Insulated Roof & Wall Panels. Daylighting Systems. Natural Light Translucent Polycarbonate Systems

Transcription

1 Insulated Roof & Wall Panels Daylighting Systems Natural Light Translucent Polycarbonate Systems

2 Daylighting Systems Kingspan provides daylighting solutions that deliver the optimum balance between energy efficiency requirements and the use of natural and artificial lighting. Daylighting systems offer a superior quality of daylight management unrivalled within the industry, whilst still providing designers and architects maximum flexibility and industry leading guarantees. Daylighting is essential for healthy living. It is an established fact that ample daylight improves a general feeling of well-being in the workforce and improves productivity and safety. The Building Code of Australia states: A space within a building used by occupants is to be provided with openings to admit natural light consistent with its function or use. The most effective method of providing even, consistent daylight, particularly in large buildings, is through rooflights, which are up to three times more effective than windows at the perimeter of the building. 2

3 Contents Features & Benefits 4 Business Case 6 Product Data 8 Model Specifications 10 Construction Details 12 Side / End Lap & Fastener Locations 12 End Lap 13 End Lap & Intermediate Fasteners 14 Intermediate Spacers 15 Kingspan Wall-Lite 16 Insulated Roof & Wall Panels 18 Product Range at a Glance 18 3

4 Features & Benefits The Kingspan Polycarb Rooflight allows natural light into buildings. This transparent trapezoidal profiled system is robust enough to maintain thermal insulation and protect against weathering. Developed to complement the Trapezoidal and Foilback roofing systems, the Kingspan Polycarb Rooflight is UV resistant, lightweight and offers a standard R-value of 0.63 m 2 K/W. This product is suitable for applications on roofed buildings for the commercial, retail, educational and healthcare building sectors among others. 4

5 Features & Benefits Kingspan Polycarb Rooflights provide the following key benefits: factory manufacture and exceptional profile qualities ensure an excellent fit with adjoining Kingspan trapezoidal roof panels; highest light transmission of any comparable product in the industry, when tested to ASTM D1003, achieving 64%; maximum level of protection against discolouration and loss of light transmission <1.5% after 20 years; a life expectancy of over 25 years; fully recyclable at end of life with minimal impact on the environment; available lengths of 1,800mm to 5,850mm (incl. 150mm end lap); achieves Grade 1 surface spread of flame to BS 476: Part 7: 1987; simple fixing with no glazing experience necessary; and single component, fast installation leading to accelerated build speed. Kingspan s daylighting products are resistant to attack from mould, fungi, mildew and vermin. No urea formaldehyde is used in the construction, and the panels are not considered deleterious. Exceptional durability and resistance to UV degradation ensures tangible and quantifiable energy savings over the life time of the building when compared to other daylighting alternatives. Factory standard clear polycarbonate has solar transmission of 65%. Where reduction of solar transmission is required, Kingspan can provide polycarbonate rooflight with infra red blocking properties that can dramatically reduce the solar transmission to 40-44%. For further information please contact Kingspan. Polycarbonate also has a scrap value, potentially rendering the process of removing and disposing of the panel at end of life cost neutral / positive. Therefore using a 100% recyclable polycarbonate rooflight has both economic and environmental benefits. 5

6 Business Case Kingspan Polycarb Rooflights provide superior light transmission, not just at first build but over the lifetime of the building, when compared to conventional rooflights. This increase in natural light levels can be beneficial in two ways: better light transmission means less rooflights can be used to give the same light levels in a building the extra roof area can be replaced by Kingspan insulated roof panels which provide better thermal performance, therefore improving the overall U-value or R-value of the building; or increased levels of natural light with the same number of rooflights, providing energy savings through a reduction in lighting power (kwh). less than 3% light transmission loss over 30 years Kingspan high UV resistant Polycarb Rooflights significantly reduce the need for artificial lighting resulting in substantial energy savings. up to 70% light transmission loss over 30 years Conventional rooflights have less resistance to UV-induced degradation leading to increased loss of light transmission over time. 6

7 Business Case Light Transmission Data: Kingspan Polycarbonate vs Typical Other Conventional Rooflights Cost savings for a typical B1 office or workshop building scenario* indicates savings of up to $172,000 over 30 years. LT (%) Poly LT Other Conventional Rooflight LT $ / yr Cost Saving $ Years Years Comparison Chart Typical Other Kingspan Conventional Polycarbonate Rooflights Light Transmission 64% D % D1003 Loss of <1.5% after <12% after Transparency 20 years 3 years Yellowness At new Delta 2.4 Delta 3.7 Aged Delta 5.4 Delta 13.7 (At 20 years!) (At 3 years!) UV resistance Excellent Good R-value (m 2 K/W) *Typical B1 office or workshop building parameters: 10% other conventional rooflights with 10% PC comparison Building size: area = 1,000m 2, volume = 6,000m 3 Building location = Manchester, UK (CIBSE weather files) Building heating system: Flued radiant heater, natural gas, S.E = 0.9 Building fabric U-values as per notional building 2010 regulations Energy demands as per regulated energy demand (NCM) Installed electrical power density 3.75 W/m 2 (100 lux), Radiant fraction = 0.45 Polycarb rooflight U-value = 1.58 W/m 2 K and light transmission as stated in the report. Other conventional rooflights U-value = 1.9 W/m 2 K and light transmission as stated in report. 7

8 Product Data Building Application The Kingspan Polycarb Rooflight is suitable for use in normal factory or warehouse environments, with a roof pitch of 4 or above after deflection. System Benefits Full flexibility of intermediate fixing positions, so not dependent on exact position of intermediate purlins. Meets and exceeds requirements of: AS Methods of testing sheet roof and wall cladding Resistance to impact (sandbag) Sheet roof materials; AS Design and installation of sheet roof and wall cladding Plastic; and AS NZS 4389 Safety Mesh. U-value 1.58 W/m 2 K and R-value of 0.63 m 2 K/W when designing to Section J BCA requirements. Available Lengths Kingspan Polycarb Rooflight panels are available in standard lengths from 1,800mm to 5,850mm (incl. 150mm end lap). Longer lengths are available on request. Dimensions & Weight Dimension A core thickness nominal (mm) 20 Dimension B overall dimension (mm) 55 Weight kg/m End Lap Cut Back Standard Cut back 150mm Solar heat gain coefficient (SHGC) of Excellent light transmission up to 64% to ASTM D1003. Fully recyclable at end of life with minimal impact on the environment. Manufactured under controlled factory conditions ensures excellent fit with Kingspan Trapezoidal and Foilback roofing systems. Available in clear, opal, or IR (infra red) absorbing technologies. High degree of colour fastening means product will not discolour. Single component, fast installation leading to accelerated build speed. Simple fixing with no glazing experience necessary. Lightweight and durable. Product Tolerances Cut to Length 3mm +3mm Liner Sheet Length 3mm +3mm Thickness 3mm +3mm End Square 5mm +5mm Fixing Detail Purlin Detail Maximum purlin centres are dictated by wind-loadings. For further information please contact Kingspan. The rooflight must be fixed 4 times through crown positions only and have storm washers fitted. Loose magnetic PVC support blocks are fitted to purlin prior to positioning rooflight. Performance & Properties Air Leakage Air leakage when installed to Kingspan specification is less than 10m 3 /hr/m 2 at 50 Pascals. Kingspan Polycarb Rooflight application with Trapezoidal and Foilback Insulated Roof Panels 1000mm 333mm 333mm 333mm A 35mm B 8

9 Product Data Structural Load Span Table Span Load Uniformly Distributed Loads (kn/m 2 ) Span L in Metres Condition Type Single Span Downwards L Suction Span Load Uniformly Distributed Loads (kn/m 2 ) Span L in Metres Condition Type Double Span Downwards L L Suction Notes: The above loads are Serviceability limit state. Factor by 1.5 for Ultimate limit state. The deflection limitations are calculated in accordance with BS5427: Part 1: These load spans are based upon test with rooflights crown-fixed with storm washers to every crown and therefore make allowance for pullover. The designer must still consider attachment in the form of fastener pull-out from supports, and must therefore carry out a calculation. Downwards Load: Max deflection = 1/30th of span, but not more than 50mm. Suction Uplift: Max deflection = 1/15th of span, but not more than 100mm. Polycarbonate and Thermal Expansion Polycarbonate has a high coefficient of thermal expansion (67 x 10-6 mm/m/ C). With single-skin rooflights this can lead to problematic deflection under the influence of heat. However, the Kingspan Polycarb Rooflight is a multi-wall extruded profile construction and this reacts in a very different manner. Kingspan s in-house Research & Development Centre carried out thermal testing that has proved that deflection of the Kingspan Polycarb Rooflight under the influence of heat is negligible. Furthermore, there is no detrimental reaction around fasteners, e.g., cracking / elongation of holes. The testing was as follows: i) 40 C: 10 cycles (each cycle 30 minutes heat then 15 minutes of water spray). ii) 50 C: 10 cycles (each cycle 30 minutes heat then 15 minutes of water spray). iii) 60 C: 10 cycles (each cycle 30 minutes heat then 15 minutes of water spray). iv) 70 C: 10 cycles (each cycle 30 minutes heat then 15 minutes of water spray). v) 80 C: 10 cycles (each cycle 30 minutes heat then 15 minutes of water spray). vi) 85 C: 2 hrs heat. Additionally, the rooflight / fastener configuration has been cycled to -25 C and has proven that there is no adverse reaction at fasteners under the influence of freezing temperatures. 9

10 Model Specifications Product: Kingspan Polycarb Rooflight Application The following specification is for the Kingspan Polycarb Rooflight system used for buildings with a roof slope of 4 or above, and low to medium humidity environments. The products are in compliance with, and either meet or exceed the requirements of: Performance Light Transmission Kingspan Clear Polycarbonate Rooflights nominally transmit 64% of light to ASTM D1003. Kingspan Opal Polycarbonate Rooflights nominally transmit 58% of light to ASTM D1003. AS AS Methods of testing sheet roof and wall cladding Resistance to impact (sandbag) Sheet roof materials; Design and installation of sheet roof and wall cladding Plastic; and Solar Transmission Kingspan Clear Polycarbonate Rooflights have a solar transmission of 65% to DIN Kingspan Opal Polycarbonate Rooflights have a solar transmission of 64% to DIN AS NZS 4389 Safety Mesh. Materials & Coatings Panel 3.3Kg/m 2 clear multi-wall polycarbonate sheet with 20mm wall structure x 1000mm wide with an external Trapezoidal profile. The external face is co-extruded for UV protection. PVC coated steel reinforcing plate factory applied to male side crown of panel. Fillers & Seals 20mm vented and blocking tapes are applied to either end of the polycarbonate box to reduce the risk of condensation. A 0.9mm PVC 30mm wide support block is site fitted via magnetic strips to purlin. Infra red absorbing solutions are also available with a solar transmission as low as 40%. Thermal The thermal transmittance (U-value) for all rooflight thicknesses is 1.58 W/m²K, or thermal resistance R of 0.63 m 2 K/W when designing to Section J BCA requirements. Fire Kingspan Polycarb Rooflight has achieved a Grade 1 surface spread of flame to BS 476: Part 7: Rooflight Lengths / Span Maximum span is 3,000mm, subject to project wind loadings. Maximum length available is 5,850mm (including 150mm end lap). Exact lengths to be calculated by the cladding contractor based upon steelwork drawings. Seals and Fillers Side Lap All external side laps to be weather sealed along the full length by an unbroken 6 x 4mm butyl rubber sealant. End Lap All end laps to be 150mm and weather sealed along the full width using two unbroken runs of 6 x 4mm butyl rubber sealant and one double layer run. Refer to construction details for more information. Minimum bearing for rooflight to support at end lap is 30mm. 10

11 Model Specifications Fasteners Primary All primary fasteners to be self-tapping, self-drilling screws, manufactured from carbon steel, anti-corrosion coated, and fitted with a 16mm diameter embossed stainless steel (or aluminium) washer and storm washers. Fasteners to be located through every crown of the profile. Secondary Side laps to be stitched at 300mm centres (maximum) with carbon steel stitching screws complete with 16mm embossed washers. End laps to be tail stitched with two fasteners in each valley and one per crown. All fastener heads to be Poppy Red in colour. For further information about fixings please contact Kingspan. Construction Requirements Steelwork Tolerance The steel frame must be made and assembled to an accuracy of ±5mm between fixing planes of adjacent purlins. Installation Panels to be laid with side lap joints away from prevailing wind unless otherwise shown on drawings. All fasteners, seals and fillers to be of correct specification and installed as indicated on the project construction drawings. Fasteners to be checked and adjusted if necessary to ensure they are weather tight and external panel facing is not distorted. Safety The contractor is to determine and use a safe method of working throughout the installation and construction period, which complies with Occupational Health and Safety requirements. Crawling boards to be used when fixing rooflights. The contractor should determine and use a safe method of working throughout the installation and construction period, which complies with Occupational Health and Safety requirements. A safe work method template (although NOT project specific) is available from Kingspan. Please copy this Model Specification and include with your next specification or contact the Kingspan Technical Team on +61 (02) for further information. 11

12 Construction Details Side/End Lap & Fastener Locations Detail 1 Side Lap Kingspan Polycarb Rooflight primary and side lap fasteners Kingspan Polycarb Rooflight Kingspan insulated roof panel 4 No. main fixings with storm washers 4 No. main fixings with storm washers in each crown location, per rooflight, per purlin 4 No. main fixings with storm washers 30 min Site applied magnetic spacer Site applied spacer PVC coated steel strip (factory applied) Kingspan Polycarb Rooflight Direction of lay Kingspan Polycarb Rooflight to panel side lap Panel to Kingspan Polycarb Rooflight side lap Side lap stitched at 300mm centres with 6.3mm x 25mm stitching screws with washers 6 x 4mm butyl rubber sealant on weather side (supplied by Kingspan) Side lap stitched at 300mm centres with 6.3mm x 25mm stitching screws with washers 6 x 4mm butyl rubber sealant on weather side (supplied by Kingspan) PVC coated steel strip (factory applied) Detail 2 End Lap Kingspan Polycarb Rooflight panel tail stitcher locations PVC coated steel strip (factory applied) Side laps stitched at max 300mm centres with stitching screws (typ 6.3mm dia x 25mm long) with washers End lap stitchers Side laps stitched at max 300mm centres with stitching screws (typ 6.3mm dia x 25mm long) with washers 6 x 4mm butyl rubber sealant applied in continuous unbroken length at side lap to weather side of stitching screw 6 x 4mm butyl rubber sealant applied in continuous unbroken length at side lap to weather side of stitching screw Note: Project specific construction details must be used. 12

13 Construction Details End Lap Detail 3 End Lap Kingspan Polycarb Rooflight to Kingspan Insulated Roof Panel End lap crown stitched with stitching screws (typ 6.3mm dia x 25mm long) with washers and 2 per valley 50mm 150mm end lap 50mm Double layer of 6 x 4mm butyl rubber sealant 6 x 4mm butyl rubber sealant applied in continuous unbroken lengths at end lap Kingspan insulated roof panel Kingspan Polycarb Rooflight Additional run of 6 x 4mm butyl rubber sealant 30 min 30 min Site applied magnetic spacer (supplied by Kingspan) 4 No. main fixings with storm washer in each crown location, per rooflight, per purlin Kingspan Insulated Roof Panel to Kingspan Polycarb Rooflight 150mm end lap Double layer of 6 x 4mm butyl rubber sealant Kingspan Polycarb Rooflight 50mm 50mm Nominal 15mm Minimum 10mm 6 x 4mm butyl rubber sealant applied in continuous unbroken lengths at end lap End lap crown stitched with stitching screws (typ 6.3mm dia x 25mm long) with washers and 2 per valley Kingspan insulated roof panel Site applied magnetic spacer (supplied by Kingspan) 30 min 30 min 4 No. main fixings with storm washer in each crown location, per rooflight, per purlin 13

14 Construction Details End Lap & Intermediate Fasteners Detail 4 End Lap Kingspan Polycarb Rooflight to Kingspan Polycarb Rooflight 50mm 150mm end lap 50mm Nominal 15mm Minimum 10mm Double layer of 6 x 4mm butyl rubber sealant 6 x 4mm butyl rubber sealant applied in continuous unbroken lengths at end lap Kingspan Polycarb Rooflight Kingspan Polycarb Rooflight End lap crown stitched with stitching screws (typ 6.3mm dia x 25mm long) with washers and 2 per valley 4 No. main fixings with storm washer in each crown location, per rooflight, per purlin 30 min 30 min Additional run of 6 x 4mm butyl rubber sealant Site applied magnetic spacer (supplied by Kingspan) Detail 5 Intermediate Detail Intermediate purlin fasteners Kingspan Polycarb Rooflight Position of 4 No. main fixings with storm washers to crowns Site applied magnetic spacer (supplied by Kingspan) 30 min 14

15 Construction Details Intermediate Spacers Detail 6 Intermediate Detail Intermediate spacer location The innovative spacer is magnetic and supplied loose. This allows rooflights to be supplied without having to detail intermediate purlins and avoids problems with purlin misalignment. 2 single rows of 6x4 butyl rubber sealant Double layer of 6x4 butyl rubber sealant 15

16 Kingspan Wall-Lite Kingspan Wall-Lite is a translucent wall panel that allows natural daylight into buildings, whilst maintaining thermal efficiency and aesthetic appearance. Wall-Lite offers excellent interior levels of natural light without compromising the performance of the building. This can help to lower both energy bills and CO 2 emissions, whilst allowing occupants to enjoy high levels of daylight. The system is suitable for use as an alternative to traditional vertical daylighting systems and need not restrict design options as it integrates fully with Kingspan s range of Architectural Wall Panels. UV resistant and lightweight, Wall-Lite offers designers and installers freedom to create energy efficient buildings of distinction. Kingspan Wall-Lite application with Kingspan Architectural Wall Panel range 1000mm * Aluminium spacers to suit adjacent insulated panel thickness 38 * Building Applications Kingspan Wall-Lite is suitable for use on most types of buildings, for both vertical and horizontal applications. It is a single component system and does not require glazing experience to fit, thereby reducing installation times and the need to rely on specialist sub-contractors. For further information and availablility of Kingspan Wall-Lite, please contact Kingspan. 16

17 Kingspan Wall-Lite Image courtesy of Gazeley and Central Photography. G Park Chatterley Valley, Staffordshire, UK 17

18 Insulated Roof & Wall Panels Product Range at a Glance Insulated Roof Panels Trapezoidal - KS1000 RW Roof pitches 4 and above. (For lower pitches contact Kingspan Technical Support). Lo-Pitch - KS1000 LP* Roof pitches 1.5 and above. Kingspan K-Dek - KS1000 KD Roof pitches 0.72 and above. Single-ply membrane roofdeck. Foilback - KS1000 FB Roof pitches 4 and above. With reflective foil liner. Polycarb Rooflight - KS1000 Polycarb Roof pitches 4 and above. (For lower pitches contact Kingspan Technical Support). Roof Mounted PV System Solar Photovoltaic Solution. * UK manufacture. 18

19 Insulated Roof & Wall Panels Product Range at a Glance Insulated Wall Panels (horizontally or vertically laid) Trapezoidal - KS1000 RW Euro-Box - KS1000 EB Architectural Wall P anel. Wave - KS1000 WV Architectural Wall P anel. Plank - KS1000 PL Architectural Wall P anel. Micro-Rib - KS1000 MR Architectural Wall P anel. Mini-Micro - KS1000 MM Architectural Wall P anel. Controlled Environment Panels Flat - KS1100 CS Wall & ceiling panel. Rib - KS1100 CS Wall & ceiling panel. All Kingspan panels are manufactured to order with varying core thicknesses depending on the spanning and thermal requirements of the project. Kingspan roof and wall panels are available in a wide range of colours. 19

20 Australia: Kingspan Insulated Panels Pty Ltd Dunheved Circuit, St Marys, NSW 2760 Australia t: +61 (02) f: +61 (02) e: New Zealand: Kingspan Ltd 15 Ron Guthrey Road, Christchurch, New Zealand t: +64 (03) f: +64 (03) e: For the product offering in other markets please contact your local sales representative or visit Care has been taken to ensure that the contents of this publication are accurate, but Kingspan Insulated Panels Pty Ltd and its subsidiary companies do not accept responsibility for errors or for information that is found to be misleading. Suggestions for, or descriptions of, the end use or application of products or methods of working are for information only and Kingspan Insulated Panels Pty Ltd and its subsidiaries accept no liability in respect thereof. 12/2013