Table of contents page 1. General........................................................................................ 1 2. Safety hints...................................................................................... 1 3. Preparation of the installation work..................................................... 2 3.1 Layout plan........................................................................................ 2 3.2 Checking of the substructure............................................................ 2 3.3 Installation team................................................................................. 2 4. Transport.......................................................................................... 3 5 Unloading.......................................................................................... 4 5.1 Intermediate storage.......................................................................... 4 5.2 Protective foil.................................................................................... 5 5.3 Cutting on site................................................................................. 5 6. Installation of the arched roof.............................................................. 6 6.1 Single-shell roof system.................................................................. 6-11 6.2 Double-shell roof system.................................................................... 12-15 7. Skylight / Smoke and heat outlets.................................................... 16 7.1 Important hints............................................................................... 16 7.2 Frames.......................................................................................... 16 7.3 Single-shell roof system.................................................................... 17 7.4 Double-shell roof system.................................................................. 17 7.4.1 Installation in the crown (ridge)............................................................ 17-19 7.4.2 Installation adjacent to the crown..................................................... 20-22 8. Accessories....................................................................................... 23
1. General The is a roof system consisting of continuously bent trapezoidal profiles. In the course of laying and fastening, a system is built up providing high load-bearing capacity, shelter from the elements, thermal insulation and a vapour barrier, combined with an attractive design. For achieving this goal, especially in view of the free spans over large distances, it is very important to carefully read the mounting instructions for the Hoesch Arched Roof and to follow them step by step. Note: This symbol always signals an information about fastening material 2. Safety hints The sequence of work as described in the current installation instructions is correct and well-proven. Observation of the rules for prevention of accidents is of utmost importance. These rules are applicable to every site. Rules for prevention of accidents - employer's liability insurance association for the building trade General health and safety regulations must be adhered to ( as per the relevant local guidelines and laws, eg The Construction (Design and management) Regulations 2007 Part 4 in the UK). In addition, the following guidelines are to be observed: - 'Guideline for mounting trapezoidal steel profiles on roofs, walls, and floors' published by IFBS, Max-Planck-Str. 4, D-40237 Duesseldorf - 'Hints for roof covering with profiled steel sheet panels and strips' published by the Central Association of German Roofers. These regulations and guidelines, however, do not relieve the contractor of his responsibility to make the workers employed at site acquainted with the safety regulations and to supervise their observation. page 1/24
3. Preparation of the installation work 3.1 Layout plan Exact plans and detailed lists of parts for all areas concerned are indispensable for a correct execution of the installation work. The layout plans must contain descriptions of the elements, information on the arrangement of the profile panels, on the formation of the connection areas, on type and arrangement of anchor bolts, fasteners and connections. 3.2 Checking of the substructure Before starting the mounting work, the substructure and in particular the existing supports must be checked for completeness and dimensional accuracy as well as for their rigid connection with loadbearing elements. The supervising engineer must be advised of any discrepencies. Especially in case of the arched roof, dimensional variations in the substructure will entail serious problems. 3.3 Installation team An installation team should consist of at least 4 workers. As can be seen in the following description, three men are required for the work on the roof, and one man has to be on ground level. In view of the fact that the is not only a load-carrying system but also an element of design, the installation work has to be carried out with utmost care. Therefore, only qualified personnel with sufficient experience in installing trapezoidal profiles should do the work. The installation work has to be supervised by persons who, thanks to their expert qualification and knowledge, are able to ensure due execution. Supervision of construction works implies ordering of appropriate measures for observing the safety regulations. page 2/24
4. Transport Unlike conventional trapezoidal profiles, the arched profiles are loaded as shown in the following sketch: From the sketch it can be seen that especially in case of large spans, the height of the complete vehicle as a function of the camber is of special importance. The vehicle height must in no case exceed 4.00 m (variations due to different national regulations are possible). Moreover, it must be checked whether the required clear height actually exists in the site areas being accessible by vehicles. Possible restrictions have to be taken into consideration, and the actually useable vehicle height has to be determined in time. page 3/24
5. Unloading In general, the complete package of arched profiles which has a maximum weight of 3,000 kg is unloaded by using high-strength rubber-coated straps. The straps are attached to the two wooden pallets right and left to the centre. Do not use chains or wire ropes as they may cause damage to the profiles. Use compression-proof timbers to protect the profile edges from lateral pressure exerted by the lifting straps. For unloading profiles with a length of more than 10.0 m, use an additional spreader bar. 5.1 Intermediate storage Store the profile packages at site by fully utilizing the available space. Useful hint: in general, the profiles are packed in bundles of 20 each. Make sure that the ground to be used for an intermediate storage of the bundles is even. Place suitable wooden planks on the ground for locating the profile ends. Support the middle area of the bundles by means of adjustable trestles as shown in the sketch If the profiles are to be stored in the open air for an extended period of time, make sure that they are securely protected against rain, storm, and dirt. It is recommended to use textile covers, because they are permeable and allow humidity to evaporate quickly. Standing water between the elements must be avoided, as in the long run even coated materials will be damaged. Do not stack the packages one upon another. This would cause pressure marks in the cover shells. Secure packages that have been opened. page 4/24
5.2 Protective foil Any foil that may have been factory-applied for protecting the building parts against dirt and damage has to be removed immediately after installation of the building part concerned. Due to weathering, such foil will become brittle after a short time, and complete removal will then be almost possible. In areas where elements such as frames for skylights or for smoke and heat outlets have to be installed, the protective foil has to be removed beforehand. 5.3 Cutting on site For cutting, use compass saws with suitable saw blades. Circular metal saws shall only be used together with precise guides. Prevent the cutting area from excessive heating, since this may cause burning of the zinc layer and the plastic coating and thus lead to a failure of the corrosion protection. For this reason never use angle grinders. Moreover, take care that hot swarf caused by drilling or cutting does not burn into the coating, thus causing corrosion damage. Any swarf has to be removed immediately. page 5/24
6. Installation of the arched roof 6.1 Single-shell roof system The most important step during the mounting work is the correct positioning of the first arched element. In general, the first arched element is fastened to an existing gable construction or gable wall. However, if the gable is not yet provided with bracings or filler material, it is also possible to mount the arched element in a way to be free-standing and self-supporting. In case of low buildings, the arched roof can be completely installed by using a fork lift. The loadbearing capacity at the end of the fork lift should be at least 500 kg. When using mobile cranes, an installation fork can be used as a lifting device. By means of such an installation fork, the first arched element is taken off the package and secured on the fork arms before being lifted (see sketch.). Securing is possible by means of a device integrated in the fork or by using screw clamps. page 6/24
The correct mounting direction is shown on the lay out plan. When swinging the first element into its position, one installer has to be present at each of the supporting points. The workers must be sufficiently secured, e.g. harnesses and/or scaffolding along the outer side of longitudinal beams in case of single-bay constructions, or railings mounted on the outer side of sufficiently large girders in case of multi-bay constructions as per the relevant national safety guidlines. page 7/24
After the first element has been swivelled into the correct position, it remains suspended on the installation fork untill all clamping plates have been inserted and slightly fastened by means of the retaining screws. Fastening material to be used: 1. Arched profile HP 41 B Hexagon head bolts M 12 x length (DIN 6914), hot dip galvanized, with nut M 12 (DIN 6915) and 2 washers 12 (DIN 6916). Specially coated clamping plates (Hoesch ref. no. S35-034), fastened in each chord (e = 160 mm) or in each second chord (e = 320 mm), see lay out plan. 2. Arched profile HP 107 B Hexagon head bolts M 16 x length (DIN 6914), hot dip galvanized, with nut M 16 (DIN 6915), 2 washers 17 (DIN 916). Specially coated clamping plates (Hoesch ref. no. S35-036), fastened in each chord (e = 250 mm), see layout plan. For fastening the clamping plates, the arched shells are provided with factory-made oblong holes on the supporting points. Ensure that the upper edge of the oblong holes lies on the screws. Hole size: Profil HP 41B: 14 x 20 mm Profil HP 107B: 18 x 35 mm page 8/24
Before finally tightening the fastening screws, the element must be exactly aligned by means of a crane. Then, a corded ladder is pulled over the bent face of the arched element and fixed on both ends. A third worker has to climb up to the crown to undo the clamps used for securing the element on the laying fork. During all this time, the crane must hold the fork under tension. The crane may only release the installation fork when the worker has left the arched element. Now, the fastening screws can be finally tightened. The most difficult part of the installation work has been done. page 9/24
The clamping plates have to be sealed all-around by means of silicon. A sealing tape 5 x 20 mm is stuck on the upper chord of the last chord. The second arched element is taken off the ground by means of the installation fork on the crane, clamped and swivelled into the correct position (as described above). After the element has been slightly fastened to the supports, one worker climbs on the already mounted arched shell to the crown, checks the ridge line and screws 1 to 5 connecting screws into the longitudinal joint, starting from the middle to both sides (for screw types, see next page). The larger the arc span, the more connection points are required. After having fastened the screws, the worker has to undo the clamps on the laying fork; then he returns to the ground. The crane releases the laying fork and swivells it away. The fastening screws in the clamping plates have to be tightened. The corded ladder has to be put onto the element mounted beforehand. Meanwhile, the next arched element is taken off the ground, and the installation procedure already described is repeated. In this way, the installation work is continued. After about every third panel (depending on the span), the vertical adjustment of the elements and the horizontal alignment of the ridge line have to be checked. The corded ladder and the scaffolding are to be repositioned in accordance with the progress of work. The installation work is continued in this manner until windows rows or other elements are planned to be installed. Openings for window rows are left open at this stage. Attention: Protect openings - danger of accident! Openings for skylights or other roof cutouts are made subsequently, after completion of the installation work. During installation, make sure that top hat profiles near cutouts are correctly positioned (see layout plan). Subsequent modification of their position is not possible, compare chapter 7. The installation work is continued until the complete shell is laid. At this time or earlier if additional personnel are available, the arched elements are additionally statiched together in their longitudinal joints. page 10/24
Fastening material to be used: stainless steel thread-cutting screws, e.g. EJOT JA3-6.5 x 24/19 E22, spacing: according to laying plan, generally e = 3 screws/m. The work is to be done from the corded ladder. After completion of the erection or if possible even parallel, other work has to be carried out, i.e. gutters, roof edges, plumbing. page 11/24
6.2 Double-shell roof system For mounting the inner shell, proceed as described in item 6.1. Exception: Stitching of the arched shells in their longitudinal overlaps is achieved by means of sealed rivets instead of special sealing screws as specified for single shells. Fastening material to be used: sealed rivets Ø 4,8 mm spacing: according to layout plan, generally e = 3 rivets/m page 12/24
Only use sealed rivets! In case of standard blind rivets, the pin may get lost, and the vapour tightness of the lower shell is no longer ensured. After completion of this work, permanent use of the crane is not necessary anymore. However, the crane will be required later for pulling up the arched elements for the outer shell. Beforehand, the longitudinal joints of the inner shell have to be selaed with a sealing tape on the external surface, in order to build up a vapour seal / convection seal. Use self-adhesive aluminium strips, width: 50 mm, e.g. Scotch aluminium tape, type 425, manufacturer: 3M. self-adhesive aluminium tape Next, the spacer profiles (= top hat profiles) are to be fastened. Before being installed, these have to be provided with the trapezoidal insulating wedges which are included in the delivery. It is advisable to start fastening at the supports and to continue towards the crown. The middle top hat profile has to be positioned exactly at the crown line. The position of the spacer profiles is shown in the layout plan. Material to be used for fastening the top hat profiles on the lower shell: sealed rivets Ø 4.8 x 9.0 AL (long system), for number and spacing, see layout plan page 13/24
Stick sealing tape 5 x 50 mm onto the hat profiles for thermal insulation. When all spacer profiles are completely mounted, the mobile crane is needed once again. Meanwhile, workers should have already split up the packages containing the outer shell elements into small units of 5 to 6 panels each. These small units are taken off the ground by means of the crane and pulled to the roof surface by means of the laying fork in a way that they are positioned on the hat profiles. The spacing corresponds to their number x element cover width. Finally, the crane is used to pull up the insulating material. After this work, the crane is no more needed and can be removed. The remaining work is done manually. First, the thermal insulation material has to be put onto the inner shell. In steep roof areas (edges), the insulating material must be fixed by means of selfadhesive fastening pins and safety washers. For position and number, pls. see laying plan. page 14/24
Immediately after this step, the cover shells are taken from the stack, placed onto the inner shell provided with insulating material and fastened on the hat profiles. Fastening material to be used: example: EJOT JA 3-6.5 x 25 E16, stainless steel, number according to layout plan. In most cases, gutter sheets or similar folded parts along the eaves are to be mounted together with the roof shells. Particularities: In case of double-shell arched roof systems, - the longitudinal joints of the upper shell are generally not stitched, - generally, there are no clamping joints in the eaves' area. Attention: exceptions are possible! Always consult the layout plan. The remaining work is carried out as described in item 6.1. We once again emphasize the need of observing the minimum safety measures as described for the complete work. The safety equipment has to be removed and placed again in accordance with the progress of work. The present description is limited to descriptions of the main working processes and their routine execution. In practice, however, special requirements often have to be complied with. In general, such requirements can be clarified in an early phase on the basis of the standard procedures as described, i.e. when preparing the layout plan, so that adequate detail solutions allow the mounting work to be carried out without problem. page 15/24
7. Skylight / Smoke and heat outlets 7.1 Important hints: When cutouts in the Hoesch arched roof are required for skylights, smoke and heat outlets or trap doors always consult the structural engineer (in charge of the structural analysis of the arched roof). Cutouts in areas of the load-bearing arched shell will destroy its load-bearing function, and adjacent profiles will have to take over this additional load-bearing function which requires special measures. In any such case, a structural analysis is necessary. Generally, only skylights with a maximum width of 1.20 m (90 to the chord direction) can be installed. Please observe the regulations for prevention of accidents. 7.2 Frames The frames have to be adapted to the profile of the arched shells. Available versions: for installation in the crown of the roof installation adjacent to the crown of the roof The frames consist of welded aluminium sheet. They are proposed as single shell version, non insulated and double shell version, insulated. The upper edges have to be adapted to the types of skylight to be installed. page 16/24
7.3 Single-shell roof system In case of the single-shell roof system, load-bearing steel frames have to be installed. Such frames are visible from the building inside. For the installation of the skylight frames, see items 7.4.1 and 7.4.2. 7.4 Double-shell roof system The openings for skylight frames are generally cut into the completed roof. So when installing the hat profiles please bear in mind that they are taken as load-bearing frames. For the correct position and the required material thickness of the hat profiles, see the laying plan. 7.4.1 Installation in the crown (ridge) Basic data: skylight width = 1,200 mm skylight length = 1,200 / 1,800 / 2,400 mm profile: HP 41B Working steps: see Diagrams. 1-6. 1. Marking of the opening on the external shell Width: 1,540 mm Length: L + 140 mm, see Diagrams. 4 and 5 2. Cutting of the outer shell by means of a compass saw. The cutting depth must be such that only the outer shell is cut without getting into contact with the inner shell. Observe the stroke of the compass saw, shorten the saw blade, if necessary. 3. Remove cut parts. 4. Remove thermal insulation. page 17/24
5. Mark inner shell and cut it out. Width: 1,200 mm Length: L + 20 mm, see Diagrams 4 and 5. 6. Mount wooden planks, see Diagram 4. 7. Mount factory-prepared edge profiles, see Diagrams 4 and 5. 8. Bend up the trapezoidal profile lower chord of the outer shell, see Diagram 3. 9. Stick on sealing tapes 5 x 20, see Diagram. 3. 10. Put profile filler onto the outer shell, see Diagrams 3 and 4. 11. Mount framing and fasten it to the outer shell through each upper chord. Fasten the lateral chords to the outer shell by means of 5 screws. Fastening material to be used: i. e. EJOT JA 3-6,5 x 24/19 E 16, stainless steel. page 18/24
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7.4.2 Installation adjacent to the crown Basic data: skylight width = 1,200 mm skylight length = 1,200 / 1,800 / 2,400 mm see Diagrams 10 and 11 Working steps: see Diagrams 7 through 13. 1. Marking of the opening on the outer shell Width: 1,540 mm Length: L + 305 mm 2. Cutting of the outer shell by means of a compass saw. The cutting depth must be such that only the outer shell is cut without getting into contact with the inner shell. Observe the stroke of the compass saw. Shorten the saw blade, if necessary Attention: The opening for inserting the framing must also be cut, see Diagram 9. 3. Remove cut parts. 4. Remove thermal insulation. 5. Mark inner shell and cut it out. Width: 1,200 mm Length: L + 20 mm, see Diagrams 10 and 11. 6. Mount wooden planks, see Diagram 10. 7. Mount factory-prepared edge profiles, see Diagrams 10 and 11. page 20/24
8. Up the trapezoidal profile lower chord of the outer shell, see Diagram 9. 9. Stick on sealing tapes, see Diagram 9. 10. Put profile filler onto the outer shell, see Diagram 9. 11. Slide framing into the opening on the ridge side, see Diagrams 10 and 12. 12. Put 2 profile fillers on the flat upper edge of the framing, below the arched sheet on the ridge side, see Diagrams 10 and 12. 13. Fasten framing through each upper chord. Connect lower chord of the arched sheets on the ridge side with the framing, fasten the lateral chords to the outer shell by means of 5 screws. Fastening material to be used: i. e. Ejot lja3-6.5 x 24/19 E 16, stainless steel, See Diagrams 10, 11, 12 & 13. 14. Stick on sealing tapes 5 x 20 for closing chord. Position closing chord and fasten it. For screws, see item 13. See Diagram 13. page 21/24
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8. Accessories D e s i g n a t i o n Ref. no. Clamping plate profile HP 41B S 35-034 profile HP 107B S 35-036 S 35-034 Profile filler profile HP 41B S 35-044 profile HP 107B S 35-046 Verge profile, bent: cut to length 340 mm S 35-021 cut to length 440 mm S 35-022 cut to length 540 mm S 35-023 Top hat profile: thickness 1,00 mm S 35-011 thickness 1,50 mm S 35-012 thickness 2,00 mm S 35-013 Other flashings have to be ordered as special flashings. In this case, a sketch of the cross section is required. page 23/24
Hoesch Bausysteme GmbH Neumarkter Straße 10 8811 Scheifling Österreich Telephone: +43 (3582) 84 51-0 Telefax: +43 (3582) 84 51-230 E-mail: office@hoesch.at Internet: www.hoesch.at 2013/06 page 24/24