NOVOTEXi 440 Product and Technical Guide - Macsteel

NOVOTEXi 440Product & Technical GuideEdition 1 / 2013T H E M A C S T E E L G R O U P

1NOVOTEXi 440Company products and servicesManufacture and supply of NOVOTEXI 440 ® concealed-fix steel roof sheetingSupply of rainwater goods and roofing accessoriesSupply Purpose made rainwater goodsSupply Flashings in 6m lengths, Louvre vents and copingsOn site and factory manufactured Bull-nosing and CurvingTechnical servicesConcealed-fix roofing profile - NOVOTEXI 440NOVOTEXI 440 ® (Latin for “New Cover” 440mm effective cover width) a concealed-fix roofing profile was developed to accommodatehigh winds as a result of greenhouse gases and global warming. As our planet becomes more and more exposed to the effects of greenhousegases so global warming effects are starting to cause catastrophic weather conditions that in past years had remote occurrences ofone in 50-year cycles. In recent years, it is not unusual to see these harsh weather occurrences happening 3 times in a single year.As a result of these occurrences determining the terrain categories are becoming more and more crucial. The Structural Engineer is thekey to ensure that the roof and the roof structure can handle the wind pressures. The down time cost as a result of a storm is not an option!Thus performance of roof sheeting systems need to be verified by Structural Engineers at the planning stage. All manufacturers’ of roofingproducts should be tested and verified to ensure those systems can accommodate the wind pressures required in the design of the structure.To ensure these tests are ligitimate an independent third party authority must certify the test results e.g.: CSIR or SABS etc.SHEET PROFILEPatent Number: 2004/5204The roofing Profile covers an effective 440mm and is generally roll formed on site mostly from G550 MPa high tensile steel to anypractical length that is manageable by the roofing contractor and as low as 2 degrees pitch with no end lapping required.The center rib is designed to move freely to allow the profile to absorb wind gusts. Due to the nature of the rotational mechanism the maleand female only start to inter-lock at wind pressures of around 1.2kN/m 2 . The center rib may deflect as much as 100mm before windload starts exerting pressures on the cleats. The unique patented rotational inter-locking mechanism is what makes this concealed-fixroofing system vastly different to other concealed-fix roofing systems available in the South African market:FIG 1: Deflection undernegative loadFIG 2: Rotational MechanismOnce inter-locked the roof sheet is able to expand and contractfreely and cannot unclip between the purlin supports through foottraffic. All residual moisture between the roof sheet and theinsulation layer can still evaporate through the inter-lockingmechanism. The roof sheeting has been designed to accommodatethick composite insulation in accordance with SANS 10400XA aswell as various types of insulation board. When using 100mm x12kg/m 3 insulation blanket, no sub-structure is required whenusing NOVOTEXI 440 ® over the purlin.CapacityMacsteel Roofing manufactures and Patents their own roll forming machines and at present have 6 mobile rolling mills. We have facilitiesthat services the market on a National basis. The rolling mills are light and compact and can be containerized for shipping or trucking tofar reaching destinations.FIG 3: Roll forming on siteT H E M A C S T E E L G R O U P

2NOVOTEXi 440Quality of materials used to manufacture NOVOTEXI 440 roof sheeting:DESCRIPTIONGAUGETCT THICKNESSTENSILESTRENGTH MPACOATING MASSMASS PERLINEAR MMASS PER M 2ZINCALUME ® steel 0.47mm G550 AZ150 / AZ200 2.13kg 4.84kgClean COLORBOND steel 0.47mm G550 AZ150 2.13kg 4.84kgZINCALUME ® steel Ultra 0.47mm G550 AZ200 2.13kg 4.84kgZINCALUME ® steel 0.53mm G550 AZ150 / AZ200 2.40kg 5.50kgClean COLORBOND steel 0.53mm G550 AZ150 2.40kg 5.50kgClean COLORBOND Ultra 0.53mm G550 AZ200 2.40kg 5.50kgZINCALUME ® steel 0.80mm G550 AZ150 / AZ200 3.63kg 8.25kgGalv/Chromadek 0.50mm ISQ550 Z275 / Z200 2.43kg 5.52kgPlease see the various literatures available from the suppliers to choose the Colours and finishes. Material Warranties must be applied for prior tostarting the project.NB: The lifespan of the roofing material is determined by the coating mass applied eg: AZ150 vs. AZ200.Various web sites: www.bluescopesteel.com, chromadek@arcelormittal.com, www.rheinzink.co.za, www.safalsteel.co.zaRecommended spacings of Purlin supports:It is crucial for the Structural Engineer to determine the effective purlin spacing’s by using the design loads for each fixing cleat system:0,50mm & 0,47mm0,53mmCLIP SIZE SERVICEABILITY LOAD ULTIMATE LOAD40mm x 1.05mm G550 0.50kN/m 2 Note 1 1.65kN/m 2 Note 160mm x 1.05mm G550 0.75kN/m 2 Note 1 2.50kN/m 2 Note 180mm x 1.05mm G550 1.02kN/m 2 Note 2 3.30kN/m 2 Note 280mm x 1.50mm G230 2.10kN/m 2 Note 2 5.10kN/m 2 Note 21. This is an estimated negative load2. This is tested and verified• The Structural Engineer based on the above values will determine the end spans and intermediate spans based onthe high-pressure zones. He will also indicate what cleats will be required where.• Various configurations e.g.: putting two 60mm cleats side by side can improve the negative load capacity substantially.• If in doubt please consult the manufacturer for further assistance.• A detailed CSIR load test report is available on request.Recommended roof spansSINGLEENDINTER-NALUNSTIFF-ENEDTBA: To be advised and confirmed by the Structural EngineerSTIF-FENEDTBA TBA TBA 250 500TBA TBA TBA 250 500Recommended side cladding0,50mm & 0,47mm0,53mmROOFSOVERHANGSINGLE END INTERNAL OVERHANG1800 1200 2200 3002500 2500 3000 600Wind loading performanceThe wind resistance of NOVOTEXI 440 ® concealedfixroofing system underwent a comprehensive testingprogram overseen and witnessed by CSIR’s structuralexpert on wind loadings. (A detailed report on thisprogramme, its testing methodology and results isavailable on request.) Because of the unique windloading performance of Novotexi 440 ® (involvingactive rotational me-chanism and the deflection of thecentre rib), SANS testing requirements were used as aguideline. The system was able to sustain substantialmagnitude negative loads and therefore suitable forthe application in high pressure uplift zones derived inthe design process.T H E M A C S T E E L G R O U P

3NOVOTEXi 440Installation Procedure for NOVOTEXI 440STEP 1Prior to starting the installation we assume that the insulation layeris already installed in place over the purlins. The purpose of theStarter bar is when installing the first sheet from a gable end thatno stitching screws are used to hold this sheet in place, thus thestarter bar holds down the first female lip of the first roof sheet onlyavoiding any perforation. Should the slope have multiple purlinspacing’s it is possible to install 3m lengths at intermittent intervals.This portion is closed up with a barge flashing once the sidecladding is installed. The starter bar is manufactured from eitherGalvanized or Zincalume material and is fixed in place with waferhead self-drilling screws. As illustrated the first sheet is hooked overthe starter bar to start the installation process. The starter bar alsoallows the first roof sheet to expand and contract freely.FIG 1: Roof sheet hookedover stater barFIG 2: Starter bar fitted overfirst PurlinsSTEP 2Once the first roof sheet is laid flat and installed in place square tothe gable, end the fixing cleat must be clipped over the male lipand fixed into the purlin with wafer head self drilling screws. Careshould be taken that the fixing cleat is square to the purlin surface.FIG 1: Fixing clear overmale lipFIG 2:Align over PurlinFIG 3:Fasten Cleat to PurlinSTEP 3Taking the next roof sheet and holding this sheet at around 90degrees to the first sheet inter-lock the female over the male and layflat. Keep in mind there is usually very little tolerance +/-2mmbetween the male and female at 90 degrees. Once the sheets areinter-locked and laid flat prior to fixing the next cleats in place aneasy check is to feel the lap as illustrated to make sure the sheetsare installed properly, simply by pulling up the sheets will ensurethe lap is closed. Usually the process of pulling up the sheet feelingthe lap and securing the next fixing cleat is done simultaneously inone operation.FIG 1: Hold Sheet at 90˚ to engageFIG 2: Make sure sheet is pulled up tightSTEP 4All roofing contractors are to take special note of the following:Because Novotexi 440 ® is cut to length by friction saw during theon site rolling process this causes the female lip to flare for about120mm from the cut-off! The sheet must be closed as illustrated.Great care must be taken to make sure this operation is adhered toby all installation teams. After a section is installed and before theinstallation teams leave the site for that day the ends must beclosed as part of work in progress, even if the ends run into guttersthat need to be trimmed off closing is essential. If the structure hasa single span after a gutter and short sheets are used where theoverhang is 250mm after the last purlin these ends must be closedwith the closing tools as there is very little material to support thecleat. Bending down and bending up of roof sheeting on the eavesand ridges is seen as standard practice on all kinds of roofingsystems and the tooling Manufactured specifically for Novotexi440 ® Macsteel supply NOVOTEXI 440 ® to an approved roofingcontractor base in the various provinces that supply variouswarranties after installation. With new contractors not familiar withthe installation of NOVOTEXI 440 ® training is essential and isdone under supervision of MacSteel on request. Kicking the roofsheets to get them to engage occurs when the purlin plains are notwithin the required tolerance, this practice will not effect the performanceof the roof sheets however contractors are to wear soft soledshoes when this method is applied. Novotexi 440 ® is designed sothat there is a minimum clearance of 2mm between male andfemale at around 90 degrees.FIG 1: Closing is criticalFIG 2: Make sure sheet is closed on the endsT H E M A C S T E E L G R O U P

NOVOTEXi 440Fixing Cleats60mm & 80mm Fixing cleatsRecommended Fixings:FIG 1: #10 Wafer Head x 22mmThe fixing cleats are the heart of the system and determine the various negative wind load capacities. (Pleaseremember the thickness of the roof sheeting in NOVOTEXI 440 ® does not determine negative wind load capacity)Thickness of roofing material becomes critical when positive point loads are of concern e.g.: When secondarytrades are expected to walk on roofs after installation with additional point loads e.g.; air conditioner units orextractor fans are carried onto the roof.It is standard practice to walk in the pans or over the purlins when walking on steel roofs40mm x 1.05mm G550 AZ150 Truecore Cleat (2 Pre punched hole centre’s 20mm apart)60mm x 1.05mm G550 AZ150 Truecore Cleat (4 Pre punched hole centre’s 20mm & 50mm apart)80mm x 1.05mm G550 AZ150 Truecore Cleat (4 Pre punched hole centre’s 20mm & 50mm apart)80mm x 1.50mm G230 AZ150 Zincalume Cleat (4 Pre punched hole centre’s 20mm & 50mm apart)Various Tooling and equipment supplied by Macsteel Roofing4N.B. Also note that when specifying a 80mm or 100mm fixing cleats it is important for the Structural Engineer to specify the appropriatelip-channels or purlin to accommodate fixing the cleat, e.g.: 80mm cleat would require a 60mm or 75mm lip-channel.We strongly recommend that proper attention is given to the selection of fixings usedto fasten the cleats in place and which is used to fix the flashings etc.; To fix the cleatsinto steel a #10 x 22mm Wafer Head self drilling screw SANS1273 class 3 coatedmust be used and for timber #10 x 45mm Wafer Head type 17 point SANS1273class 3 coated to be used. The material warranties may become void if the incorrectfixings are used. (Especially on Flashings) Please refer to Kare Industries for furtherinformationBending Tool Closing Tool Seaming MachineThese tools may either be rented or purchased from Macsteel RoofingBull nosing, natural Curving and CrankingNovotexi 440 ® roofing for bull-nosed and curved sheeting is rolled with an open female lip. We roll the sheet in this state to allow theroofing contractor to install the sheets without tilting the roof sheets at 90 degrees, thus the sheets are installed horizontally. Once thesheet is inter-locked the castellated portion of the bull nose is aligned and closed with the closing tool. On the slope of the sheets everymeter is closed with the closing tool as a temporary measure. After the roof is installed the seaming machine is run along the roof sheetto seam up the sheet. Roof structures that have a radius larger than 38m can be supplied without any castellation and the roll formingmill will roll a natural curve during site rolling. With curved structures less than 38m a crank every meter or so has to be cranked toachieve the radius.Closing the Bull nose using the closing tool. Prior to seaming close the sheet every meter or so.Trapezium StiffenerThis was designed to create a walkway on roofs wherethere are secondary trades and maintenance crews thatcarry heavy loads exceeding the allowable point loads onthe centre rib. This member is installed under each roofsheet during the installation process between two purlins.After installation the walkway is demarcated on top of theroof sheeting to indicate the safe walking areas.Splicing plateTrapezium stifner intalled under centre ribT H E M A C S T E E L G R O U P

5NOVOTEXi 440Insulation board brackets:These brackets are available in various sizes and aresupplied to maintain the spacing’s between the roofsheeting cleats and the board.Solar panel brackets:This bracket was recently developed to secure solar panels ontothe Novotexi 440 ® roof sheets without causing any damage orperforation. This bracket creates a base to fit various kinds ofsupporting structures on top of the roofing system without hinderingthe expansion and contraction of the roofing system.Available on request.Closures, polyclosures, bending pans and flashing brackets:Serrated closures are used under the flashings and are supplied in narrow or broad flute. If closures are used it is common practice to fixthe closure into the flute of the roof sheeting and then fix the head-wall flashing into the closure and not into the roof sheet. Using thismethod water cannot leak into the roof because the perforation is concealed by the flashing. Poly closures are used in conjunction withthe closure as illustrated and are supplied in a set of male and female. Bending up and down of the pans is standard practice wheninstalling low pitched NOVOTEXI 440 ® and is critical to stop water running up the underside of the roof sheeting especially on the eavesends. Flashing brackets are supplied if no closures are used to fix the flashings without perforating the sheets.Serated Closure Broad FluteSerated Closure Narrow FluteFIG1:Poly Closure with flashing bracket FIG2:Pan bending up ridge FIG3:Pan bending down eaves FIG4:Pan bending toolContact usHead Office:Cnr Molecule and Helium Roads,Valconia,BrakpanSouth AfricaPostal:P.O. Box 420Brakpan1540South Africa-Tel: +27 11 741-5600Fax: +27 11 813-3693email: info@macroofing.co.zaweb: www.macsteel.co.zaT H E M A C S T E E L G R O U P