCREW WITH WASHER METAL PURLIN METAL PURLIN Dessin 18 Dessin 21 Washer minimum diameter: 16 mm 13 14

8 DURACOR 10 INSTALLATION DETAILS 1 2 RIDGES HIPS DURACOR Ridge element is manufactured from the same material and to the same high specification as the sheets. Flexible double wings accommodate a wide range of roof angles. HIP DETAIL (14 cm min) Install hips before ridge. Lay support boards and trimming purlins. Fix the ridge units to trimming purlins. Cut and dress units and overlay with ridges. 12,5 cm Start fixing the ridge at the opposite end of the roof from prevailing winds and maintain a 12.5 cm overlap Dessin 23 minimum. Use a string line to align and fix at every corrugation. The ridge should overlap the top sheet by a minimum of 14 cm. END ROOF 13 cm 9.5 cm 12 cm A. Using DURACOR ridges units. B. Using a piece of metal. 100 cm 88 cm IMPORTANT. On the top of the roof, each ridge is fixed on every corrugation. If the distance between the last intermediate purlin and the ridge purlin is too big, then install an extra purlin. Dessin 22 Length: 1000 mm Width (flat): 485 mm Thickness: 2,9 mm - Weight: 1.3 kg - Weight per m²: 2,7 kg 1. DURACOR corrugated roofing sheet 2. RIDGE ELEMENT 3. METAL PURLIN / WOODEN BATTEN 40/60 or 50/70 / FULL DECKING 4. FASTENER with washer, Ø 16 mm minimum RIDGE END-FINAL FIXING Finials can be cut from exterior quality plywood to finish ridge units at the verge

9 DURACOR 10 INSTALLATION DETAILS 3 VERGE 4 EAVES DETAILS The maximum sheet overhang at the eaves is 7 cm. Adjust the distance of the first purlin from the fascia accordingly. 70 mm WITHOUT VERGE ELEMENT On wood framing, fasten timber bargeboards level with top of finished DURACOR 10 roof. 5 EAVES TRAY The eaves tray can be made of plastic or metal. They may be used to reduce the overhang at eaves and secure waterproofing. 6 EAVES VENTILATION STRIPS WITH A VERGE ELEMENT OR A RIDGE ELEMENT WITH A METAL ELEMENT Fix to the eaves purlin to stop ingress of birds and large insects, whilst allowing free airflow Dessin 36

10 DURACOR 10 INSTALLATION DETAILS 7 VALLEYS 75 mm (min) 9 CURVED ROOFS/DOMES 50 cm 75 mm (min) 50 cm 36 cm 36 cm 36 cm 36 cm 36 cm centre 75 mm (min) 7 cm min. 500 cm Valleys are formed by lining a plywood base with metal or bituminous membrane. 8 Over the dome with a full sheet laid with double corrugations side lap and 30 cm end lap. Support on purlins at centres. For purlin centres on side walls revert to. WALL ABUTMENTS Wall abutments can be waterproofed with standard metal elements or with durable fashing tapes. Z profiles applied against the wall are recommended to ensure full watertightness