Euroclad Guide To Design and Installation of Trapezoidal Systems

August 2007
Design and installation

recommendations
DESIGN AND INSTALLATION RECOMMENDATIONS
1
Specification and installation
Roofs 5
Lightning protection 7
Flashings information 7
Wall cladding 8
Curved profiles 9
Liner sheets 10
Fragility 11
Summary of non-fragility status 12
Cut edge protection 16
Cantilever 16
Penetrations 16
Weights and calculations (table) 17
Handling and storage 19
Guidance on breather membranes 19
Inspection and maintenance
Wind loads 21
Cleaning of pre-finished steel 21
Washing 21
Annual inspection (table) 22
Removing mould 22
Touch-up painting 23
Suppliers of complementary products 23
Acoustic performance
Research 25
What is noise? 25
Measurement 25
Double skin constructions 26
Mineral fibre density and system comparison (graph) 27
Perforation 28
Single and double skin system comparison (graph) 29
Trapezoidal acoustic performance (graph) 30
The building regulations
Calculation of U-values 31
Thermal bridging 31
Air permeability 32
Corus Colorcoat
Products and services 37

References
Relevant publications 39
Contents
3
In the following pages we have attempted to
outline some of the basic parameters for fixing
Euroclad trapezoidal profiles successfully.
For the most part, the advice given will be
sufficient, however, there will always be a
number of unusual requirements or problems
which arise and in those instances it would be
wise to contact Euroclad for particular advice.
In the same respect, when a method for fixing
is listed below, it is not necessarily the only
method of achieving a successful result.
To list every possible permutation and
combination would be impossible.
Introduction
The ones listed are those that have been
found to be successful, others do exist.
Please read the sections relevant to your
particular needs carefully and if any questions
arise do not hesitate to contact Euroclad
where further clarification can be given.
5
Roofs
Euroclads profiles are used extensively in the roofing of
both new and refurbished buildings. Those identified in
the sections on roofing profiles are ideally suited to this
application, however, certain criteria must be adhered to
if the profile is to achieve its full potential.
The use of trapezoidal weather sheets should be avoided
where the pitch is below 4. For pitches below this,
Euroclad Euroseam or Secret fix should be considered.
Please refer to product specific literature in these
instances. The following summary refers to trapezoidal
profiles only.
Specification and installation
Table 1. Size, shape and position of sealant(s) for typical 150mm End lap and Side lap details
Profiles: 914/38mm, MW5R and 1000/32mm
*Where a seal is required at the bottom of the lap to keep out dirt and trapped water a bead of premium quality neutral cure silicone sealant positioned
approximately 15mm from the bottom of the lap is suggested. The silicone sealant should ideally conform to classification ISO 11600 - F - 25 LM of
BS EN ISO 11600 : 2003 and adhesion to the substrates involved verified.
Figure 1. Typical end lap detail
See MCRMA Technical Paper 16, for further details.
Built-up
systems
Profiled
metal to
metal
combinations
Roof pitch Side lap End lap
Less than 5 Not recommended Not recommended
5 to 10 Fixings at not greater than 450mm centres Two lines of sealant (central or asymmetric primary fixing position)
The lap should also be sealed with a A single run of 6 x 5mm or 6mm bead sealant positioned 15mm from each
continuous bead of mastic end of the lap
Above 75 As above The sealing of the end laps may be omitted unless severe conditions are anticipated
10 to 15 Fixings as above, but the sealant may be As above
omitted (dependent on local conditions)
Profiled
metal to
GRP
rooflight
combinations
Less than 5 Not recommended Not recommended
5 to 10 Fixings at not greater than 450mm centres Two lines of sealant (central or asymmetric primary fixing position)
The lap should also be sealed with a A single run of 6 x 5mm or 6mm bead sealant positioned approximately
continuous bead of mastic 10 15mm either side of the primary fixing*
Or alternatively:
Three lines of sealant (central primary fixing position)
A single run of 6 x 5mm, 6 x 8mm bead sealant positioned 15mm from each
end of the lap with an 18 x 4 or 22 x 5mm U-section positioned beneath the
line of the primary fixing
Above 75 As above The sealing of the end laps may be omitted unless severe conditions are anticipated
10 to 15 Fixings as above, but the sealant may be As above
omitted (dependent on local conditions)
6
1. Pitch
The pitch of the roof should be chosen to guarantee
good drainage, taking into consideration the local
conditions (i.e. maximum wind load and snow loadings).
Whenever possible the pitch should exceed 15.
When a pitch of less than 15 is specified the following
fixing is recommended.
2. Primary fixing
It is recommended that the profiles should be fixed
with self-sealing, self-tapping screws from a reputable
manufacturer. They can be positioned in the trough or
crest of a profile, at a frequency of every trough or crest
for end laps and every other trough or crest at
intermediate purlins.
3. Secondary fixing
It is recommended that all roof profiles are side stitched
with the appropriate fixings at centres not greater than
450mm unless particularly severe conditions are
anticipated.
4. Gauge
Euroclad recommend the use of at least 0.7mm gauge
in all roof situations. It will often be the case that
reference to the load tables will reveal that 0.5mm
material will satisfy the design load. However, where a
gauge less than 0.7mm is specified, provision should be
made to avoid damage during erection and subsequent
roof traffic when point loadings may become more
critical.
5. Direction of lay
Particular reference should be made to the underlap
and overlap configuration of the particular profile
specified. The sheets should then be laid as Figure 2.
The side laps should, where possible, be laid away
from the direction of the prevailing wind.
6. Drilling and cutting
All holes must be drilled and not punched. It is
imperative that the residue swarf be immediately swept
off the sheet to avoid unsightly staining.
All cutting of profiled sheet on site should be achieved
with a nibbler tool or cladding saw. These tools are
designed to impart the minimum of heat to the sheet.
The sheet should not be cut with a carborundum disc
or portable circular saw.
Any slight surface damage which may have occurred
during fixing should be made good with either touch-up
paint or PVC paste which is supplied to match all
pre-finished steel colours.
7. Translucent sheet
Available in GRP to suit all Euroclad profiles. These can
be supplied as single sheets, double skinned, or triple
skinned. The double or triple skin can be achieved as
a factory sealed unit, or when Euroclad liner is specified,
as two or three independent sheets which can be
constructed on site to achieve a satisfactory rooflight.
It is essential to effectively seal against moisture, or
condensation problems may arise. Each rooflight
manufacturer has their own technical departments.
Please refer to MCRMA Technical Paper 1 for
further details.
Figure 2. Direction of lay
SPECIFICATION AND INSTALLATION
7
Lightning protection
Lightning is formed as a result of a natural build-up of
electrical charges within storm clouds that discharge to
earth. The magnitude of the electric current can range
from around 3,000 and 200,000 amps with potentials of
100 million volts. The calculated probability of structurally
damaging lightning strikes is once in every 500 years.
In general, a building with metal roof and wall cladding
will provide the best overall protection against lightning,
especially when taking account internal electronic
equipment, which may be affected by the electro-magnetic
effects of lightning.
The main components of a lightning
protection system comprises of:
Air terminations
Down conductors
Earth terminations.
Air terminations
It is the air termination networks that have the greatest
interface with the roofing and consist of conductors on
a 10 x 20m grid. Metal roof cladding provides a good air
termination network.
Down conductors
The air termination network must be securely fastened
to the down conductors which should be at 20m centres
around the perimeter of the building. Structural steelwork
or a reinforced concrete structure can be used as the
down conductors.
Earth terminations
These are connections between the down conductors
and an earthing electrode driven into the ground.
A detailed explanation of the above is given in
BS6651 : 1999 Code of Practice for Protection of
Structures against Lightning, the notes are intended
to be for guidance only and it is recommended that a
lightning systems engineer be consulted.
Flashings information
Euroclad manufacture flashings using some of the most
up to date equipment in Europe. The flexibility of the
manufacturing process allows the widest choice to the
specifier.
The computer controlled power presses and folders
allow Euroclad to produce details with an accuracy and
consistency which has been hitherto unachievable.
These presses and the use of the best available materials
guarantees the quality of the product to the customer.
All flashings, unless otherwise specified, will be supplied
in 0.7mm gauge for steel and 0.9mm for aluminum.
These are available in colours and finishes which can
match or contrast with the cladding dependent upon
specification.
The standard length is 3.658m (12 feet) with the extra
length helping the client maintain a good line and
minimising joints. The joints can be either lapped or butt
jointed and, where required, the butt joints are 150mm
in length.
Where curved sheeting is specified, curved flashings can
be manufactured to suit.
The drawings are indicative of good practice for each of
the details, but other methods may be equally effective.
However the details are arranged, it is important to
incorporate the following flashings requirements
whenever possible.
1 450mm spacing (or every other corrugation)
between primary fixings.
2 For open shaped flashings, a minimum 150mm
lap on roofs and minimum 100mm lap on walls
is required.
3 For closed shaped flashings, butt straps should
be used.
4 Butt straps should fit within the flashing, with an
allowance for sealant thickness.
5 Never leave edges of flashings un-stiffened.
Either return a short edge or fold it back flat on
itself (welt).
6 Sealants should be placed as near to cut edges
as possible.
7 Avoid any detail that can trap or dam water.
8
8 Arrange overlaps away from the prevailing wind.
9 Paint cut edges when there is a risk of water
collecting on them.
10 Avoid large flat areas in the design (200mm 250mm).
If necessary, incorporate a shadow line within the
larger flat face.
11 Use factory pre-fabricated corners, rather than
on-site cutting and bending.
12 Care should be taken in the design and installation
to ensure air permeability is minimised, using profiled
fillers where necessary.
Further information can be found in the MCRMA
Technical Paper No. 11: Flashings for Metal Roof and
Wall Cladding. This publication includes extensive
and comprehensive guidance for the design, installation
and maintenance of flashings employed in the modern
building envelope.
Wall cladding
Ideally suited to the cladding of the walls of developments
including retail, educational, health service, commercial
and industrial. All the trapezoidal profiles in the product
range are suitable for use in vertical applications.
Aesthetics are undoubtedly the main criteria upon which
vertical cladding is chosen. The cladding may be fixed
vertically, horizontally or even diagonally but the
specification of reverse profile as depicted in the
cladding section of the brochure imparts certain
advantages to the aesthetics irrespective of the manner
in which the sheets are laid.
Advantages of the reverse profile
a Reduces the shade effect, and with its narrower
trough and wide crest the colour of the sheet is
highlighted rather than the shadow.
This effect is even more noticeable when cladding
is laid horizontally.
b Effectively hides the fixings which are fixed in
the trough.
c If horizontal cladding is used a very effective profiled
corner piece can be incorporated successfully.
Horizontally laid wall cladding
Without doubt this is one of the most difficult applications
for profiled sheet. Aesthetics are obviously paramount and
great care is needed to guarantee a successful result.
One of the most common problems is the uneven effect
resulting from careless fixings. The precise alignment of
end laps is critical.
However, with certain precautions observed the result
can be very effective and several features can be
incorporated to give a building a particularly pleasing
appearance. One of the options open to horizontal
cladding is to incorporate profiled mitred corners or
curved profiled corners (either crimped or smooth).
Several key points need to be observed to ensure a
successful result:
a Sheets are laid from the bottom up i.e. the first
sheet laid is the one adjacent to the drip detail.
b Cover width must be checked on each sheet as fixed.
c Alignment of end laps requires time and care.
d Sheets should be fixed in every trough.
e The inclusion of a feature band in the cladding
must be approached with care, as any stretching
or shrinking of the cover width by the fixer to
accommodate such a feature will have an adverse
affect upon the aesthetics of the elevation.
f Steelwork must be checked carefully since
inaccuracies will be telegraphed through the
cladding sheet.
g Do not use forward PVDF for horizontal cladding.
h Always use 0.7mm gauge for horizontal sheets.
Vertically laid wall cladding
The standard method of fixing wall cladding with the
profiles running from eave to drip details. Although the
profiled sheet lends itself to this application, care must
be taken to ensure a successful result:
a Irrespective of profile, side laps, where possible,
should be laid with the overlap away from the
prevailing wind.
b End laps should be a minimum of 100mm.
c Irrespective of profile, the stitching of side laps
is at the discretion of the cladding contractor.
Where deemed necessary side laps should be fixed
at 600mm centres.
d The primary fixing of the profile is generally
accomplished in the trough using self-tapping,
self drilling fixings, from a reputable manufacturer.
e Under normal UK urban conditions, fixing should be
used in every trough for end laps and every other
trough at intermediate purlins.
f All holes should be drilled, not punched.
g 0.5mm gauge material is usually specified.
9
Curved profiles
When fixing curved profiles, certain basic rules should be
followed to ensure a high quality appearance is achieved:
a Throughout the project the need for care is
paramount since the curved profiles are extremely
rigid and cannot be adjusted during fixing, as is
possible with non-curved sheets.
b A complete tier of sheets must be completed before
moving on to the next tier.
c When ordering, remember that most of Euroclad
profiles are handed and therefore direction of lay
should be indicated so that the sheets can be
supplied with the correct underlap/overlap
configuration.
d Where mitred corners are designed they should
be fitted first, and cladding laid away from them
(Figure 3). This then involves a slip flashing where
the sheets meet (Figure 4).
e Curved profiles may be specified in either 0.5mm,
0.7mm or 0.9mm gauge Corus Colorcoat
pre-finished steel.
Figure 3. Mitred corners and cladding
lay-out direction
Figure 4. Three alternative methods of
incorporating a slip flashing
10
Liner sheets
1 Euroclad liner sheets are usually specified with
Euroclad outer sheet and hence are designed with
a common cover width to minimise problems when
fixing. They can, however, be used successfully in
conjunction with a variety of systems.
2 In the over-rail system the liner sheet is laid first.
Four primary fixings per panel are recommended
which have the function of temporarily securing the
sheets and helping to maintain cover width and
position before the spacer system is fully secure.
3 The insulation quilt is laid from ridge to eave allowing
generous side and end laps to prevent gaps. The rail
and bracket system is used to trap the insulation and
then is secured by the recommended fixings to the
cladding rail. The use of the rail and bracket system
in this manner overcomes the problems of the
integrity of the system relying upon the compression
of the insulation quilt and minimises the thermal
bridge effect.
4 If the liner sheet is being employed as a vapour
control layer, the side and end laps must be sealed
and fixings with an integral sealed washer must be
used.
5 The weather sheet is fixed to the spacer system with
the appropriate fixings.
6 Because of the flexibility of the sheet, care should be
taken not to spread the cover width of the liner sheet
when the fixings are installed.
7 The maximum spans for the 19/20mm liner
sheets are:
0.4mm 2.0m
0.5mm 2.1m
0.7mm 2.2m.
8 Liner sheets should be laid in tiers with the insulation
and outer sheet.
9 Liner sheets are to be treated as fragile, until
correctly installed.
10 If large areas of liner sheets only are fixed lining out,
damage may be caused because of the temporary
nature of the primary fixing and the danger of traffic
imposing loads that the panel is not designed to
support.
11 Translucent sheets in either GRP or polycarbonate
are available to suit Euroclad liner sheets.
12 With the new focus on air-tightness, the effective
sealing of the liner in both built-up and composite
constructions is fundamental to the system
performance.
Both in controlled small-scale tests and practical air
permeability tests in actual buildings, a correctly
sealed metal liner successfully passes Building
Regulations criteria.
The specification for sealing Euroclad liner sheets
is as follows:
a Side lap sealing 50mm x 1mm butyl sealing
strip (polybond or similar).
b End lap sealing 4mm butyl mastic bead,
or a 6mm x 2mm, or a
9mm x 3mm rectangular
section is recommended,
fixed in each corrugation.
Position the sealant in straight, unbroken
lines covering the sheet laps.
Place into corrugations or troughs.
Do not stretch the sealant.
Ensure continuity and effectiveness of seal,
especially at corners of sheets and at all
penetrations of pipes, ducts, rooflights etc.
11
Fragility of Euroclad profiled sheets
In summary ACR(CP)001 : 2003 Recommended Practice
for Work on Profiled Sheeted Roofs states:
That a non-fragile assembly should be specified.
That a competent company is chosen to carry out
roof work.
That the classification of the roof assembly can be
confirmed by the supplier and that test data can be
provided to support the classification.
That drawings are available which can be used to
set out the sequence of operations to fit sheets to
a non-fragile classification.
That the conditions affecting guarantees of
non-fragility should be clearly stated
That special consideration should be given to
Class C constructions
That specific information relating to maintenance of
the products and which is relevant to non-fragility is
provided for inclusion in the Health and Safety file.
That materials handling should be reduced wherever
possible i.e. by ordering sheets to be packed in
sequence as they will be used or by splitting packs
on the ground before positioning on the roof.
In addition the HSE Question and Answer brief for
the Construction Industry on the Work at Height
Regulations 2005 states that Collective control
measures should always take priority over personal
control measures.
All of the above are provided for by Euroclad Elite Systems.
During the construction phase
The ability to use the fixed liner as a working platform
during installation of the outer sheet can also speed the
construction process and allow work under the lined out
roof to progress. Sheets or rooflights which have not
been fixed to achieve a non-fragile classification must be
treated as fragile.
Euroclad profiles can be fixed to be non-fragile during the
construction phase.
The ACR(M)001 : 2005 test for non-fragility is a basic
test to establish whether a roof assembly is fragile or
non-fragile. It does not necessarily mean that walking on
the roof will not damage the roofing product. Walkable
is not recognised as a defined term by HSE and it
should not be confused with non-fragile.
However, in practice standard >30mm deep 0.7mm steel
liner and deck profiles allow workers to walk on the
sheets with less risk of causing foot traffic damage than
shallower profiles or thinner gauges. 19/1000 profile in
0.7mm for example, although it can be fixed to achieve
Class B, is still more prone to damage by foot traffic than
profiles deeper than 30mm.
More care is required when a 0.4mm liner or 0.7mm steel
perforated liner is used. Additional fixing requirements
also apply to achieve Class C, such as the use of crawl
boards and additional sheet end lap length. 0.4mm steel
liner and 0.7mm perforated liners are more prone to
damage by foot traffic.
Fixing requirements for Euroclad profiles to achieve
non-fragile classification are given in a number of
Euroclad drawings. These are available to download
from the Euroclad website: www.euroclad.com.
After construction phase
Sections 65-69 of ACR(CP)001: 2003 give guidance on
maintenance requirements and minimum non-fragile
classifications.
Class C non-fragile assembly is acceptable for low
maintenance roofs.
Class B non-fragile assembly is required for both
medium and high maintenance roofs.
All Euroclad external roof sheets and 0.7mm liners
(excluding perforated liners) can be fixed to achieve
Class B.
12
Classification:
Fragile: If the bag passes through an assembly
it is classified as fragile.
Class C non-fragile: if the assembly retains the
sandbag after one drop it is classified Class C
non-fragile.
Class B non-fragile: if the assembly retains the bag
after a second round of impacts the assembly is
classified Class B non-fragile.
Class A non-fragile: on inspection of the assembly
after the second round of impacts by a competent
person. If the assembly shows no signs of damage
that will affect the long term strength or weatherability
of the assembly, then the assembly may be classified
Class A, non-fragile.
The following recommendations, which have been
generated from the test programme, have taken into
account known variables and allow for a very good
degree of confidence. For instance, wherever results
were felt to be marginal or may be affected by poor site
practice tests were repeated, if necessary, until a good
degree of confidence was present. No items which may
have assisted the performance of the systems and are
subject to site conditions were used in the test
programme ie no sealants or spacer brackets assisting
the liner profile performance.
Consult the Euroclad Technical Department if any
assistance is required or the application is unusual.
Incorrect installation, total failure of associated
components, abuse and exceptional circumstances could
all still jeopardise non-fragility within the 25 year period.
Long term non-fragility can therefore not be guaranteed.
Summary of non-fragility status
All elements should be regarded as fragile until fixed to
the specified standards
0.4mm steel liner profiles
19/1000 liner 0.4mm steel
19/1000 0.4mm thick steel liner profile, fixed as shown
in Euroclad Ltd Drawing FR4, can be classified C
non-fragile on any span up to and including 1.8m, for
both in plane and curved roofs, and for spans up to
1.8m on hips with any angle.
Also see ACR (CP)001 : 2003 Recommended Practice
for Work on Profiled Sheeted Roofs Annex B, which
gives recommendations re the use of crawl boards and
gives a great deal of guidance re: the usage of Class C
Assemblies and the potential risks which need to be
managed and considered.
The document recognises the potential risk from elements
which may be engineered to pass Class C being close
to the boundary between fragile and non-fragile.
Euroclad did not engineer the system to pass, allowed a
good margin for site error and normal site practice and
this was confirmed by an independent consultant.
The same profile used in 0.7mm gauge can be fitted
to achieve Class B using normal methods see below.
However, we still recommend >30mm deep profiles in
the majority of cases as these are more resistant to foot
traffic damage.
20/914 and 20/1066 liner 0.4mm steel
20/914 and 20/1066 0.4mm steel liner profiles, fixed as
shown in Euroclad Ltd Drawing FR6, can be classified
C non-fragile on any span up to and including 1.8m,
for both in plane and naturally curved roofs, and for spans
up to 1.8m on hips with any angle.
0.7mm steel liner profiles
19/1000 0.7mm thick steel liner profile, fixed as shown
in Euroclad Ltd Drawing FR2, can be classified C
both in plane and naturally curved roofs, and for spans
13
MW5 Liner 0.7mm steel
MW5 0.7mm thick steel liner profile, fixed as shown
in Euroclad Ltd Drawing FR3, can be classified B
MW5 liner 0.7mm steel fully or pan perforated
MW5 0.7mm thick steel liner profile, fully or pan
perforated, fixed as shown in Euroclad Ltd Drawing FR7,
can be classified C non-fragile on any span up to and
including 2.1m, for both in plane and curved roofs, and
for spans up to 1.8m on hips with any angle.
Also see ACR (CP)001: 2003 Recommended Practice for
Work on Profiled Sheeted Roofs Annex B, which gives
recommendations re the use of crawl boards and gives
a great deal of guidance re the usage of Class C
Assemblies and the potential risks which need to be
managed and considered. The document recognises the
potential risk from elements which may be engineered to
pass Class C being close to the boundary between
fragile and non-fragile. Euroclad did not engineer the
system to pass, allowed a good margin for site error and
normal site practice and this was confirmed by an
independent consultant.
32/1000 0.7mm steel liner profile, fixed as shown in
Euroclad Ltd Drawing FR1, can be classified B
20/1066 & 20/914 liner 0.7mm steel
20/1066 and 20/914 0.7mm steel liner profiles, fixed as
shown in Euroclad Ltd Drawing FR5 can be classified B
MW5 deck 0.7mm steel
MW5 0.7mm thick steel deck profile, fixed as shown
38/914 deck 0.7mm steel
MW5 0.7mm thick steel deck profile, fixed as shown
in Euroclad Ltd Drawing FR9 can be classified B
MW5 roof profile 0.7mm steel
MW5 0.7mm thick steel roof profile, fixed as shown
32/1000 roof profile 0.7mm steel
32/1000 0.7mm thick steel roof profile, fixed as shown
38/914 roof profile 0.7mm steel
38/914 0.7mm thick steel roof profile, fixed as shown
non-fragile on any span up to and including 2.1m,
for both in plane and curved roofs, and for spans up to
Euroseam roof profile 0.9mm aluminium
Euroseam 0.9mm thick aluminium profile, fixed as shown
in Euroclad Ltd Drawing FR16 can be classified B
both in-plane and curved roofs and for spans up to
SF500 profile 0.7mm steel
SF500 0.7mm steel profile, fixed as shown in Euroclad
Ltd Drawing FR17 can be classified B non-fragile on
any span up to and including 2.1m, for both in-plane and
curved roofs and for spans up to 1.8m on hips with any
angle.
Trapezoidal profiles in aluminium
These should be considered fragile until further notice.
14
Rooflights
The National Association of Rooflight Manufacturers
guidance note 2006/1, clearly sets out the requirements
for rooflights where profiled metal or fibre cement roofs
have been separately demonstrated to be non-fragile
without rooflights and is based on a large number of
tests carried out by rooflight manufacturers.
Rooflights should never be walked on even if fixed to a
non-fragile standard.
Appendix
ACR(CP)002: 2005 gives guidance on Safe Working on
Fragile Roofs.
Test method
The test method used was the ACR(M)001: 2005 Test
for Non-Fragility of Profiled Sheeted Roofing Assemblies,
which is recognised by HSE as an acceptable way of
determining the non-fragility of a roof construction.
The test involves dropping a 45kg sand bag from a height
of 1.2m, onto the roof cladding assembly, which has to
be supported by a standard test frame. Provided the bag
does not fall through the construction, the cladding
assembly can be classed as non-fragile. To warrant this
classification, the roof must be able to withstand the test
in any location.
Tests were carried out by Mr Peter Roberts, an
independent consultant and Mr Paul Clayton, Euroclad
Technical Manager.
Test rig
The test rig was made available by Brett Martin Daylight
Systems and was generally in compliance with the rig
defined in ACR(M)001: 2005. The purlins were 175/160,
which have the necessary minimum I
xx
value of 235mm
4
.
Purlins were braced as required.
Constructions tested
Tests were carried out over a range of profiles and a
range of purlin centres from 0.600m up to 2.1m, on
simulated hips and on simulated curved roof
arrangements.
Based on previous experience, dropping the bag near the
underlapping side lap of the sheets at midspan between
purlins was expected to be the most likely worst case,
for all purlin spacings, and any failure was expected to
occur at the nearest end lap (downslope or upslope) or
sheet end position of a multi-spanning sheet.
Testing was carried out to verify the worst case.
Additional testing was carried out on profile variants to
establish the most effective solution, i.e. the end lap and
sheet end fixing edge distance was varied, as was the
size of washer and number of fixings if necessary.
The length of the end lap, the number and location of the
fasteners at both sheet ends and intermediate supports
and the fastener edge distance, are the usual critical
variables. In some cases the washer size is also a critical
factor. All tests used 5.5mm diameter fixings.
No seals were used at end or side laps in any of the
tests, as any contribution they made to the strength could
not necessarily be relied upon on site, e.g. if the sheets
were damp.
No spacer system was fitted as any contribution to liner
performance made by additional fixings through the liner
sheet may not always be present on site e.g. if the spacer
brackets were fitted later. In the case of external sheets
the spacer system would have improved performance so
was not used to allow the worst case to be assessed.
Drawings for Euroclad non-fragile installations,
can be found at: www.euroclad.com
15
Table 2. Fixing specification of typical construction (carbon steel)
Purpose Gauge Description Fixing frequency
SFS fixings
Notes: 1. The above assumes normal U.K. urban conditions. If a more severe environment is anticipated, please refer to Euroclad, or the fixing manufacturer.
2. All fixings must have a sealed washer and external fixings should also have a colour coded cap. 3. Equivalent products are available from several fixing
manufacturers. 4. If aluminium sheets are used all fixings should be stainless steel. 5. Position bracket in first valley that forms the underlapping side of the lap.
Fixing of liner sheet ends 1.2mm - 3.0mm SFS code SD3 - T15 - 5.5 x 25 1 per valley (for end laps)
3.0mm - 12.5mm SFS code SD14 - T15 - 5.5 x 32 every other valley (for intermediate purlins)
Fixing of spacer bracket to sheeting rail 1.2mm - 3.0mm SFS code SD3 - 5.5 x 25 Typically 2 per bracket @ 1m centres
3.0mm - 12.5mm SFS code SD14 - 5.5 x 32 (see note 5 below)
Fixing of weathersheet to rail SFS code SDP3 - T16 (or T19) - 5.5 x 25 1 per valley (for end laps)
every other valley (for intermediate purlins)
Side stitching of outer sheet 1.2mm - 3.5mm SFS code SLP2 - T - A14 - 4.8 x 20 450mm centres
Purpose Gauge Description Fixing frequency
EJOT fixings
Fixing of liner 1.2mm - 3.0mm EJOT code LS25 1 per valley (for end laps)
3.0mm - 12.5mm
EJOT code HS38
Fixing of spacer bracket to sheeting rail 1.2mm - 3.0mm
EJOT code LS25
2 per bracket @ 1m centres
3.0mm - 12.5mm
EJOT code HS38
(see note 5 below)
Fixing of weathersheet to rail
EJOT code JT2 x 25
1 per valley (for end laps)
Side stitching of outer sheet 0.5mm - 2.0mm
EJOT code SF25 G16
450mm centres
1, 2 3mm Carbon steel fasteners Austenitic stainless steel fasteners
8/3, 13/3, Sinusoidal profile fasteners
Purlins (roof) Rails (wall)
SD3 - T15 - 5, 5 x 60 - Hex head. Plus M6 x 28 x colour SX3/20 - 34 - S16 - 5, 5 x 52 - Hex head. Plus M6 x 28 x colour
Selawasher and 28 x colour deep Selacover cap
Selawasher and 28 x colour deep Selacover cap
Rails (wall) Wall (valley fix) SDP3 - T16 - 5, 5 x 25 x colour 5 x 3/10 - L12 - A12 - 5, 5 x 28 x colour
4 14mm Carbon steel fasteners Austenitic stainless steel fasteners
Purlins (roof) Rails (wall)
SD14 - T15 - 5, 5 x 66 - Hex head. Plus M6 x 28 x colour SX14/38 - S16 - 5, 5 x 61 - Hex head. Plus M6 x 28 x colour
Selawasher and 28 x colour deep Selacover cap Selawasher and 28 x colour deep Selacover cap
Rails (wall) Wall (valley fix) SDP14 - T16 - 5, 5 x 36 x colour - Sela moulded head SX14/12 - L12 - A12 - 5, 5 x 38 x col-irius powder coated head
Timber Carbon steel fasteners Austenitic stainless steel fasteners
Purlins (roof)
Roof (crown fix) TDA - T - T16 - 6 5 x 76. Plus M6 x 28 x colour Selawasher TDA - S - S16 - 6, 5 x 76. Plus M8 x 28 x colour Selawasher
and 28 x colour deep Selacover and 28 x colour deep Selacover
Rails (wall) Wall (valley fix) TPC - T T16 - 6, 3 x 38 x colour - Sela moulded head TPC - S - S16 - 6, 3 x 38 x colour - Sela moulded head
Stitching fasteners general fixing of flashings
SLP2 - A14 - 4, 8 x 20 x col SDL3 - L12 -T15 - 5, 5 x 25 x col SLP2 - S - A14 - 4, 8 x 20 x col SXL2 - L12 - A14 - 5, 5 x 22 x col
Sela moulded head Irius powder coated head Sela moulded head Irius powder coated head
16
Cut edge protection
Discussing the prospect of using pre-finished steel
sheets for cladding buildings will invariably raise the
question of cut edge corrosion, it is a natural concern.
A fear that many architects and design engineers have
experienced is that a sheared edge of a pre-finished steel
sheet will corrode when exposed to the atmosphere.
It is a chemical fact that when steel and zinc are in contact
in the presence of moisture there is an automatic
electro-chemical action which slows down the corrosion.
Cut edge protection is further enhanced by using a
Galvalloy
metalic coating instead of zinc. Corus

Colorcoat HPS200
and Colorcoat Prisma
are
manufactured with Galvalloy
metalic coatings as
standard. Because of this, Corus are able to include
cover for cut edge protection for the life of the guarantee.
It is usually necessary during the course of cladding a
structure that either the pre-finished steel sheet or the
flashings will be cut on site. To ensure that the ability of
the zinc to protect the steel is not impaired, these cuts
must be achieved with the correct tools. Above all, heat
must not be created during the process because of the
risk of damage to the zinc and therefore a corresponding
reduction in the life expectancy of the roof or cladding.
However, the exposed edge may be treated with an
approved edge protection paint system to enhance its
resistance to atmospheric pollution. The edge referred
to here is that defined by the profile shape in cross
section i.e. the cut end of the sheet. Painting the edges
will considerably enhance the durability of the paint
coating and the substrate in the region of the cut edge
and will also reduce the possibility of pattern staining.
Suppliers who offer paint systems approved by Corus
for use with their products are listed below:
Becker Industrial Coatings Limited
Goodlass Road
Speke
Liverpool
L24 9HJ
Telephone: +44 (0)151 448 1010
Akzo Nobel Coatings Limited
PO Box 37
Crown House
Hollins Road
Darwen
Lancashire
BB3 0BG
Telephone: +44 (0)1254 760760
Covac Limited
Eagle House
Bilton Way
Lutterworth
Leicestershire
LE17 4JA
Telephone: +44 (0)1455 556631
The paint systems from these companies can be
applied to the area of the cut edge with a brush or
other suitable means.
Cantilever
Projecting cantilevers should be restricted to 400mm.
Penetrations
Maximum size of penetration without additional structural
support is 300mm.
17
Table 3. Weights of profiled sheets and their calculations
Typical fixing layout
Typical arrangement for Euroclad 32/1000 and 19/1000
liner sheets, using a rail and bracket spacer system.
0.4mm 1000/19 1000 1115 Liner 3.498 3.498 572 286
0.5mm 1000/19 1000 1115 Liner 4.372 4.372 457 229
0.7mm 1000/19 1000 1115 Liner 6.121 6.121 327 163
0.5mm MM10 1000 1230 HPS200
/ Prisma
/ PVDF/ Liner 4.823 4.823 415 207

0.7mm MM10 1000 1230 HPS200
/ Prisma
/ PVDF/ Liner 6.753 6.753 296 148

0.4mm 914/20 914 1025 Liner 3.518 3.215 622 311
0.4mm 1066/20 1066 1200 Liner 3.531 3.764 531 266
0.5mm 1066/20 1066 1230 HPS200
/ Prisma
/ PVDF/ Liner 4.525 4.823 415 207

0.7mm 1066/20 1066 1230 HPS200
/ Prisma
/ PVDF/ Liner 6.334 6.753 296 148

0.9mm 1066/20 1066 1230 HPS200
/ Prisma
/ PVDF/ Liner 8.682 8.682 230 115

0.5mm 1000/32 1000 1230 HPS200
/ Prisma
/ PVDF/ Liner 4.823 4.823 415 207

0.7mm 1000/32 1000 1230 HPS200
/ Prisma
/ PVDF/ Liner 6.753 6.753 296 148

0.9mm 1000/32 1000 1230 HPS200
/ Prisma
/ PVDF/ Liner 8.682 8.682 230 115

0.5mm MW5 1000 1230 HPS200
/ Prisma
/ PVDF/ Liner 4.823 4.823 415 207

0.7mm MW5 1000 1230 HPS200
/ Prisma
/ PVDF/ Liner 6.753 6.753 296 148

0.9mm MW5 1000 1230 HPS200
/ Prisma
/ PVDF/ Liner 8.682 8.682 230 115

0.5mm 914/38 914 1230 HPS200
/ Prisma
/ PVDF/ Liner 5.277 4.823 415 207

0.7mm 914/38 914 1230 HPS200
/ Prisma
/ PVDF/ Liner 7.388 6.753 296 148

0.9mm 914/38 914 1230 HPS200
/ Prisma
/ PVDF/ Liner 9.499 8.682 230 115

0.7mm SF500 500 695 HPS200
/ Prisma
/ PVDF 7.686 3.843 524 262

0.7mm Euroseam 400 587 HPS200
/ Prisma
/ PVDF 8.056 3.223 621 310

0.5mm 13
1
/2/3 990 1230 HPS200
/ Prisma
/ PVDF 4.872 4.823 415 207

0.7mm 13
1
/2/3 990 1230 HPS200
/ Prisma
/ PVDF 6.821 6.753 296 148

0.9mm 13
1
/2/3 990 1230 HPS200
/ Prisma
/ PVDF 8.769 8.682 230 115

Gauge Profile
Cover
width
Coil
width
Corus Colorcoat
pre-finished steel product kgs/m

2
Steel
kgs/Linear metre
L/m per
2 tonne bundle
L/m per
1 tonne bundle
Density
kgs/m
2
Steel
7842.636
Mill finish
aluminium
2715.00
One side coated
aluminium
2745.000
Gauge m
2
tonne m
2
tonne m
2
tonne
0.40 318.770 920.810 910.747
0.50 255.016 736.648 728.597
0.55 231.833 669.680 662.361
0.60 212.514 613.874 607.165
0.65 196.166 566.653 560.460
0.70 182.154 526.177 520.427
0.90 141.676 409.249 404.776
1.20 106.257 306.937 303.582
18
0.9mm 914/38 914 1230 Stucco 3.288 3.006 665 333
0.9mm 1000/32 1000 1230 Stucco 3.006 3.006 665 333
0.9mm MW5R 1000 1230 Stucco 3.006 3.006 665 333
0.9mm Euroseam 300 487 Stucco 3.967 1.190 1681 840
Gauge Profile
Cover
width
Coil
width Coating kgs/m
2
Aluminium
kgs/Linear metre
L/m per
2 tonne bundle
L/m per
1 tonne bundle
0.5mm MM10 1000 1230 ARS / PVDF 1.688 1.688 1185 592
0.7mm MM10 1000 1230 ARS / PVDF 2.363 2.363 846 423
0.9mm MM10 1000 1230 ARS / PVDF 3.039 3.039 658 329
0.5mm 914/20 914 1025 ARS / PVDF 1.539 1.407 1422 711
0.5mm 1066/20 1066 1230 ARS / PVDF 1.584 1.688 1185 592
0.5mm 1000/32 1000 1230 ARS / PVDF 1.688 1.688 1185 592
0.7mm 1000/32 1000 1230 ARS / PVDF 2.363 2.363 846 423
0.9mm 1000/32 1000 1230 ARS / PVDF 3.039 3.039 658 329
0.9mm MW5 1000 1230 ARS / PVDF 3.039 3.039 658 329
0.9mm Euroseam 300 487 ARS / PVDF 4.010 1.203 1662 831
Gauge Profile
Cover
width
Coil
width Coating kgs/m
2
Aluminium
kgs/Linear metre
L/m per
2 tonne bundle
L/m per
1 tonne bundle
Rail and bracket systems
Gauge System Weight Component Unit
1.6mm Eurobar Rail 1.080 kgs Per metre
1.2mm Eurobar Bracket 83mm 0.054 kgs Each
Gauge System Weight Component Unit
1.5mm Eurobar Extra 1.2m Bar 1.920 kgs Each
1.5mm Eurobar Extra Bracket 135mm 0.290 kgs Each
1.5mm Eurobar Extra Mast 135mm 0.230 kgs Each
19
Handling and storage
The following comments refer to the trapezoidal profiles
and not to Secret fix or Euroseam, which have particular
packing/handling notes in the relevant section.
Every profiled sheet and flashing is carefully inspected
before despatch and consignments are packed in edge
wrapped strapped bundles. It must be emphasised that
these sheets and flashings are quality products and
should be handled accordingly.
On arrival at the site, care should be taken in the
offloading; avoid unnecessary handling of the sheets,
lifting (not dragging) them directly off the bundles.
When hoisting bundles and sheets into position, protect
the edges and ensure that the pressure across the sheets
and flashings does not cause distortion. Use rope, not
chains, for hoisting.
Note: Euroclad pallets are not suitable for
crane off-load.
If a protective, strippable film has been applied
to the coating, this should be removed from the
underlap edge prior to fixing and the remainder
removed within two weeks.
Failure to observe simple but essential precautions when
storing and handling galvanised and pre-finished steel
roofing and cladding sheets on site, leads to repeated
complaints of corroding and damage. Investigation shows
that in almost every case damage is due to negligence
prior to use. The most common fault is exposing stacked
sheets to the weather for weeks, even months often
lying in long grass. Avoid careless handling.
To ensure that sheets do not deteriorate when
stored on building sites, the following precautions
are essential:
Do not leave uncovered stacks lying in the open.
Store under cover and away from open doorways.
If stacks cannot be kept under cover, erect a simple
scaffolding around them and cover with a waterproof
sheet, tarpaulin or polythene, but leave space between
cover and sheets to allow air to circulate.
Store stacks off the ground and on a slope, so that should
rain penetrate the covering, the water will drain away.
Inspect the storage site regularly to ensure that
moisture, despite the above precautions, has not
penetrated the stock.
Do not store sheets where people will walk across them.
Observe these precautions and they will save you
trouble, time and money.
Guidance on breather membranes
It is no longer necessary to install a breather membrane
in the majority of twin skin metal roofing cladding
applications.
This is the latest advice from the Metal Cladding and
Roofing Manufacturers Association (MCRMA) and is
the result of work which has recently been carried out
by the Building Research Establishment (BRE),
in collaboration with the MCRMA, to examine in detail
the factors that determine the risk of condensation
within twin skin metal roofs.
This work has demonstrated that, if a well sealed liner is
used in conjunction with vented fillers for the outer sheet,
only small amounts of condensation may occur on the
external sheet over the winter and there will not be
sufficient accumulation to cause dripping or running.
Therefore, so long as the cladding is installed with a high
standard of workmanship with appropriate detailing,
especially a well sealed liner, it is not necessary to install
a breather membrane except in cases where there is
likely to be an unusually high internal moisture load.
Previously, the best practice advice contained in the
second edition of the BRE publication Thermal insulation:
avoiding risk (BR 262) published in 1994, suggested that
a breather membrane be placed between the insulation
and the outer skin of a twin skin metal roof, in order to
prevent any dripping or running of condensed water onto
the insulation.
This was based on the best information available at the
time, which suggested that although the primary means
of preventing condensation problems was a well sealed
liner sheet or vapour check below the insulation, a
breather membrane would provide a second line of
defence. This would be especially important in the case
of buildings with high internal moisture loads such as
swimming pools.
This latest work will be taken into account in the new
version of Thermal Insulation: Avoiding Risks which has
been prepared to accompany the new edition of
Approved Document L2 of the Building Regulations.
Building designers and building control officers may well
like to take this latest guidance into account in both
current and future projects.
DESIGN AND INSTALLATION RECOMMENDATIONS MR 21
Wind loads (BS 6399 : Part 2)
The wind load affecting a particular construction may be
calculated with careful reference to the above standard.
At critical points in a structure the suction loads created
often exceed all other imposed loads. In these
circumstances it is a combination of the profiles strength
and the number and strength of the fasteners which
become critical. It is often necessary to increase the
specification of the fasteners in the high load areas.
Cleaning of pre-finished steel
There are stages during its life cycle that a pre-finished
steel clad building may need cleaning. It is often the case
that during the construction, building debris of various
types will be deposited both on the roof and walls. For
the pre-finished steel to achieve its anticipated life to first
maintenance all debris must be cleared as soon as
possible. If the building is in a particularly dirty
environment it may need cleaning during its life.
There is a requirement for many pre-finished steels to
have annual inspections and maintenance to maintain
the validity of the guarantee. However, Corus Colorcoat
HPS200
does not require this and is maintenance free

for the lifetime of its guarantee.
Swarf
It is imperative that all swarf is removed from the pre-
finished surfaces. The heat imparted to the swarf could
have melted the paint and zinc and the remaining cold
reduced mild steel will rut very quickly upon exposure to
the elements. In any case, if the swarf is not removed it
rusts and gives the effect that the sheet itself is
deteriorating.
All surfaces must be cleaned and particular attention
paid to surfaces where the swarf could accumulate,
such as drip detail.
Cement on pre-finished steel
Often deposits of cement are inadvertently left on the pre-
finished steel cladding. Wet cement/mortar mixes are
very alkaline during the wet/curing stage, and may leave
residual staining on the surface, and more particularly
attack the exposed, sheared edge.
Immediate removal is essential. Thick deposits should be
removed carefully with a blunt wooden scraper, taking
care not to damage the surface.
Removal of residual mortar stains should be accomplished
with neat vinegar and a soft scrubbing brush.
Finally, all areas should be rinsed off with cold clean water.
General debris
Often left on roofs, their danger is that the damage
caused prevents drainage and encourages ponding.
Continued ponding will have a detrimental effect on the
life expectancy of the pre-finished steel finishes.
Once the roof/walls are fixed all should be rinsed with
cold clean water and all debris removed.
Other deposits
No matter what, solvents and abrasive type cleaners
should be avoided in cleaning any pre-finished steel
surface. Caulking compounds, tar and similar substances
may be removed with mineral spirits. Always clean
surfaces down from top to bottom and follow immediately
with a thorough rinsing with clean fresh water. It must be
pointed out that over cleaning or scrubbing can do more
harm than good.
Repair to the surface
If scratches are made in the pre-finished steel surface
these are easily repaired with the application of air drying
plastisol, polyurethane or PVDF touch-up paint, available
from Euroclad. It must be emphasised that these paints
are only for touching in small areas and are not suitable
for application over large areas.
There are few exterior materials whose appearance and
performance will not benefit from regular inspection,
together with any maintenance that might be necessary
at the time. Such activities will repay the careful building
owner and the occupier by giving them the best possible
performance from the product.
Washing
Regularly wash away dirt and debris that have not been
removed by natural rainfall.
Areas of cladding that lie beneath overhanging building
details, such as those beneath gutters, for example, are
particularly susceptible to a build-up of dirt. Such
accumulations may hold water and pollutants, which can
lead to 'wet poultice' corrosion.
Wash cladding with fresh water, using a hose and a
soft cloth.
In areas where heavy industrial deposits dull the surface,
use a good quality household detergent (10% solution in
water) or a proprietary cleaner (follow manufacturer's
instructions). Always rinse thoroughly with clean water.
Inspection and maintenance
22
Guidelines
1 Do not use a concentration of detergent greater
than the 10% solution mentioned above nor a
concentration of a proprietary cleaner greater than
that recommended by the manufacturer.
2 Do not use organic solvents or abrasive cleaners.
3 Mineral spirits may be used to remove caulking
components, tar, and similar substances, but the
surface must then be washed immediately and
thoroughly in the manner described above.
4 Always wash coated surfaces from top to bottom.
5 After washing, always rinse the cladding immediately
and thoroughly to remove all detergents and cleaners.
6 Do not over-clean or scrub the surface since that can
spoil the high-quality finish.
Removing mould
Corus Colorcoat
products have been specially

formulated to resist fungal growth and therefore this
should not be a problem in most geographical areas.
However, some types of local environment are particularly
conducive to mould growth, e.g. areas of wet, dark, or
wooded surroundings or low-lying marshland. In these
areas, mould will grow, even on inert materials such
as glass.
Mould can be removed by treating the affected surface
with a basic solution of the ingredients shown below (by
weight), which should be available from local chemical
suppliers. Before applying the mixture, wash the surface
of the cladding first, as described under Washing above.
Then apply the mixture to all surfaces using a low-
pressure spray or cloth. Rinse the cloth frequently and
change it and the mixture as necessary to prevent any
grit or abrasive particles scratching the building. All
surfaces must be rinsed with cold water within 24 hours
of applying the mixture.
The mixture
You should refer to the manufacturers' health and safety
information before using the chemical ingredients listed
below.
Good quality household detergent or proprietary cleaner 0.5
Trisodium phosphate 3.0
5% sodium hypochlorite solution 25.0
Fresh water 71.5
Total 100.0
Table 5. Annual inspection
* These items should be checked as soon as possible after the building has been erected and as part of the annual inspection.
Table 4. Ingredient by weight
Check for Potential problems Action
Blocked gutters They can cause overflow into the building Remove debris
Build-up of debris on sheets Such debris retains water and pollutants, forming a 'poultice', Remove the debris and, if necessary, wash the area as
which can cause corrosion described under Washing
Retention of dirt in areas of cladding not This detracts from the appearance of the building and, Wash the area as described under Washing
washed naturally by rainwater, if ignored, can cause the paint coating to break down
e.g. below overhangs
Mould growth This rarely occurs, but can arise in extreme conditions Wash the area and treat it for mould growth as described
under Removing mould
Local damage* If the damage has broken through the paint coating, Assess the extent of the damage and either repair it with
the steel substrate may be exposed to attack touch-up paint (see page 23) or replace the sheets through
the original cladding supplier
Swarf (from drilling), rivet stems, and These items themselves can corrode and stain the Remove the debris and, if necessary, wash the sheet
other fixing debris* sheet surface surface as described under Washing
Faulty or inappropriate fasteners* Such fasteners can cause leaks or can corrode and stain Replace the fasteners and any missing caps
the sheet surface, or both
Areas at cut edges or surfaces that need Use specialist contractors and approved maintenance paints
over-painting from listed suppliers (see page 16)
INSPECTION AND MAINTENANCE
23
Touch-up painting
Slight scuffs are best left untreated. If the sheet has
been scratched down to the substrate, it should be
repaired with standard touch-up paint. Ensure that the
applied paint is no wider than the original scratch.
Since touch-up paints are air-drying, they will, over time,
change colour differently from the original paint coating,
so keep the applied area as small as possible.
Suppliers of complementary products
Cleaners:
British Flowplant Group
Units 11-15
Stadium Court
Barbot Hall Industrial Estate
Rotherham
South Yorkshire
S62 6EW
Telephone: +44 (0)1709 838308
Perpetual Environmental Limited
Hayden Lane
Nuffield
Oxon
RG9 5TX
Tel: +44(0)1491 641945
Touch-up paints:
Breakwells Paints
1 Harden Road
Leamore
Walsall
West Midlands
WS3 1EL
Telephone: +44 (0)1922 400444
This company can arrange a technical visit to supply a
specification and can also recommend contractors who
carry out this work.
Over-painting:
Akzo Nobel Industrial Coatings
PO Box 37
Crown House
Hollins Road
Darwen
Lancashire
BB3 0BG
Telephone: +44 (0)1254 760760
D.R. Chemicals
Viking Way
Winchwen Industrial Estate
Swansea
SA1 7DA
Telephone: +44 (0)1792 701135
McKLords
Units 7 & 8
Tirllwyd Industrial Estate
Kinmel Bay
Borough of Conwy
LL18 5JA
Telephone: +44 (0)1745 585995
25
Noise and its control is becoming an increasingly
important aspect of building design. The purpose of
this section is to highlight that Euroclad are able to
advise on the performance of various configurations of
cladding systems with regard to their acoustic properties.
Research
All of the information referred to in this section is based
upon the research carried out by Building Acoustics
Group, Department of Applied Acoustics, University of
Salford.
What is noise?
Noise is sound which can be annoying, which can
interfere with enjoyment of normal activities, and can
sometimes be harmful.
Sound propagates through the air as a pressure
disturbance or wave, superimposed on the atmospheric
pressure.
In general terms the greater the variation in pressure,
the louder the sound.
The pitch, or frequency, of the sound is determined by
the spacing of the waves (or its wavelength).
Measurement
Sounds are measured using sophisticated instruments
which act approximately in the same way as the human
ear, but convert the incoming pressure waves into an
electrical signal which can be read on a meter.
The range of sound pressures is very large, approximately
in the ratio 1 to 10,000,000 from the quietest to the
loudest sounds.
Meters are calibrated to a logarithmic scale, reading in
decibels (dB) to give more meaningful values, especially at
the lower levels.
The scale below shows typical Sound Pressure Levels
(SPL) in dB and the corresponding actual pressures for
various well known noises.
Please refer to MCRMA Technical Paper 8 for
further guidance.
Acoustic performance
Table 6. Typical sounds and their dB ratings
Sound pressure
level*dB
Pressure
N/m
2
x 10
Small jet at take off 120 20,000,000
Sheet metal shop near grinder 110
Noisy factory with riveting 100 2,000,000
Heavy lorry at 5m 90
Busy street or workshop 80 200,000
Radio/TV in living room 70
Restaurant, store, general office 60 20,000
Quiet office 50
Outside residential area at night 40 2,000
Inside bedroom at night 30
Recording studio 20 200
Sound proof room 10
Threshold of hearing 0 20
*Note X dB = 20 log P/P where P = 20 x 10 N/m2.
26
The acoustic performance of these constructions is
affected not only by the performance of the individual
metal sheets but also by the insulation material and the
construction details (see Figures 6 and 7).
Figure 6. Double skin system Figure 7. Composite panel
Double skin constructions
Most metal cladding is either built up on site to form an
insulated double skin system or it may be supplied as a
factory made composite panel.
ACOUSTIC PERFORMANCE
27
Mineral fibre density and
system comparison
Soft insulation such as mineral wool can act to dampen
out vibration in the panel, but it should not be packed too
tightly or it will provide bridging to other components.
Rigid foam insulation used by competitors such as in
factory made or site assembled composite panels, has
an acoustic bridging effect so its acoustic insulation
value is relatively low (typically Rw 26 dB).
Filling the profile completely with densely bonded
material wool slabs can also adversely affect the
acoustic insulation of the construction, as will fixing
details and the cladding span.
23 kgm 90 kgm 100 kgm
Composite panel Built-up system
Figure 8. Comparing the effect of density and softness of mineral fibre insulation
70
60
50
40
30
20
10
0
S
R
I

v
a
l
u
e
s

(
d
B
)
100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000
Frequency (HZ)
Typical Trapizodal Wall (Scotland) Acoustic Performance (.30 'U' Value)
7
60
20
1
100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000
S
R
I

Frequecy (HZ)
Figure 9. Comparing a site assembled system and a composite panel
60
50
40
30
20
10
0
Frequency (HZ)
S
R
I

v
a
l
u
e
s

(
d
B
)
100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000
Perforation
Ideally the less the mechanical linkage or bridging
between the individual layers of the construction and
between the cladding and the support structure, the
higher the acoustic insulation. Any fixings, therefore,
have an adverse effect on the acoustic performance, but
are clearly essential for the installation of the structure.
Point fixing, such as widely spaced screws, is better
acoustically than a line of closely spaced rivets.
However, if there is any distortion of the laps of the
sheets between fixings, thus creating gaps, the high
frequency noise insulation can be reduced.
The examples above illustrate the way in which the
acoustic insulation performance of the cladding can be
affected by materials and design. In some situations it
is necessary to influence the internal acoustics of the
building by reducing reverberation, either to control the
build up of noise, or to make the space more acceptable
for a particular activity.
This can be achieved by perforating the liner to allow the
noise to be absorbed by the fibrous insulation. Generally,
to achieve absorption across the widest possible
frequency range, a minimum perforation ratio (hole
area/sheet area) of approximately 30% should be used,
spread evenly across the whole surface. Euroclad
recommend a pattern of 3mm holes on 5mm staggered
centres (see illustration). If the ratio is less than this, the
high frequency absorption is reduced significantly.
Note that this amount of perforation will reduce the
strength of the liner and the use of thicker material such
as 0.7mm should be considered.
An example of the absorption coefficients for a
construction with a perforated liner is shown in
Figure 10.
28
Example of standard perforation pattern
ACOUSTIC PERFORMANCE
29
Note: covering the absorbent material, or using a vapour
control layer between the perforated liner and the
acoustic insulation can adversely affect the absorption
characteristics.
Perforating the liner may also reduce the acoustic
insulation value (i.e. for transmitted sound) for the
construction as shown in Figure 11.
Single and double skin system comparison
Technical assistance
As part of the research, Salford have created a computer
programme which will allow the performance of various
proposed constructions to be compared.
Single skin steel sheet Double skin system with fully perforated liner
30% perforated liner Solid liner
Figure 10. Comparing sound absorbtion coefficients of a single skin cladding with perforated liner
1.0
0.8
0.6
0.4
0.2
0.0
Frequency (HZ)
A
b
s
o
r
b
t
i
o
n

c
o
e
f
f
i
c
i
e
n
t

C
L
100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000
Figure 11. Effect of perforated liner on sound insulation of a double skin system
70
60
50
40
30
20
10
0
S
R
I

v
a
l
u
e
s

(
d
B
)
100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000
Frequency (HZ)
Trapezoidal acoustic performance
30
914/38mm 0.7mm, 170mm (27kgs @0.040), 0.4mm 20mm Steel Liner (Weighted SRI Rw = 43.6 dB)
Figure 12. Typical trapezoidal roof acoustic performance (.25 U-value)
80
70
60
50
40
30
20
10
0
S
R
I

v
a
l
u
e
s

(
d
B
)
100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000
Frequency (HZ)
Figure 13. Typical trapezoidal wall acoustic performance (.35 U-value)
80
70
60
50
40
30
20
10
0
S
R
I

v
a
l
u
e
s

(
d
B
)
100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000
Frequency (HZ)
Figure 14. Typical trapezoidal wall (Scotland) acoustic performance (.30 U-value)
80
70
60
50
40
30
20
10
0
S
R
I

v
a
l
u
e
s

(
d
B
)
100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000
Frequency (HZ)
31
Calculation of U-values
1 Approved Document L2 requires that the U-values
of metal site assembled and composite panel walls
and roofs must be less than or equal to 0.35 W/m
2
K
and 0.25 W/m
2
K respectively (the corresponding
values in Scottish Technical Standard J are 0.30
W/m
2
K and 0.25 W/m
2
K). These values include
associated components such as gutters and smoke
vents, however, rooflights, windows and doors have
separate values.
2 Because the method for calculating U-values
contained in BS EN ISO 6496 and CIBSE Guide A
does not apply to metal roofing and cladding systems,
more complex methods must be used.
3 If the construction is one of those covered in BRE IP
5/98, the U-value can be obtained from the graphs
or other information in the IP and corrected for air
spaces and compression of the insulation by the
profiles using the equations in the IP.
4 If the component contains independent linear
features that can be represented by a series of
two-dimensional models, use a two-dimensional
model and combine the results from the different
models.
5 If the component contains repeating point thermal
bridges, such as clips, develop a three-dimensional
model to calculate the heat flows and then the
U-value.
Thermal bridging
1 Approved Document L2 requires that the building
fabric should be constructed so that there are no
significant thermal bridges or gaps in the insulation
layer(s) within the various elements of the fabric, at
the joints between elements and at the edges of
elements such as those around window and door
openings. It is also necessary to account for
penetration of the insulated envelope by features
such as safety harness posts or rafters which project
to support a canopy or gutter.
2 It is necessary to consider both the risk of
condensation on each individual thermal bridge and
the effect of the increased heat loss through thermal
bridges on the overall heat from the building.
3 If a detail contains metal components crossing the
insulation that would not otherwise be present in a
plane element, surface condensation may occur in
humid environments. The severity of the bridge, and
therefore the risk of condensation, is determined by
the F-factor, which is calculated by modelling the
structure. If this type of thermal bridge is to be
included in a building which is likely to have a humid
internal environment, consideration should be given
to redesigning the detail.
4 It is also necessary to calculate the contribution of
the thermal bridges to the overall heat loss from the
building by using the linear thermal transmittance
(-value) and then following the procedures specified
in BRE IP17/01. If the total heat loss through the
thermal bridges is greater than 10% of that through
the plane areas, individual details must be modified
to reduce the loss through the bridges.
5 The parameters needed to comply with Part L via
IP 17/01 (the F-value and the -value) are given in
the MCRMA Technical Paper 14 for a range of
details that should cover most metal clad buildings.
Means of improving the thermal performance of each
detail are presented. It will be necessary to use a
three-dimensional thermal model to calculate the
F-value and the -value for all other details.
The building regulations
*Source: Corus Colorcoat
Technical Paper, End of life options for pre-finished

steel buildings, 2006.
32
Air permeability
Approved document L (2006)
Air-tightness is measured in m
3
of air per hour per m
2
of building envelope at an applied pressure of 50 Pa.
The area of the building envelope includes the walls,
roof and floor slab. In practice, the floor slab can be
considered air-tight.
The concept of air-tightness was first introduced into
Building Regulations in England and Wales in the 2002
revision of: Approved Document L. In this document,
a maximum allowable air leakage rate of 10m
3
/h/m
2
was introduced for all buildings other than dwellings
greater than 1000m
2
.
The 2006 update to Part L has extended this further.
All buildings must be pressure tested, unless the floor
area is less than 500m
2
, when a default value of
15m
3
/h/m
2
can be used. For buildings over 500m
2
,
a maximum reasonable design limit for air tightness is
10m
3
/h/m
2
. The new requirements are less prescriptive
than 2002. However, it will be difficult to meet the
overall building CO
2
emission rate without a reasonably
air-tight building envelope.
Air-tightness is tested using a number of large
mobile fan units, to pressurise the building to 50 Pa.
The volume of air leakage is divided by the cladding
(including floor slab) area.
Achieving air-tightness
In a typical pre-finished steel-clad building, the air-
tightness barrier is provided by the interior, or liner,
side of the envelope. While the outer sheet of an
insulated envelope will provide weather protection,
and will be sealed in order to prevent water leaks,
it is important that it is not relied upon for air-tightness.
The first step in constructing an air-tight building,
is to identify the liner as the air-tightness barrier and
ensure this is focused in the design and construction
of the building envelope. This system can provide
extremely good air-tightness, using good detailing
and construction.
Air-tightness, for a built-up system, is achieved by the
liner sheet. Sealant tapes, or beads, are used to seal
the overlap joints between adjacent sheets. The
insulation cavity is ventilated, through the ribs of the
external profiled sheet, to minimise condensation risk.
*Source: Corus Colorcoat
Technical Paper, End of life options for pre-finished

steel buildings, 2006.
THE BUILDING REGULATIONS
33
Table 7. Side lap joint configurations and
corresponding air leakage rates
Joint details Leakage rate m
3
/h/m
Unsealed unstitched
>
10.00
>
10.00
Unsealed stitched @ 450mm
>
5.00
>
5.00
External sealant tape
>
0.20
>
0.20
External sealant tape and
stitching @ 450mm
>
0.20
>
0.20
Internal sealant bead
>
0.25
>
0.40
Internal sealant bead and
stitching @ 450mm
>
0.20
>
0.20
0.4mm liner 0.4mm liner
Thermal insulation
External side
lap tape
Liner sheet
Internal sealant bead
Trapezoidal roof sheet
Side laps
Side laps are formed where the profiled edge of
one sheet overlaps the edge of the adjacent sheet.
Liner sheets are typically 0.4mm, or 0.7mm gauge.
The joint is sealed by using an external tape, which
is placed over the joint line of the cavity side of the
liner sheet.
The joint can be reinforced with stitcher screws or rivets,
which are a requirement for some firewall constructions.
The use of a good quality sealant tape, such as Polyband,
or T-foil, will produce a good quality air resistant joint.
When using an external tape, it is important to note that
stitchers will not provide an additional air-tightness,
although they can add to the longevity of the joint.
34
End laps
End laps are formed where the profiled edge of one
sheet overlaps the edge the adjacent sheet. Liner sheets
are typically 0.4mm, or 0.7mm gauge. The joint is
sealed using a sealant bead, which is placed inside the
overlap joint.
Fixings should be installed in the trough of each profile
to provide compression of the sealant bead.
The use of a good quality sealant bead will produce a
good quality air resistant joint.
Table 9. Built-up systems recommended joint sealing practice
Joint details Recommendation Leakage rate m
3
/h/m
Side lap joint External sealant tape
<
0.20
Internal sealant bead, stitched @ 450mm
<
0.20
Side lap flashing joint Internal sealant bead, stitched @ 450mm
<
0.20
End lap joint Internal sealant bead, stitched every valley
<
0.30
End lap flashing joint Bonded EPDM or PE filler block, stitched every valley
<
0.25
Table 8. Side lap joint configurations and
corresponding air leakage rates
Joint details Leakage rate m
3
/h/m
Unsealed, stitched alternate valleys
<
45.00
<
45.00
Unsealed, stitched every valley
<
15.00
<
15.00
Internal sealant bead, stitched
alternate valleys
<
1.00
<
0.50
Internal sealant bead, stitched
every valley
<
0.30
<
0.30
External sealant tape, stitched
alternate valleys
<
0.20
<
0.20
External sealant tape, stitched
every valley
<
0.20
<
0.20
0.4mm liner 0.4mm liner
Sealant bond
Liner sheet
Tape
Liner sheet
THE BUILDING REGULATIONS
35
Conclusion
In summary, it is worth remembering that steel is an
inherently air-tight material, so the only air-leakage paths
in a steel building envelope are where there are holes left
at junctions. Adopting the approaches detailed in this
publication should minimise holes at the majority of
junctions. It should be noted, however, that a target
air-leakage rate of 10 5 or even 3m
3
/m
2
/h allows, on
average, a hole of 700mm
2
, 380mm
2
or 200mm
2
for
every 1m.
Given that the target air-tightness is for the whole
building (including all openings, interfaces, floors, roof
and walls). it is essential that the techniques described
here are adopted for the areas which are relatively easy
to control, since holes will inevitably appear elsewhere
in the construction.
Experience has shown that with close attention to
detail, steel clad buildings should have no difficulty
achieving air-leakage rates of no more than 5m
3
/m
2
/h,
and often have even less than 3m
3
/m
2
/h. However,
air-leakage is highly dependant on building geometry.
Simple, large buildings have proportionately less
potentially-leaky interfaces than more complex,
small ones.
Corus Colorcoat HPS200
and Colorcoat Prisma
pre-finished steel in Blue, Sirius and Goosewing Grey.

Corus Colorcoat HPS200
pre-finished steel in Augusta Green.

37
Colorcoat
products
and services
To ensure the long-term performance and
appearance of the building, it is important that the
pre-finished steel product is specified alongside
the cladding system.
Corus Colorcoat
Products and Services

The Colorcoat
brand provides the recognised mark of

quality and metal envelope expertise exclusively from
Corus. Over the course of 40 years Corus has developed
a range of technically leading Colorcoat
pre-finished
steel products which have been comprehensively tested
and are manufactured to the highest quality standards.
These are supported by a range of services such as
comprehensive guarantees, colour consultancy and
technical support and guidance.
Colorcoat HPS200
Exclusive coating technology, superior performance and

the unique Confidex
Guarantee make Colorcoat

HPS200
the most specified pre-finished steel product in

Europe for roof and wall cladding. Now maintenance free
for up to 30 years.
Colorcoat Prisma
The ideal choice to deliver eye-catching buildings that

will stand the test of time. Technically and aesthetically
superior to PVDF (PVF2), Colorcoat Prisma
is readily
available in the most popular solid and metallic colours.
All backed up with the unique Confidex
Guarantee
providing cover for up to 25 years on walls.
Repertoire
Colour Consultancy
The Repertoire
Colour Consultancy can advise on

colours and colour strategies using a range of standard
shades, as well as discussing individual bespoke colour
requirements. Corus can match almost any shade from
physical swatches to commonly used references such
as RAL, NCS and British Standard and more unusual
standards.
Confidex
Guarantee
Offers the most comprehensive guarantee for pre-finished
steel products in Europe and provides peace of mind for
up to 30 years. Unlike other guarantees, Confidex
covers cut edges for the entirety of the guarantee period

and does not require mandatory annual inspections.
Confidex Sustain
Provides a combined guarantee which covers the

durability of the Colorcoat
pre-finished steel product

and makes the pre-finished steel building envelope
CarbonNeutral the first in the world. Unavoidable CO
2
emissions from the pre-finished steel cladding system
including fixings and insulation, are measured from cradle
to grave and the impact offset. More than just offsetting,
the aim is to encourage specification of the most
sustainable pre-finished steel products and cladding
systems.
Colorcoat
Building manual
Developed in consultation with architects and other
construction professionals, the Colorcoat
Building
manual incorporates over 40 years of Colorcoat
expertise. It contains information about sustainable

development and the creation of a sustainable
specification.
Colorcoat
Technical papers
Working closely with the Corus Colorcoat
Centre for the

Building Envelope based at Oxford Brookes University
and the Steel Construction Institute, Corus has produced
a number of technical papers. These address key
construction issues such as the creation of an airtight
building envelope and end of life options for pre-finished
steel cladding systems.
For more information about Corus Colorcoat
products and services visit www.colorcoat-online.com

or call the Colorcoat Connection
helpline on
+44 (0)1244 892434.
Colorcoat, Colorcoat Connection, Confidex, Confidex Sustain, Galvalloy, HPS200, Prisma and Repertoire are trademarks of Corus.
39
Recommended good practice for daylighting in metal clad buildings MCRMA Paper Number 1
Curved sheeting manual MCRMA Paper Number 2
Secret fix roofing design guide MCRMA Paper Number 3
Metal wall cladding detailing guide MCRMA Paper Number 5
Profiled metal roofing design guide MCRMA Paper Number 6
Acoustic design guide for metal roof and wall cladding MCRMA Paper Number 8
Flashings for metal roof and wall cladding: Design, detailing and installation guide MCRMA Paper Number 11
Fasteners for metal roof and wall cladding: Design, detailing and installation guide MCRMA Paper Number 12
Guidance for the design of metal roofing and cladding to comply with Approved Document L2 : 2001 MCRMA Paper Number 14
Guidance for the effective sealing of end lap details in metal roofing constructions MCRMA Paper Number 16
References
Metal cladding: Assessing thermal performance BRE IP 5/98
Assessing the effects of thermal bridging at junctions and around openings BRE IP 17/01
Conservation of fuel and power in dwellings Building Regulations AD L1
Conservation of fuel and power in buildings other than dwellings Building Regulations AD L2
Conservation of fuel and power Part J - Scotland
Creating an air-tight building envelope Colorcoat
Technical paper
40
Notes and contacts
Euroclad Limited
Wentloog Corporate Park
Cardiff
CF3 2ER
Telephone +44 (0)29 2079 0722
Facsimile +44 (0)29 2079 3149
E-mail sales@euroclad.com
Internet www.euroclad.com
Euroclad (Ireland) Limited
Unit 4
Newhall Industrial Estate
Naas
Co. Kildare
Telephone 00 353 (0) 45 435 470
Facsimile 00 353 (0) 45 435 472
Internet www.euroclad.com
The details and information contained in this publication are correct at time of going to press. Euroclad reserves the right to change details and specifications without
prior notice. No responsibility is assumed for errors or misinterpretations resulting from the information contained in this publication.
Typical construction details are illustrative only and no liability is accepted. 3K/08.07

Euroclad Guide To Design and Installation of Trapezoidal Systems

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Design and installation

Products and services 37

metalic coating instead of zinc. Corus

and Colorcoat Prisma

/ PVDF/ Liner 4.823 4.823 415 207

/ PVDF/ Liner 6.753 6.753 296 148

/ PVDF/ Liner 4.525 4.823 415 207

/ PVDF/ Liner 6.334 6.753 296 148

/ PVDF/ Liner 8.682 8.682 230 115

/ PVDF/ Liner 4.823 4.823 415 207

/ PVDF/ Liner 6.753 6.753 296 148

/ PVDF/ Liner 8.682 8.682 230 115

/ PVDF/ Liner 4.823 4.823 415 207

/ PVDF/ Liner 6.753 6.753 296 148

/ PVDF/ Liner 8.682 8.682 230 115

/ PVDF/ Liner 5.277 4.823 415 207

/ PVDF/ Liner 7.388 6.753 296 148

/ PVDF/ Liner 9.499 8.682 230 115

/ PVDF 7.686 3.843 524 262

/ PVDF 8.056 3.223 621 310

/ PVDF 4.872 4.823 415 207

/ PVDF 6.821 6.753 296 148

/ PVDF 8.769 8.682 230 115

pre-finished steel product kgs/m

does not require this and is maintenance free

products have been specially

Technical Paper, End of life options for pre-finished

Technical Paper, End of life options for pre-finished

and Colorcoat Prisma

pre-finished steel in Blue, Sirius and Goosewing Grey.

pre-finished steel in Augusta Green.

Products and Services

brand provides the recognised mark of

Exclusive coating technology, superior performance and

Guarantee make Colorcoat

the most specified pre-finished steel product in

The ideal choice to deliver eye-catching buildings that

Colour Consultancy can advise on

covers cut edges for the entirety of the guarantee period

Provides a combined guarantee which covers the

pre-finished steel product

expertise. It contains information about sustainable

Centre for the

products and services visit www.colorcoat-online.com

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