Download PDF - Kalzip

CI/SfB (27) Xh 

September 2006 

Kalzip Ltd 

Hi-Point TM off-site roof system

Benefits 

Hi-Point... off-site 

roof system with 

the benefits built-in 

A superior, simple and safer method of 

roof construction 

Health & safety 

• Main construction is carried out on the factory floor 

significantly 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 and 

collections 

Quality control 

• Single source manufacturer 

• Components and build quality can be monitored under 

controlled factory conditions 

Speed & design flexibility 

• Simultaneous roof construction allows faster project 

completion 

• 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 client 

requirements 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 of 

insulation thicknesses and densities to ensure optimum 

performance and complete design flexibility, whilst helping to 

meet the Target Emissions and Building Emissions Rates. 

2 Hi-Point off-site roof system

Hi-Point... raising the roof 

lowering the risk 

Raising the roof lowering the risk 

Hi-Point from Kalzip provides off-site solutions for roof 

construction in the military, education, health, residential and 

commercial building sectors. It is manufactured at a dedicated 

site in Haydock, home to Kalzip and the Kalzip portfolio of 

products and systems. 

Promoted by the Government through the Department of 

Trade and Industry (Dti) and highlighted by the Latham and 

Egan Reports off-site construction techniques are ideally 

suited to fast-track building projects. 

With factory assembled modules, construction is no longer 

dependent on the weather, waste is eliminated and quality 

standards can be guaranteed. Moreover, the construction 

environment can be made significantly safer as the 

requirement for working at height is considerably reduced. 

Described as a modern method of construction off-site roof 

manufacture 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 of 

space available to construct and store the roof modules onsite. 

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-site 

construction is ideal. This involves the preassembly of almost 

all the components at the factory premises, transportation to 

site and then lifting into position using facilities already on site. 

Hi-Point off-site roof system 3

Technical information 

Hi-Point technical information 

Hi-Point can be divided into two categories termed as 

‘primary’ and ‘secondary’ frame. The primary frame is classed 

as the module structure and the secondary frame includes the 

purlins to roof coverings. 

The primary frame is manufactured from cold rolled, 

lightweight galvanised steel sections in the form of lipped and 

open channels. The cold rolled sections are dimensionally 

accurate, extremely robust, non-combustible and can be 

installed very quickly. 

Roof coverings may be either single or double skin and the 

type of roof construction will depend on the U-value and any 

other client requirements. Hi-Point offers a variety of coverings 

including self-supporting and fully supported standing seam, 

composite panels, membrane, trapezoidal profiles, metal tiles 

and roof preparation for concrete tiles. 

Table 1 Typical pitch requirements 

Mono-pitch Duo-pitch Barrel vault 

Roof 

covering Warm Cold Warm Cold Warm Cold 

Kalzip 1.5° 1.5° 1.5° 1.5° 

Traditional metals 

5° 5° 5° 5° 

Superdeck membrane roof 

0.5° 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 1 shows the typical pitch requirements of the above 

mentioned roof coverings. 

Dead load structure 

The dead weight structure design accommodates both live 

and dead loads, which may be uniformly distributed or 

concentrated at various locations. 

Live loads are non-permanent such as environmental loads 

produced by snow and wind. The weight of the temporary 

construction materials and occupant floor loads can be 

classed as live loads. 

Dead loads are the weight of the materials in the structure 

itself and any items permanently placed on to it. 

The primary frames transmit a series of point loads via the 

vertical members onto the load bearing structure below the 

frame, as table 2. 

Table 3 Design parameters 

Load bearing structure 

Design parameters - module 

Type 

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

4.0 30 3.2 

Mono-pitch Off-site X

Technical information 

Roof geometry 

Hi-Point encompasses the three main types of standard roof 

geometry 

- mono-pitch 

- duo-pitch 

- barrel vault 

Table 3 (shown bottom left) outlines the design parameters 

appropriate to the above geometries. 

Lifting 

The complete roof modules can be lifted by either the purlin 

brackets, or the top mounted lifting plates. These plates are 

only used with standing seam solutions and are fixed by 

means of four split clamps under the lifting plate. 

Mono-pitch 

The plates, or the purlin brackets, are fixed close to the lifting 

trusses on the lightweight modules so that the main frames 

can resist bending whilst performing the lifts. 

Duo-pitch 

Lifting plate and clamps on 

Kalzip standing seam 

Purlin lifting brackets 

British Standards 

Hi-Point off-site roof structures are designed in accordance 

with 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 thin 

gauge sections 

Barrel vault 

All materials are pre-galvanised to BS EN 10147 1992 

and BS EN 10143 1993. 


When Hi-Point off-site is on-site 

When Hi-Point off-site... 

Manufactured and assembled into volumetric modules under factory controlled conditions, off-site manufacturing is ideal for sites 

where 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 the 

specified roofing. The modules are subsequently delivered to site to meet timed delivery schedules. The scaffolding is only 

erected to facilitate completion of the brickwork. 


...is on-site 

When Hi-Point off-site is on-site 

Hi-Point offers ground level site assembly of two-dimensional fabricated frames to provide three-dimensional modules. All 

structural components such as purlins are incorporated together with pre-prepared roofing and acoustic/insulation material as 

specified. 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 are 

achievable as transportation is not required. 


High speed Hi-Point dramatically cuts installation time 

High speed Hi-Point 

dramatically cuts 

installation time 

The roof installation programme for a multi-storey luxury 

apartment block in Liverpool was dramatically cut to just 

two days, thanks to the use of the new Hi-Point roofing 

system from Kalzip. 

At 27 storeys the residential development, which is part of the 

mixed use Unity Project, presented numerous challenges, not 

least 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 Architectural 

and main contractors Laing O’Rourke. The striking 1.5 degree 

pitched Hi-Point gull wing roof, which sits 94 metres above the 

ground, proved to be the ideal solution. 

The full 22 modules, which were precision manufactured and 

assembled by Kalzip under factory controlled conditions, were 

lifted and bolted into position in just two days allowing 

significant reductions to be made in both the roof installation 

programme and the overall site time. 

The frames for the roof sections were constructed from cold 

rolled channel sections produced by Kalzip Construction and 

Engineering Products, and, as whole life performance and 

durability were also important factors in the specification of the 

roof, the Hi-Point system was equipped with a fully insulated, 

built up Kalzip system. Incorporating steel liner panels from 

Kalzip Panels and Profiles the system was topped with 1.2 mm 

clad stucco embossed Kalzip 400 aluminium standing seam 

sheets. A range of Kalzip fabrications including verge and roof 

flashings, mono ridge and verge capping details, were also 

specified in a stainless steel finish to complement the wall 

panels, all of which were manufactured by the Kalzip 

Fabrication department. 

The 398 square metre Kalzip standing seam roof also features 

a 25 metre long thermoplastic polyolefin (TPO) walkable 

insulated membrane gutter, produced in two modules for 

connection on site. Fully recyclable, the TPO gutters are also 

environmentally friendly and produce no harmful gas emissions 

during the manufacture or the hot-air welding process. 


High speed Hi-Point dramatically cuts installation time 


Putting Hi-Point to the test 

On top form 

This new educational facility in the north of England has 

benefited from the rapid, economical and safety advantages 

associated with Hi-Point off-site roofing construction. 

Installation and finishing, including the soffits, were completed 

in just five days. 

Comprising five volumetric modules - totalling 235 square 

metres of Kalzip standing seam - the roofs were delivered 

complete with verges (on the end modules), fixed mono-ridge 

corners and first flashings, eaves corners and gutters. Even 

the fall restraint system was pre-fitted at the factory ready for 

cabling on site. 

All five roofs were delivered on the same day to meet a strict, 

sequential unloading programme. Once lifted by crane and 

installed, the remaining finishing tasks were completed from 

the safety of a scissor-lift platform. 

All the designs, details and drawings were produced by Kalzip 

Hi-Point to ensure cohesion and accuracy and provide a single 

source of guarantee for the client. 




The six hour roof 

Putting Hi-Point to the test, the MOD/Defence Estates urgently 

required ten new accommodation buildings within an 

extremely tight, if not almost impossible, timescale. 

After lifting into position, 748 square metres of pre-coated 

Hi-Point standing seam roofing were installed in just six hours. 

Thereafter the weathering process of joints, gutters and 

fascias was completed. 

The roofing components were manufactured at the dedicated 

Hi-Point factory in Haydock and transported to site as a ‘kit of 

parts’ for assembly. Due to both the number and size of the 

roofs, assembly took place on a nearby, disused World War II 

runway where the roofs could be ‘called off’ and installed as 

required.

Download PDF - Kalzip

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?