Gerard Battenless Profiles

Transcription

1 Manual Gerard Battenless Profiles Canyon Shake Barrel Vault NB Tile January 2015

2 This Manual is designed as an instructional tool to clearly depict to the contractor, installer, distributor and architect, recommended installation techniques and procedures to confidently estimate and install a Canyon Shake, Barrel Vault and NB Tile Battenless roofing system by Gerard Roofing. This manual depicts generally practiced application techniques only, which should not be substituted for local building code specifications. Gerard Roofing carries product appproval reports for most building code agencies in North America which should be referenced for specific local requirements (visit website at gerardusa.com). These methods have been developed by Gerard Roofing as proven acceptable and tested methods of installing Gerard Stone Coated Steel Roofing. Gerard Roofing does not construe that these are the only methods but again are the tried and true proven techniques that are currently practiced by the majority of trained installers. This manual emphasizes common roofing practices in use today. If application techniques vary from those illustrated in this manual or if using this manual for applications not covered, please consult the technical department at As Gerard Roofing has no control over the installation techniques used, no warranty can be made relating to the installation of Gerard products. Product Approval Reports for various areas are available which should be analyzed for additional procedures after careful review of this manual. A careful study of this manual will give a full comprehension of a Canyon Shake, Barrel Vault and NB Tile roof installation. Gerard Roofing assumes no liability for either incorrect installation of its products or personal injury that may occur as a result of installing such products. The installation methods demonstrated in these materials are not the only ways to install Gerard products, but have been developed as a reference guide using acceptable, tested and proven methods for the standard installation of Gerard products. Contractors and installers should at all times use their professional judgment, and modify and tailor such methods where appropriate or necessary to suit each specific installation or any applicable local building codes or ordinances. Due to the fact that Gerard has no control over the actual installation techniques used, no warranty is expressed or implied relating to installation of the product. Gerard s liability with respect to Gerard products is limited exclusively to its standard written limited lifetime warranty. Please Note: It is the responsibility of the installer to adhere to local building codes. 2 Gerard Roofing TM

3 Table of Contents General Information General Information Review 4 Tools - Gerard Cutter and Gerard Break 5 Panels and Accessories 6-9 Estimating Quick Step Estimate 10 Roof Preparation 11 Framing - Gable / Eaves / Ridge / Hip Valley Flashing 14 Panels - Layout and Rake, Ridge, Hip Trim Details EZ Vent Ventilation - 2 Alternatives 20 Pipe Jack Flashing Details 21 Optional Rubber Boot Pipe Flashing Details 22 Chimney / Skylight Flashing Details 23 Maintenance Maintenance 24 3

4 General Information Storage Product must be kept covered, well ventilated and dry until installed. If the stacked tiles become wet, they should be immediately separated and dried. Please refer to MCA minimum performance guidelines for more detailed standard practice information relating to site storrage of metal roofing. Roof Traffic The Battenless tiles by Gerard are installed from the eaves up. When walking on the installed tile is required, walk on the front edge of the low sections. Footwear When it is required to walk on the Gerard tiles, rubber soled athletic type shoes or similar soft soled footwear is recommended to avoid coating damage and to provide a super grip for safety. Roof Pitch The Gerard tile is designed to be installed from a minimum of 4:12 pitch up to a vertical face in all climates and down to 3:12 pitch in warm weather climates. For slopes under 3:12, the tiles generally act only as a decorative roof covering. In this type of installation please consult our technical department and the local building officials. Underlayment Underlayment is generally required by most building codes. When allowed by the building code, underlayment is not required in re-roofing over existing composition roofs when the existing roof is in acceptable condition to act as the roofs underlayment. The exception to this condition will be in areas of extreme weather conditions where the underlayment should be of a type approved by the local building code and official. When installing over open rafters a self-supporting underlayment is recommended. Galvalume The Gerard Stone Coated Steel Roof System is produced exclusively from long lasting Galvalume Steel. The Galvalume coating will react unfavorably if in direct contact with lead or copper in a wet environment. Rain water run-off from copper roofs onto a Gerard Roof should be avoided as can beaggressive in nature and may attack the finishes. Only a- pproved fasteners should be used. Please consult the technical department for recommendations. Pressure Treated Battens The use of pressure treated lumber should NOT be used when installing Gerard roofing products, and will void the lifetime limited warranty offered by Gerard on such products. Any questions call our technical department at Use of Fasteners in Saltwater Areas All exposed fasteners used for the installation of Gerard Roofing products on ocean front properties must be installed using stainless steel fasteners. Severe Weather Conditions If the area is prone to severe ice, snow, water or wind, additional measures may be required. Please contact the Gerard technical department for more detailed procedures Labor A minimum two man crew is recommended from start to finish. This will ensure a cost effective, quality installation. A qualified two man crew is generally able to install one square (100ft ) per hour under normal circumstances. 4

5 General Information True-Cut Shear This tool is used to cut the Gerard panel across or length ways. The legs are re - movable for ease of handling. The Tru- Cut Shear is reversible for left-handed or right-handed use. Comes with reversible blade. Weight: 57 lbs. (27 kg) Gerard Break This universal tool is designed to perform four specific tasks: 1. Half panel bends up or down across the width of the panel for hip, valley, gable and roof to wall terminations. 2. Full panel bends up or down across the width of a panel for ridge, pitch change or roof to wall. 3. Bend flat stock or re-bend exisitng flashings. 4. Complete a tapered folded return across the width for finished end details. Weight: 132 lbs. / 60 kg Replacement Handle Grip Part No: Replacement Top Blade Part No: Replacement Bottom Blade Part No: NOTE: Replacement parts are available for Gerard tools. Contact Inside Sales. 5

6 General Information Canyon Shake Actual 16-1/2 x 45 Exposure 13-7/8 x 42-1/4 Coverage 24.5 / sq. Weight 5.83 lbs. Shake Cap Stone Coated 15-1/4 x 6 Fascia Metal Stone Coated 3-1/2 or 5 wide x 120 Drip Edge Metal Painted finish - White, Brown or Gray 2 or 3-1/2 wide x 120 Trimless Rake Metal Stone Coated 3 x 120 6

7 General Information Barrel Vault Actual 15-5/8 x 45-1/8 Exposure 13-1/2 x 43 Coverage 25 / sq. Weight 5.4 lbs. Gerard Mission Trim Stone Coated 15-1/4 x 6 Bird Stop Eaves Stone Coated 3-3/4 or 5 x 120 Bird Stop Top Row Stone Coated 4 wide x 120 Barrel Vault Foam Closure Non-stone Coated 3/4 x 46 7

8 General Information NB Tile Actual 16 x 46 Exposure 14-1/4 x 42-3/4 Coverage 23.7 / sq. Weight 6.6 lbs. Gerard Mission Trim Stone Coated 15-1/4 x 6 Fascia Metal Stone Coated 3-1/2 or 5 wide x 120 Drip Edge Metal Painted finish - White, Brown or Gray 2 or 3-1/2 wide x 120 8

9 Battenless Manual General Information Accessories Common to All Profiles Z Bar Metal Cor-A-Vent Chimney Saddle Flash Wind Soffit Flash (Ridge Vent Insert) Stone Coated 3 x 120 (Common to Vented Ridge Using Cor-A-Vent) Non-stone Coated 18-1/2 x 47-1/2 EZ Vent (Profiled to match) (Two Alternatives - See Pg. 20) Flat Stock Stone Coated 16-1/4 x Valley Non-Stone Coated 120 Fasteners 8d (0.131) x 2-3/8 Ring Shank, Corrosion-Resistant Nail or #10 x 2-1/2 Corrosion Resistant Screw Pipe Jack Flash Stone Coated End Disc - Stone Coated (Mission Trim) Neoprene Rubber Boot (thru roof flash) NP1 or Equivalent Professional thermoplastic sealant Super fexible Scellant thermoplastique profesional Super fexible 30# Felt (min.) or Equivalent Finishing Kit 9 Gerard Roofing Technologies TM

10 Estimating Determine How Much Material You Will Need: Quick step method, USA Standard (approximate). 1.) Determine roof square foot / feet with-out waste. 2.) Add linear feet of hips and valleys. Multiply by 2. 3.) Add totals from steps 1 and 2. 4.) Multiply total by This yields roof square feet including waste. 5.) Divide total from step 4 by 100. This yields roof squares. Example: Hip Length ft. 18 ft. Overall Fascia Length 50 1) 50 x 36 = 1800 sf without waste 2) Hip x 4 = 84 x 2 = 168 linear feet. 3) = ) 1968 x 1.06 = ) 2086 / 100 = sqs. Note: Gerard Barrel Vault - 25 panels per square Gerard NB Tile panels per square Gerard Canyon Shake panels per square 10

11 ROOF PREPARATION RIDGE EAVE VALLEY RAKE Gerard Battenless profiles can be installed over composition shingle or over solid sheathing (solid sheathing will require code approved underlayment). 1. Re-roof over composition shingles, the procedures are as follows: 1- Cut back existing shingles flush with the perimeter of the roof. (see Figure A) 2- Remove existing drip edge. 3- Remove hip and ridge cap. Figure A Notes 1- Make sure deck attachment is to code but at a minimum.8d x 2 3/8 Ring Shank Nails spaced 6 O.C. 2- Minimum underlayment should be ASTM D226 Type II 30# felt fastened according to code. 3- If a fire barrier is required any UL listed fire barrier is approved when installed according to code. 4- Local building codes govern. 2. Remove existing and roof over deck, procedures as follows: 1- Remove all exisitng roofing materials to deck. Ensure deck is to local code. 2- New underlayment according to local code requirmeents. 3- Install required valley materials per local codes including water barrier underlay. 4- If a fire barrier is required any UL listed fire barrier is approved when installed according to code. 5- Local building codes govern. 11

12 RAKE / GABLE / EAVES DETAILS Set 2x2 Nominal in 1-1/4 from edge Rake/Gable Detail for Barrel Vault & NB Tile 1x2 or 1x3 Nominal (2x2 optional) Rake/Gable Detail for Canyon Shake 1x3 or 1x4 at eaves. 1- Install nominal wood nailer along rake/gable/eave. See diagram left for batten size and location. 2- Wood support material to be nailed every 6 with 16d ring shank nails or #10 screws of sufficient length to penetrate 1 min. existing structure. 3- A 1 x 4 at the eave is recommended to maintain the pitch of the first course. Note: Pressure Treated Lumber. Lumber should not be pressured treated. If treated lumber is required by local codes, a roofing membrane material must be used to isolate the treated lumber. Stainless steel fasteners must be used when working with treated lumber for fastening. Typical Eave Detail RIDGE / HIP 1. Position two 2x2 s over the center of the ridge or hip or spaced depending on trim. 2. Note fastener requirements above. Ensure fasteners penetrate the framing member below a minimum of 1 spaced 12 on center. 3. At hips, the battenless panels will be cut and bent up to the nailers later. Approx. 5 outside to outside Rake /Gable Universal Ridge / Hip Detail - Non-Vented for Mission Trim & Shake Cap Typical Ridge / Hip Detail - Non-Vented for Mission Trim Only 12

13 Fascia Fascia Battenless Manual Note: - Measure down 2 from center of ridge of existing roof and cut gap on each side to give a net vent opening of 1 after 2 x2 ridge board applciation - As shown three 2 x 2 may be too tall if the roof is a steep pitch. Ajust height of ridge nailers as necessary. - Suggest install insect screen at vent cuts. Roof Deck 1 Rake / Gable/ Rafter Universal Vented Ridge Detail - for Mission Trim and Shake Cap EAVES DETAILS Barrel Vault Panel 1 x 3 or 1 x 4 Roof Deck Bird Stop Eave Install Bird Stop eave fascia with.8d x 2-3/8 ring shank 16 o/c Barrel Vault Bird Stop Eave Cross-section Bird Stop Eave Fascia Top View NB Tile or Canyon Shake Panel 1 x 3 or 1 x 4 Roof Deck Note first course panel overhang requirement page 10. Gerard Fascia Metal Install fascia metal at eave with.8d x 2-3/8 ring shank 16 o/c NB Tile or Canyon Shake Tile Eave Detail 13

14 VALLEYS 1- Install valley fastening with 8d x 2-3/8 ring shank nails or #10 x 2-1/2 24 o/c up valley each side through the outside pan. 2- If more than one length is required it must be overlapped 6 and set in a bead of sealant. 3- Panels will extend into the valley to the first 3/8 diverter for open valley or to center divider and bend down in return for closed valley. (see details) 4- Cut and bend as per detail. Note to cut 1 ¼ l onger than the measurement and bend the 1-1/4 into the valley (this will seat the cut panel securely into the valley metal). 5- Using ¾ sharp point screwsm, fasten the nose of the panel to the top shelf of the panel below. Take care not to penetrate the valley metal. 6-2 vent mesh as required in high velocity hurricane or wind zones (HVHZ). Note 6 Deck Open Valley Detail Drawing Note 6 Deck Closed Valley Detail Drawing Ensure that the full width of the valley overlaps the top flange of the starter strip and extends slightly beyond the lower edge of the starter strip. Place sealant between the lower edge of the valley and the starter strip. Trim lower edge of the valley as needed. Fasten and seal in outer channel Note: Location of valley at edge of fascia should be at the beginning of the first inside flutes of the valley. (See diagram to left) Place sealant Note: Do not penetrate the valley with stitch screws care must be taken. 14

15 LAYOUT AND INSTALLATION OF PANELS 1- Barrel Vault panels installed left to right. Canyon Shake and NB Tile can be installed either way. Note to adjust for irregular fascia or special eave overhang requirements. Allow for adequate overhang at first course minimum 1/4 (6 mm) ranging to maximum 3/4 (19 mm). 2- Barrel Vault installation is started at the left side aligning with Bird Stop Eave fascia contour. Canyon Shake and NB Tile start with full panel moving either way over installed fascia metal 3- Measure up from eave on the furthest outside points of roof deck the same overall measurement as the panel you are installing, less 1/4. Drive a nail on each side of deck and string a line between the two. Before installing any panels, measure along the eaves to ensure all of the panels will overhang the fascia. Adjust the string line as needed. 4- Begin installing panels as laid out in previous points. Make sure to stagger panels a minimum of 1 pan or 1 pickup point; this will ensure your sidelaps do not line up vertically. 5- Continue installing panels course by course upwards until you have installed the last possible full course. NOTE: The panel courses must start and remain straight. Chalk line first course Eaves line Barrel Vault Install Pattern Note overhang requirements in point 1 above at first course. PANELS: 6- The first course is fastened through the back flange with a minimum 5-8d x 2-3/8 Ring Shank Nails or #10 x 2-1/2 screws. 7- After the first course is installed, fall back and install 5 fasteners per panel. (see next page) 8- After all full panels are laid, open areas requiring cut panels are measured. Panels are cut and bent to fit. Add minimum upturns required on panels prior to cutting. 9- The panels must turn up 1 ½ at the gable and hips against the wood batten. NOTES: - For installations in high velocity wind zones see applicable product evaluation reports and local building code requirements. - Ensure same type of fastener is used throughout the installation. Do not intermix nails and screws for panel fastening.. 15

16 Typical Panel & Fastener Cross-Section Gerard s NB Tile, Canyon Shake, Barrel Vault Ring Shank Nails Or Screws Roof Deck Underlayment (Check local code requirments) Canyon Shake Barrel Vault NB Tile Note: Barrel Vault exposed front fasteners located in transistion area of panel front edge between barrel and flat water channel. Do not locate fastener in flat, water channel area of panel. Refer to Gerard producut evalaution reports for fastening requirements in high wind regions. Valley Hip Gable and Sidewall Bends and Cuts 16

17 Fascia Battenless Manual RAKE TRIM DETAILS 1- Mission Trim and Shake Cap used to complete the rakes, hips and ridges. 2- Three 8d x 2 3/8 Ring Shank Nails or #10 x 2-1/2 screws used to secure trims. Two fasteners into the sides. The third fastens into the top of the cap. 3- Seal and chip top fastener. Gerard Shake Cap Gerard Mission Trim Fascia Rake Detail - Shake Cap Canyon Shake Rake Detail - Mission Trim Barrel Vault or NB Tile HIP / RIDGE DETAILS 2 x 2 fastened every rafter nails not exceed 12 o/c Roofing Underlayment 5 outside to outside Trim Cap fastened with 8d ring shank nails or #10 screws at 2 points. Barrel Vault or NB Tile Cut and Bend to Slope Mission Trim Hip Detail 2 x 2 fastened every rafter nails not exceed 12 o/c Roofing Underlayment 5 outside to outside Trim Cap fastened with 8d ring shank nails or #10 screws at 2 points. Barrel Vault or NB Tile Cut and Bend to Slope Mission Trim Ridge Detail 17

18 HIP / RIDGE DETAILS Trim Caps fastened with 8d ring shank nails or #10 screws at top of cap into batten. Seal and chip fasteners. Shake Cap Mission Trim Shake Cap Mission Trim 2x2 fastened into every rafter. Fastener not to exceed 12 o/c Panel cut, bend and installed per details 2x2 fastened into every rafter. Fastener not to exceed 12 o/c Panel cut, bend and installed per details Roof Underlayment Roof Underlayment Roof sheathing Minimum 15/32 Universal Ridge Detail Roof sheathing Minimum 15/32 Universal Hip Detail Note: Cap mounted as illustrated to provide vent opening. Adjust opening to code venting requirments. Trim Caps fastened with 8d ring shank nails or #10 screws at top of cap into batten. Seal and chip fasteners. Cap Vent Opening Wind Soffit Flash Shake Cap Mission Trim Note: As shown three 2 x 2 may be too tall if the roof is steep pitch. Adjust height of ridge nailers as necessary. Wind Soffit Flash Underlayment Foam Closure Bird Stop Top Row (Barrel Vault) Top Row Wind Soffit (Canyon Shake & NB Tile) Roof Sheathing Mnimum 15/32 Vented Ridge Detail Note: Measure down from center of ridge and cut gap on each side to give a net vent opening after 2 x2 ridge board installed. Adjust opening according to local building code venting requirements Note: Detail shown is typical application of ridge venting with Gerard Panel roof application of re-roof over exisitng roof. Refer to all standard application procedures as outlined in the Gerard install manuals and evaluation report instructions. 18

19 RIDGE DETAILS 1- Universal Ridge/Hip Detail - Stack two 2 x 2 battens on top of each other to form a solid backer to nail into. See details page 12 this manual. 2- Turn panel up 2 on to ridge nailer. If ridge venting is desired, using Cor-A-Vent, see page 13 of this manual. In areas of High Velocity Wind Zones (HVWZ) the use of EZ Vent is recommended. Check local building code requirements and applicable product evaluation reports. See page 15 for two alternative to EZ Vent. 3- Install Bird Stop Top Row with foam closure under it. See Figure 1 below. 4- Install mission trim with two 8d (.131) x 2-3/8 ring shank nails or #10 x 2-1/2 screws through the ridge cap and into nailer. See Figure 2 below. Figure 2. Figure 3. 19

20 Battenless Manual - EZ Vent Options Gerard Product - E Z Vent Two (2) Alternatives EZ Vent is available for all Gerard profiles.. Alternative A Co Pan urs el e C Co Pan urs el e B Notes; - EZ Vent flat panel installs atop bottom Foam closure panel course A. - Panel course B installs over EZ Vent both ends. Left and right side panels over the EZ Vent will require on-site modifications to fit proper. - Panel course C installs atop panel course B and foam closure requied at back of EZ Vent. - Front nose of panel course C sits down into channel backside of EZ Vent over metal bird edge. lt A ta n e ZV Co Pan urs el e B E Co Pan urs el e A Foam Closure Alternative B Co Pane urs l e B Co Pan urs el e C ure m a Fo s Clo B lt ta en V EZ Notes: - EZ Vent panel installs atop foam closure and panel course A. - Panel course B EZ Vent laps over left side, under right side. - Panel course C atop foam closure and panel B course. - Foam closure sits on flat area backside of EZ Vent panel. - The front nose of panel C course sits down into metal channel backside of EZ Vent panel. ure m Co Pane urs l e B 20 a Fo s Clo Co Pan urs el e A Gerard Roofing Technologies TM

21 Pipe Jack Flashing Dry In - Install Underlayment To Deck and Around Pipe Full Panel Installed Around Pipe Install Pipe Flash and Second Panel Fitted over Flashing Fit Second Panel Over Securely. Lap Panels Properly. Caulk and Chip Around Pipe Flashing Pipe Jack Flashing Details Buildings requiring a dry-in state, should have all conflicting sub-trades complete their work before applying Gerard roof panels. Standard pipe jack galvanized or flexible membrane flashing. NOTE: Do not use lead, copper or other dissimiliar metal flashings without a separation barrier between. 21

22 Optional Stand Pipe Flashing - Masterflsh TM Optional Masterflash Stand Pipe Flashing - Neoprene rubber boot flashing can be installed on-site quickly and easily. Be sure to follow manufacturer s recommended installation guidelines. - Prior to installing the boot flashing, cut roof panel tight to vent pipe and caulk. - Measure stand pipe to be flashed and select boot flashing with an opening approximately 20% smaller than pipe diameter. If necessary, trim opening to 20% smaller than pipe diameter. - The following are suggested guidelines. Consult with manufacturer s guidelines, any applicable building codes and product evaluation reports. TM F Measure for correct pipe size Choose pipe opening and trim. Pipe using water Trace Flashing 7 Apply NP1 Sealant under base, leading edge and press into place. Fasten with screws securing to panel 22

23 CHIMNEY / SKYLIGHT FLASHING DETAILS 1- All panels that turn up at chinney should have a minimum 2 turn up on them. 2- Measure and cut Top Row Flashing even with the front of the chimney, allow enough top edge to wrap around the chimney Cut panels for the side of the chimney bending the panels cut 2. The first panel cuts at the sides of the chimney will have bend ups protruding forward below the front of the chimney.these need to be cut at an angle and bend back down and secured to the top surface of the lower chimney cut and top row closure, secured with sharp point ¾ screws, caulked and chipped. At the back of the chimney, install chimney saddle as shown. Extend saddle minimum 2 past each side of the chimney. See saddle detail and notes below. Install foam closure on the saddle prior to installing the next row of panels. Apply bead of sealant across foam closure. Panels are fastened through the front downward turn in the panel, foam closure and saddle in to the sheathing. Z bar is used to cover all bent up edges

24 Maitenance Maintenance Caulking We recommend that the caulking be checked for cracking and signs of undo stress every 5 years on any roof system. As caulking is typically utilized at intersections associated with differing roof and wall planes, as well as with mechanical roof protrusions, one must recognize the different expansion rates of these materials to appreciate the stress the caulking must be subjected to which is why we recommend and supply a long life thermal plastic rubber based sealant that is compatible with our roof coating. Washing Gerard s coating in general terms, is comprised of acrylic and ceramic stone that does not support fungi growth. However if you wish to remove any discoloration from airborne pollutants and/or fungus off your roof then we recommend washing it with a mild solution of chlorine (2%) and detergent. This should be applied and rinsed with a low pressure washer. Moderate scrubbing with a soft bristle brush may be used on tougher stains. For stucco and mortar droppings, moisten the area slightly and use moderate pressure with a wooden paddle to try and dislodge. After cleaning the area, it should be dried and inspected for coating damage. Touch up moderate scuffing using Gerard finishing kit. Please note the sections on the previous page regarding footwear and roof traffic. Gutters When gutters have been installed on the eaves of the roof, ensure that they are below the plane of the roof. Gutters should be cleaned regularly so that the water will drain freely and not back up on or under the Gerard roof system. Chimneys Chimneys can be a major maintenance item. Masonry fireplaces absorb water; this may lead to leaking through the masonry and behind the flashings. Spalling of stone and degradation of mortar are also common problems associated with water penetration. Ensure your flashings are installed properly, sealed well and as always, follow local building codes. It is advisable to recommend regular sealing of brick and stone to your clients. Touch-up and Completion Complete a final Inspection of the roof. Touch up superficial scuffs with the provided Finishing Kit. Remove all debris from the roof, gutters and jobsite. 24

25 955 Columbia Street Brea, California ROOFS 1632 Third Street, Leesburg, Forida Chase Road, Suite 100 Mesquite, Texas Erie Street, Kansas City, Missouri Website: Gerard Battenless Product manual is a component of Gerard Roofing Technologies and as such is intended to be used with Gerard product only. All information printed in this manual is copyrighted and is the property of Gerard Roofing Technologies and may not be reproduced without written permission of Gerard Roofing Technologies. Please Note: It is the responsibility of the installer to check the website for any updates or changes in the application of this product(s).