Kalzip Ltd

Hi-PointTM off-site roof system

CI/SfB (27) XhSeptember 2006

Hi-Point... off-siteroof system withthe benefits built-inA superior, simple and safer method ofroof construction

Health & safety

• Main construction is carried out on the factory floorsignificantly reducing risk of working at height

• Risk of injuries from falling debris reduced

• Strict adherence to Work at Height Regulations 2005

• Embraces CDM Regulations

Cost savings

• Reduced on-site costs - less scaffolding, less supervision,fewer operatives

• Reduced contractor preliminaries

• Condensed site programme

• Reduced exposure to damage

• Complete system including accessories

• Fewer deliveries to site

• Fewer skips required on site reducing drop offs andcollections

Quality control

• Single source manufacturer

• Components and build quality can be monitored undercontrolled factory conditions

Speed & design flexibility

• Simultaneous roof construction allows faster projectcompletion

• Fewer crane lifts on-site

• Following trades can commence earlier

• Client gains access to finished building earlier

Environment

• Little or no packaging requirements

• Recyclable products used as a priority where clientrequirements allow

• Solar PV laminates can be utilised within OSC supply

• System can be adapted for use with sedum roofs

• Less time on site - lower use of utilities

• Factory production reduces waste materials

Hi-Point roof constructions are available with a range ofinsulation thicknesses and densities to ensure optimumperformance and complete design flexibility, whilst helping tomeet the Target Emissions and Building Emissions Rates.

Benefits

2 Hi-Point off-site roof system

Hi-Point from Kalzip provides off-site solutions for roofconstruction in the military, education, health, residential andcommercial building sectors. It is manufactured at a dedicatedsite in Haydock, home to Kalzip and the Kalzip portfolio ofproducts and systems.

Promoted by the Government through the Department ofTrade and Industry (Dti) and highlighted by the Latham andEgan Reports off-site construction techniques are ideallysuited to fast-track building projects.

With factory assembled modules, construction is no longerdependent on the weather, waste is eliminated and qualitystandards can be guaranteed. Moreover, the constructionenvironment can be made significantly safer as therequirement for working at height is considerably reduced.

Described as a modern method of construction off-site roofmanufacture is commonly referred to as ‘off-site construction’but equally, it can be assembled adjacent to the building.

On-site construction is preferred where there is plenty ofspace available to construct and store the roof modules on-site. The components are delivered to site as a ‘kit of parts’ready for assembly and installation.

If space is limited for a particular project, then off-siteconstruction is ideal. This involves the preassembly of almostall the components at the factory premises, transportation tosite and then lifting into position using facilities already on site.

Hi-Point... raising the rooflowering the risk

Raising the roof lowering the risk

Hi-Point off-site roof system 3

Technical information

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Hi-Point technical informationHi-Point can be divided into two categories termed as‘primary’ and ‘secondary’ frame. The primary frame is classedas the module structure and the secondary frame includes thepurlins to roof coverings.

The primary frame is manufactured from cold rolled,lightweight galvanised steel sections in the form of lipped andopen channels. The cold rolled sections are dimensionallyaccurate, extremely robust, non-combustible and can beinstalled very quickly.

Roof coverings may be either single or double skin and thetype of roof construction will depend on the U-value and anyother client requirements. Hi-Point offers a variety of coveringsincluding self-supporting and fully supported standing seam,composite panels, membrane, trapezoidal profiles, metal tilesand roof preparation for concrete tiles.

Table 1 shows the typical pitch requirements of the abovementioned roof coverings.

Dead load structureThe dead weight structure design accommodates both liveand dead loads, which may be uniformly distributed orconcentrated at various locations.

Live loads are non-permanent such as environmental loadsproduced by snow and wind. The weight of the temporaryconstruction materials and occupant floor loads can beclassed as live loads.

Dead loads are the weight of the materials in the structureitself and any items permanently placed on to it.

The primary frames transmit a series of point loads via thevertical members onto the load bearing structure below theframe, as table 2.

Load bearing structure

Table 1 Typical pitch requirements

Mono-pitch Duo-pitch Barrel vault

Roofcovering Warm Cold Warm Cold Warm Cold

Kalzip 1.5° 1.5° 1.5° 1.5°

Traditional metals5° 5° 5° 5°

Superdeck membrane roof0.5° X 0.5° X X X

Trapezoidal 5° 5° 5° 5°

Metal tile 15° 15° 15° 15° X X

Concrete tile 22.5° 22.5° 22.5° 22.5° X X

Table 2 Principles of dead load structure

Table 3 Design parameters

Design parameters - module

Typeof roof Condition Span (m) Angle (°) Height Ht (m)

4.0 >4.0 30 >30 3.2 >3.2

Mono-pitch Off-site X <15 X X

On-site

Duo-pitch Off-site X X X

On-site

Barrel vault Off-site X X X

On-site

_

<_<_<_

Technical information

Hi-Point off-site roof system 5

Roof geometryHi-Point encompasses the three main types of standard roofgeometry

- mono-pitch

- duo-pitch

- barrel vault

Table 3 (shown bottom left) outlines the design parametersappropriate to the above geometries.

LiftingThe complete roof modules can be lifted by either the purlinbrackets, or the top mounted lifting plates. These plates areonly used with standing seam solutions and are fixed bymeans of four split clamps under the lifting plate.

The plates, or the purlin brackets, are fixed close to the liftingtrusses on the lightweight modules so that the main framescan resist bending whilst performing the lifts.

British StandardsHi-Point off-site roof structures are designed in accordancewith the British Standard codes as listed below:

• BS 6399 Part 1 1996: Dead and imposed loads

• BS 6399 Part 2 1997: Wind loads

• BS 6399 Part 3 1988: Imposed roof loads

• BS 5950 Part 5 2000: Design of cold formed thingauge sections

All materials are pre-galvanised to BS EN 10147 1992and BS EN 10143 1993.

Lifting plate and clamps onKalzip standing seam

Purlin lifting brackets

Mono-pitch

Duo-pitch

Barrel vault

When Hi-Point off-site is on-site

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When Hi-Point off-site...Manufactured and assembled into volumetric modules under factory controlled conditions, off-site manufacturing is ideal for siteswhere space for ‘on-site’ construction is at a premium but speed of installation and reduced working at height risks are a benefit.

Thermal and acoustic materials as well as preparatory finishes such as bullnoses and flashings can be incorporated into thespecified roofing. The modules are subsequently delivered to site to meet timed delivery schedules. The scaffolding is onlyerected to facilitate completion of the brickwork.

When Hi-Point off-site is on-site

Hi-Point off-site roof system 7

...is on-siteHi-Point offers ground level site assembly of two-dimensional fabricated frames to provide three-dimensional modules. Allstructural components such as purlins are incorporated together with pre-prepared roofing and acoustic/insulation material asspecified. The modules are crane-lifted into position, thereby reducing working at height risks.

Before final installation modules can be site measured to accommodate construction tolerances and larger modules areachievable as transportation is not required.

High speed Hi-Pointdramatically cutsinstallation timeThe roof installation programme for a multi-storey luxuryapartment block in Liverpool was dramatically cut to justtwo days, thanks to the use of the new Hi-Point roofingsystem from Kalzip.

At 27 storeys the residential development, which is part of themixed use Unity Project, presented numerous challenges, notleast because of its location in the heart of the city centre.Owing to the scale of the project; speed of installation,increased safety and reduced man-hours working at height,were prime considerations for designers Dane Architecturaland main contractors Laing O’Rourke. The striking 1.5 degreepitched Hi-Point gull wing roof, which sits 94 metres above theground, proved to be the ideal solution.

The full 22 modules, which were precision manufactured andassembled by Kalzip under factory controlled conditions, werelifted and bolted into position in just two days allowingsignificant reductions to be made in both the roof installationprogramme and the overall site time.

The frames for the roof sections were constructed from coldrolled channel sections produced by Kalzip Construction and

Engineering Products, and, as whole life performance anddurability were also important factors in the specification of theroof, the Hi-Point system was equipped with a fully insulated,built up Kalzip system. Incorporating steel liner panels fromKalzip Panels and Profiles the system was topped with 1.2 mmclad stucco embossed Kalzip 400 aluminium standing seamsheets. A range of Kalzip fabrications including verge and roofflashings, mono ridge and verge capping details, were alsospecified in a stainless steel finish to complement the wallpanels, all of which were manufactured by the KalzipFabrication department.

The 398 square metre Kalzip standing seam roof also featuresa 25 metre long thermoplastic polyolefin (TPO) walkableinsulated membrane gutter, produced in two modules forconnection on site. Fully recyclable, the TPO gutters are alsoenvironmentally friendly and produce no harmful gas emissionsduring the manufacture or the hot-air welding process.

High speed Hi-Point dramatically cuts installation time

8 Hi-Point off-site roof system

High speed Hi-Point dramatically cuts installation time

Hi-Point off-site roof system 9

Putting Hi-Point to the test

10 Hi-Point off-site roof system

On top formThis new educational facility in the north of England hasbenefited from the rapid, economical and safety advantagesassociated with Hi-Point off-site roofing construction.Installation and finishing, including the soffits, were completedin just five days.

Comprising five volumetric modules - totalling 235 squaremetres of Kalzip standing seam - the roofs were deliveredcomplete with verges (on the end modules), fixed mono-ridgecorners and first flashings, eaves corners and gutters. Eventhe fall restraint system was pre-fitted at the factory ready forcabling on site.

All five roofs were delivered on the same day to meet a strict,sequential unloading programme. Once lifted by crane andinstalled, the remaining finishing tasks were completed fromthe safety of a scissor-lift platform.

All the designs, details and drawings were produced by KalzipHi-Point to ensure cohesion and accuracy and provide a singlesource of guarantee for the client.

Putting Hi-Point to the test

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Putting Hi-Point to the test

The six hour roofPutting Hi-Point to the test, the MOD/Defence Estates urgentlyrequired ten new accommodation buildings within anextremely tight, if not almost impossible, timescale.

After lifting into position, 748 square metres of pre-coatedHi-Point standing seam roofing were installed in just six hours.Thereafter the weathering process of joints, gutters andfascias was completed.

The roofing components were manufactured at the dedicatedHi-Point factory in Haydock and transported to site as a ‘kit ofparts’ for assembly. Due to both the number and size of theroofs, assembly took place on a nearby, disused World War IIrunway where the roofs could be ‘called off’ and installed asrequired.