Mounting Instructions for INTERFALZ® ALUDECK® Standing Seam ...

Mounting Instructions for INTERFALZ® ALUDECK® Standing Seam ...

MountingInstructions forINTERFALZ ®ALUDECK ®Standing SeamProfilesflexible building.sustainable thinking.

MOUNTINGINSTRUCTIONSTable of contentsGeneral information41.9. Flashings381.9.1. Ridge381.0. INTERFALZ ®51.9.2. Eaves421.9.3. Verge441.1. Introduction to INTERFALZ ®51.9.4. Transverse joint461.2. Product range and warranty61.10. Roof fittings481.10.1. Curbs for light domes and RWA481.3. Transport and storage –1.10.2. Ventilators50incoming goods inspection111.10.3. Roof anchors/fall protection511.10.4. Floor gratings/step grids521.4. Quality131.10.5. Bar-shaped pawl(planetary carrier)531.5. Possible fields of application131.10.6. Snow guard541.10.7 Strip lights551.6. Installation181.6.1. General information181.11. Miscellaneous561.6.2. Holder mounting191.11.1. Roof overhangs561.6.2.1. General information191.11.1.1. Roof overhang1.6.2.2. Holder spacing with purlin roofs24without supporting bar561.6.2.3. Holder spacing with truss roofs251.11.1.2. Roof overhang1.6.2.4. Holder spacing withwith supporting bar56Prodach roofs261.11.2. Curved profiled panels571.11.2.1. Mechanically curved panels581.7. Installing the INTERFALZ ® panels271.11.2.2. Naturally curved panels591.7.1. Verge271.11.3. Conical profiled panels591.7.2. Anchor point291.7.3. Prodach311.7.4. INTERFALZ ® with claw-shaped belt321.7.5. INTERFALZ ® with thermal bits321.8. Flanging322 ■

Table of contents2.0. ALUDECK ®602.11. Miscellaneous662.1. Introduction to ALUDECK ®602.11.1. Roof overhangs2.11.2. Curved profiled panels66662.2. Product range and warranty603.0. Working672.3. Transport and storage –3.1. Edging67incoming goods inspection613.2. Separating672.4. Quality613.3. Drilling and screwing682.5. Possible fields of application623.4. Welding682.6. Installation622.6.1. General information624.0. Removing dirt682.6.2. Holder mounting622.6.2.1. General information625.0. Required tools692.7. Installing the ALUDECK ® panels636.0. Standard accessories and tools702.7.1. Verge632.7.2. Anchor point642.8. Flanging642.9. Flashings642.9.1. Ridge642.9.2. Eaves642.9.3. Verge642.9.4. Transverse joint642.10. Roof fittings642.10.1. Curbs for light domes and RWA642.10.2. Ventilators652.10.3. Roof anchors/fall protection652.10.4. Floor gratings/step grids652.10.5. Bar-shaped pawl652.10.6. Snow guard663 ■

MOUNTINGINSTRUCTIONSGeneral informationGeneral informationEconomic aspects are increasingly in the focusof the building industry. The ALUFORMINTERFALZ ® and ALUFORM ALUDECK ®roofing systems documented herein contributeto cost-conscious planning and building.Based on the realisation of scientific findings,they ideally combine the excellent corrosionresistance and low weight of aluminium with anon-penetrative joining technique and a highload-bearing capacity of the profiles. The nonpenetrativejoining technique, combined withthe profiles gliding on the holders, enables theinstallation of long profiled panels with slightroof pitches of up to 1.5° (2.6 %). When a ridgeseal is additionally applied to the INTERFALZ ®flange, the roof pitch can be reduced to 0.6°(1.0 %).version is available for download on theInternet at System GmbH & Co. KG assumes noliability for any errors contained in thesemounting instructions. Claims for damagescannot be asserted based on their application.These mounting instructions primarily dealwith the installation of INTERFALZ ® profiles.The ALUDECK ® mounting instructions merelycontain those information which are differentfrom part one. Thus, the INTERFALZ ® mountinginstructions must be observed as wellwhen installing ALUDECK ® profiles.The two systems ALUFORM INTERFALZ ® andALUFORM ALUDECK ® vary mainly in thegeometry of the profiled panels and in the waythey are installed.These installation instructions are to serve asa guideline and support for the fitter installingthe Aluform systems. They take into accountthe currently applicable rules and standards.It is assumed that the respective applicableaccident prevention rules are known. Hence,they will not be detailed here. The mountinginstructions do not constitute any exemptionfrom the responsibility for one’s own actions.Moreover, they are not subject to revisionservice. Since new technical developments andinformation to improve the mounting processesare incorporated continuously, an updated4 ■

ALUFORM INTERFALZ ® and ALUFORM ALUDECK ® · Introduction1.0. INTERFALZ ®1.1. Introduction to INTERFALZ ®In accordance with the provision in certificationZ.14.1-419 (for aluminium profiles), the profiledpanels may be fitted only by thosecompanies which have been trained and authorisedby the manufacturer accordingly. Thedesigner or installer has to prepare a designinstruction for the installation of the profiledpanels.The general technical approval must be availableat the site. It can be requested from themanufacturer or downloaded on the Internetat as well.In addition, the documents required at thebuilding site include an installation plan showingthe positions of the profiled panels, thepositions of the holders and their connectionwith the substructure as well as the connectiondetails to be realised (ridge, eaves,verges and the like). The stipulation in part 9of DIN 18807 may be used as a guideline concerningits scope.Basis of the installation plan is the proof ofstability and fitness for use which must be furnishedat any rate.Prior to the beginning of the mounting work,the work performed by the preceding trades isto be examined for adherence to the geometricdimensions stated in the approved plans.In case of any deviations, the customer mustbe informed.5 ■

MOUNTINGINSTRUCTIONSProduct range and warranty1.2. Product range and warrantyAluform INTERFALZ ® 50/333Sheet thicknesst N (mm)Weight(kg/m 2 )3330,83,1 40,93,5449501,03,9399 1309950328Cover width 333Aluform INTERFALZ ® 50/429Sheet thicknesst N (mm)Weight(kg/m 2 )4290,82,950,93,3249501,03,6899 113 113 9950424Cover width 429Aluform INTERFALZ ® 65/305Sheet thicknesst N (mm)Weight(kg/m 2 )3050,83,4564650,93,8699 102 99300Cover width 3051,04,2965Aluform INTERFALZ ® 65/333Sheet thicknesst N (mm)Weight(kg/m 2 )3330,83,350,93,7664651,04,176599 13099328Cover width 333Aluform INTERFALZ ® 65/400Sheet thicknesst N (mm)Weight(kg/m 2 )4000,83, 1 70,93,5664651,03,956599 99 99 99396Cover width 400The weights apply to aluminium profiles. Other overall widths and materials are available upon request.6 ■

Product range and warrantyAluform INTERFALZ ® 65/500Sheet thicknesst N (mm)Weight(kg/m 2 )50064650,80,91,02,973,343,7 16599 99 99 99 99495Cover width 500Aluform INTERFALZ ® 65/305 DFSheet thicknesst N (mm)Weight(kg/m 2 )3056499,5 101 99,5300Cover width 305650,80,91,03,433,864,2965Aluform INTERFALZ ® 65/333 DFSheet thicknesst N (mm)Weight(kg/m 2 )33364650,80,91,03,343,764,1765113,5 101 113,5328Cover width 333Aluform INTERFALZ ® 65/434 DF without corrugationsSheet thicknesst N (mm)Weight(kg/m 2 )43464650,80,91,03,073,463,8465430Cover width 434Aluform INTERFALZ ® 65/434 DFSheet thicknesst N (mm)Weight(kg/m 2 )43464650,80,91,03,073,463,84114 101 101 11465430Cover width 434The weights apply to aluminium profiles. Other overall widths and materials are available upon request.7 ■

MOUNTINGINSTRUCTIONSProduct range and warrantyAluform INTERFALZ ® 65/400 DFSheet thicknesst N (mm)Weight(kg/m 2 )40064650,80,91,03,163,563,9597 101 101 9765396Cover width 400Aluform INTERFALZ ® 65/500 DFSheet thicknesst N (mm)Weight(kg/m 2 )500656496,5 101 101 101 96,5496Cover width 500650,80,91,02,973,343,7 1The weights apply to aluminium profiles. Other overall widths and materials are available upon request.The INTERFALZ ® element is a trough-shapedstanding seam profile which is normally madeof AlMn1Mg0.5 alloy aluminium (natural finishor coated) by means of roll formers.Profiled panels made of:❚ steel,❚ stainless steel,❚ copper and❚ zinchave also been manufactured before andcontinue to be available in sheet thicknesseswhich are different from the ones stated in theproduct range above.When using profiled panels made of copper orzinc, please turn to the factory for adviceconcerning their special properties.The profiled panels can be finished both at thefactory and on site with the help of mobile rollformers. When they are finished at the factory,the panel length is limited to 30 m for transport-relatedreasons.Moreover, the profiled panels can be finishedso that they are straight, convex or concave orwith convex/concave curving in one panel.Bending (curving) can be done on site using amobile machine as well.It is also possible to manufacture conical profiledpanels and to bend them by way of curving.Crimp-curved profiled panels areavailable only upon request at the factory.8 ■

Holder systemThe INTERFALZ ® profiles are fixed by meansof holders (clips) encompassed by the flangesof the INTERFALZ ® panels.These flanges are made mechanically in thecourse of installation, ensuring the constructionof a non-penetrative and rainproofroof. When exposed to temperature-relatedchanges in length, the roof panels can slidealong the holders free of constraint forces.The sliding movement must not be impeded byother structural components.❚ Normal holder made of aluminium❚ Holder made of aluminium with deburredhead❚ Plastic holder made of Ultramid❚ Thermal bits in combination with plasticholdersAluminium holder Thermal holderDue to the extensive range of overall widths,profile heights and curvatures as well as surfacefinishes, optimal design possibilities andadaptations to the building geometry can berealised. The profiled panels can be equippedwith an anti-condensation or anti-drummingcoating in order to improve the properties interms of building physics.Anti-condensation coatings are available independence on the panel length either in theform of fleece or a Grafotherm coating.Thermal bitPanels with paint coats come with a protectivefilm on the large flange. Panels made of theabove-mentioned alloy are fit for seawater asper DIN 81249-1. INTERFALZ ® and ALUDECK ®systems can be used as lightning absorptionand conducting devices in accordance withDIN EN 62305-3.Holders in various heights and in the designsbelow are available for fixing the profiledpanels on various substructures:9 ■

MOUNTINGINSTRUCTIONSHolder system, warrantyHolder Holder Usetype height (mm) for profiles65 65 50/65DF80 80 50/65/50DF/65DF100 100 50/65/50DF/65DF120 120 50/65/50DF/65DF140 140 50/65/50DF/65DF160 160 50/65/50DF/65DF180 180 50/65/50DF/65DF200 200 50/65/50DF/65DF220 220 50/65/50DF/65DF240 * 240 * 50/65/50DF/65DF* Thermalholder onlyPlastic holders for thermal bits which can beturned in are available in the heights 80, 100and 120 mm.With panel lengths exceeding 18 m, the use ofplastic holders or holders with deburred headsis generally recommended (holders with deburredheads only up to a panel length of30.0 m). Profiled panels made of copper mayonly be installed in combination with plasticholders as a rule.Warranty is excluded where:❚ Buyer/fitter has violated the valid rules andregulations and/or the generally acceptedrules of the specialised trade.❚ The damage happened at the building siteand the surface coating has been damaged.❚ The handling and processing guidelines andparticularly the transport and storageinstructions have not been observed.❚ Consequential damage occurred due toinadequate construction in terms of buildingphysics.❚ The components have not been used inaccordance with the application intended bythe manufacturer or the certificationrespectively.❚ The technical documents (executionplanning) have not been observed.In addition to the profiled panels, an extensiverange of accessories (fasteners, profile fillers,ridge filler plates and the like) is available tothe fitter. See section 6 – Accessories.Mounting tools such as folding machines, upwardand downward folding tools, as well asmanual flanging pliers can be borrowed fromthe factory.Delivery and warranty are based on the“General Terms and Conditions of Delivery andPayment” of Aluform System GmbH & Co. KG.10 ■

Transport, storage and incoming goods inspection1.3. Transport, storage and incominggoods inspectionThe delivery time of the profiles depends onprofile shape, sheet thickness, and coating andmust be arranged with the factory. The deliverytime of profiled panels that are longerthan 19.50 m and finished at the factory maybe extended due to the transport authorisationswhich need to be obtained and due toroute surveys which may be necessary.The profiled panels are transported to thebuilding site using vehicles suitable for therespective panel length where they are stowedon wooden pallets. The number of profiledpanels per pallet and vehicle depends on theoverall width of the profile. Normally, 2 - 3panels are placed next to each other on onepallet, up to each 44 panels being stacked. Inthat process, every other panel is turned.Accessories and folded parts are delivered incartons, in boxes or on pallets.6m>8mPallets holding panels in a length of up to 6 mcan be unloaded and handled using a forklifttruck with maximum fork spread.The services performed by Aluform end at thebuilding site, unloading being excluded. Whena delivery arrives, it must be ensured that thedelivery vehicle can both access the buildingsite and drive within the building site area itself.Unloading is done by the customer whohas to provide suitable equipment to ensuresmooth unloading. The weights of the packagescan be found in the delivery note or on thepackage sticker or enquired in advance by contactingthe factory. For packages containingvery long profiled panels, the customary maximumgross weight of 3.0 t/ package may beexceeded for reasons related to the capacityutilisation of the trucks.Profiled panels of up to 8 m in length can behandled by means of a hoisting machine(crane) and belts. The belts must be spread soas to prevent damage above the pallet.For profiled panels in a length of more than 8m a traverse with belts is to be used as slinggear. The belts must be spread as well. The requiredtraverse length and number of belts dependson the panel length. The maximum loadper suspension point must not exceed 0.8 t.Overhangs of more than 4.5 m with aluminiumand 2.5 m with zinc and copper must be avoided.11 ■

MOUNTINGINSTRUCTIONSTransport, storage and incoming goods inspectionIn cases where the goods are picked up by thecustomer, the services provided by AluformSystem GmbH & Co. KG end as soon as thecustomer’s vehicle is being loaded. Suitablevehicles and load straps must be provided bythe customer. The same details as given aboveapply to unloading in this case as well.When the profiles are roll-formed at the buildingsite, the roll former and the coils neededfor roll forming are delivered to the buildingsite. In this case, the leaflet “Guidelines forUsing the Mobile Roll forming Machine onSite” must be observed. The services providedby Aluform System GmbH & Co. KG end uponthe handover of the roll-formed profiles at thebuilding site.Where the profiled panels are to be depositeddirectly on the roof, the load-bearing capacityof the existing roof structure needs to be takeninto account. In order to avoid having to rotatethem on the roof later on, the profiled panelsshould be deposited such that the small flangefaces the intended direction of installation.The INTERFALZ ® pallets are to be stored at anangle. The packages must be covered with amaterial that protects them from the weatherand is permeable to air (also during interruptionsof the mounting work). The formation ofcondensate inside the stack is to be prevented.Profiled panels with uncoated surfaces whichare not mounted immediately upon their deliveryshould be stored in a roofed and ventilatedplace if possible. Accessories are to bestored in locked area where they are protectedfrom the weather.When storing profiled panels with an anticondensationor anti-drumming coating, thefollowing additional issues are to be taken intoaccount:❚ Direct contact of the coating with soiledsurfaces must be avoided.❚ The coatings must not be soaked - neither bydirect rain nor by contact with other wetsurfaces.❚ Profiled panels with a Grafotherm anticondensationcoating or an anti-drummingcoating must not be pushed across otherstructural parts or across each other.The profiled panel packages are identified asfollows when delivered:❚ Packing slip showing content and packageweight❚ CE label❚ Information on the protective film❚ Information on unloading and storageThe mentioned documents are to be observedaccordingly or handed over to the builder respectively.12 ■

Quality · Possible fields of applicationWhere visible defects in the material are foundon receipt, a corresponding confirmation bythe forwarder must be obtained, and the supplieris to be notified immediately. The numberof packages is to be checked for completenessand correspondence of the content with thepurchase order and/or shipping documents.This applies to the number of items as well asprofile, delivered lengths, sheet thicknesses,and surfaces. The supplier is to be notified ofany deviations without delay. Transportdamage which cannot be found at the time ofdelivery is considered to be direct damage aswell but must also be reported prior to theinstallation by all means. The same applies tothe delivered accessories.1.4. QualityINTERFALZ ® is a quality product of AluformSystem GmbH & Co. KG. Its properties aremonitored at the manufacturing site by theinternal quality control department. Regularexternal monitoring is conducted in accordancewith the certification.The insulating material used is an insulationfelt made of mineral wool which is packedduring the installation of the INTERFALZ ®panels such that there is no cavity betweenthe bottom of the INTERFALZ ® panel and theinsulating material. This is normally done byfitting an insulating layer which is approx.2 cm thicker than the intended final dimension.Exceptions to this are the Prodach roof, theroof with claw-shaped belt, the roof variantinvolving thermal bits where non-compressibleinsulation (also in combination with compressibleinsulation) is used, and the couple roofwhere there is an air space between insulationand INTERFALZ ® panel.A functional vapour/convection barrier that isproperly connected to adjacent structuralparts is to be ensured with all insulated roofs.Several customary roof structures whereINTERFALZ ® panels can be applied are describedbelow. The descriptions do not include all possibleapplications.1.5. Possible fields of applicationINTERFALZ ® profiled panels are proper forboth non-insulated and insulated roofs. Theyare suitable for all customary substructuresand roof shapes. Owing to the range of variousholder heights, it is possible to work with anyinsulating material thickness, as required forthe respective object.13 ■

MOUNTINGINSTRUCTIONSStructural variants of a roof structureNon-insulated purlin roofNon-insulated purlin roofs are usually built onnon-insulated buildings or buildings with anaerated attic. Purlin and thus holder spacing(span) depends on the existing load and on theload-bearing capacity of the profile. Applyingan anti-condensation coating to the profiledpanels is normally recommendable.Purlin roof as a non-ventilated roofIn insulated purlin roofs, the inner shell isparallel to the INTERFALZ ® panel. The load istransferred through holders fixed on spacingprofiles that are set at a right angle to theprofiling of the upper shell. If the division ofholder and purlin spacing is equal, the load istransferred directly to the purlins through thespacing profiles. In this case, the inner shellonly supports the thermal insulation. If thepurlin spacing is greater or if the holderspacing is halved within the peripheral areas,the inner shell is also used to transfer the load.Truss roof as a non-ventilated roofThis roof structure is often used in industrialand non-residential construction. The loadbearingelement is a supporting shell made oftrapezoidal (steel) profiles spanned across thetrusses. In order to ensure even load distribution,the holders are positioned in an offsetpattern on the supporting shell.14 ■

Structural variants of a roof structureInsulated couple roof structureThis type of roof is predominantly used onresidential construction. In this roof structure,an air space remains between insulation androof shell. Hence, the roof needs to be designedas a ventilated roof. Any condensate mustbe dissipated through sufficient ventilation(also where INTERFALZ ® panels with an anticondensatecoating are used). Sheathing isrecommendable where drift snow is likely tooccur.Thermally insulated roof on visible plankingand spacing structureThis is mainly used in residential construction.The planking is designed as visible planking.A wooden spacing structure spanning therafters is anchored in the rafters so that theholders can be fixed. The roof structure withvapour barrier and packed insulation is thesame as that of the insulated purlin roof.INTERFALZ ® DF as a Prodach roofing systemThis system comprises an upper shell made ofINTERFALZ ® DF profiles which are attached bymeans of holders to a U-shaped rail which isembedded in a non-compressible insulationlayer. This rail is fastened to the supportingshell only in specific places. Thus, thisstructure is nearly free of thermal bridges.With roof structures designed as truss roofs,the rails are installed diagonally as well.15 ■

MOUNTINGINTERFALZ ®Structural variants of a roof structureINTERFALZ ® DF panels on plankingThis is used either as a non-insulated roof oras a roof above an aerated attic. The holdersare positioned in an offset pattern for loaddistribution in the same way as with the trussroof. The planking must be at least 26 mmthick. The screw is visible from below.INTERFALZ ® on foam glassIn this roof structure the insulation consists offoam glass. The INTERFALZ ® profiles are attachedusing holders which are fixed to claw platespressed into the insulation. The claw platesmust be sealed with a cover sheet. The furtherroof construction can be done directly on topof the cover sheet with DF profiles or by fittinganother layer of compressible insulation andnormal profiles. This roof system has its owncertification Z-14.4-475.INTERFALZ ® on non-compressible insulationwith claw-shaped beltIn this roof structure, a “claw-shaped belt” ispressed into non-compressible insulation andattached to the supporting shell. TheINTERFALZ ® panels are fixed using holdersattached to the claw-shaped belt. The furtherroof construction can be done directly on topof the non-compressible insulation with DFprofiles or by fitting another layer of compressibleinsulation and normal profiles.16 ■

Structural variants of a roof structureINTERFALZ ® on thermal bitsThis fastening system enables the fastening ofan INTERFALZ ® thermal holder without installingcustomary mounting rails on non-yieldinginsulating materials. The thermal bit is pressedinto the non-yielding insulation and fixed usingspecial screws. Then the appurtenant thermalholder with an eccentric socket is placed onthe upper part of the thermal bit and attachedby turning it. Once it is attached to the bit, theposition of the holder can still be slightlyadjusted. The further roof construction can bedone directly on top of the non-compressibleinsulation with DF profiles or by fitting anotherlayer of compressible insulation and normalprofiles.17 ■

MOUNTINGINTERFALZ ®Installation · General information1.6. Installation1.6.1. General informationWhen installing INTERFALZ ® panels, thefollowing principles must be observed:❚ Each panel must be flanged and anchoredimmediately after installation. In this way, itis prevented both from being lifted by thewind and from slipping.❚ The mounting work is to be interrupted incase of strong wind. INTERFALZ ® profiles havea large surface for the wind to act upon.Thus, great wind forces can develop.Open packages are to be secured.❚ When the mounting work is interrupted, thelast profile and open packages must beprotected from the wind.❚ Contact corrosion in case of combinationwith other materials must be prevented.❚ Profiled panels with anti-drumming orGrafotherm coating must never be pulledacross the substructure.❚ The area at the eaves is to be removed ordisabled where profiled panels with anticondensatefleece are used.❚ INTERFALZ ® panels can be accessed duringthe mounting work when flanged on one sideor after the mounting work (flanged on bothsides) without taking any load distributionmeasures as long as the spans stated in thetable below are adhered to (limit span).When the spans stated in the table are exceeded,load distribution measures must be taken(normally by using timber planks, grade S10,with a cross section of 4 x 24 cm and in alength of more than 3.0 m). They can be placedin the trough of the profiled panel or acrossthe flanges. The planks must be securedagainst slipping.Profile50/33350/42965/30565/33365/40065/500DF ProfileLimit spans (m) for the sheet thickness (mm)Accessibility during the mounting workAccessibility after the mounting work0,8 0,9 1,0 0,8 0,9 1,01,90 1,95 2,00 2,44 2,62 2,801,81 1,86 1,91 2,44 2,62 2,802,10 2,20 2,30 3,70 3,80 3,902,10 2,20 2,30 3,70 3,80 3,901,70 1,80 1,90 3,10 3,20 3,20- - 3,00 - - 3,00Installation on non-compressible substrate only; hence, no limit spans.18 ■

Holder mounting · General information1.6.2. Holder mounting1.6.2.1. General informationThe arrangement of the holders, their numberand spacing can be found in the installationplan. In order to ensure the respective insulationthicknesses, holders in various heights areavailable. Moreover, height adjustments can bemade by way of additional spacing structuresor by placing thermal caps or height compensationelements. The actual purpose of thethermal caps is however the avoidance of thermalbridges in insulated structures. Thermalcaps are available in heights of 5, 10 and15 mm. The use of height compensationelements is permissible only in combinationwith thermal holders.Small flangeLarge flangeDirection of installationPrior to screwing down the holders, the respectiveroof area must be measured. In thisprocess, the location of planned roof fittingssuch as light domes or roof hatches must betaken into account.Holder spacing is determined based on thewidth of the INTERFALZ ® profiles using a pieceof string. First, the holders on ridge and eavesare placed. By spanning a piece of string betweenthe two holders, the holders to be placedin between can be mounted such that they areflush. In order to compensate structural tolerances,the spaces can be made up to 3 mmwider. The distance between holders mustnever be shorter than the width of theINTERFALZ ® panel.The holders must be flush. When mounting theholders, the intended direction of installationis to be observed.19 ■

MOUNTINGINTERFALZ ®Holder mounting · General informationNote concerning the special screwsOnly approved joining elements may be usedto fasten the holders on the substructure.Those include:❚ Sealing screws for timber or steelsubstructures 2 mm,❚ Sealing screws for steelsubstructures 2 mm or aluminium 3 mm❚ Drilling screws❚ Claw blind rivets❚ Special screwsNote concerning the special screwsThe fasteners Ejot JT3-X-2 as well as SFS SDK2and SFS SDK3 were developed specifically forbeing screwed to thin steel and/or aluminiumsubstructures. They prevent the screw frombeing “overtightened” during holder mountingas the conical part of the shank “grinds into”the hole (SFS) or the teeth underneath thescrew head grind into the holder (Ejot). Tighteningthe SFS–SDK screws requires a specificscrewdriver attachment. Number and type ofthe connections can be found in the detailsdescribed in the installation plan as well.The foot of the aluminium holder has twodifferent bore holes serving for the followingfasteners:❚ Ø 7.0 mm for fasteners with a diameter of6.3 or 6.5 mm respectively❚ Ø 6.1 mm for special screws, drilling screws orclaw blind rivetsAs a minimum, each 2 screws per holder are tobe fastened centrally opposite to each other ordiagonally. There must not be any bore chipsbetween the holder and the substructure.Jamming the holders due to uneven tighteningtorques or distorting them is to be avoided.20 ■

Note concerning the special screwsThe foot of the thermal holder has 4 holeswith a diameter of 6.1 mm. As a minimum,each 2 screws are to be fastened diagonally.The connection can be made using drillingscrews or claw blind rivets. The mentionedspecial screws are not permitted or not suitablefor fixing plastic holders. Special systemfasteners are supplied to fix the thermal bit.Aluminium holder foot3010106,17,06020 20 106,17,060For easier holder mounting, it is recommendableto make some mounting jigs.6,16,1Examples:❚ Spacer made of hardwood or metal thelength of which equals the distance betweenthe holdersHolder for profile 65/305305 – 60 = 245 mm = jig lengthWhere the holder spacing is to exceed thesystem dimension, that difference is to beadded.❚ Longer metal rail with punched out holes forthe holder feet. The first hole is placed onthe first holder, and all other holders can beinserted in the other holes and fastenedwithout making any measurements.❚ Another option with insulated roofs (e.g.purlin roof) is mounting the holders to thedistance profiles in advance at a workshop.Thermal holder foot6010 20 20 106,110501070right way wrong way wrong way21 ■

MOUNTINGINTERFALZ ®InstallationHolders on various substructuresHolder on timber purlin or wooden spacers(Normally without thermal cap)❚ Sealing screw❚ Drilling screw for woodRecommended screwing depth 50 mmHolder on steel purlingWith or without thermal cap❚ Sealing screw❚ Drilling screwHolder on steel supporting shell(Normally with thermal cap)❚ Ejot JT3-X-2-6.0 x L❚ SFS SDK3-S-377-6.0 x L❚ Claw blind rivet 5.2 x L❚ Drilling screwHolder on steel distance profileHolder on steel distance profile❚ Ejot JT3-X-2-6.0 x L❚ SFS SDK3-S-377-6.0 x L❚ Claw blind rivet 5.2 x L❚ Drilling screw22 ■

InstallationHolder on Prodach rail(Normally without thermal cap)❚ Ejot JT3-X-2-6.0 x L❚ SFS SDK3-S-377-6.0 x L❚ Claw blind rivet 5.2 x L❚ Drilling screwHolder with thermal bit❚ Drilling screw IF2-S-SQ3-6,0 x LWith regard to the fasteners used, it is to bemade sure that their drilling performance andtightening zone are in correspondence.(See section 6 – “Accessories”)Where tapping screws* are used, primarydrilling is to be done as follows:SubstructureMaterialMaterial thickness(mm)Drill diameter(mm)Steel 2,0 – 4,9 5,35,0 – 6,9 5,5 7,0 5,7Aluminium 3,0 – 4,9 5,0 5,0 5,3Wood 0.7x screw ø,normally 4.5 mm*The information applies to fasteners sold by Aluform. If screwsfrom other manufacturers are used, the values may vary slightly.23 ■

MOUNTINGINTERFALZ ®Holder spacing with purlin roofs1.6.2.2. Holder spacing with purlin roofsIn non-insulated purlin roof structures, onerow of holders is placed on every purlin. Inareas exposed to increased suction loads,shorter purlin distances may be arranged. Ininsulated purlin roof structures, an intermediatestructure normally has to be incorporatedas the partition of the supporting shell isnot in correspondence with the overall widthof the INTERFALZ ® panel.In special cases, profiles can be manufacturedin overall widths that are in correspondencewith the latticing of the supporting shell.It makes sense to place the intermediatestructure on top of the purlin underneath andconnect it to the same to make sure that loadsare transferred directly into the purlin. If thestructure cannot be placed on top of the purlin,or if the holder spacing must be shortenedin the peripheral areas, proof must be furnishedthat the supporting shell can bear theresulting loads – see specification in the installationplan.RidgeVergea aHolderaINTERFALZ +Supporting shellCover width INTERFALZEavesTruss spacingTruss spacinga = Holder spacing = Purlin spacing24 ■

Holder spacing with truss roofs1.6.2.3. Holder spacing with truss roofsThe truss roof has a supporting structuremade of trapezoidal steel profiles which isspanned across the trusses. In a distanceequalling the overall width, a continuous rowof holders is placed on the eaves and on theridge. Where holders are screwed to an eavesboard, it is to be made sure that their height isthe same as that of the following holders. Inthe following holder rows the holder is offsetby each one supporting shell rib spacing inrelation to the eaves.In this way, a diagonal holder pattern is created,and the supporting shell is loaded evenly.Due to the increased suction loads the peripheraland corner areas are exposed to, it maybe necessary to shorten the holder spacingthere compared to the “normal area”.Holders in truss roofs with normal spacingRib spacingSupporting shellSupporting shellRidgeHolderHolder spacingVergeINTERFALZCover width INTERFALZTruss spacingTruss spacingEaves25 ■

MOUNTINGINTERFALZ ®Holder spacing with Prodach roofsHolders in truss roofs with shortened holder spacing in the peripheral and corner areasusing the example of a single pitch roofRib spacingSupporting shellRidgeHolderVergeSupporting shellINTERFALZHolder spacingCover width INTERFALZEavesTruss spacingTruss spacingAreas exposed to increased suction loads1.6.2.4. Holder spacing with Prodach roofsThe installation workflow for Prodach roofs isdescribed in chapter 1.7.3. Holder mounting isdescribed there as well.26 ■

Installing the INTERFALZ ® panels · Verge1.7. Installing the INTERFALZ ® panels1.7.1. VergeAfter the holders have been placed, the installationof the INTERFALZ ® panels begins at theverge. The panel packages have been depositedon the roof before or are lifted onto theroof in the course of the mounting work suchthat the small flange faces the direction ofinstallation. At this point, two verge designsare possible:a.) Verge with extruded verge profileThe large flange is seamed prior to mounting,and the panel with the small flange is pressedinto the holder. After that, the extruded vergeprofile is twisted in over the large flange andjoined with the supporting structure. Anotheroption is to seam the large flange prior tomounting and then twisting it in the verge profilethat has been attached to the supportingstructure and selected to suit the respectiveINTERFALZ ® profile height. The small flangecovers the next holder.27 ■

MOUNTINGINTERFALZ ®Installing the INTERFALZ ® panels · Vergeb.)Verge with verge cap,U-shaped verge profile and verge battenThe first INTERFALZ ® panel covers the holders,the small flange facing the direction of installationagain. Then the large flange is seamed(Operate machine!).After that, the U-shaped verge profile is placedon the large flange and riveted to the samewith a spacing of approx. 500 mm (distance toholders: at least 100 mm). The connection withthe holder is made by screwing (at least 2drilling screws or tapping screws) the vergecap to the holder. The verge batten is clippedon over the U-shaped profile and the vergecap by hooking it into the long flank of theU-shaped profile and twisting it.28 ■

Anchor point1.7.2. Anchor pointBased on the predefined anchor point design,the anchor point is made now (to prevent thepanel from slipping), or the second panel is installedand immediately flanged to the precedingpanel. Where the anchor point can bemade after the installation of the second panelonly (variant involving screwing through theweb), the first panel needs to be secured so itwill not slip.Anchor points are subject to static verification.The intended design and locations within theroof structure can be found in the installationplan. For information on flanging and possiblemachine settings, see section 1.8.Possible anchor point designs are shown in thefollowing pictures:ca. 45°Niet10–12Riveted anchor pointA hole is drilled into the holder head throughthe small flange at an angle of approx. 45° to1. Drilling a rivet holeaccommodate one (or several) blind rivets.The rivet head is covered by the large flangeof the next panel. To make sure that the forcesacting upon the roof pitch are absorbed, itmay be necessary to place a longer holder.2. Mounting the rivet andhooking in the seam profile3. Ready for flanging29 ■

MOUNTINGINTERFALZ ®Anchor pointM8 screw withsealing washersand nutAnchor point made by screwing the panelsdown through the websAn M8 threaded screw with a locknut is driventhrough both profile webs and the holder.Sealing washers have to be added on bothsides (screw head and nut).External ridge flashingDistance compensationAnchor pointINTERFALZAnchor point made by screwing the panelsin the trough bottom to the substructureTapping screws or drilling screws are screwedinto the supporting structure through thetrough bottom. Height compensation may benecessary. Holder arrangement can be omittedin this area.When completing the roof by installing theroof flashings (ridge, verge, eaves), it is to beobserved that temperature-related changes inthe INTERFALZ ® panel length always propagateaway from the anchor point. Thus, the anchorpoint is usually made on the ridge, andthe change in length is allowed for at the gutteroverhang.The coefficient of linear expansion tof various materials is shown in the tablebelow.MaterialCoefficient of linear expansion t(mm/mK)Aluminium 0,024Copper 0,017Stainless steel 0,016Zinc 0,029The anticipated temperature-related change inlength is calculated as follows: 0 * t *tWhen anchor points are made by screwing thepanels through the webs and/or the troughbottom, the screwed connection should belocated between upturn and profile filler andcovered by the ridge flashing. When furtherinstalling the INTERFALZ ® panels until theentire roof is completed, the panels are placedon the preceding panel with the large flangeon top of the small flange at a slight angle.Now the panel is aligned (flush with the eaves),and then its small flange is pushed into thenext row of holders.30 ■

Anchor point · ProdachLength tolerances of the INTERFALZ ® panelsare accommodated at the ridge. Where foldingthe panels upward at the ridge end is no longerpossible after the installation for structuralreasons, this needs to be done before thepanels are mounted (see section 1.9.1).Furthermore, it is to be taken into account thatcertain roof fittings can constitute anchorpoints as well.Heat insulationVapour barrierStep 1 – Milling out the portions for the railMill out a portionof the insulation forthe mounting rail.1.7.3. ProdachThe installation workflow for the erection of aProdach system is similar to that of a trussroof. The company Rockwool provides asystem for the Prodach construction consistingof a non-compressible and water-repellentmineral wool insulating slab and a U-shapedmounting rail which has to be milled into theinsulation.Push the mounting rails intothe milled-out portion.Step 2 – Installing the railsFix screws to make aconnection with the substructure.The rail is fixed to the supporting shell using asystem fastener only in certain places whichminimises heat losses due to existing thermalbridges. INTERFALZ ® DF panels are used asroof cladding. Their trough bottoms restdirectly on the insulation. Finally, the panelsare mounted and flanged as described insection 1.8.Step 3 – Installing the holderMount the holders to the rails.Hook in and flange the INTERFALZ ® profiles.Step 4 – Installing the panels31 ■

MOUNTINGINTERFALZ ®INTERFALZ ® with claw-shaped belt · INTERFALZ ® with thermal bitsFlanging1.7.4. INTERFALZ ® with claw-shaped beltIn this system, a claw-shaped belt is pressedinto a non-compressible insulation, similarly tothe Prodach roof. Milling is not necessaryhere. The claw-shaped belt is fixed to the supportingshell using a system fastener only incertain places. Claw-shaped belts are availablewith and without punched spacing holes.The claw-shaped belt is positioned either parallelto the eaves or diagonally depending onthe existing supporting structure. The INTERFALZ ®holders are screwed to the claw-shaped belt. Inthe course of further roof construction,the INTERFALZ ® DF panels can either be placeddirectly on the non-compressible insulation,or another layer of compressible insulation incombination with INTERFALZ ® in a height of50 or 65 mm is applied.1.7.5. INTERFALZ ® with thermal bitsThe holders are positioned with the help ofstring in the same manner as described for thetruss and/or purlin roof above. Then the bitsare pressed into the non-compressible insulationusing a special tool. In order to be able tobring the bit into the correct position, it ismarked with a groove accordingly. Where bitheight and insulation thickness do not match,either the bit must be shortened or an additionalspacing structure must be in place. The bitis fixed to the supporting shell using at least2 system fasteners. Afterwards, the holderwith the 14 mm foot thickness and correspondingheight is twisted onto the bit. If the holderis mounted centrally, it can still be adjusted by9 mm to both sides later on. The further roofconstruction can be done directly on top ofthe non-compressible insulation with DF profilesor in combination with compressibleinsulation and normal profiles. A special tool isavailable for mounting the thermal bits.1.8. FlangingEach INTERFALZ ® panel must be flanged assoon as it has been installed. This is done bymeans of a flanging machine which can beborrowed from the factory or purchased. Thedirection of travel is arbitrary with panels thatare not abutted. The machine can move fromthe eaves to the ridge and back. Prior to flanging,it must be checked if the flanges are properlyseated in the holders so as to avoidfaulty flanging. Flanging is to be done suchthat the panels can still slide across the holdersproperly. When the flanging work is executedcorrectly, the flange has the followingexternal dimensions:Sheet thicknessFlange width(mm)(mm)0,8 – 1,0 21 – 22The flanging machine has to be set accordingly.The machine is positioned at the open flangebefore flanging, then “brought together” whenthe front pair of rollers grips, and then it canindependently run along the flange.32 ■

FlangingSheet thicknesses from 0.9 mm require preflangingof the area where the machine is positionedto begin flanging using manual flangingpliers. The INTERFALZ ® panel and especiallythe flange must be free from dirt in order tobe flanged. Paint-coated INTERFALZ ® panelsmust be flanged using plastic rollers as a rule.The protective film on the profiled panel (normallyon the large flange only with colouredmaterial) is removed only after flanging.In case of faulty flanging or if any INTERFALZ ®panels need to be exchanged, the flange canbe opened again using a “flange openingdevice” which is attached to the rear end ofthe machine.spring tension via the lateral knurled nuts.The knurled nuts are secured against beingturned out of position by means of threadedpins.❚ Setting the rollers to the web height of50 mm or 65 mm profiled panelsThis is normally done at the factory. Thesetting is to be checked prior to flanging.❚ Replacing the roller sets❚ Knurled wheel for adjusting the number ofrevolutions and thus the flanging speedThe technical data of the machine are asfollows:InputvoltagePowerconsumptionWeight230 – 240 V 1200 W 15,0 kg~50/60 Hz (Continuousoperation)The flanging machine comes with thefollowing setting options:❚ Setting of the flanging width using acontrivance for gap setting at the front andrear openings in the machine. Contrivanceoutward = smaller flange; contrivance towardthe centre = larger flangeWhere setting by means of the gapcontrivances is not sufficient, the flangewidth can also be adjusted by modifying the33 ■

MOUNTINGINTERFALZ ®FlangingFlange width setting optionsShifting thegap settingAdditionaloption byadjusting thespring tensionSetting options for the height of the guide rollersLoosening thehexagonal sockethead screwShifting theroller holder upor down34 ■

FlangingSwitching optionsFlanging rollersSwitching onand offMachine with a set of steel rollersAdjusting the numberof revolutions and thusthe speed of operationPlastic rollers35 ■

MOUNTINGINTERFALZ ®FlangingFlanging1. Manual flanging of the area where the machine is positionedto begin flanging3. Machine closed2. Positioning the open machine 4. Flanging36 ■

FlangingOpening flangesGroove for attaching the flange opening deviceMachines with a flange opening device37 ■

MOUNTINGINTERFALZ ®Flashings · Ridge1.9. Flashings1.9.1. RidgeUpturns at the ridge end and the ridge fillerplate in combination with filler block P servefor sealing the profiled panel at the ridgeagainst drift snow and water. For makingupturns, a special upward folding tool isavailable for each profile.Using that tool, the end of the profiled panel isfolded up by approx. 45° making sure that theprofiled panel does not crack laterally at theupturn. Then the ridge filler plate is twistedinto the profile and fastened to the flanges bymeans of blind rivets.1. Positioning the upward folding tool3. Upward folding complete2. Making an upturn4. Finished upturn38 ■

RidgeThe distance of the ridge filler plate to the profiledpanel end depends on the intended ridgedesign. It should however measure 120 mm.The filler block is shoved underneath the rearfold of the ridge filler plate, a surface pressurehaving to be applied on all sides in order toachieve proper tightness. In order to preventthe profiled panels from getting jammed underthe ridge filler plate, incorporating non-compressibleinsulation in the ridge area isrecommendable. An additional distance profilecan be riveted on the flanges to support theridge sheeting.ThermalinsulationVapourbarrierHolder withthermal capRidge fillerplateFiller blockUpfoldTrapezoidal profileTruss39 ■

MOUNTINGINTERFALZ ®RidgeUpturnExternal ridgeflashingRidge fillerplateFiller blockDistanceprofileSpacingstructureInternal ridge flashingDepending on the overall width of the profiledpanel, the ridge flashings are riveted to theridge filler plates centrally or at the thirdpoints (no riveting in the flange area). Sheetsmust overlap by at least 100 mm and sealed inaddition or made flush using a baffle plate.The sheets must not be joined at the overlap.Fix baffle plates on one side only, the distancebetween the fastening points being maximally333 mm.In case that the anchor point is not located onthe ridge and it needs to be movable, appropriatesliding elements are available.Hips can be made by welding to a splitINTERFALZ ® panel which is aligned with thehip as well.A prefabricated ventilated ridge is available forventilated roofs. Hips are designed and builtlike gabled roof ridges. Since the profiledpanels have to be cut at the ridge at an angle,profile filler blocks in a length of 1.0 m andvariable ridge filler plates without punched outareas for the corrugation are available forsealing. They must both be adapted to therespective bevel on site.40 ■

Ridge · HipVentilated ridgePrefabricatedventilated ridgeRidge filler plate Filler block Distance profileHip41 ■

MOUNTINGINTERFALZ ®Eaves1.9.2. EavesThe edges of the profiled panels at the eavesend include a chamfer at the eaves end, flangefiller, an eaves angle and sealing tape to befitted between the eaves angle and theINTERFALZ ® panel. So as to avoid restraintsbetween eaves gutter and eaves angle as a resultof temperature-related changes in theprofiled panel length, a certain excess length(gutter overhang) of the profiled panel beyondthe plug-in gutter outlet is necessary. Whendetermining the measure “A” as shown in thedrawing below, a freedom of movement of1.0 mm/m of the profiled panel must beincluded in the design in Central Europe.INTERFALZGutter overhang-1/3A 20-2/3A = freedom of movement1.0 mm/m of the profiled panelIf the temperature differs from the valuesstated above, the required gutter overhangcan be calculated based on the formula insection 1.7.2.For making the chamfer at the eaves end,appropriate downward folding tools areavailable as well.After downward folding and applying theflange filler at the eaves end (apply the flangefiller prior to flanging and/or in the course ofpanel mounting), the eaves angle is to bemounted. The eaves angle is attached approx.20 mm (with the opening facing forward) fromthe panel front edge. Depending on the eavesdesign, sealing tape is to be fitted between theeaves angle and the INTERFALZ ® panel. Foreasier mounting, it is clamped to the profiledpanel by means of locking pliers or a screwclamp and then riveted. The flange filler is normallyfixed together with the eaves angle. Asthe eaves angle also has a static function (loaddistribution), the eaves have to be riveted ateach rib of the trough bottom in case of overhangsprojecting more than 25 cm over theholder.Where the anchor point is located on the ridgeand the profiled panels are mounted at 15 - 20°C,the required gutter overhangs are as follows:Panel lengthUp to 20 mUp to 30 mUp to 40 mUp to 50 mMore than 50 mGutter overhang60 mm70 mm80 mm90 mm50 mm + 0,5 x L (m)L = panel length42 ■

EavesOnly profiled panels of equal length are joinedwith an eaves angle. Where it is locatedbetween two profiled panels of differentlengths, the eaves angle has to be abutted.2. Folding down1. Positioning the downward folding tool 3. Finished chamferHolder withthermal capChamferVapourbarrierThermalinsulationGutter sheetCurtaingutterEaves angleFlangefillerGutterbracket43 ■

MOUNTINGINTERFALZ ®Verge1.9.3. VergeThe way to begin the mounting work at theverge has been described based on two optionalvariants already in section 1.7.1. Installingthe opposite verge side is to be started in thesame way. The verge may have to be executedeither as an upward or downward verge (connectionto higher building and/or attic).When using the one-piece verge profile, eitherthe small flange is hooked into the vergeprofile first and then the large flange of theINTERFALZ ® profile is pressed onto the smallflange of the preceding panel in the same wayas it is done at the beginning of the mountingwork, or the panel is installed normally withthe verge profile being twisted into the largeflange.The cover sheets are to be fixed to the vergeprofile or to the verge batten. Joints have tooverlap by 10 cm (with additional sealingwhere necessary). Overlaps must not beconnected with each other.For forming transitions, fitted panels with aflange are made profiled on one side and, ifrequested, additional bends are available aswell. However, they are maximally 6.0 m longso that they have to be joined and sealed tomake longer panels. With roof pitches of lessthan 5° the joints should be welded.44 ■

VergeBracketas holderVergeflashingVerge profileThermal insulationVapour barrierBracketAttic coveringTwo-piecespacingstructureHolderSupporting shellVapour barrierThermal insulationVerge profileDistanceplate45 ■

MOUNTINGINTERFALZ ®Transverse joint1.9.4. Transverse jointINTERFALZ ® panels finished at the factory canbe delivered in lengths of up to 30 m.If finished at the building site, virtually infinitefabrication is possible as long as there areappropriate conditions at the building site.Transverse joints in the profiled panels arethus avoidable and should be executed onlywhen absolutely necessary (e.g. in case ofrestricted mounting options).During flanging it is to be observed that theflanging machine may be operated in the directionof the roof pitch only.Joints must be sealed. Transverse joints withroof pitches of less than 5° should be welded,and transverse joints with roof pitches of lessthan 2.9° must be welded.46 ■

Transverse jointThe following pictures show the recess areasneeded to make the joint and the joint formingoptions.Joint as an anchor pointPanel 2Panel 1„a“Direction of installationMoveable jointPanels 1 and 2 flangedPanel 4“a” recess areaPanel 3Notching of the large flange only with a sheet thickness of 1.2 mm47 ■

MOUNTINGINTERFALZ ®Roof fittings · Curbs for light domes and RWA1.10. Roof fittingsWelded-in curb1.10.1. Curbs for light domes and RWAWhen it comes to the installation of curbs,Aluform System GmbH & Co. KG cooperateswith renowned manufacturers and can provideboth insulated and non-insulated curbs invarious dimensions. Curbs can be sealed orwelded in. Curbs should be welded in with roofpitches of less than 5° and must be welded inwith roof pitches of less than 2.9°.Since the equipment mounted on the curbsmust be accessible for regular maintenanceand thus people must be able to walk on theprofiled panels, it is recommendable with insulatedroofs to fit non-compressible insulationin the area around the curb in addition toinstalling appropriate floor gratings.Detailed fitting instructions will be delivered toyou along with the curbs.The replacement of parts of the substructurewhich may be necessary to install the rooffittings must be taken into account already atthe time of planning.Weld up the profiles at the front.48 ■

Roof fittings · Curbs for light domes and RWASealed curbCurb welded to panels on both sidesPosition the curb on the existingsubstructure and seal.The flashing designis the same as thatof the ridge.Joint formationis the same asthat oftransversejoints.Flange the panels and rivet the joints.Fitting a light dome with a profiled flangeVapour barrierFlange fillerLight domeCurbCover sheetFiller blockFiller plateINTERFALZ®®INTERFALZ holderwith thermal cap Non-compressible insulationDetailed fitting instructionsSee mounting instructions of the light dome manufacturerSupporting shellInsulation49 ■

MOUNTINGINTERFALZ ®Ventilators1.10.2. VentilatorsThere are 2 options to make pipe ductsthrough the INTERFALZ ® panel:❚ Welding the pipe duct into the roof cladding❚ Sealing a pipe fed through the roof claddingby means of a pipe collar. The relevantmounting instructions will be deliveredtogether with the pipe collars.In insulated roofs the pipes must be connectedto the vapour/air barrier.50 ■

Roof anchors and fall protection1.10.3. Roof anchors and fall protectionFall protection for INTERFALZ ® systems isavailable both as single attachment points andin the form of rope systems. Both systems arefastened to the flanges of the INTERFALZ ®panels without penetrating them. All systemshave been tested for use with the INTERFALZ ®system. Single attachment points as well asthe rope system can be used with widths of305 to 500 mm.Mounting instructions are included in everydelivery of single attachment points. Ropesystems may be installed only by certifiedcompanies or under the supervision of anAluform employee.The sheet thickness of the profiled panelsmust be at least 0.8 mm for all systems, andthe distance between holders may be max.2.50 m. Consulting and sale of the systems isprovided by Aluform Bernsdorf.51 ■

MOUNTINGINTERFALZ ®Floor gratings and step grids1.10.4. Floor gratings and step gridsFloor gratings and step grids are used wherepeople need to access the roof regularly, maintain roof fittings or superstructures.The short gratings, platforms and continuousfloor gratings supplied by Aluform SystemGmbH & Co. KG have been tested for theirfitness as per DIN EN 516. The gratings areused as follows:❚ Short grating (460 x 250 mm) as single stepgrids in the direction of walking and roof pitch.❚ Platform (800 x 250 mm) as single step gridsin the direction of walking and roof pitch orstep grids in front of individual equipment❚ Floor grating (1,500 x 250 mm) as footbridgesrunning parallel to ridge or eaves.The floor gratings and platforms are fastenedto holders made of cast aluminium which areattached to the flanges of the INTERFALZ ®panels by way of screwed connections withoutpenetrating the roof cladding. Floor gratingsmay also be fastened using bar-shaped pawlsmade of aluminium.Perforations in the floor grating holders enablethe alignment of the grating pitch withthe roof pitch. With continuous floor gratings,the individual gratings are to be joined by formingbutt joints. The longitudinal expansion ofthe INTERFALZ ® panels must not be impededby the clamping forces.It is to be taken into account already at thetime of detailed planning that the spacing ofthe holders for the INTERFALZ ® panels (span)must not exceed the “limit span after installation”.52 ■

Bar-shaped pawl1.10.5. Bar-shaped pawl (planetary carrier)Bar-shaped pawls made of stainless steel oraluminium serve for the non-penetrative fasteningof accessories or supports of solar collectorson the INTERFALZ ® panels.They are fixed to the flanges of theINTERFALZ ® panels using clamping screws.For that purpose, the clamping screw is opened,and then the bar-shaped pawl is spreadand put over the flange. The tightening of theclamping screw must not prevent the profiledpanel from sliding. Hence, the clamping screwis to be fastened with a tightening torque of8 Nm.The elements to be attached to thebar-shaped pawl can be connected using thebore holes in the ascending lug.Provided bore hole = ø 7.0 mm.53 ■

MOUNTINGINTERFALZ ®Snow guardThe long flank of the stopper points at the ridge.1.10.6. Snow guardSnow guards must be mounted where peopleor goods are endangered by masses of snowfalling down or where the load-bearing capacityof lower roofs would be insufficient tobear that snow. If snow guards need to bemounted on the roof, their number and positioningcan be found in the execution plan.Snow guards consist of:❚ Snow guard mounting links❚ Snow stoppers (in 2 different designs)❚ Circular tubesAll parts are made of aluminium.The following table shows the usual arrangementof individual parts when mounting snowguards.The number of rows required depends on theexisting snow load, on the roof pitch and onthe panel length. You can find more detailedinformation in the installation plan or obtainthem from our application consultants.ProfileUsual arrangement of snow guard mounting link and snow stopperSnow guard mounting linkSnow stopper50/333 Every other web 1 piece/trough50/429 Every web 2 pieces/trough65/305 Every other web 1 piece/trough65/333 Every other web 1 piece/trough65/400 Every web 2 pieces/trough65/434 Every web 2 pieces/trough65/500 Every web 2 pieces/troughThe stated figures are based on experience and must be verified to be used for a specific object.They apply to DF profiles as well.54 ■

Snow guard · Strip lightsMounting the snow guard is done inaccordance with the following sequence:❚ Attach the mounting links.❚ Feed through the tube(s) and connect thetubes using tube connectors.❚ Adjust and align the snow guard system.❚ Tighten all screws. The required tighteningtorque for the screw connections of the snowguard mounting links is 25 Nm.❚ Mount the stoppers.1.10.7. Strip lightsStrip lights are available measuring 65/305,both insulated and non-insulated. Minimumquantities must however be purchased. More–over, only every fourth panel may be a striplight.They are mounted as follows:❚ Install INTERFALZ ® panels to both sides of astrip light. (Observe holder spacing of305 mm.)❚ Folding the large flange adjoining the striplight.❚ Lay the strip light onto the INTERFALZ ® panelon both sides.❚ Clip the strip light filler plates on the flangesof the strip lights; seam the filler plate.❚ The filler plates are connected to ridge andeaves by riveting them to the flanges of theINTERFALZ ® panel so as to prevent shifting.The strip lights must be recessed in this areain order to prevent damage caused bydifferent length variations.Note: There is a separate set of rollers forflanging the strip light filler plates.55 ■

MOUNTINGINTERFALZ ®Miscellaneous · Roof overhangs1.11. Miscellaneous1.11.1. Roof overhangsRoof overhangs at the verge are possible onlywith an appropriate substructure. Roofoverhangs at the eaves or ridge end can beexecuted with or without a supporting bardepending on the size of the overhang.A roof overhang at the eaves or ridge end isthe distance between the last holder on theeaves or on the ridge and the outer edge ofthe profiled panel.The certification requires a panel overhang ofat least 100 mm to ensure the load-bearingcapacity at the end bearings.Roof overhangs cannot be walked on prior toflanging and before the eaves angle has beenmounted. It is generally recommended toimplement load-distribution measures in thisarea.The expectable profiled panel length variationtowards the eaves must be taken into accountin the construction of the gutter and/ordownpipes. Roof overhang with supporting barWith a roof overhang design as described insection above, only a limited projectionof the roof is possible. It can be increased byfitting supporting bars. For that purpose,supporting bars with appropriate heights areinstalled in the profiled panel joints, stretchingover at least two spans of the substructure onthe building side and end on the eaves sideapprox. 60 mm before the edge of the profiledpanel. Chamfer, eaves angle and flange fillermust be fitted at the panel end.abSupportingbar1.11.1.1. Roof overhang without supporting barRoof overhangs projecting by up to 1/6 of theadjacent span can be realised without verification.Greater roof overhangs are subject tostatic verification based on the bearing valuesin the certification.To mount gutters, a support bracket can befitted at the end of the roof overhang to whichthe gutter brackets can be fastened. Thesupport bracket must be secured againstshifting in the flange by riveting or screwing itdown (see anchor point options).aEaves angle astransverse stiffening elementb56 ■

Curved profiled panelsThe gutter brackets can be mounted at the end ofthe supporting bar here as well. When mountingthe supporting bars, it is to be made surethat they are flush. Both the supporting barand the way it is fastened to the substructureare subject to static verification.The bearing values of the supporting bars canbe enquired by contacting the factory.The precise design can be found in theexecution plan.curved profiled panels, the specifications insections and must be observed.1.11.2. Curved profiled panelsProfiled panels can be curved mechanicallyboth at the factory and at the building site orcurved (cambered) naturally. Mechanicalcurving facilitates smaller radii than naturalcurving. The maximum possible rise of thepanels curved at the factory depends primarilyon the maximum transport height and measuresapprox. 1800 mm. Bends with larger risescan be carried only by way of special transportsor need to be curved at the building site.When they are curved at the building site, it iseasier to respond to changed dimensionalratios as well.In this context, the leaflet “Guidelines forUsing the Mobile Shaping Machine on Site”must be observed.The flashings are formed in the same way as itis done with straight panels. The verge flashingcan however not be formed using continuousverge profiles and/or U-shaped vergeprofiles due to the curvature. Only shortpieces are to be fitted here. When installing57 ■

MOUNTINGINTERFALZ ®Mechanically curved panels1.11.2.1. Mechanically curved panelsThe curving process may cause the webs ofthe profiled panels to be deformed outward sothat the overall width is increased by up to 3 mmand the respective holder spacing (in thetransverse direction of the profiled panel)must be adapted accordingly. The actual overallwidth is to be determined by measuring theprofiled panels prior to mounting the holders.When panels are curved, approx. 400 – 600 mmat both panel ends remain straight for technologicalreasons. This can be undesirable in caseof small radii so that the panel ends have tocut off at the building site. (Please, keep thatin mind when placing your purchase order!)When it comes to profiled panels with varyingradii (convex and concave) in one and thesame profiled panel, transitional areas ofsimilar dimensions as mentioned above areformed as well. There must not be any holdersin such areas unless they constitute anchorpoints. Whenever a holder functions as ananchor point in a transitional area or at theend of a bend, a second anchor point must notbe made.The following radii can be achieved by way ofcurving:Examples of possible curving radiiMaterialAlu; mill finish - stuccoAlu; mill finish - smoothAlu; colouredSteel; galvanised, colouredStainless steel, t = 0.6 mmTitanium zinc; natureTitanium zinc; weatheredCopperConvex profile – radii in m65/305 65/305 50/333 65/333 65/333 65/400 65/400 65/500 65/500DF DF DF DF1,0 4,0 - 1,0 4,0 1,0 4,0 1,0 4,02,0 6,0 2,0 2,0 6,0 2,0 6,0 2,0 6,01,0 4,0 - 1,0 4,0 1,0 4,0 1,0 4,09,0 15,0 - 9,0 15,0 9,0 15,0 9,0 15,09,0 15,0 - 9,0 15,0 9,0 15,0 9,0 15,03,0 10,0 - 3,0 10,0 3,0 10,0 3,0 10,04,0 12,0 - 4,0 12,0 4,0 12,0 4,0 12,05,0 12,5 - 5,0 12,5 5,0 12,5 5,0 12,5MaterialAlu; mill finish - stuccoAlu; mill finish - smoothAlu; colouredSteel; galvanised, colouredStainless steel, t = 0.6 mmTitanium zinc; natureTitanium zinc; weatheredCopperConcave profile – radii in m65/305 65/305 50/333 65/333 65/333 65/400 65/400 65/500 65/500DF DF DF DF9,0 15,0 - 9,0 15,0 9,0 15,0 9,0 15,010,0 16,0 10,0 10,0 16,0 10,0 16,0 10,0 16,09,5 15,5 - 9,5 15,5 9,5 15,5 9,5 15,514,0 18,0 - 14,0 18,0 14,0 18,0 14,0 18,014,0 18,0 - 14,0 18,0 14,0 18,0 14,0 18,015,0 20,0 - 15,0 20,0 15,0 20,0 15,0 20,016,0 21,0 - 16,0 21,0 16,0 21,0 16,0 21,017,0 22,0 - 17,0 22,0 17,0 22,0 17,0 22,0When curving INTERFALZ ® panels made of aluminium, a protective film must be provided overthe entire surface with radii of less than 10.0 m.58 ■

lNaturally curved panels · Conical profiled panels1.11.2.2. Naturally curved panelsIn natural curving the profiled panels are manufacturedand delivered to the building sitestraight (or are roll-formed there) and bentover a specifically curved substructure duringmounting. In this context, the information providedin section above has to be observed.The minimum panel length for natural curvingis 10.0 m.In order to avoid that the profiled panels areoverstrained at the bearings (holder area) andto achieve a proper curvature, the holderspacing normally needs to be shortened. Moreinformation on this subject can be obtainedfrom the application engineering departmentat the factory.1.11.3. Conical profiled panelsAll profiled panels (web height of 50 mm;web height of 65 mm and DF profiles) can bemanufactured conically and also curved to beconical. The minimum overall width of conicityis 110 mm (200 mm if subsequent curving isintended); the maximum overall width is600 mm.The minimum panel length is 4500 mm.When the stated dimensions are adhered to,there is no limit to length.Possible radii achievable by way of mechanicalor natural curving can be obtained uponrequest.Min 110The following table shows examples of achievableradii:Sheet thickness (mm)Profile 0,8 0,9 1,0Convex Concave Convex Concave Convex Concave65/305 36,0 40,0 40,0 45,0 48,0 50,065/30565/40050/33350/42937,0 38,0 37,0 40,0 40,0 42,0Other profiles can be supplied upon request.Max 60059 ■

MOUNTINGALUDECK ®ALUDECK ® · Introduction · Product range and warranty2.0. ALUDECK ®2.1. Introduction to ALUDECK ®The ALUDECK ® system is governed bycertification Z-14.1-172.In the following sections, only those aspectswill be discussed which are different comparedto INTERFALZ ® . For the rest, the INTERFALZ ®mounting instructions are to be observed.2.2. Product range and warrantyAluform ALUDECK ® 65/305Sheet thicknesst N (mm)Weight(kg/m 2 )30564100650,70,81,01,22,963,384,205,0565305Aluform ALUDECK ® 65/400Sheet thicknesst N (mm)Weight(kg/m 2 )40064100 100400650,70,81,01,22,743,133,914,6465The ALUDECK ® element is a trough-shapedstanding seam profile which is continuouslymade of AlMn1Mg0.5 alloy aluminium mymeans of roll formers. Both profiles, 65/305and 65/400, can be produced by means of thestationary roll former only. Hence, the panellength is limited to 30 m for transport-relatedreasons.The profiled panels can be finished so thatthey are straight, convex or concave or withconvex/concave curving in one panel. Bending(curving) can be done on site using a mobilemachine as well.In contrast to the way INTERFALZ ® profilesare mounted, ALUDECK ® panels are “twisted”into the holders only.60 ■

Product range and warranty · Transport and storage · QualityHolders in various heights and in the designsbelow are available for fixing the profiledpanels on various substructures:❚ Normal holder❚ Holder with deburred head❚ Slide holder.2.3. Transport and storage -incoming goods inspection- See section 1.3Normally, 2 – 3 panels are placed next to eachother on one pallet, up to each 30 panelsbeing stacked.The different holder designs can be used withthe following panel lengths:❚ Panels in a length of up to 20 m = normalholder❚ Panels in lengths of 20 – 30 m and curvedpanels = holder with deburred head❚ Panels in a length of more than 30 m =slide holder2.4. Quality- See section 1.410016HH1 64648060606060HolderdesignationHeight H1(mm)Height H(mm)0 16 8080 80 144100 100 164120 120 184140 140 20461 ■

MOUNTINGALUDECK ®Possible fields of application · Installation · Holder mounting2.5. Possible fields of applicationALUDECK ® can be used for all applicationsmentioned in section 1.5. with regard to thenormal INTERFALZ ® profile as well.They cannot be used for the followingapplications:❚ Prodach❚ Installation on foam glass❚ Installation with thermal bits❚ Installation on claw-shaped belt2.6.2. Holder mounting2.6.2.1. General informationThe applicable principles are the same asthose applicable to mounting the INTERFALZ ®profiles. Due to the fact that the holder headof the ALUDECK ® holders has an asymmetricaldesign, the direction of installation must betaken into account here as well. The lowernose of the holder has to point in the directionof installation when mounted.2.6. Installation2.6.1. General informationWhen installing ALUDECK ® panels, the sameprinciples are to be followed as those applicableto INTERFALZ ® panels. Since the panelsare not flanged to the holders, fixing an anchorpoint is required immediately after eachpanel has been installed.Where slide holders are used, it is to be madesure that their holder support will not moveout of the holder foot as a result of temperature-relatedchanges in length. For thatpurpose, the small flange must be riveted tothe holder head similarly to the anchor pointexecution or pressed in on both sides next tothe holder head. If necessary, longer holdersare to be used.With a view to being able to walk on thepanels, the following limit spans must beadhered to:Profile65/30565/400Limit spans (m) with a sheet thickness of (mm)Accessibility during mountingAccessibility during mounting0,7 0,8 0,9 1,0 1,2 0,7 0,8 0,9 1,0 1,22,00 2,30 2,65 * * * * * * *1,80 2,20 2,60 3,00 3,20 3,00 3,35 3,70 4,00 4,20*No span. The span following from the external load can be applied.62 ■

Installing the ALUDECK ® panels · Verge2.7. Installing the ALUDECK ® panels2.7.1. VergeThe panels are installed in the same way asthe INTERFALZ ® panels. Only the verge profilesBt. 8429 can be used to begin installing at theverge. The large flange does not have to beflanged to be inserted into the verge profile.The ALUDECK ® panels are installed by“twisting” the large flange onto the smallflange of the preceding panel which alreadyrests on the holder.63 ■

MOUNTINGALUDECK ®Anchor point · Flanging · Flashings · Roof fittings2.7.2. Anchor pointAnchor points can be executed in the sameway as it is done with INTERFALZ ® panels asfollows:❚ Riveted anchor point❚ Anchor point made by screwing the panels inthe trough bottom to the substructureDue to the different form of the profile webscompared to INTERFALZ ® , the anchor pointcan be formed on the web only by using additionalsheet metal mounting links.2.9. Flashings2.9.1. Ridge- See section Eaves- See section 1.9.2.The edge at the eaves end includes a chamferat the eaves end, profile filler N and an eavesangle.Anchor point formation through additionalsheet metal mounting links2.9.3. Verge- See section 1.9.3.The verge cannot be executed in the variant:❚ Verge cap❚ U-shaped verge profile❚ Verge batten2.9.4. Transverse jointTransverse joints are not possible withALUDECK ® .2.8. FlangingNo flanging, except with curved panels –see section Roof fittings2.10.1. Curbs for light domes and RWA- See section 1.10.1.Due to the fact that ALUDECK ® panels cannotbe abutted, only the variant where the curbsare welded in is permissible as a rule.64 ■

Roof fittings · Bar-shaped pawl2.10.2. VentilatorsIn addition to the options of either welding fancovers and/or pipe ducts into the roof claddingor sealing them using a pipe collar, AluformSystem GmbH & Co. KG offers a ventilatormade of cast aluminium. The ventilator issealed in the trough bottom of the ALUDECK ®panel by means of a base plate, a counterplate and an EPDM seal. Mounting is done ontop of the roof. The corrugations of theALUDECK ® panels are incorporated in the castplates.With insulated roofs, the ventilator is fittedwhile installing the roof. In that process, itmust be made sure that the flexible hose isconnected to the vapour/air barrier properly.Tubes in diameters from 50 to 125 mm can beconnected to the flexible hose leading into theattic.Each ventilator is delivered together withcorresponding mounting instructions.Ventilation capScrewed connectionBase plateEPDM sealCounter plateFlexible hose2.10.3. Roof anchors/fall protection- See section 1.10.3.The clamps of the fall protection elementsmatch the ALUDECK ® flange form.2.10.4. Floor gratings/step grids- See section 1.10.4.The clamps of the step grid holders match theALUDECK ® flange form.2.10.5. Bar-shaped pawl- See section 1.10.5.The bar-shaped pawl is only available instainless steel design. Due to the asymmetricalgeometry of the ALUDECK ® flanges, this barshapedpawl is available for “left hand sideinstallation” and “right hand side installation”.65 ■

MOUNTINGALUDECK ®Snow guard · Miscellaneous2.10.6. Snow guard- See section 1.10.6.The clamps of the snow guard mounting linksmatch the ALUDECK ® flange form.The following table shows the usual arrangementof individual parts when mounting snowguard equipment. The exact arrangement canbe found in the execution plan.ProfileUsual arrangement of snow guardmounting link and snow stopperSnow guard mountinglink, component 7520Snow stopper,component 751965/305 Every other web 1 piece/trough65/400 Every web 2 pieces/troughThe ALUDECK ® panels are flanged using machineswith steel rollers. Thus, it must be madesure that the flanges are absolutely clean duringseaming. In case of coloured material, theflange may have to be lubricated a little inorder to prevent the varnish coat from beingdamaged.ALUDECK ® panels are normally curved by wayof roll bending without any sharp bends in theprofile flanges. The profile 65/305 can also bebent by creating uniform indentations in thebottom flange.2.11. Miscellaneous2.11.1. Roof overhangs- See section Curved profiled panels- See section 1.11.2.When mounting curved profiled panels, “twisting”them in as it is done with straight panelsis not possible. Curved profiled panels (alsowhere natural curving is intended) must be positionedvertically on the holders from above.For that purpose, the ALUDECK ® profiled panelshave to be manufactured at the factory suchthat they have an appropriate “open” seam.That seam is then crimped in the same way asit is done with the INTERFALZ ® panels. If openseams are required, this must be communicatedalready when ordering the profiled panels!The flanging machines for ALUDECK ® andINTERFALZ ® are different.The following radii can be achieved that way:a.) Curving by creating indentations in thebottom flange - ALUDECK ® 65/305 - convexSheet thickness(mm)Smallest radius(m)0,7 5,0 10,00,8 5,0 20,01,0 5,0 40,01,2 6,0 40,0b.) Curving without indentations -smallest possible radius (m)Largest radius(m)ProfileSheet thickness, convex (mm)0,7 0,8 1,0 1,265/305 Standard 10,0 8,0 3,5 2,5Limit - - 2,2 -65/400 Standard 10,0 8,0 4,0 3,0Limit - - 3,0 -ProfileSheet thickness, concave (mm)0,7 0,8 1,0 1,265/305 Standard 26,0 18,0 16,0 14,0Limit - - - -65/400 Standard 26,0 20,0 17,0 17,0Limit - - - -66 ■

Working · Edging · SeparatingNaturally curved panels- See section profiled panels finished using the stationaryroll former at the factory can be supplied.Minimum bending radii (m) applicable toon-site bending – convexSheet thickness(mm)0,70,81,01,2Radius for 65/305 or 65/400 profile40,060,0100,0120,03.0. Working3.1. EdgingDepending on the quality of the material, minimumbending radii need to be adhered to.They are as follows:Material qualitySmallest edging radiiH44 (half hard)2.5 x sheet thicknessH46 (3/4 hard)3.5 x sheet thicknessH48 (hard)5.0 x sheet thicknessThe stated radii apply to working temperaturesof approx. 20°C. In case of hart material,edges of 180° (fold-overs) are to be avoided.Coloured material should have a protectivefilm.The material is to be marked with soft pencils,grease pencils or felt tip pens only – either onthe reverse side of the part or on theprotective film. Never use a scribing iron.3.2. SeparatingStraight cuts are made using a hand-heldcircular saw with a carbide-tipped coarsetoothsaw blade (9 – 20 mm tooth pitch) orwith a carbide-tipped toothed blade pluscutting wax. Mount a guide rail.In exceptional cases, a hacksaw can be used.Cut out recesses by means of an electricnibbler, making a hole before for the nibbler tostart. All cuts made on site must be deburredand covered by flashings as a rule.67 ■

MOUNTINGALUDECK ®Drilling and screwing · Welding · Removing dirt3.3. Drilling and screwingUse HSS special drill bits for drilling. (Do notregrind special drill bits.)Choose a bore diameter which is appropriatefor the thickness of the supporting structureand for the fastening element used. Tightentapping screws, screwed into steel at approx.600 rpm and drilling screws screwed into steelat 1200 – 1800 rpm. (Do not use an impactscrew driver!) Use the depth stop and do notcurve against the sealing washers of sealingscrews.Drive the screw through all join parts. Place asealing washer on the drill bit to avoid scratchescaused by the drill chuck.3.4. WeldingThe process mostly applied to weld aluminiumis TIG welding (argon inert gas), requiring amotor generator set or electric powerconnection. Operate the welding equipment ata no-load voltage of 42 V. A welding cablelength of up to 20 m is possible.Perform welding work only where it is dry andwindless. Make sure that the welding point iscovered by inert gas. Place a shield or tentwhere necessary.The parts to be welded must be clean, free ofgrease and dry. In case of coated sheets, thevarnish coat must be removed before weldingapprox. 30 mm around the weld seam area.The joints can be either butt joints or lap joints(better variant). Another option is a butt jointwith a narrow strip of the material laidunderneath. Fire-sensitive materials must beprotected against inflammation or damage.4.0. Removing dirtNatural dirt should be removed as quickly aspossible. This can be done applying warmwater and a neutral dishwashing detergent ora soap solution by means of soft brushes orsponges. If pressure washers are used, it is tobe made sure that no water enters the jointsor flashings.68 ■

Removing dirt · Required toolsWhere special cleaning agents are used, theinformation provided by the cleaning agentmanufacturer is to be observed. Prior to applyinga special cleaning agent, try it on a sparepanel or in a hidden area of the roof. Makesure that the special cleaning agent is environmentallycompatible. Always clean in the directionof the roof pitch from the top down.Finally, it is sufficient to rinse with clear, warmwater.The following cleaning agents have proven tobe suitable:❚ Biochem – general purpose cleaner for dirt❚ Biochem – special cleaning agent for glueresidues from the protective filmUncoated profiled panels can be treated withabrasive cleaning agents (pH value between5 and 8) in addition to the actions mentionedabove using both brushes and special sponges(e.g. Scotch-Brite). Scrub marks will definitelybe visible on the profiled panel after cleaning.As the natural patina of the aluminium isroughened in the abrasive cleaning process,those areas will look lighter than theneighbouring areas at first.5.0. Required tools❚ Flanging machine (INTERFALZ ® or ALUDECK ® )❚ Set of plastic rollers, INTERFALZ ®❚ Power drill❚ Power screwdriver with depth stop and,if needed, special bit❚ Flange opening device, INTERFALZ ®❚ Manual flanging pliers (INTERFALZ ® orALUDECK ® )❚ Upward folding tool depending on the profileshape❚ Downward folding tool depending on theprofile shape❚ Seaming pliers❚ Various metal shears❚ Jaw wrench, AF 19❚ 1 set of Allen keys❚ Measuring tools❚ Jigs for holder mounting, as necessary❚ Tensioning string❚ Drill bits❚ Rubber malletWet storage stains can be removed by way ofheavy abrasion only. Abrasive cleaningnormally does not cause any reduction in theload-bearing capacity. In case of slight stainingit is recommendable to deliberate aboutwhether or not cleaning is even necessary asthe surface will gradually blend during thetime of use. Drilling chips or other depositsproduced during the mounting work are to beremoved right away.69 ■

ACCESSORIESAccessories INTERFALZ ®6.0. Standard accessories and toolsPart no.Type/dimensions(mm)Design/materialDesignation9001Type 65H = 65 mmFALZRIPP holder9002Type 80H = 80 mm9003Type 100H = 100 mm9004Type 120H = 120 mm9005Type 140H = 140 mmAluminiummill-finishedH9006Type 160H = 160 mm9007Type 180H = 180 mm606090089009Type 200H = 200 mmType 220H = 220 mmThe holders are available in double length as well.– Observe different part numbers.9013Type 65H = 65 mmFALZRIPP thermal holder9014Type 80H = 80 mm9015Type 100H = 100 mm9021Type 140H = 140 mmUltramidplastic materialH9018Type 185H = 185 mm90199020Type 200H = 200 mmType 220H = 220 mm6070770 ■

Accessories INTERFALZ ®Part no.Type/dimensions(mm)Design/materialDesignationFALZRIPP thermal holder9190Type 65H = 65 mm9191Type 120H = 120 mmUltramidplastic materialwitheccentric socketH9192Type 160H = 160 mm1460709193Type 240H = 240 mm71 ■

ACCESSORIESAccessories INTERFALZ ®Part no.Type/dimensions(mm)Design/materialDesignation9053Type 80FALZRIPP thermal bit9054Type 100Ultramidplastic material9055Type 1209010TK 564 x 64 x 5Thermal cap9011TK 1064 x 64 x 10Polyamide9012TK 1564 x 64 x 159051Type 570 x 60 x 5 mmHeight compensation elementUltramidplastic material9052Type 1070 x 60 x 10 mm9042Type 65Supporting bar9043Type 809044Type 100904590469047Type 120Type 140Type 160Aluminium,mill-finishedL = 6.0009048Type 1809049Type 2009050Type 22072 ■

Accessories INTERFALZ ®Part no.Type/dimensions(mm)Design/materialDesignation9056for profile 50/333FALZRIPP filler plate9057for profile 50/429905890599060for profile 65/305for profile 65/333for profile 65/400Aluminium, bright-rolledAluminium, stuccoAluminium withcoloured coating9061for profile 65/4349062for profile 65/5009063for profile 65/305 DFFALZRIPP DF filler plate906490659066for profile 65/333 DFfor profile 65/400 DFfor profile 65/434 DFAluminium, bright-rolledAluminium, stuccoAluminium withcoloured coating9067for profile 65/500 DF9113250 – 450 mmVariable filler plates9114for profile 65/...450 – 750 mm9115750 – 1000 mm9116250 – 450 mm9117for profile 50/...450 – 750 mm9118750 – 1000 mm9119250 – 450 mm9120for profile 65/... DF450 – 750 mm9121750 – 1000 mm90689070for profile 50/333for profile 50/429FALZRIPP filler block9072for profile 65/3059074for profile 65/333Cellularpolyethylene9076for profile 65/4009078for profile 65/4349080for profile 65/50073 ■

ACCESSORIESAccessories INTERFALZ ®Part no.Type/dimensions(mm)Design/materialDesignation9085for profile 65/305 DFFALZRIPP DF filler block9086for profile 65/333 DF9087for profile 65/400 DFCellularpolyethylene9088for profile 65/434 DF9089for profile 65/500 DFFALZRIPP flange filler9025for profile 50/...Cellularpolyethylene9026for profile 65/...FALZRIPP DF flange filler9027 for profile 65/... DFCellularpolyethylene9028for profile 65/...L = 1000 mmFALZRIPP filler block longCellularpolyethylene9029for profile 50/...L = 1000 mm74 ■

Accessories INTERFALZ ®Part no.Type/dimensions(mm)Design/materialDesignationSpacing profile9151L = 6000 mmAluminium,mill-finishedSliding element9152 60 x 60 Aluminiumfor profile 65/...Fitted panelfor profile 50/...Aluminium, bright-rolledAluminium, stuccoAluminium withcoloured coatingfor profile 65/... DFVerge cap/verge hook9082Type 50Aluminium9083Type 65U-shaped verge profile908419 x 40 x 20 x 1.5d = 1.5 mmL = 6000 mmAluminium75 ■

ACCESSORIESAccessories INTERFALZ ®Part no.Type/dimensions(mm)Design/materialDesignationVerge batten7626d = 1.5 mmL = 6000 mmMill-finishedVerge profile8429L = 6000 mmfor profile 65/...Mill-finished8470for profile 50/...for profile 65/... DF84 (69)169090Universal40 x 20 x 2L = 6000 mmEaves angleAluminium9091Universal70 x 30 x 2L = 6000 mmVentilator with cap9170Diameter100 – 150 mmAluminium, uncoatedAluminium withcoloured coating9171Diameter150 – 200 mm76 ■

Accessories INTERFALZ ®Part no.Type/dimensions(mm)Design/materialDesignationPlatform9172Tread:800 x 250 mmAluminium,uncoatedShort grating9173Tread:460 x 250 mmAluminium,uncoatedContinuous floor gratings9174Tread:1500 x 250 mmAluminium,uncoated77 ■

ACCESSORIES Accessories INTERFALZ ®Part no.Type/dimensions(mm)Design/materialDesignationFloor grating bracket9175250 x 250 mmAluminium,uncoatedSingle attachment pointIndustry7651L = 550 mmW = depending onthe overall widthStainless steel,uncoated78 ■

Accessories INTERFALZ ®Part no.Type/dimensions(mm)Design/materialDesignationCircular aluminium tube7522d = 32/2L = 6000 mm(3000 mm)Aluminium, uncoatedColoured coatingas per RALSnow guard mounting link incl. fasteners9180H = 77 mmL = 185 mmAluminium, uncoatedColoured coatingas per RALSnow stopper incl. fasteners9181Type ESAluminium, uncoatedColoured coatingas per RAL9182Type ZSESZSFloor grating bracketType KH9176 Roof pitch of 0 – 20° AluminiumAdjustable79 ■

ACCESSORIESAccessories INTERFALZ ®Part no.Type/dimensions(mm)Design/materialDesignationBar-shaped pawl/planetary carrier9092Type AHorizontalinstallationStainless steelBar-shaped pawl/planetary carrier9093Type BVerticalinstallationStainless steelBar-shaped pawl/9094Type SKLInstallation of solarcollectorsAluminiumplanetary carrierBar-shaped pawl/planetary carrier9095Type SKKInstallation of solarcollectorsAluminiumBar-shaped pawl/9096Type S5Installation ofvariousroof superstructuresCast aluminiumplanetary carrier80 ■

INTERFALZ ® tools and machinesPart no.Type/dimensions (mm)DesignationFALZRIPP flanging machine7700For flanging sheetthicknesses0.7 – 1.0 mm220 VIncl. steel boxFALZRIPP flange opening device7714Compatible withthe flanging machine81 ■

ACCESSORIESINTERFALZ ® tools and machinesPart no.Type/dimensions (mm)DesignationFALZRIPP manual flanging pliers7702 for flanging by hand9200for profile 50/333FALZRIPP upward folding tool9201for profile 65/3059202for profile 65/3339203for profile 65/4009204for profile 65/333 DF9205for profile 65/434 DF9206for profile 50/4299207for profile 65/5009208for profile 65/305 DF9209for profile 65/400 DF9210for profile 65/500 DF82 ■

INTERFALZ ® tools and machinesPart no.Type/dimensions (mm)Designation921192129213for profile 65/305for profile 65/33350/333for profile 65/400INTERFALZ ® downward folding tool9214for profile 65/333 DF9215for profile 65/434 DF9216for profile 50/4299217for profile 65/5009218for profile 65/305 DF9219for profile 65/400 DF9220for profile 65/500 DF83 ■

60ACCESSORIESAccessories ALUDECK ®Part no.Type/dimensions(mm)Design/materialDesignation7447Holder 0H = 80 mm(without thermalinsulation)ALUDECK ® holder74487449Holder 80H = 144 mm(for 80 mm thermalinsulation)Holder 100H = 164 mm(for 100 mmthermal insulation)Aluminium,mill-finishedHH1 647450Holder 120H = 184 mm(for 120 mmthermal insulation)60607451Holder 140H = 204 mm(for 140 mmthermal insulation)ALUDECK ® sliding holder7452HGLAD / BH = 80 mm(without thermalinsulation)Aluminium,mill-finished10064168060Thermal cap745964 x 64 x 5PE746165 x 64 x 1584 ■

Accessories ALUDECK ®Part no.Dimensions(mm)DesignDesignation7463Clip barHolder 0Clip bar74647465Clip barHolder 80Clip barHolder 100Aluminium,mill-finished7466Clip barHolder 120rk/smoothALUDECK ® filler plate7457for profile 65/305SP/smoothPVdF/smoothrk/smooth7458for profile 65/400SP/smoothPVdF/smoothrk/smoothRidge filler plate up to a width of 650 mm(Greater widths upon request)7462for ALUDECK ® 65/305and 65/400SP/smoothPVdF/smooth85 ■

ACCESSORIESAccessories ALUDECK ®Part no.Dimensions(mm)DesignDesignationALUDECK ® profile filler N7431for profile 65/305Cellularpolyethylene7456for profile 65/400ALUDECK ® profile filler P7457for profile 65/305Cellularpolyethylene7458for profile 65/400Profile filler block7667for profile 65/L = 1000 mmCellularpolyethylene86 ■

Accessories ALUDECK ®Part no.Dimensions(mm)DesignDesignationVerge profile8429L = 6000 mmmill-finished84 (69)168424universal30 x 40 x 2L = 6000 mmmill-finishedColoured coatingas per RALEaves anglemill-finished8425universal25 x 70 x 2.5L = 6000 mmColoured coatingas per RALSpacing profile7460L = 6000 mmmill-finishedCircular aluminium tubeAluminium,uncoated7522d = 32/2L = 6000 mm(3000 mm)Coloured coating asper RAL87 ■

ACCESSORIESAccessories ALUDECK ®Part no.Dimensions(mm)DesignDesignationSnow stopper including fastenersAluminium,uncoated7519H = 60 mmL = 120 mmColoured coating asper RALAluminium,uncoatedSnow guard mounting link incl. fasteners7520H = 60 mmL = 120 mmColoured coating asper RAL75237526Installation onthe left hand sideB = 20 mmH = 37 mmL = 38 mmInstallation onthe right hand sideB = 20 mmH = 37 mmL = 38 mmStainless steel,uncoatedBar-shaped pawl including fastenersleft hand sideright hand side88 ■

Accessories ALUDECK ®Part no.Dimensions(mm)DesignDesignationVentilator connecting pieceAluminium,uncoatedIncl. flexible hoseDN 50-1257650H = 300 mmB = 200 mmL = 300 mmColoured coating asper RALShort grating7467Tread:460 x 250 mmStainless steelPlatform7468Tread:800 x 250 mmAluminium,uncoated89 ■

ACCESSORIESAccessories ALUDECK ®Part no.Dimensions(mm)DesignDesignationFloor grating bracket7469250 x 250 mmAluminium,uncoatedContinuous floor grating7664Tread:1500 x 250 mmAluminium,uncoatedFall protection7470L = 550 mmW = depending onthe overall widthStainless steel,uncoated(Schematic illustration only;the actual designmay be different.)90 ■

ALUDECK ® tools and machinesPart no.Dimensions(mm)DesignationALUDECK ® upward folding tool7715for profile 65/3057716for profile 65/400ALUDECK ® downward folding tool7717for profile 65/3057718for profile 65/400ALUDECK ® flanging machine7713For flanging with open lock220 VIncluding steel box91 ■

ACCESSORIESALUDECK ® tools and machinesPart no.Dimensions(mm)DesignationALUDECK ® manual flanging pliers7720For flanging by hand with open lock(Schematic illustration only;the actual design may be different.)92 ■

FastenersPart no.Type/dimensions(mm)Design/materialDesignation73375.2 x 25.4Clamping range:7.9 - 12.7Structure withTK 5 mmClaw blind rivetBulb-TiteAluminium/aluminium73385.2 x 22.2Clamping range:4.8 - 9.5Structure without TK7301-6.3 x 25 E16Sealing screw for connectionwith metal substructureStainless steel, e.g. JZ3-For aluminium > 2.5 mmSteel ST 37 > 2.0 mmStainless steel7302-6.3 x 38 E167354-6.5 x 32 E16Sealing screw for connection withmetal/timber substructureStainless steel, e.g. JA3-For aluminium < 3.0 mmSteel ST 37 < 2.0 mmWood > 60 mm7328-6.5 x 64 E16Stainless steel7355-6.5 x 75 E1693 ■

ACCESSORIESFastenersPart no.Type/dimensions(mm)Design/materialDesignation7339-6.0 x 25Clamping range:up to 9 mmDrilling screw for connection withmetal substructure*Stainless steel, e.g. Ejot JT3-X-2For aluminium 0.80 - 2.0 mmSteel ST 37 0.75 - 1.5 mm7340-6.0 x 25Clamping range:up to 20 mmStainless steelCarbon steel7341-6.0 x 25Clamping range:up to 30 mm7342-6.0 x 25Clamping range:6 – 18 mmDrilling screw for connection withmetal substructure*Stainless steel, e.g. SFS SDK2 – S – 377For aluminium 0.90 - 2.5 mmSteel ST 37 0.63 - 1.25 mmStainless steelCarbon steel7344-6.0 x 25Clamping range:6 – 13 mmStainless steel, e.g. SFS SDK3 – S – 377For aluminium 2.0 - 3.2 mmSteel ST 37 1.25 - 3.2 mmFALZRIPP anchor point fastenerStainless steel screwM8 x 25With 2 sealingwashers and locknutStainless steelClamping range:15 mm* Not permitted and/or not suitable for screwing down plastic holders.94 ■

Tools in generalPart no.Dimensions(mm)DesignationComplete DAM 37055Special two-speed screwdriver with depthstop and additional handle220 V600 W600/1800 rpm7056K – 3/8“ x 65SW 3/8Screwdriver bit suitable for DAM 37057M – 8 x 65SW 8Attachment device DS-K377070ZA 1/4“for tightening SFS – SDK screwsK = clamping nutM = magnetic nutSW = width across flats (AF) inch/mm95 ■

ACCESSORIESTools in generalPart no.70587059706070617062706370647065706670677068Dimensions(mm)Ø 4.5 x 125Ø 4.5 x 175Ø 5.3 x 95Ø 5.3 x 125Ø 5.3 x 175Ø 5.5 x 95Ø 5.5 x 125Ø 5.5 x 175Ø 5.7 x 95Ø 5.7 x 125Ø 5.7 x 175DesignationHSS drill bit96 ■

Plain sheetsPart no.Dimensions(mm)DesignDesignation8085.22000 x 1250 x 1.0*2000 x 1255 x 0.8rk/gluncoatedglSP varnishglPVdF varnishPlain sheet8085.44000 x 1250 x 1.0*4000 x 1255 x 0.8rk/gluncoatedglSP varnishglPVdF varnish2000 x 625 x 1.0Overall width 1830rk/gluncoatedSprocket sheet P for ALUDECK ® 65/3058431glSP varnish*2000 x 625 x 0.8Overall width 1830glPVdF varnishExample: 8085.2 = sheet 8085 length: 2000 mm8085.4 = sheet 8085 length: 4000 mmrk = coarse-patterned/stuccogl = smoothSP = two-layer polyester varnish/protective varnish on reverse sidePVdF = PVdF metallic varnish/protective varnish on reverse side97 ■

Aluform System GmbH & Co. KGDresdener Straße 15D-02994 BernsdorfPhone: +49 (0) 35723 99-0Fax: +49 (0) 35723 99-401Email:©

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