Lo-pitch. Insulated Panels. Low Pitched and Curved Insulated Roof System. Insulated Panels to the Power of CI/SfB.

Transcription

1 Insulated Panels CI/SfB (47) Nh2 March 2005 Lo-pitch Low Pitched and Curved Insulated Roof System Approved to LPS 1181 Certificate No s. Holywell 260a/13 Kingscourt 186a/05 Insulated Panels to the Power of Insurer Approved Systems

2 Superior specification and construction for roof slopes of 1.5 or curved roofs of 150m radius and above 2

3 Introduction 5 Market Sectors 6 Product Data 10 Model Specifications 16 Construction Details Panel Dimensions Detail 27 End Lap Detail 28 Ridge Detail 29 Eaves Detail Valley Gutter Detail 32 Verge Detail Curved Roof Panel 35 3

4 Introduction The low pitched roof system and the alternative to standing seam roof systems which provides guaranteed specification performance compliance and reliability for the overall life of the building. Kingspan KS1000 LP/CR insulated roof systems are available in steel and aluminium specifications and suitable for Lo-pitch, Curved and Architectural roofing applications. These roof cladding systems provide high performance construction solutions with a durability warranty package of up to 25 years to first maintenance with overall life expectancy of up to 40 years. The superior specification and long term installed reliability of KS1000 LP/CR roof systems provide building owners with a cost effective, low air leakage and high performance package which allows reduced M&E plant, energy operating costs and reduced CO2 emissions. Loss Prevention Council and Factory Mutual Approved Systems are available. Welded end laps specifications are available for plain aluminium systems which eliminate end laps. Approved to LPS 1181 Certificate No s. Holywell 260a/13 Kingscourt 186a/05 4

5 System Benefits Complies with HSE and CDM safety requirements. Lo-pitch roof minimum slope 1.5 degrees. Curved roof minimum radius 150 metres. Available in aluminium and steel. Lengths up to 28.5 metres - site welded end laps available with plain aluminium facings. Property & Business Risk Protection Loss Prevention Certification Board (LPCB) certified external cladding systems can be classified as non-combustible building by the Association of British Insurers (ABI). Fully complies with Part L2 (England & Wales) and Part J (Scotland) and Part L (Ireland) Regulations and Standards. Lifetime insulation continuity, thermal performance and airtightness (5m 3 /hr/m 2 ) certainty. Accelerated build speed through pre-engineered, single component, single-fix installation, reduces site time by up to 50%. Environmentally sustainable system Zero ODP and non-deleterious. Energy efficient performance reduces M&E plant and lifetime operating costs by up to 40%. Environmentally sustainable solutions reduce lifetime Carbon Dioxide (CO 2) emissions by up to 40%. Complies with Parts E & H Resistance to the passage of sound for non-domestic buildings. For residential, domestic, education and healthcare building applications, BB93 and HTM 2045 solutions, consult Kingspan Technical Design Bureau. Lifetime durability steel up to 25 years to first maintenance and overall life expectancy of up to 40 years. Lifetime durability aluminium up to 40 years to first maintenance and overall life expectancy of up to 60 years. Rooflight systems available. Can incorporate safety and fall arrest systems. Quality approved to IS0 9001:

6 Market Sectors Mamhilad COMMERCIAL COMMERCIAL Maynooth Business Park RETAIL Morrisons Shopping Centre Fairways Hotel, Dundalk LEISURE LEISURE Carlingford Marina 6

7 St Caddoc s School REFURBISHMENT St Caddoc s School REFURBISHMENT Castle Primary School EDUCATION Millfield College EDUCATION North Western Health Board HEALTHCARE HEALTHCARE North Western Health Board 7

8 Market Sectors Queens Towers, Holland RESIDENTIAL TECHNOLOGY Phototronics, Manchester ELECTRONICS LG Electronics, Newport Big Yellow LOGISTICS 8

9 LOGISTICS Morrisons Distribution INDUSTRIAL Parcel Force, Coventry 9

10 Product Data Application The KS1000 LP/CR Roof is a high specification system suitable for building applications for new build and refurbishment. i) roof slopes 1.5 and above after deflection. ii) curved roofs 150 metre radius and above. Product Reference KS1000 LP/CR-LPCB Approved to LPS 1181 Certificate No s. Holywell 260a/13 Kingscourt 186a/05 KS1000 LP-FM Application Description Lo-pitch & curved roof panel with Loss Prevention Certification Board (LPCB) approval for roof applications. Lo-pitch roof panel with Factory Mutual (FM) approval for roof applications. For KS1000 CR contact Kingspan Technical Design Bureau Dimensions & Weight Insurer Approved System 1000mm cover width A B A - Core Thickness (mm) * 100* B - Overall Dimension (mm) Weight kg/m 2 0.5/0.4 steel Weight kg/m /0.4 steel Weight kg/m 2 0.7/0.5 alum *These panel thicknesses comply with Part L2 (England & Wales) and Part J (Scotland) Aluminium faced panels are not LPCB and FM certified. 10

11 Product Tolerance Cut to Length -5mm +10mm Liner Sheet Length -5mm +10mm Cover Width -0mm +3mm Thickness -2mm +2mm End Square -3mm +3mm Available Lengths Panel lengths 1.8 to 28 metres are supplied. Panels less than 1.8m long can be supplied but do not have a cut back as standard and are subject to extra charge. Please contact our Quotations Hotline for full costs. Panel Length Panel End Cut Back Panels can be supplied with a cut back of 75mm or flush ends. Panels less than 1.8m long which require a cut back can be provided, but will be charged at full 1.8m price, plus cutting cost. Please contact our Quotations Hotline for full costs. End Lap It is recommended that panels are used in continuous lengths from ridge to eaves with no end laps. However, where an end lap must be used the flush end of the down slope panel has a factory fitted end lap stitching plate. Cover Cap The cover cap is made from 0.5mm thick steel coated to the same specification as the weather sheet of the panels. The caps are supplied in lengths up to 12 metres. Panels less than 1.8m long which require a cutback are subject to extra charge. 11

12 Product Data Materials - Steel Substrate HPS200/Celestia*: ZA255 Galvalloy hot-dip zinc-aluminium alloy coated steel (= 95% Zn/=5% Al) to BS EN : 1995, Grade Fe E220G with a Z275 zinc coating. PVDF*: Galvatite, hot-dipped zinc coated steel to BS EN : Grade Fe E220G with a Z275 zinc coating. Standard external sheet thickness 0.5mm, standard internal sheet thickness 0.4mm. Other thicknesses can be supplied to special order. Coatings - External Weather Sheet HPS200 Plastisol: Nominal 200 micron thick high performance coating applied to the weatherside of the panel. Designed to achieve high levels of durability and colour stability, is highly resistant to damage in transit and on-site. Celestia*: Nominal 120 micron thick Plastisol coating 16 metallic colours. Reverse side of sheet coated with a light grey polyester coating. The sheet is available in either plain or stucco embossed finish. Coatings - Internal Liner Sheet Lining Enamel: Nominal 15 micron thick coating developed for use for the internal lining of insulated panels. Standard colour is bright white with an easily cleaned surface. HPS200 Plastisol: Nominal 200 micron thick coating used in areas where there is high internal humidity, or a corrosive environment. Stelvetite Food & Hygiene Safe: This is a nominal 20 micron thick chemically inert polymer film bonded to steel suitable for cladding the interior of cold stores, food processing buildings and other hygiene applications. Reverse side of sheet coated with a light grey polyester coating. The sheet is available in either plain or stucco embossed finish. Materials - Aluminium Substrate Aluminium substrate, Grades 3003/4/5 series. Standard external sheet thickness 0.7mm, standard internal sheet thickness 0.5mm. Coatings - External Weather Sheet PVDF: Nominal 25 micron thick stoved fluorocarbon coating which has excellent colour stability even at temperatures as high as 120 C. ARS Abrasion Resistant: Nominal 28 micron thick polyester or polyurethane resin reinforced with polyamide high durability coating with exceptionally good handling characteristics. Silicone Polyester: An economical coating with medium term life for worldwide use. Alternatively the weather sheet can be supplied in mill finish, stucco embossed. Coatings - Internal Liner Sheet Standard internal facing is white polyester coated, plain or stucco embossed. Insulation Core Polyisocyanurate (PIR): with zero ozone depletion (Zero ODP). Available in LPCB and FM insurer approved certified product range. For KS1000 CR/FM please contact Kingspan Technical Design Bureau. Seals Factory Applied Side Lap Tape All side laps have a factory applied anti condensation tape. * Please note we do not recommend a PVDF or Celestia coating on roof applications. Therefore we only stock a limited range of colours in these two coating ranges. Please contact Quotations to discuss once colour reference is known. 12

13 Performance Thermal Insulation Panel Thickness (mm) U value W/m 2 K * * U - Thermal transmittance W/m 2 K * U Value calculated in accordance with the method required by the Building Regulations Part L2 (England & Wales) and Building Standards Part J (Scotland) Biological Kingspan 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. Fire Steel and aluminium outer and inner facings have Class 1 surface spread of flame to BS 476: Part 7: 1987, and are Class 0, as defined by Building Regulations. The panel surfaces are rated FAA/SAA to BS 476: Part 3: KS1000 LP/CR insurer approved panels are available with FM and LPCB certification, with steel facings. For KS1000 CR/FM contact Kingspan Technical Design Bureau. Acoustics KS1000 LP/CR panels comply with Building Regulations Part E for non-domestic buildings. For residential, domestic, education and healthcare building applications, BB93 and HTM 2045 solutions, consult Kingspan Technical Design Bureau. All KS1000 LP/CR panels have a single figure weighted sound reduction Rw = 25dB. Sound Reduction Index (SRI) Tested Frequency Hz k 2k 4k SRI db Quality & Durability Kingspan Insulated Panels are manufactured from the highest quality materials, using state of the art production equipment to rigorous quality control standards, complying with ISO 9001: 2000 standard, ensuring long term reliability and service life. Guarantees & Warranties Kingspan will provide external coating and product warranties and guarantees on an individual project basis. Packing Standard Packing KS1000 LP/CR panels are stacked weather sheet to weather sheet (to minimise pack height). The top, bottom, sides and ends are protected with foam and timber packing and the entire pack is wrapped in plastic. The number of panels in each pack depends on panel thickness and length. The table below is shown as a guide. Typical pack height is 1100mm. Maximum pack weight is 1500kg. Panel Core Thickness No. panel/pack (max.) Sea Freight Fully timber crated packs are available on projects requiring delivery by sea freight shipping, at additional cost. Alternatively, steel containers can be used. Special loading charges apply. Delivery All deliveries (unless indicated otherwise) are by road transport to project site. Off loading is the responsibility of the client. Site Installation Procedure Site assembly instructions are available from the Kingspan Technical Design Bureau. Building Regulations & Standards Kingspan insulated roof and wall systems conform to the following Building Regulations and Standards (Non-domestic buildings): i) Approved Document A: Structure (England & Wales) ii) Approved Document B: Fire (England & Wales) iii) Approved Document E: Resistance to the Passage of Sound (England & Wales) iv) Approved Document Part L2: Conservation of Fuel & Power (England & Wales) v) Building Standard Part D: Structural Fire Precautions (Scotland) vi Building Standard Part H: Resistance to the Transmission of Sound (Scotland) vii) Building Standard Part J: Conservation of Fuel & Power (Scotland) viii) Building Standard Part L: Conservation of Fuel & Energy (Ireland) 13

14 Product Data Structural Unfactored Load/Span Table (use calculated design windload values unfactored) SPAN Core Load Uniformly Distributed Loads (kn/m 2 ) CONDITION Thickness Type Span L in Metres (mm ) SINGLE SPAN 45 Downwards Suction Outer Sheet 60 Downwards mm steel Suction Inner Sheet 80 Downwards mm steel Suction L 100 Downwards Suction DOUBLE SPAN 45 Downwards Suction Outer Sheet 60 Downwards mm steel Suction Inner Sheet 80 Downwards mm steel Suction L L 100 Downwards Suction Notes: 1. Values have been calculated using the limit state method described in the European Recommendations for the Design of Sandwich Panels (ECCS document No ), taking imposed loads, temperature and creep into account. 2. For each value individual and combined load cases with appropriate load factors and temperatures have been considered. These are detailed under Structural Performance in the Building Design Section. 3. The Table is for medium and light coloured panels, as recommended by Kingspan for roofs. 4. The following deflection limits have been used: Downward loading L /200 Suction loading L / For intermediate values linear interpolation may be used. 6. The actual wind suction load resisted by the panel is dependant on the number of fasteners used and the material of the purlin. The fasteners calculation should be carried out in accordance with the appropriate standard. For further advise please contact Kingspan Technical Design Bureau. 7. The allowable steelwork tolerance between bearing planes of adjacent purlins is +/- 5mm. 8. Load span tables for panel specifications not shown are available from the Kingspan Technical Design Bureau. 9. FM approved panels spans must be limited to a maximum of 1.8 metres in single or double span conditions. 14

15 15

16 Model Specifications KS1000 LP/Zero ODP/LPCB Lo-Pitch Roof System Lo-Pitch of 4 or above Roof LPS 1181 Grade EXT-B Ref No: 1/5.74A/LPS-B Application The following specification is for the KS1000 LP/Zero ODP/LPCB Lo-Pitch Insulated Roof Panel used for buildings with roof slopes of 4 and above with internal humidity class environments 1-4 inclusive as defined in BS EN ISO 13788:2002. For internal humidity class environment 5 i.e. swimming pools contact Kingspan Technical Design Bureau. KS1000 LP is Loss Prevention Certification Board LPCB certified to LPS 1181 Grade EXT-B. Materials & Coatings External Weather Sheet Substrate to be 0.5mm thick steel S220GD+ZA eutectic Galvalloy hot-dip zinc coated steel to BS EN10214: External coating to be Plastisol, nominal 200 micron thick. Colour Standard SC. Reverse to have a light grey polyester coating. Insulation Core To consist of 80mm thick, closed cell, with zero ozone depletion (Zero ODP) and LPCB certified polyisocyanurate (PIR) insulation. The auto-adhesive properties of the core bond the external and internal sheets together, and control the panel thickness achieved during manufacture. Internal Liner Sheet Substrate to be 0.4mm thick hot-dip zinc coated Steel to BS EN10147: Internal coating to be Lining Enamel, nominal 15 micron thick. Colour - White. Reverse to have a light grey polyester coating. Cover Caps To be made from 0.5mm thick steel coated to the same specification as the external weather sheet of the panels and used in typical lengths up to 12000mm. Performance Thermal Insulation The panel must have a thermal transmittance (U value) of 0.25 W/m 2 K calculated using the method required by the Building Regulations Part L2 (England & Wales) and Building Standards Part J (Scotland). Fire The external and internal faces of the panel to be Class 0 in accordance with the Building Regulations when tested to BS 476: Parts 6: 1989 and Part 7: The panel must be rated SAA when tested to BS 476: Part 3: The system has passed all the requirements of LPS 1181: 2003: Part 1: Issue 1 ceiling lining test. Airtightness Overall airtightness for complete envelope less than 10m 3 /hr/m 2 at 50Pa. 16

17 Seals & Fillers Side Joint All side joints have a factory applied anti-condensation tape. End Lap All external end laps to be 75mm long, and weather sealed along the full width using a single unbroken run of 18mm wide x 4mm thick U section butyl rubber sealant tape, Class A, Ref NFRC TB93. In addition a single unbroken run of non-curing mastic applied across the complete width of the panel. End laps to be tail stitched with carbon steel stitching screws, complete with 14mm diameter bonded stainless steel washers. Tail stitching to be positioned 25mm upslope from end lap and five number per panel. Fasteners to penetrate the factory applied end lap stitching plate positioned in the downslope panel at the flush end. An additional 150mm length of gun applied non-curing mastic to be applied over 4 way laps. Profiled Fillers Where flashings are fixed across the profile of the insulated panel, EPDM closed cell foam fillers should be used to seal and close the profile. Seal the top, bottom and sides of each profiled filler with non-setting gun-grade sealant, Scapa Tapes Ref: 0100 or similar. The flashing and filler to be supported using an apex dam Ref: LP1. Junctions Junctions between the roof panel system and walls / penetrations insulated with PIR board insulation any gaps filled with Alfasbond FR or similar fire rated gun applied canister urethane insulation. Internal face of panel to be air sealed along the full length by an unbroken 6mm diameter butyl rubber sealant tape, Class A, Ref NFRC TB93. Fasteners Primary All primary fasteners must be the high threaded type, manufactured from carbon steel and fitted with a 16mm diameter bonded stainless steel washer. All fasteners to be located at the side profile of the panel. To comply with the requirements of BS 6399: Part 2: 1997, it may be necessary to provide additional fixings in areas of high local suction. Secondary Flashings to be stitched at 450mm centres (maximum) with carbon steel, stitching screws, complete with 14mm diameter bonded stainless steel washers with integral colour matched heads. Fasteners General Note Recommended fasteners are available. For a full list contact Technical Design Bureau. 17

18 Model Specifications KS1000 LP/Zero ODP/LPCB Lo-Pitch Roof System Lo-Pitch of 4 or above Roof LPS 1181 Grade EXT-B Ref No: 1/5.74A/LPS-B Construction Details Flashings All external flashings to be made from 0.63mm thick steel to the same specification as the outer sheet of the panel. Colour Standard. All flashings to be weather sealed at laps and along the full length by an unbroken bead of 20mm wide x 3mm thick butyl rubber sealant tape, Class A, Ref NFRC TB93. All internal flashings to be made from 0.4mm thick steel substrate, to the same specification as the inner sheet. Colour white. All internal flashings to be air sealed at laps and along the full length by an unbroken bead of 6mm diameter butyl rubber sealant tape, Class A, Ref NFRC TB93. End laps to be air sealed with Scapa Tape Vapourflex or similar, or gun-grade sealant. Panel Lengths Exact lengths to be determined by the cladding contractor from the steelwork drawing, but typically using minimum number of panels from ridge to eaves up to a maximum panel length of 28.5 metres. Construction Requirements Steelwork Tolerance The steel frame must be made and assembled to an accuracy of L/600 between fixing planes of adjacent purlins, +/- 5mm. Installation All fasteners, seals and fillers to be of correct specification and installed as indicated on the project construction drawings. Site cut panels must provide accurate, true lines with no distortion. Panels to be cut with powered reciprocating type saw and all exposed site cut panels to be treated with a suitable edge protection lacquer. Cut openings for outlets, vents, flues etc. to be the minimum size necessary. Remove all swarf and any foreign matter immediately from the external surface of panels. 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 HSE & CDM requirements. NBS Format Specification H43 - Metal Composite Panel Cladding/Covering To be read with Preliminaries/General conditions. 122A - Metal Composite Roof Cladding Drawing reference(s): Supports: Cold rolled purlins Bearing width: 50mm Pitch: Min 4 or above (Finished roof slope after deflections). Manufacturer and reference: Kingspan roof cladding system for standard internal and external environments and Loss Prevention Certification Board certified to LPS 1181 Grade EXT-B. Test results: LPS 1181: 2003: Part 1: Issue 1, ceiling lining tests: Passed all requirements. Panels: Profile reference: KS1000 LP/Zero ODP/LPCB - Lo-Pitch Insulated Roof Panel. External facings: Material: Galvalloy hot-dip ZA255 coated steel to BS EN 1021, Grade S220GD+ZA. Thickness: 0.5mm Finish/Colour: Nominal 200micron Plastisol, Standard colour. Internal facings: Material: Hot-dip zinc coated steel to BS EN Thickness: 0.4mm Finish/Colour: Lining Enamel, colour White. Core insulation: Zero ODP and LPCB certified. Panel thickness: 115mm overall (80mm core) End laps: 75mm. End lap sealant: Single line of 18mm x 4mm U shaped butyl rubber sealant, Class A, Ref NFRC TB93, site applied at lap in external facings. Single line of non-setting gun-grade, Scapa Tapes, Ref: 0100 or similar, site applied at lap in external facings. Non-setting gun-grade, Scapa Tapes, Ref: 0100 or similar, site applied to corners of profile at end lap. Side lap sealant: Two anti-condensation tapes, factory applied at butt joint between panels. Fasteners: As determined by Clause 220C. Number and location: Primary fasteners: As determined by Clause 197A, but with each panel fixed to each support using not less than two fastenings, located through the side panels as recommended by cladding manufacturer. Secondary fasteners: Stitch external end laps using five fastenings per panel, located 25mm upslope from end lap, penetrating factory applied stitching plate on underside of down slope panel. S U L P 18

19 KS1000 LP/Zero ODP/LPCB Lo-Pitch Roof System Lo-Pitch of 4 or above Roof LPS 1181 Grade EXT-B Ref No: 1/5.74A/LPS-B Cover Caps: Material: As per external facings. Thickness: 0.5mm Finish/Colour: Colorcoat as per external facings, colour standard. Sealant: Single line of non-setting gun-grade, Scapa Tapes, Ref: 0100 or similar, site applied at 4 way laps. Factory applied sealant tape at junction with panels. Accessories: Profiled fillers as Clause 300A. Apex dams and profiled fillers as per manufacturers recommendations, where flashing cross the profile of the panel. Apex dams as determined by Clause 310A. Thermal Transmittance (U Value) calculated using the method required by the Building Regulations Part L2 (England & Wales) and Building Standards Part J (Scotland): 0.25 W/m 2 K Air leakage rate of 10m 3 /hr/m 2 at 50 Pa. Other requirements: Internal face of panel to be air sealed along the full length by an unbroken run of 6mm diameter butyl rubber sealant Class A, Ref NFRC TB A - Attachment Determine the number and location of cladding fasteners recommended by the cladding manufacturer to resist wind loads calculated in accordance with BS 6399:Part 2 Standard Method and BS 5427: Part 1. Calculate wind loads on roof and wall cladding appropriate to location, exposure, roof height, building shape and size in accordance with BS 6399: Part 2 Standard Method and BS 5427: Part 1. Basic wind speed (Vb): m/s Altitude factor (Sa): Direction factor (Sd): Seasonal factor (Ss): 1 Probability factor (Sp): 1 Terrain and building factor (Sb): External and internal size effect factors (Ca): 1 External pressure coefficients (Cpe): As determined from BS 6399: Part 2, Clauses 2.4 and 2.5. Internal pressure coefficients (Cpi): As determined from BS 6399: Part 2, Clause 2.6. Dominant opening: 220C - Fasteners Recommended Manufacturer: One of the following: SFS Intec Limited, tel Ejot UK Limited, tel Mage Fasteners Limited, tel Ash and Lacy Building Systems Limited, tel Primary fasteners: High threaded screws with bonded washers. Type(s), size(s) and drilling capacity: As recommended by fastener manufacturer to suit type and thickness of supports, and thickness of cladding panels. Screw material: Anti-corrosion coated carbon steel. Washer material: Grade 304 austenitic stainless steel. Washer size: 16mm diameter. Heads: Not coloured Secondary fasteners: Stitching screws with bonded washers. Screw/washer material: As primary fasteners. Washer size: 14mm diameter. Heads: Integral colour matched heads. 275A - Continuity Thermal Insulation Junctions between the roof panel system and walls/ penetrations insulated with PIR board insulation any gaps filled with Alfasbond FR or similar fire rated gun applied canister urethane insulation. Placement: Secure and continuous with cladding/covering insulation. 300A - Profiled Fillers Drawing reference(s): Manufacturer and reference: Premier Sealant Systems Limited Ref: E25 or similar, type to suit cladding profile. Material: EPDM foam. Colour: Black. Fixing: Seal the top, bottom and sides of each profiled filler with a non-setting gun-grade, Scapa Tapes, Ref: 0100 or similar. Locate where shown on drawings and wherever necessary to close off corrugation cavities from the inside and outside of the building. Ensure a tight fit and leave no gaps. 310A - Purpose Made Cold Formed Metal Accessories External Drawing reference(s): Material/finish: As external face of cladding. Thickness: 0.63mm Colour: To match external face of cladding. Workmanship as section Z11. Fixing: Stitch to external face of panels at 400mm centres using secondary fasteners as specified for the cladding system. Sealing: Single line of 20mm x 3mm butyl rubber sealant Class A, Ref NFRC TB93, site applied between flashing and panel. 311A - Purpose Made Cold Formed Metal Accessories - Internal Drawing reference(s): Material/finish: As internal face of cladding. Thickness: 0.4mm Colour: White. Workmanship as section Z11. Fixing: Stitch to internal face of panels at 450mm centres using stainless steel secondary fasteners as specified for the cladding system. Sealing: Single line of 6mm diameter butyl rubber sealant Class A, Ref NFRC TB93, site applied between flashing and panel. End laps to be air sealed with Scapa Tapes Vapourflex or similar, or gun-grade sealant. 19

20 Model Specifications KS1000 LP/Zero ODP/LPCB Lo-Pitch Roof System Lo-Pitch of 4 or above Roof LPS 1181 Grade EXT-B Ref No: 1/5.74A/LPS-B Detail 1 - Side Lap Detail 2 - End Lap Snap-on matching/ contrasting cover cap Factory applied anti-condensation tape Panel fastener 25mm 75mm Position of tail stitching screws 18mm x 4mm U section butyl rubber end lap sealant Continuous bead of gun-grade sealant Concealed through fastener Factory applied end lap stitching plate Detail 3 - Fastener Locations Note: For curved end lap detail please see page 35. End lap tail stitching screws Panel fastener Detail 4 - Ridge Detail Ridge flashing with 150mm sealed butt straps Cover cap Profiled filler set back 80 to 100mm to prevent bird attack Site applied Alfasbond fire rated (FR) canister insulation Apex dam (Ref: LP1) Bead of non-curing gun-grade sealant Profiled filler sealed top and bottom with gun-grade sealant KS1000 LP/LPCB insulated roof panel Internal ridge flashing with 150mm overlap sealed with Vapourflex or gun-grade sealant 2 No. runs of non-curing gun-grade sealant Air seal - 8mm Ø butyl rubber sealant Purlin Note: For KS1000 CR (Curved) Model Specification construction details contact Kingspan Technical Design Bureau. 20

21 KS1000 LP/Zero ODP/LPCB Lo-Pitch Roof System Lo-Pitch of 4 or below Roof LPS 1181 Grade EXT-B Ref No: 1/5.74B/LPS-B Application The following specification is for the KS1000 LP/Zero ODP/LPCB Lo-Pitch Insulated Roof Panel used for buildings with roof slopes of 1.5 or curved roofs of 150m radius and above with internal humidity class environments 1-4 inclusive as defined in BS EN ISO 13788:2002. For internal humidity class environment 5 i.e. swimming pools contact Kingspan Technical Design Bureau. KS1000 LP is Loss Prevention Certification Board (LPCB) certified to LPS 1181 Grade EXT-B. Materials & Coatings External Weather Sheet Substrate to be 0.5mm thick steel S220GD+ZA eutectic Galvalloy hot-dip zinc coated steel to BS EN10214: External coating to be Plastisol, nominal 200 micron thick. Colour Standard. Reverse to have a light grey polyester coating. Insulation Core To consist of 80mm thick, closed cell, with zero ozone depletion (Zero ODP) and LPCB certified polyisocyanurate (PIR) insulation. The auto-adhesive properties of the core bond the external and internal sheets together, and control the panel thickness achieved during manufacture. Internal Liner Sheet Substrate to be 0.4mm thick hot-dip zinc coated Steel to BS EN10147: Internal coating to be Lining Enamel, nominal 15 micron thick. Colour - White. Reverse to have a light grey polyester coating. Cover Caps To be made from 0.5mm thick steel coated to the same specification as the external weather sheet of the panels and used in typical lengths up to 12000mm. Performance Thermal Insulation The panel must have a thermal transmittance (U value) of 0.25 W/m 2 K calculated using the method required by the Building Regulations Part L2 (England & Wales) and Building Standards Part J (Scotland). Fire The external and internal faces of the panel to be Class 0 in accordance with the Building Regulations when tested to BS 476: Parts 6: 1989 and Part 7: The panel must be rated SAA when tested to BS 476: Part 3: The system has passed all the requirements of LPS 1181: 2003: Part 1: Issue 1 ceiling lining test. Airtightness Overall airtightness for complete envelope less than 10m 3 /hr/m 2 at 50Pa. Seals & Fillers Side Joint All side joints have a factory applied anti-condensation tape. End Lap All external end laps to be 75mm long, and weather sealed along the full width using a single unbroken run of 18mm wide x 4mm thick U section butyl rubber sealant tape, Class A, Ref NFRC TB93. In addition a single unbroken run of non-curing mastic applied across the complete with of the panel. End laps to be tail stitched with carbon steel stitching screws, complete with 14mm diameter bonded stainless steel washers. Tail stitching to be positioned 25mm upslope from end lap and five number per panel. Fasteners to penetrate the factory applied end lap stitching plate positioned in the downslope panel at the flush end. An additional 150mm length of gun applied non-curing mastic to be applied over 4 way laps. Profiled Fillers Where flashings are fixed across the profile of the insulated panel, EPDM closed cell foam fillers should be used to seal and close the profile. Seal the top, bottom and sides of each profiled filler with non-setting gun-grade sealant, Scapa Tapes Ref: 0100 or similar. The flashing and filler to be supported using an apex dam, Ref: LP1. Junctions Junctions between the roof panel system and walls / penetrations insulated with PIR board insulation any gaps filled with Alfasbond FR or similar fire rated gun applied canister urethane insulation. Internal face of panel to be air sealed along the full length by an unbroken 6mm diameter butyl rubber sealant tape, Class A, Ref NFRC TB93. Fasteners Primary All primary fasteners must be the high threaded type, manufactured from carbon steel and fitted with a 16mm diameter bonded stainless steel washer. All fasteners to be located at the side profile of the panel. To comply with the requirements of BS 6399: Part 2: 1997, it may be necessary to provide additional fixings in areas of high local suction. Secondary Flashings to be stitched at 450mm centres (maximum) with carbon steel, stitching screws, complete with 14mm diameter bonded stainless steel washers with integral colour matched heads. Fasteners General Note Recommended fasteners are available from SFS Intec Ltd, Ejot UK Ltd, Mage Fasteners Ltd, or Ash and Lacy Building Systems Ltd. 21

22 Model Specifications KS1000 LP/Zero ODP/LPCB Lo-Pitch Roof System Lo-Pitch of 4 or below Roof LPS 1181 Grade EXT-B Ref No: 1/5.74B/LPS-B Construction Details Flashings All external flashings to be made from 0.63mm thick steel to the same specification as the outer sheet of the panel. Colour Standard. All flashings to be weather sealed at laps and along the full length by an unbroken bead of 20mm wide x 3mm thick butyl rubber sealant tape, Class A, Ref NFRC TB93. All internal flashings to be made from 0.4mm thick steel substrate, to the same specification as the inner sheet. Colour - white. All internal flashings to be air sealed at laps and along the full length by an unbroken bead of 6mm diameter butyl rubber sealant tape, Class A, Ref NFRC TB93. End laps to be air sealed with Scapa Tapes Vapourflex or similar, or gun-grade sealant. Ridge and Eaves The outer sheet of the panel must be turned up and turned down using cladding manufacturers supplied tool at ridge and eaves respectively. Panel Lengths Exact lengths to be determined by the cladding contractor from the steelwork drawing, but typically using minimum number of panels from ridge to eaves up to a maximum panel length of 28.5 metres. Construction Requirements Steelwork Tolerance The steel frame must be made and assembled to an accuracy of L/600 between fixing planes of adjacent purlins, +/- 5mm. Installation All fasteners, seals and fillers to be of correct specification and installed as indicated on the project construction drawings. Site cut panels must provide accurate, true lines with no distortion. Panels to be cut with powered reciprocating type saw and all exposed site cut panels to be treated with a suitable edge protection lacquer. Cut openings for outlets, vents, flues etc. to be the minimum size necessary. Remove all swarf and any foreign matter immediately from the external surface of panels. 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 HSE & CDM requirements. NBS Format Specification H43 - Metal Composite Panel Cladding/Covering To be read with Preliminaries/General conditions. 122A - Metal Composite Panel Drawing reference(s): Supports: Cold rolled purlins Bearing width: 50mm Pitch: Min 1.5 or above (Finished roof slope after deflections). Manufacturer and reference: Kingspan roof cladding system for standard internal and external environments and Loss Prevention Certification Board certified to LPS 1181 Grade B. Test results: LPS 1181, Issue 3, ceiling lining tests: Passed all requirements. Panels: Profile reference: KS1000 LP/Zero ODP/LPCB - Lo-Pitch Insulated Roof Panel. External facings: Material: Galvalloy hot-dip ZA255 coated steel to BS EN 10212, Grade S220GD+ZA. Thickness: 0.5mm Finish/Colour: Nominal 200 micron Plastisol, standard colour. Internal facings: Material: Hot-dip zinc coated steel to BS EN Thickness: 0.4mm Finish/Colour: Lining Enamel, colour White. Core insulation: Zero ODP and LPCB certified. Panel thickness: 115mm overall (80mm core) End laps: 75mm. End lap sealant: Single line of 18mm x 4mm U shaped butyl rubber sealant, Class A, Ref NFRC TB93, site applied at lap in external facings. Single line of non-setting gun-grade, Scapa Tapes, Ref: 0100 or similar, site applied at lap in external facings. Non-setting gun-grade, Scapa Tapes, Ref: 0100 or similar, site applied to corners of profile at end lap. Side lap sealant: Two anti-condensation tapes, factory applied at butt joint between panels. Fasteners: As determined by Clause 220C. Number and location: Primary fasteners: As determined by Clause 197A, but with each panel fixed to each support using not less than two fastenings, located through the side panels as recommended by cladding manufacturer. Secondary fasteners: Stitch external end laps using five fastenings per panel, located 25mm upslope from end lap, penetrating factory applied stitching plate on underside of down slope panel. 22

23 KS1000 LP/Zero ODP/LPCB Lo-Pitch or Curved Roof System Lo-Pitch of 4 or below Roof LPS 1181 Grade EXT-B Ref No: 1/5.74B/LPS-B Cover Caps: Material: As per external facings. Thickness: 0.5mm Finish/Colour: Colorcoat as per external facings, colour standard. Sealant: Single line of non-setting gun-grade, Scapa Tapes, Ref: 0100 or similar, site applied at 4 way laps. Accessories: Profiled fillers as Clause 300A. Apex dams and profiled fillers as per manufacturers recommendations, where flashing cross the profile of the panel. Apex dams as determined by Clause 310A. Thermal Transmittance (U Value) calculated using the method required by the Building Regulations Part L2 (England & Wales) and Building Standards Part J (Scotland): 0.25 W/m 2 K Air leakage rate of 10m 3 /hr/m 2 at 50 Pa. Other requirements: Internal face of panel to be air sealed along the full length by an unbroken run of 6mm diameter butyl rubber sealant, Class A, Ref NFRC TB93. Turn up and turn down using cladding manufacturers supplied tool at ridge and eaves respectively. 197A - Attachment Determine the number and location of cladding fasteners recommended by the cladding manufacturer to resist wind loads calculated in accordance with BS 6399: Part 2 Standard Method and BS 5427: Part 1. Calculate wind loads on roof and wall cladding appropriate to location, exposure, roof height, building shape and size in accordance with BS 6399: Part 2 Standard Method and BS 5427: Part 1. Basic wind speed (Vb): m/s Altitude factor (Sa): Direction factor (Sd): Seasonal factor (Ss): 1 Probability factor (Sp): 1 Terrain and building factor (Sb): External and internal size effect factors (Ca): 1 External pressure coefficients (Cpe): As determined from BS 6399: Part 2, Clauses 2.4 and 2.5. Internal pressure coefficients (Cpi): As determined from BS 6399: Part 2, Clause 2.6. Dominant opening: 220C Fasteners Recommended Manufacturer: One of the following: SFS Intec Limited, tel Ejot UK Limited, tel Mage Fasteners Limited, tel Ash and Lacy Building Systems Limited, tel Primary fasteners: High threaded screws with bonded washers. Type(s), size(s) and drilling capacity: As re-commended by fastener manufacturer to suit type and thickness of supports, and thickness of cladding panels. Screw material: Anti-corrosion coated carbon steel. Washer material: Grade 304 austenitic stainless steel. 23 Washer size: 16mm diameter. Heads: Not coloured Secondary fasteners: Stitching screws with bonded washers. Screw/washer material: As primary fasteners. Washer size: 14mm diameter. Heads: Coloured plastic heads. 275A - Continuity Thermal Insulation Junctions between the roof panel system and walls/penetrations insulated with PIR board insulation any gaps filled with Alfasbond FR or similar fire rated gun applied canister urethane insulation. Placement: Secure and continuous with cladding/covering insulation. 300A - Profiled Fillers Drawing reference(s): Manufacturer and reference: Premier Sealant Systems Limited Ref: E25 or similar, type to suit cladding profile. Material: EPDM foam. Colour: Black. Fixing: Seal the top, bottom and sides of each profiled filler with a non-setting gun-grade, Scapa Tapes, Ref: 0100 or similar. Locate where shown on drawings and wherever necessary to close off corrugation cavities from the inside and outside of the building. Ensure a tight fit and leave no gaps. 310A - Purpose Made Cold Formed Metal Accessories External Drawing reference(s): Material/finish: As external face of cladding. Thickness: 0.63mm Colour: To match external face of cladding. Workmanship as section Z11. Fixing: Stitch to external face of panels at 400mm centres using secondary fasteners as specified for the cladding system. Sealing: Single line of 20mm x 3mm butyl rubber sealant, Class A, Ref NFRC TB93, site applied between flashing and panel. 311A - Purpose Made Cold Formed Metal Accessories - Internal Drawing reference(s): Material/finish: As internal face of cladding. Thickness: 0.4mm Colour: White. Workmanship as section Z11. Fixing: Stitch to internal face of panels at 450mm centres using stainless steel secondary fasteners as specified for the cladding system. Sealing: Single line of 6mm diameter butyl rubber sealant, Class A, Ref NFRC TB93, site applied between flashing and panel. End laps to be air sealed with Scapa Tapes Vapourflex or similar, or gun-grade sealant.

24 Model Specifications KS1000 LP/Zero ODP/LPCB Lo-Pitch Roof System Lo-Pitch of 4 or below Roof LPS 1181 Grade EXT-B Ref No: 1/5.74B/LPS-B Detail 1 - Side Lap Detail 2 - End Lap Snap-on matching/ contrasting cover cap Factory applied anti-condensation tape Panel fastener Position of tail stitching screws 25mm 75mm 18mm x 4mm U section butyl rubber end lap sealant Continuous bead of gun-grade sealant Concealed through fastener Factory applied end lap stitching plate Detail 3 - Fastener Locations Note: For curved end lap details please see page 35 End lap tail stitching screws Panel fastener Detail 4 - Ridge Detail Ridge flashing with 150mm sealed butt straps Cover cap Profiled filler set back 80 to 100mm to prevent bird attack Outer sheet turned up Site applied Alfasbond fire rated (FR) canister insulation Apex dam (Ref: LP1) Bead of non-curing gun-grade sealant Profiled filler sealed top and bottom with gun-grade sealant KS1000 LP/LPCB insulated roof panel 2 No. runs of noncuring gungrade sealant Air seal - 8mm Ø butyl rubber sealant Internal ridge flashing with 150mm overlap sealed with Vapourflex or gun-grade sealant Purlin Note: For KS1000 CR (Curved) Model Specification construction details contact Kingspan Technical Design Bureau. 24

25 25

26 Construction Details 26

27 Panel Dimensions 1000 cover width A B Fastener location Anti condensation tape (Factory applied) 3mm Radius External weather sheet Fastener location 53 3 Anti condensation tape (Factory applied) Insulation core Internal liner sheet Note: Two sets of construction details have been produced to give the building designer flexibility within the Part L2 calculation for the total building heat loss Alpha (α). The decision on the choice of STANDARD or ENHANCED details is taken by the building designer and is determined from the Part L2 total heat loss methodology. A mixture of both standard and enhanced details may be required for some projects. Available Panel Thicknesses Insulation Overall Panel Core (A) Thickness (B) Note: Above dimensions are theoretical, actual dimensions will vary due to manufacturing tolerances. Exactly precise dimensions must always be measured from actual samples All dimensions in millimetres. 27

28 Construction Details End Lap Detail Snap-on cover cap over lower cover cap End of cover cap pointed with mastic Cover cap 18mm x 4mm U section butyl rubber sealant End lap fixing/ stitching screw 10mm Max 75mm End lap 25mm 15mm 75mm factory formed joint Continuous bead of gun-grade sealant 2 runs of noncuring gungrade mastic to side joint Factory fitted end lap stitching plate 30mm Min 10mm Min Minimum of 300mm between panel end lap and cover cap end lap Continuous bead of non-curing gun-grade sealant End Lap Stitching Screw Locations 28

29 Ridge Detail STANDARD Mineral fibre insulation ENHANCED Ridge flashing with 150mm sealed butt straps Cover cap Profiled filler set back 80 to 100mm to prevent bird attack Site applied Alfasbond or similar fire rated (FR) canister insulation Outer sheet turned up with roof slopes below 4 Apex dam (Ref: LP1) Bead of non-curing gun-grade sealant Profiled filler sealed top and bottom with gun-grade sealant Air seal - 8mm Ø butyl rubber sealant KS1000 LP/LPCB insulated roof panel Internal ridge flashing with 150mm overlap sealed with Vapourflex or gungrade sealant or similar STANDARD Building Regulations Part L2 Thermal Data fmin = 0.97 Ψ = 0.01 W/mK The above values are only applicable to the components on this detail. Changes to the components will have an effect on the given values. 2 No. runs of non curing gungrade sealant Air seal - 8mm Ø butyl rubber sealant ENHANCED Purlin Building Regulations Part L2 Thermal Data fmin = 0.97 Ψ = W/mK The above values are only applicable to the components on this detail. Changes to the components will have an effect on the given values. 29

30 Construction Details Eaves Detail Parapet Detail -Boundary Wall Gutter Parapet flashing with 150mm sealed butt straps Mineral fibre insulation site applied Butyl rubber sealant Parapet rail with air seal - Vapourflex or similar to rail joints Air seal - 6mm Ø butyl rubber sealant Profiled filler sealed top and bottom with gun-grade sealant Air seal - 6mm Ø bead of gun-grade sealant 4mm Ø butyl rubber sealant Air seal - 6mm Ø butyl rubber sealant KS1000 MR/ LPCB wall panel horizontally laid KS1000 RW/ LPCB wall panel vertically laid Sheeting rail Mineral fibre insulation site applied 60mm 35mm min Top sheet turned down on site with roof pitches below 4 Gun-grade seal at panel joints inline with 8mm butyl Air seal - 8mm Ø butyl rubber sealant 2mm external non-thermally broken factory made gutter with PIR insulation to 0.25 or 0.35 W/m 2 K U-value 75mm KS1000 LP/LPCB insulated roof panel Purlin Direction of lay STANDARD Building Regulations Part L2 Thermal Data 0.25 W/m 2 K gutter fmin = 0.48 Ψ = 1.63 W/mK 0.35 W/m 2 K gutter fmin = 0.48 Ψ = 1.72 W/mK 0.35 sole width 300mm and depth 150mm, values for other widths available on request. The above values are only applicable to the components on this detail. Changes to the components will have an effect on the given values. Gutter outlet Eaves beam gutter support ENHANCED ENHANCED Site applied Alfasbond or similar fire rated (FR) canister insulation Site applied PIR board insulation ENHANCED Site applied Alfasbond or similar fire rated (FR) canister insulation Factory made thermally broken membrane lined gutter with PIR board insulation to 0.25 or 0.35 W/m 2 K U-value Building Regulations Part L2 Thermal Data 0.25 W/m 2 K gutter fmin = 0.90 Ψ = 0.13 W/mK 0.35 W/m 2 K gutter fmin = 0.90 Ψ = 0.21 W/mK 0.35 sole width 300mm and depth 150mm, values for other widths available on request. The above values are only applicable to the components on this detail. Changes to the components will have an effect on the given values. 30

31 Eaves Detail Eaves Detail - External Gutter Gutter support 0.63mm thick doubled sided plastisol coated 75mm Approx 200mm fixing centres 200mm fixing centres Top sheet turned down on site with roof pitches below 4 0 Gun -grade sealant at panel joints inline with 8mm butyl 20mm x 3mm butyl rubber sealant Stitching screw fixings for gutter brackets KS1000 LP/LPCB insulated roof panel Double sided Plastisol Highline type gutter Eaves beam 20 mm mm 35 mm 20 KS1000 MR/ LPCB wall panel horizontally laid Air seal - Vapourflex or similar sealant * is to be applied over any breaks in supporting secondary steelwork to give a continuous bearing face. STANDARD Building Regulations Part L2 Thermal Data fmin = 0.95 Ψ = 0.31 W/mK The above values are only applicable to the components on this detail. Changes to the components will have an effect on the given values. * Air seal - 8mm Ø butyl rubber sealant STANDARD Mineral fibre insulation site applied ENHANCED Site applied Alfasbond or similar fire rated (FR) canister insulation Air seal - 6mm Ø butyl rubber sealant ENHANCED Building Regulations Part L2 Thermal Data fmin = 0.95 Ψ = 0.13 W/mK The above values are only applicable to the components on this detail. Changes to the components will have an effect on the given values. 50mm Gutter support 0.63mm thick HPS200 coating both sides Cover cap 40mm 30mm Stitching screw fixings for gutter brackets Internal liner sheet Concealed through fastener 31

32 Construction Details Valley Gutter Detail Valley Gutter Detail Cover cap Top sheet turned down on site with roof pitches below 4 75mm Gun-grade seal at panel joints inline with 8mm butyl Air seal - 8mm Ø butyl rubber sealant 2mm external non-thermally broken factory made gutter with PIR insulation to 0.25 or 0.35 W/m 2 K U-value Stanchion head tie if necessary as steelwork design Gutter outlet offset to miss stanchion head tie Air seal - 8mm Ø butyl rubber sealant Purlin STANDARD Building Regulations Part L2 Thermal Data 0.25 W/m 2 K gutter fmin = 0.74 Ψ = 1.07 W/mK 0.35 W/m 2 K gutter fmin = 0.71 Ψ = 1.38 W/mK 0.35 sole width 600mm and depth 150mm, values for other widths available on request. The above values are only applicable to the components on this detail. Changes to the components will have an effect on the given values. Valley Gutter Detail Cover cap ENHANCED 75mm Gun-grade seal at panel joints inline with 8mm butyl Top sheet turned down on site with roof pitches below 4 Air seal - 8mm Ø butyl rubber sealant Factory made thermally broken membrane lined gutter with PIR board insulation to 0.25 or 0.35 W/m 2 K U-value Stanchion head tie if necessary as steelwork design Gutter outlet offset to miss stanchion head tie Air seal - 8mm Ø butyl rubber sealant Purlin ENHANCED Building Regulations Part L2 Thermal Data 0.25 W/m 2 K gutter fmin = 0.96 Ψ = 0.13 W/mK 0.35 W/m 2 K gutter fmin = 0.96 Ψ = 0.25 W/mK 0.35 sole width 600mm and depth 150mm, values for other widths available on request. The above values are only applicable to the components on this detail. Changes to the components will have an effect on the given values. 32