the neo Fortecom® Installation Manual - The Rooflight Company

the neo Fortecom ®Installation ManualIssue 01 | May 2011

SECTION 1 - How to use this manual> Welcome > GeneralWELCOMEThank you for choosing a neo rooflight. We are sure that neo will provide a high-quality finishing touch to yourproject. This guide is intended to assist building contractors and homeowners in receiving, handling and installingthe neo rooflight. Please take the time to read and carefully follow these instructions. Particular attention should bepaid to the ‘Important Information’ section at the back of this installation guide.GENERALPlease note: the minimum roof angle at which neo can be installed is 20 degrees.Please note: the maximum roof angle at which neo can be installed is 70 degrees.Please note: the following installation details pertain to COLD ROOF construction andSLATE tile type. Some installation details may vary depending on the roof constructionand tile type being used. Always view this manual in conjunction with the cross sectionalinstallation details relevant to your project. See the section ‘Suggested installation details’in this manual.Use the ‘Contents’ section to access the specific information you need to install the rooflight. In order to access theinformation you require in order to install neo you will need to know:1. The neo rooflight model to be installed.2. The type of roof construction to be used, e.g. warm roof or cold roof.3. The type of roof tile to be used, e.g. clay tiles, slate, interlocking tile, pantile, zinc or lead sheet, etc.4. The thickness of the roof finishes from the top of structural rafters to the general line of the top of the rooffinishes.TEXT- Highlighted in BOLD indicates a point of special importance.3

SECTION 1 - How to use this manual> Contentsq ContentsqPageSECTION 1 - How to use this manual 3SECTION 2 - Prior to installation 5SECTION 3 - Structural opening sizes 6SECTION 4 - Preparing the roof 7SECTION 5 - Installing the rooflight 16SECTION 6 - Finishing the interior 22SECTION 7 - Suggested installation details 23SECTION 8 - Important Information 284

SECTION 2 - Prior to installation> Receiving the rooflight > Transport & storageSingle rooflight as deliveredrecyclable doublednylon binding toallow the box to beretied togetherrecyclablecardboardpackingRECEIVING THE ROOFLIGHTUNLESS the packaging is completely undamagedwe recommend that the rooflight packaging istemporally opened to allow inspection of thegoods for damage. Follow the instructions on thedelivery checking and advice label.uOnce the rooflight has been checked,repackage it in the original packaging for safestorage until the rooflight is to be installed.product ID& transportinformationTRANSPORT & STORAGEdelivery &checking adviceuOne set of nylon banding is doubled in eachdirection to allow sufficient material to retie thepackaging together.uuuKeep the rooflight in its original packaging and store off the ground in a secure covered dry place until it isrequired for installation.When transporting the rooflight in its box, carry the box by lifting it from the underside rather thanlifting by its strapping.Stack multiple units carefully and only as many units high as is set out on the transport informationlabel on the box.uuOnly remove the rooflight from its packaging when it is required for installation.Once unpacked carry the rooflight by lifting it from the underside of the baseplate.uMark the original box with the window number/location and keep all accessories and linings in the original boxuntil they are required. When the installation is complete and all accessories/linings are used, recycle all of thepackaging materials.store in a covereddry secure areado not stack too highor allow to get wet5

SECTION 3 - Structural opening sizes> Tile type: Slate and Clay tilesTILE TYPE: SLATE AND CLAY TILESTo derive the structural framing dimensions for neo you will need to have the following information to hand:uuThe neo model reference number to be installed.The type of roof construction to be used e.g. cold or warm.Follow the appropriate information pathway to derive the structural framing dimensions below.Cold roof construction typeRooflightmodelStructural framingdimensionsWidth (mm) x Length (mm)structuralopeningneo 38Pneo 57Pneo 63Pneo 94Pneo 150P907 x 1412907 x 18071062 x 16071062 x 21021387 x 2187neo 63Lneo 94Lneo 150L1402 x 12671897 x 12671982 x 1592Cold Roof -Insulation is between the raftersneo 41Sneo 93S1062 x 12671387 x 1592Warm roof construction typeRooflightmodelStructural framingdimensionsWidth (mm) x Length (mm)structuralopeningneo 38Pneo 57Pneo 63Pneo 94Pneo 150P687 x 1007687 x 1402842 x 1202842 x 16971167 x 1782neo 63Lneo 94Lneo 150L1182 x 8621677 x 8621762 x 1187Warm roof -Insulation is on top of the raftersneo 41Sneo 93S842 x 8621167 x 11876

SECTION 4 - Preparing the roof> Structural framing and support around the rooflightSTRUCTURAL FRAMINGS AND SUPPORTS AROUND THE ROOFLIGHTIntroduction.There are two main tasks to be undertaken to provide an opening in the roof and structural supports for neo.1. Forming the Structural Opening.2. Installing the Structural Bearers.uuThe first task undertaken in all installations, whether to a new or existing roof, is formation of a structural opening.Go to page 8The second task is installation of structural bearers within the formed structural opening.Go to page 10Ply linings:Cold roof - Ply linings are required between the structural supports and structural bearers in all cold roofinstallations. See section ‘Suggested installation details’ in this manual.Warm roof - Ply linings are required to be fixed outside the structural bearers in all warm roof installations. Seesection ‘Suggested installation details’ in this manual.1. Forming the structural openinggo to page 82. Installing the structural bearersgo to page 107

SECTION 4 - Preparing the roof> Forming the structural openingsFORMING THE STRUCTURAL OPENINGuForming a structural opening in a roof for a neo is straightforward. The opening is formed using structuralmembers which re-route structural loads from the roof above around the structural opening.Note: All structural member sizing and fixings around the structural opening are to be asdetailed by the Project Architect/Structural Engineer. Our drawings are indicative only.uWhere neo is to be installed in a new roof the structural members can be designed to reduce the necessity forcutting and trimming.uWhere neo is to be installed in an existing roof the structural opening may require additional structural membersto be inserted and/or existing members cut and re-supported in order to facilitate installation in the locationrequired.neo - in a new roofneo - in an existing rooftrimmed rafterclearstructuralwidthtrimmingraftersjambstructuralsupportsnew trimmingrafters addednew structuralsupport rafterclearstructuralwidthremoved raftersectionclearstructurallengthclear structurallengthtrimming raftersnew structuralsupport rafternew trimmingrafters added8

SECTION 4 - Preparing the roof> Height of the structural bearers > Installing the structural bearersHEIGHT OF THE STRUCTURAL BEARERSThe intention of this installation guide is to achieve an installation of neo that presents the glazing nominally flushto the general level of the top of the roofing material. Such an install achieves the inconspicuous appearancecharacteristic of neo.It is most important that installers read and apply the contents of this section.INSTALLING THE STRUCTURAL BEARERSIn all installations neo sits on structural bearers once installed. The positioning of the structural bearers is dependant on:u Roof type (e.g. cold or warm roof)u Roof finish (e.g. slate, clay tile etc)For flush installation the top of the structural bearers needs to be located 110mm below the general line of theroof finish. For cold roof installation the structural bearers need to be 100mm minimum height in order toaccommodate the rooflight baseplate within the roof cavity.Please see the worked examples below.Cold roofgeneral line ofthe roof finishWarm roofgeneral line ofroof finishWBP or marineply liningA110mm110mm100mmMINABstructuralbearersstructuralbearersWBP or marineply liningCsection at jambsection at jambCOLD ROOF(A) Thickness of roof finish (this is the dimension from the top of thestructural supports to the general line of the roof finish)(B) The depth the bearers sit below the structural memberWARM ROOF(A) Thickness of roof finish (this is the dimension from the top of thestructural supports to the general line of the roof finish)(C) The height the bearers sit above the structural memberIn this example A = 50mm (25mm batten + 25mm slate)The top surface of the bearers is required to be 110mm below thegeneral line of the roof finish.Where:B = 110 – ATherefore: B = 110 – 50 B = 60mm (in this example)In this example A = 175mm (100mm insulation + 25mm counterbatten + 25mm batten + 25mm slate)The top surface of the bearers is required to be 110mm below thegeneral line of the roof finish.Where: C = A - 110Therefore: C = 175 – 110 C = 65mm (in this example)9

SECTION 4 - Preparing the roof> Installing the structural bearers - Jambs and HeadINSTALLING THE STRUCTURAL BEARERS - JAMBS AND HEADOnce the fixing height of the structural bearers is derived they can be fixed to the main structural supports.COLD ROOF: The structural bearers at the HEAD and JAMBS of the structural opening are to be two 50mm widetimber members. JAMB structural members bearers extend continuously from head to cill and the HEAD structuralbearers are cut to fit within the jamb structural bearers. We recommend use of threaded rod fixings with largerecessed washers and locknuts as shown below. Locating fixings at centres as specified by the project StructuralEngineer.WARM ROOF: The structural bearers at the HEAD and JAMBS of the structural opening are to be 100mm wideand fixed directly on top of the structural support and trimming rafters. JAMB structural members bearers extendcontinuously from head to cill and the HEAD structural bearers are cut to fit within the jamb structural bearers asshown below. Fixing type and spacing to as specified by the project Structural Engineer.Cold RoofJamb & HeadWarm RoofJamb & Head1.2.3.1.COLD ROOFOn ‘thin’ roof constructions such as cold roof, neo is installedbetween the structural supporting rafters.The structural bearers should be strongly fixed to their flankingstructural supports (see note above).Fixing components:1. locknut2. threaded bar3. washerWARM ROOFOn ‘thicker ‘ roof constructions such as warm roof, neo is installedon top of the structural supporting rafters.The structural bearers require to be strongly screwed down ontothe structural supports. For larger neo rooflights consider usingstainless steel brackets in addition to screw fixings.1. screw fixings as specified by projects Structural Engineer10

SECTION 4 - Preparing the roof> Prepared opening > Tilting filletpPrepared OpeningTrim the opening within the roof to the correct size required forthe model of rooflight being installed.Install the cill tilting fillet (we recommend hardwood or treatedsoftwood). Its purpose is to support the cill flashing andflashing substrate. Note: Details shown here are for COLDROOF construction. See section ‘suggested installationdetails’ in this manual for appropriate WARM ROOF detail.qInstalling the cill tilting fillet12

SECTION 4 - Preparing the roof> Tilting fillet > Rooflight membranepInstalling the head tilting filletInstall the head tilting fillet as shown (we recommendhardwood or treated softwood).Fold and trim the roofing membrane around the structuralopening as shown. If battening at this stage lightly tack thebattens at the jambs only.qTrim & finish the roofing membrane13

SECTION 4 - Preparing the roof> Roofing membrane tray > Cill flashing substratepRoofing membrane trayInstall a roofing membrane tray at the cill of the opening asshown. The membrane tray is to pass over the cill tilting filletand terminate over the general roofing membrane.Install a 15mm thick WBP or marine-quality ply flashingsubstrate at the cill of the opening as shown. It is to beinstalled over the membrane tray shown above and ofsufficient length to ensure that the cill flashing finishes at theheight of the cill rooftiles. Ensure a 5mm MIN gap betweenthe 2 halves of the substrate.qCill flashing substrate14

SECTION 4 - Preparing the roof> Battening up to the cill > Battening up to the jambspBattening up to the cillIt is recommended that the roof is battened up to the cill of theopening at this stage. Ensure that the roofing membrane traywhich was previously fitted is located underneath the battens.Batten spacing is determined by the roof covering being used.Adjust the battening and tiling to course and fit around thestructural opening.When battening around the opening the battens at the jambsare to come up to the outside faces of the structural opening(COLD ROOF) as shown. Whilst installing these make surethat the ends of the battens are only ‘tacked’ in place at thisstage. This is to ensure the rooflight is weathered in correctlyat a later stage of the installation.qBattening up the jambs15

SECTION 5 - Installing the rooflight> Lead cill flashing > Installing the rooflightpLead cill flashingInstall a code 3-5 lead flashing (depending upon the weatherexposure) to the cill of the opening as shown. Side lap to beminimum 150mm. Length of flashing to be sufficient to givethe tile-recommended headlap. Lay a continuous thick beadof low-modulus neutral cure silicone along the flashing.Lift the rooflight into the opening being careful NOT to pick therooflight up by the perimeter extrusion or cill flashing.If your rooflight model has a motorised configuration, be sureto allow enough room the cill of the rooflight for the cable toescape the frame without becoming trapped or over-twisted.qInstalling the rooflight16

SECTION 5 - Installing the rooflight> Fixing the rooflight > Perimeter silicone filletpFixLocate all of the fixing points at the perimeter of the rooflight. Drillpilot holes and fix the coach bolts with a large flat washer and a springwasher through and into the structural bearers. ONLY TIGHTEN THECOACH BOLTS UNTIL THE SPRING WASHER HAS FLATTENEDOUT. OVER TIGHTENING OF THE COACH BOLTS CAN CAUSEDAMAGE TO THE ROOFLIGHT FRAME. Ensure all marked fixingpoints are used.Install a thick continuous fillet of low-modulus neutral curesilicone to full length and width of the jambs and head of therooflight perimeter as shown.qPerimeter silicone fillet17

SECTION 5 - Installing the rooflight> Installing the jamb flashing > Installing the head flashingImage BImage A‘CLICK’Image CN.B. Installation of thejamb flashing can befacilitated by openingthe rooflight casement(model dependent).pInstalling the jamb flashingOrientate the jamb flashing over the jamb extrusion as shown in imageA. Grasp the extrusion in the middle and pull the flashing back towardthe rooflight slowly until it clicks (image B). Next push the flashing backoutward toward the battens to engage the flashing onto the extrusion(image C). Ensure the flashing bites onto the rooflight extrusion - pushthe top and bottom of the flashing into place. The excess felt on the jambflashing should be positioned toward the head of the rooflight as shown.The felt attached to the jamb flashings should go OVER thegeneral roofing membrane but UNDER the battens which maybe in place. Repeat for the opposing side. Next, lay the headflashing over the head fillet. Fold, boss and tuck the flashing backinto the baseplate rollover. There may be a requirement to trimthe head flashing around the jamb battens depending upon theirpositioning.qInstall the head flashing18

SECTION 5 - Installing the rooflight> Installing the head roofing membrane > WeatheringpInstall the head roofing membraneLay the strip of roofing felt over the head flashing and ensure ittucks UNDER the next lap in the general roofing membrane.The combination of the head flashing and the roofing felt beinglapped in this way, ensures moisture will run up and over thetilting fillet, onto the baseplate and finally off the roof.qWeathering19

SECTION - Installing the rooflight> Tiling the jambsSECTION 5 - Installing the rooflight> Complete the tiling> Tiling the jambs > Complete the tilingpTile the jambsTile the jambspUse the edge of the jamb flashing as a guide to tile up to and tilethe jambs. Use Ensure the edge the of weathering jamb flashing foam attached as a guide to the to tile jambup to andflashings tile is the folded jambs. down Ensure and away the weathering from rooflight foam attached when layingto thethe tiles.jamb flashings is folded down and away from the rooflightwhen laying the tiles.The head of the rooflight can now be tiled.. We recommend the useof The eaves head tiles. of Complete the rooflight the can tiling now around be tiled.. the We head recommend of the rooflightaccordingly.the use of eaves tiles. Complete the tiling around the head ofthe rooflight accordingly.qComplete the tilingComplete the tiling2121

®®SECTION SECTION - Finishing 6 the- Finishing interiorthe interior> InstallingInstalling thethe headhead andand cillcill liningslinings> Installing the head and cill linings > Installing the jamb linings> InstallingInstalling thethe jambjamb liningsliningspBaseplateBaseplate liningslinings-HeadHead Head andand and CillCill CillInstall the cill and head linings as shown. Orientate the liningInstall the the cill cill and and head head linings linings as shown. as shown. Orientate Orientate the lining the liningwith the fixing holes aligned to the securing brackets located inwith with the the fixing fixing holes holes aligned aligned to the to the securing securing brackets brackets located located inthe rooflight baseplate recess. (as shown by the dashed line in thethe in rooflight the rooflight baseplate baseplate recess. recess. (as shown (as shown by the dashed by the dashed line in the lineabove image). Secure in place using screws provided. Cover theabove in the image). above Secure image). in Secure place using place screws using provided. screws Cover provided. thescrew heads by inserting the timber plugs until flush to the surfacescrew Cover heads the screw by inserting heads the by timber inserting plugs the until timber flush plugs to the until surface flushof the lining.of to the the lining. surface of the lining.Install the jamb linings as shown. The installation method is theInstall the jamb linings as as shown. The The installation method method is the issame as that used for the head and cill linings.same the same as that as used that for used the for head the and head cill and linings. cill linings.qBaseplateBaseplate liningslinings - JambJamb - 2222 22

SECTION 7 - Suggested installation details> Drawing identificationDRAWING IDENTIFICATIONSLATE ROOF FINISHCold roof construction drawing number: NE_100INSTWarm roof construction drawing number: NE_101INSTPage2425CLAY TILE ROOF FINISHCold roof construction drawing number: NE_102INSTWarm roof construction drawing number: NE_103INST262723

SECTION 8 - Important Information> Maintenance > Guarantee > AdvisoryCare & MaintenanceTo achieve the maximum service life from neo it is important that scheduled care and maintenance is undertaken.The following procedures are to be performed at least every six months, and more frequently in exposed or marinelocations.uuuRooflight cleaning – Clean neo’s glass, baseplate and casement, in particular the exposed external surfaces.Clean the baseplate and casement with warm water containing a weak solution of car wash fluid using a naturalbristle brush, and rinse with clean water.Before cleaning, clear the exterior of the rooflight of any debris that may have collected. Excessive buildup ofleaves, twigs, roof tile chips, etc can cause the rooflight to leak. Furthermore chemicals contained within thedebris can have a detrimental effect on the paintwork finishes.Glass cleaning - On models of neo in which the casement can open to 90º (see ‘Rooflight weights and openingangle’) it is possible to clean the glass from the inside. On models that cannot achieve 90º casement openingcleaning can be effected from inside using a cleaning tool obtainable from the Rooflight Company. When cleaningfrom the inside ensure the casement is securely held open and do not put arms or hands through any of themoving parts.Gas strut maintenance - The gas struts that assist in the opening of the rooflight require to be operated at leastonce a month. This keeps the seals lubricated and helps ensure that pressure is maintained. The gas strutsshould also be kept clean and free of dirt - especially the piston rod. Wipe the piston rod with a clean dry greasefreecloth or a piece of clean kitchen towel.AdvisoryStandard rooflight: All the information provided in this document refers to a standard specification neo rooflight.Install in accordance with this manual: The Rooflight Company cannot accept any liability if neo is not installedstrictly in accordance with the instructions contained in this manual and implicit in the ‘Suggested InstallationDetails’.Structural support: Structural supports for neo are to be designed and supervised during construction by therooflight installer’s or project Structural Engineer.Gas struts: neo has integral gas struts which assist the opening casement and support it when fully open. The gasstruts are highly pressured and care is required when operating them. Do not attempt to adjust or dismantle them.28

SECTION 8 - Important Information> Rooflight weight and opening angle > Further InformationRooflight weights and opening angleWhen handling and installing neo its weight should be considered and adequate means employed to move therooflight into position to reduce the risk of accidents..RooflightmodelApproximatecasementweight(kg)Approximatebaseplateweight(kg)Maximumopeningangle*(degrees)neo 38Pneo 57Pneo 63Pneo 94Pneo 150P2836374965263131384390505030N/Aneo 63Lneo 94Lneo 150L3749653138439090N/Aneo 41Sneo 93S284726359090Further InformationAll of the images in this guide are diagrammatic (with some components omitted for clarity). They should be used asa reference and may not be a true representation of the installation.Installation instructions are regularly reviewed and we reserve the right to update or amend these details withoutalteration to this guide.* Please note: opening angles are approximate and may be slightly less than stated, due to the effect of gas springbalancing. Where ‘N/A’ is shown - rooflight models are fixed closed and do not open.June 201029

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A trading name of the Metal Window Company Ltd.Wychwood Business CentreMilton RoadShipton-under-WychwoodOX7 6XUTel: 01993 833 108Fax: 01993 831 066Email: info@therooflightcompany.co.ukWeb: www.therooflightcompany.co.ukThe neo rooflight is a registered trademark of The Metal Window Company Ltd.In the interest of continuous product development, it may be necessary to amend specification without alteration to technical literature.All drawings and designs are the Copyright and Designright of The Metal Window Company Ltd.