Insulated Panels. Insulated Roof Systems. Kingspan X-dek. KS1000 XD Longspan Roofpanel. Systems. Insurer Approved

Transcription

1 Insulated anels Insulated Roof Systems ingspan X-dek S1000 XD Longspan Roofpanel Insurer Approved Systems

2 Clear span Capability of up to 6 meters X dek TM Frame-to-Frame Long Spanning Insulated Roof Deck X dek TM is an insulated roof deck combining a structural deck, FIREsafe insulation and a metal top sheet into one product. Designed to support a choice of site applied standing seam or membrane finishes, X dek TM provides a clear span capability of up to 6 metres, and is faster to install than alternative built-up roof deck systems. The internal face of the deck is pre-finished with a fresh white inner finish, providing a smooth clean interior appearance. X dek TM is suitable for flat roof applications and is available with a ingspan Warranty guaranteeing the thermal and structural performance of the panel for up to 25 years. ingspan X-dek 1

3 Faster to install than alternative built up roof systems Introduction Contents Introduction 1 ey Features 3 Design Versatility 5 Green Roofs 6 roduct Data 7 ingspan Roof anel S1000 XD X dek TM 9 Fixing solution 10 Load Span Tables 11 Site Handling and Installation 21 Build Speed 22 Construction Details Ridge 13 Valley Detail 13 Cut-back Detail 14 But joint Detail 14 Roof to Brickwork Junction 15 Gable Wall arapet 16 Roof/Skylight 17 Smoke Vent 17 Eaves Detail 18 Eaves Detail 19 External Gutter Detail 20 Expansion Joint 20 ingspan X-dek 2

4 ey Features X-dek TM is a frame-to-frame insulated structural roof deck ey features include: Structural & Design Up to 6 metre spanning capability. Suitable for flat roof applications. Choice of membrane suppliers. Choice of standing seam systems. Requires no/limited secondary steelwork. Lengths available up to 15 metres. rovides a clean internal pre-finished interior building surface. Fast Installation Ability to use pack-to-roof mechanical handling removes need for manual handling. Reduced time on roof due to ease of installation. Reduction in quantity of components traditionally used on site eg. vapour control layer, fasteners etc. Facilitates earlier slab, services and fit-out trades - providing faster project completion and handover. Accelerates roof construction time. Internal Clean, white internal appearance Suitable for suspension of internal lighting, secondary sprinkler pipe runs, heating/cooling ducting, roof ventilation & others, please consult the ingspan Technical Service. Guarantees & Warranties X-dek TM is covered by the ingspan Warranty, providing a guarantee of up to 25 years for thermal and structural performance. ingspan X-dek 3

5 X-dek requires less steelwork and therefore leaves a more aestetically pleasing finish. ey Features X-dek TM Flat Roof X-dek TM Flat Roof Conventional Flat Roof Built-up assembly System Benefits re-engineered, frame-to-frame structural insulated roof deck. Fully complies with national safety requirements. Suitable for frame-to-frame spanning of up to 6 metres. Rapid, single component, single-fix installation up to 1,200m 2 per day. End-of-life solutions are available. U-Value 0.19 W/m 2. X-dek TM can contribute significantly to the air tightness of roof solution due to lack of cavities between steel deck and insulation Firesafe insulated panel system. Can be used as part of the flat roof system (XD TR 20, XD TR 27, XD Steel) or as a unique complete system (XD VC available). ingspan X-dek 4

6 Design Versatility roducts compatible with X-dek TM include: Range of single ply membranes including VC/TO/TE etc. Standing seam options. Mechanically fixed systems. Adhered systems. Range of bitumen waterproof systems including Asphalt and Torch-on solutions. S 1000 XD TR20 TR20 B A 335 mm 333 mm 332 mm 1000 mm A=100/80 B=108 S 1000 XD TR27 TR27 B A 335 mm 333 mm 332 mm 1000 mm A=100/80 B=108 S 1000 XD Steel Steel B A 335 mm 333 mm 332 mm 1000 mm A=100/80 B=108 Water-tight works Each S1000 XD panel-roof must be finished with waterproof membrane. S1000 XD can be used with conventional site applied membrane finished flat roof applications, which provides the specifier with a wide range of finish possibilities. Due to the type of the top finish (steel, TR20 or TR27) different types of membrane can be used and different technique of fastening can be used. lease see the table below which indicates the possible top solutions S1000 XD top option in relation to Waterproof finish solution (Application Table) olymer membranes VC, TO, EDM, Bitumen Membranes Adhered Mechanically fixed Torch-on Mechanically fixed steel, TR27 (VC fleece backed) steel, TR27 TR20 Steel, TR20 The installation of particular roofing membrane must be carried out according to the Supplier instructions in relation to the membrane fixing method. The water-tightness and durability of the roof is very much dependent on the way that the top membrane has been fitted. ingspan X-dek 5

7 Design Versatility Green Roofs Green Roofs Extensive roof gardens are areas of vegetation close to those found in nature and which to a great extent look after themselves and develop naturally. They require plants that are suitable to extreme conditions and offers a high capacity for regeneration. These mainly self contained areas are made up from mosses, succulents, herbs and grasses. The vegetation is left to natural conditions. Intensive roof gardens can include the planting of small and medium shrubs, grassed areas and occasionally trees. They may cover whole areas at the same level, be stepped or form islands. Because of their flexibility in layout and use they offer just as many possibilities as a traditional ground level garden. The plants used make substantial demands on the layers, and they require regular watering and feeding. X-dek TM is suitable for: Intensive Green Roof double-span double-span Extensive Green Roof 5m Double-span Brown roof ingspan X-dek 6

8 roduct Data Application X-dek TM panels are insulated membrane covered roof panels suitable for flat roofs for all building applications except where there are low temperature internal conditions. The S1000 XD panel secures the base for final waterproof covering of the roof installed by others. X-dek panels are insulated roof panels suitable for flat roofs roof slope > 1% X-dek is the long-span composite roofing panel, which provides the necessary structural strength and stiffness and the required level of thermal insulation. An outer membrane is applied on site as a waterproof barrier. The S1000 XD panels are suitable for Green Roof solutions The XD panels can be used as standard panel and as a part of steel structure structural panel (restraining for the rafters) roduct tolerance Cut to Length - 5 mm + 5 mm Width -2 mm +2 mm Thickness -2 mm +2 mm End Square -3 mm +3 mm Flatness (per meter) -2 mm +2 mm Available lengths Standard lengths 2.5 to 13.5 meters metres maximum can be supplied but are subject to a transport surcharge. All the anels are manufactured with CUT-BAC (on bottom trapezoidal steel) the standard cut-back is 50mm, the maximum available is 630mm mm ingspan X-dek 7

9 Material Steel Internal skin: Hot-dipped zinc coated steel according to EN 10326:20. Grade S350GD+Z275 coated with olyester 25 microns RAL 9002 standard thickness 0.9.mm, on special request available 1.1mm. External skin: Hot-dipped zinc coated steel according to EN 10326:20. Grade S220GD+Z275 thickness 0.7.mm galvanised steel with a 5 microns clear film conversion layer for bonding to. Available profiles on top sheet: MiniBox or Flat. TR20 Bitumen impregnated glass fiber membrane suitable for multi layer torch on systems, TR27 Glass tissue facing suitable for mechanically fixed or fully adhered single ply VC or EDM membrane. Insolution core The rigid closed cell insulation core is available in the following specification: Isophenic rigid foam IN (HCFC Free), nominal density of 40 kg/m 3. Available nominal thickness of the core 80mm and 100mm. Seals Factory Applied Side Joint Seal All side joints have a factory applied anti-condensation tape made of standard E side foam. erformance Thermal Insulation λ=0,022 W/m: anel Thickkness (mm) R value [(m 2 )/W] U Value [W/m 2 ] 80 / Option I 4,21 0,23 80 / Option II 4,03 0,24 Fire ingspan S1000 XD roof panels has been tested according to EN1365 as load bearing roof element. The ratings achieved are presented in the table below: anel Type fire Rating Max. bending moment S1000 XD 80 TR20 REI knm S1000 XD 100 TR27 REI knm S1000 XD 100 (steel) REI knm roduct Data Acoustics S1000 XD (X-dek TM ) panels have acoustic parameters as below: Type of panel arameters according to Type of panel EN ISO 717-1:1999 RA1 [db] RA2 [db] RW [db] S1000 XD 80/ S1000 XD 80/100 TR20/TR27 Sound absorption factor: α av= 0,1 Weight anel thickness XD 80 XD 100 Internal Steel Thickness Steel-Steel [kg/m 2 ] TR 20 / TR27 [kg/m 2 ] VC [kg/m 2 ] 0,9 21,4 15,9 16,9 1,1 23,7 18,2 19,2 0,9 22,2 19,1 17,8 1,1 24,6 19,1 20,1 roduct Data 100 / Option I 5,12 0, / Option II 4,86 0,20 Biological ingspan panels are normally immune to attack from mould, fungi, mildew and vermin, no urea formaldehyde is used in the construction, and the panels are not considered deleterious. Quality and durability ingspan Insulated panels are manufactured from the highest quality materials, using state of the art production equipment to rigorous quality control standards, complying with ISO9001 standard, ensuring long term reliability and service life. Guarantees & Warranties ingspan will provide external coating and product warranties and guaranties on an individual project basis. ingspan X-dek 8

10 ingspan Roof anel S1000 XD X dek TM ADVANTAGES & BENEFITS ü ü ü ü ü ü ü ü ü Unique engineered solution of composite panel dedicated especially for FLAT ROOFS Big load bearing capacity of panel secured by bottom deep trapezoidal deck gauge at least 0.9mm roduct solution allows to carry out installation of panels regardless of the weather conditions. IN insulation core fully fills the whole section of XD panel providing maximum thermal performance. Very low unit weight of XD panels, depending on option amounts from 14 up to 25 kg/m 2 Rapid installation process one panel + waterproof membrane, instead of few layers one by one. The top finish of XD panel can be prepared for application of various waterproof membranes. This gives the designer/contractor the chance to choose any type of waterproof membrane. The panels are offered with required accessories for final finish. S1000 XD panels are manufactured from the highest quality materials, using state of the art production equipment to rigorous quality control standards, complying with ISO9001:2000 standards. 25 years guarantee on thermal, static and fire performance of XD panels ossibile application on roof slope starting from 1%. Low risk of human factor in installation. Single part system safe and easy to install. ossibility of installation directly to the steel rafters. urlin sub-structure not required. Reduction of steel consumption. Bottom deep trapezoidal deck can provide the lateral restraint for the rafters. At built-up systems the installation must be carried out at dry conditions to avoid capture of water and humidity at insulation core and between the layers of roof. Increase of moisture by 1% of volume at insulation layer of MMMF decreases the thermal insulation roughly by 15%. Excellent thermal performance of roof, which reduces the heating costs and emission of CO 2 of whole building. U-value range: 80 mm thick core 0,23 W/m mm thick core 0,19 W/m 2 Continuous IN core eliminates the cold bridges and the risk of interstitial condensation Due to very low humidity absorption factor for the IN foam, the risk of physical degradation of insulation core (increase of lambda value) is very small Rigid IN core allows to walk safely over the panels very low risk of mechanical compression of insulation core no visible traffic paths after installation and less stress on the laps / joints of the membrane over the lifetime of the building. Lower dead load of roof covering which results in savings at steel section design. Fast track construction enables to start internal works earlier and finally can reduce the overall installation time, offering the owner the earlier operation of the building. Waterproof membrane delivery can be in scope wof ingspan or Roofing Contractor The Contractors can use their experience at installation of various waterproof membranes. All roofing elements available at one supplier. Technical support from one company Reliability of experienced solutions and materials which guarantee long durability of whole roofing The installation of various smoke-vents, roof-lights, fans and other technical equipment is possible on the XD panels. Factory controlled high quality Guaranteed long term reliability, service life and technical performance of panels. ingspan X-dek 9

11 Fixing solution S1000XD - option 1 S1000XD - option 2 reliminary hole filled with UR canister Spreader plate Steel support Site applied butyl sealant Direct fastener at each rib - diameter min 5,5 + washer 19mm S1000XD TR20/TR27 Steel support Site applied butyl sealant Through fasteners (long) at each rib - diameter min. 5,5 reliminary hole filled with UR canister Steel support Site applied butyl sealant Direct (short) fastner at each rib - diameter min 5,5 + washer 19mm Roof anel Fixing Solution The minimum support width at the ends should be 40mm, the width of the intermediate support (depending on static calculations) should be at least 100mm. The fasteners must be applied at each rib over the supporting element; exact quantity of fasteners must be specified by the engineer due to local wind suction conditions. For Double Span panels the general layout of the panels can be arranged in two ways: Regular or Chessboard pattern see below. ingspan recommends to specify chessboard pattern for double span applications Chess board pattern (Uniformly distributed load for each rafter) Regular (Unequal load for each rafter) ingspan X-dek 10

12 LOAD SAN TABLES for S1000 XD TR20/TR27 One span Static scheme Bottom deck gauge [mm] The core thickness Load Case Load Type Uniformly distributed load kn/m 2 at given span 4.00m 4.50m 5.00m 5.50m 6.00m 0.9 XD 80 XD 100 ULS SLS ULS SLS Downward Upward Downward Upward Downward Upward Downward Upward Two span Static scheme Bottom deck gauge [mm] The core thickness Load Case Load Type Uniformly distributed load kn/m 2 at given span 4.00m 4.50m 5.00m 5.50m 6.00m itt van felette fehérbe 0.9 XD 80 XD 100 ULS SLS ULS SLS Downward Upward Downward Upward Downward Upward Downward Upward One span Static scheme Bottom deck gauge [mm] The core thickness Load Case Load Type Uniformly distributed load kn/m 2 at given span 4.50m 5.00m 5.50m 6.00m 6.50m 1.1 XD 80 XD 100 ULS SLS ULS SLS Downward Upward Downward Upward Downward Upward Downward Upward Two span Static scheme Bottom deck gauge [mm] The core thickness Load Case Load Type Uniformly distributed load kn/m 2 at given span 4.50m 5.00m 5.50m 6.00m 6.50m itt van felette fehérbe 1.1 XD 80 XD 100 ULS SLS ULS SLS Downward Upward Downward Upward Downward Upward Downward Upward REMARS: ULS Ultimate Limit State indicated loads should be compared with factored (design) loads SLS Serviceability Limit State indicated loads should be compared with characteristic(un-factored) loadsi Maximum permissible deflection limit (SLS): L / 200 The minimum width of supports: at ends 40mm, intermediate 120mm. The dead load of panels is included in the above figures. ingspan X-dek 11

13 LOAD SAN TABLES for S1000 XD ext. steel 0.7/int. steel 0.9mm Static scheme itt van felette fehérbe The core thickness XD 80 XD 100 All loads in kn/m 2 for given span in meters Load Case Downwards 3,82 3,12 2,65 2,15 1,70 1,35 1,05 0,80 Upwards 4,52 3,77 3,16 2,56 2,12 1,78 1,52 1,28 a min [mm] Downwards 4,15 3,45 2,91 2,47 2,01 1,63 1,31 1,02 Upwards 5,06 4,26 3,61 2,95 2,46 2,07 1,77 1,53 a min [mm] Static scheme The core thickness Load Case All loads in kn/m 2 for given span in meters Downwards 3,82 3,13 2,61 2,22 1,90 1,62 1,40 1,20 XD 80 Upwards 4,52 3,77 3,19 2,75 2,40 2,11 1,87 1,68 a min [mm] itt van felette fehérbe XD 100 b min [mm] Downwards 4,03 3,44 2,89 2,47 2,02 1,71 1,47 1,27 Upwards 5,06 4,26 3,65 3,16 2,76 2,44 2,18 1,95 a min [mm] b min [mm] LOAD SAN TABLES for S1000 XD ext. steel 0.7/int. steel 1.1mm Static scheme The core thickness Load Case All loads in kn/m 2 for given span in meters Downwards 4,50 3,67 3,05 2,38 1,87 1,49 1,16 0,89 XD 80 Upwards 5,26 4,36 3,51 2,84 2,35 1,97 1,68 1,45 a min [mm] itt van felette fehérbe Downwards 4,85 4,00 3,37 2,75 2,20 1,78 1,45 1,14 XD 100 Upwards 5,82 4,88 3,98 3,24 2,69 2,27 1,94 1,68 Static scheme The core thickness XD 80 a min [mm] All loads in kn/m 2 for given span in meters Load Case Downwards 4,49 3,67 3,05 2,58 2,21 1,91 1,66 1,46 Upwards 5,26 4,36 3,70 3,18 2,77 2,28 2,16 1,93 a min [mm] Load Span Tables b min [mm] itt van felette fehérbe Downwards 4,84 4,00 3,36 2,87 2,42 2,07 1,79 1,56 XD 100 Upwards 5,82 4,88 4,17 3,61 3,16 2,80 2,49 2,24 a min [mm] b min [mm] REMARS: The above values of loads are characteristic. For Each value individual and combined load cases with appropriate load factors and temperatures have been considered. For Intermediate values linear interpolation may be used. Values have been calculated using the limit state method according to EN 14509, taking imposed loads and temperature into account. Maximum permissible deflection limit: downwards and upwards L / 200 a min the minimum width of end supports; b min the minimum width of intermediate supports The dead load of panels is included in the above figures. ingspan X-dek 12

14 D0.0.1.a. XD Ridge reliminary hole, filled with UR canister 4 Site applied insulation c D8.9. XD Valley Detail Site applied insulation 4 reliminary hole, filled with UR canister ingspan X-dek 13

15 D XD Cut-back Detail Site applied insulation gap > 10 mm Cut - back size mm reliminary hole, filled with UR canister D XD But joint Detail Site applied insulation gap > 10 mm reliminary hole, filled with UR canister Trapezoidal XD profile filler Back putty Construction Details ingspan X-dek 14

16 D c. XD Roof to Brickwork Junction Membrane coated metal flashing for hot air welding at 200 mm groove filled with sealant at 200 mm 155 Hot air weld min. 300 mm reliminary hole, filled with UR canister 31 at 200 mm 112 at 200 mm D XD Roof to Brickwork Junction Membrane coated metal 31 at 200 mm 406 groove filled with sealant 31 at 200 mm 155 Hot air weld min. 300 mm reliminary hole, filled with UR canister Site applied insulation gap min. 10 mm ingspan X-dek 15

17 D XD Gable Wall arapet Hot air weld w 2 at 500 mm at 500 mm Membrane coated metal flashing for hot air welding Site applied insulation gap min. 10 mm < L< 400 mm reliminary hole, filled with UR canister Trapezoidal XD profile filler Back putty D5.5.2.a XD Gable Wall arapet Hot air weld w 2 at 500 mm at 500 mm chessboard pattern Membrane coated metal flashing for hot air welding Site applied insulation 150 < L< 400 mm reliminary hole, filled with UR canister Construction Details ingspan X-dek 16

18 D a. XD Roof/Skylight yramid/dome Type Gun grade sealant-high temperature rated reliminary hole, filled with UR canister min. 150 mm Hot air weld Membrane coated metal flashing for hot air welding Site applied rigid poliurethane board 106 Rooflight upstand by others Site applied insulation D a. XD Smoke Vent Gun grade sealant Hot air weld Membrane coated metal reliminary hole, filled with UR canister Site applied insulation ingspan X-dek 17

19 D XD Eaves Detail Hot air weld Membrane coated metal flashing for hot air welding Site applied insulation reliminary hole, filled with UR canister at 150 mm Overflow Site applied rigid polyurethane board alternatively ingspan insulated gutter Galvanised gutter support D XD Eaves Detail Hot air weld Site applied rigid insulation fully adhered reliminary hole, filled with UR canister at 500 mm at 500 mm Membrane coated metal flashing for hot air welding 07 Site applied insulation Construction Details 02 ingspan X-dek 18

20 D XD Eaves Detail Site applied rigid insulation fully adhered Hot air weld Membrane coated metal flashing for hot air welding 07 reliminary hole, filled with UR canister mm 08 at 150 mm 130 Membrane coated metal Site applied insulation 28 Membrane outlet fixed to roof panel 02 D8.8. XD Eaves Detail Roof outlet Site applied insulation Hot air weld reliminary hole, filled with UR canister ingspan X-dek 19

21 D0.5.a. XD External Gutter Detail reliminary hole, filled with UR canister Individually designed flashing steel thickness min. 1,1 mm Steel cover flashing cut to the XD bottom deck shape 08 at 500 mm >80 mm Trapezoidal XD profile filler Back putty 08 chessboard pattern D20.2. XD Expansion Joint Hot air weld E elastic pipe reliminary hole, filled with UR canister Note: This joint allows up to 30 mm expansion. Construction Details Expansive filler ingspan X-dek 20

22 Site Handling and Installation Typically the panels are stored in bundles crown-to-crown manner, for turning the panels (50%) there is recommended to use special vacuum-pump device with a 180 rotation unit. The equipment is called RotaBoy. The RotaBoy equipment can be obtained directly from the Manufacturer Viavac, or can be hired from local ViaVac office or their representative. Address of the nearest office you can find at When panels are supplied with a plastic protective film this should be removed immediately after site installation. Site assembly instructions are available from the ingspan Technical Services. Sealants & Fillers The panels need to be fitted as close together as possible to assure a certain airtightness. At each side joint it is necessary to apply butyl rubber sealing tape. For further panels stability, proper joint tightness and alignment, and fire-resistance of the S1000 XD panels, the stitching screws must be applied along the side lap of the panels. The stitching screws are usually applied from the bottom side of roof, however the application from the top is also possible. Recommended distance of the stitching screws are: 500mm for the applications where fire resistance is required, mm for the applications where fire resistance is not required. 21 Site applied 03 - max at 500 mm centres if the fire performance is required - max at 1000 mm centres if the fire performance not required Roof-penetrations When positioning the roof-penetration you always need to take in consideration the position of the grooves on the top of the panel. When the roof-penetrations are larger then 300mm the openings must be additionally reinforced with extra supporting elements to compensate the loss of capacity of the panel. Units fitted on the top of the roof must be checked by structural engineer concerning extra loads which can be applied onto the panel and if any additional support is required due to this elements. ingspan X-dek 21

23 Inspections It is recommended that the roofs made of S1000 XD panels should be inspected at least once a year according to ingspan Standard Inspection and Maintenance rules. During the roof inspections all participants must obey the health and safety rules and regulations. Build speed Multipart Built-up Systems roject size 5000 m 2 roject size m 2 ingspan Insulated system Fast Build cuts site time by 100% reduces prelims and attendance costs. roject size 5000 m 2 roject size m 2 weeks ingspan X-dek 22 Maximises investor/occupier trading income opportunity. Factory manufactured system facilitates zero defect installation and build quality. Site Handling Build Speed

24 ingspan Insulated Roof, Wall & Facade Systems Architectural Wall Systems IN Core S1000 SF Secret Fix S1000/1150 TF Through Fix S1000/1150 TC Through Fix S1000 TT Thermatile Hanging System S1000 RW Trapezoidal Mineral Fibre Core S1000/1150 T Through Fix S1150 FA Acoustic Through Fix S1000 FH Secret Fix S1000 FR Through Fix Roof Systems IN Core S1000 RW Trapezoidal S1000 SX Trapezodial S1000 SM Flat S1000 RT RoofTile S1000 XD X-DE Mineral Fibre Core Rooflights S1000 RM Flat S1000 FF Trapezoidal S1000 HTL Hybrid Therma Light S1000 RW/GR40 Trapezoidal S1000 FF/GR40 Trapezoidal Details for the following countries: Austria, Belorussia, Bosnia & Herzegovina, Bulgaria, Croatia, Czech Republic, Denmark, Estonia, Finland, Germany, Hungary, India, Latvia, Lithuania, oland, Romania, Russia, Serbia, Slovakia, Slovenia, Ukraine can be found by visiting our website