Uniclass

L3525:G33:P4
CI/SfB
(25.9) Hh
July 2016

RoofDek
Structural roof decking and trays
RoofDek Introduction

About Tata Steel Contents

Tata Steel, formerly known as Corus, is one of Europe's largest steel 3 Introduction
producers. We serve many different and demanding markets
worldwide, including aerospace, automotive, construction, energy 4 Shallow deck profile range
and power, and packaging. Our primary steelmaking operations in
the UK and the Netherlands are supported by a global sales and 6 Deep deck profile range
distribution network.
8 Liner tray profiles
Innovation and continuous improvement are at the heart of our
performance culture. We aim to create value by offering a sustainable
10 Acoustic profiles
and value-added steel product range supported by unrivalled customer
service. By working in partnership with you, we find the best solutions
13 Technical information
to meet your needs and help your business to perform.

Our European operations are a subsidiary of Tata Steel Group, one of 14 Structural design
the world’s top ten steel producers. With a combined presence in
nearly 50 countries, the Tata Steel Group including the Europe 15 Diaphragm design
operations,
Tata Steel Thailand and NatSteel Asia, has approximately 80,000 16 Acoustic systems
employees across five continents and a crude steel production capacity
of over 28 million tonnes. 18 Roof Safety

We are able to offer a wide range of products, systems and services

19 Service and support
specifically developed for the construction market. These include
Colorcoat® pre-finished steel products, roof and wall cladding systems
20 Sustainability
for the building envelope, hot rolled and tubular sections for the
primary structure, lintels and other ancillary construction components.
21 Case Study
Peacehaven

22 Case Study
West Cheshire College

23 Case Study
West Burton Power Station

2

Introducing RoofDek
Structural roof decking and trays
Tata Steel offers the most comprehensive range of structural roof decking all under one UK
manufacturer’s roof
To offer the structural deck specifier more choice, we can supply additional profiles to
compliment our UK manufactured range from Tata Steel Europe.
Technically the best, with a structural design
service providing diaphragm design for decks
and full support calculations for all profiles.
With decks ranging from 32mm to 210mm
deep and a range of structural trays, we
support all types of insulated roof systems:
• Single ply membrane
• Standing seam systems
• Green roofs
• Slates and tiles
• Three ply felt
• Asphalt
Quality assurance
To provide the best quality and the most up to
date design information, Tata Steel is quality
assured to BS ISO 9001:2000 Quality systems.
Tata Steel is an active member of MCRMA
(Metal Cladding and Roofing Manufacturers
Association), SPRA (Single ply Roofing
Association), BCSA (British Constructional
Steelwork Association) and supports R&D
throughout the industry.
01244 892 199 | www.tatasteelconstruction.com/roofdek
RoofDek Introduction
Professional support
Tata Steel maintains a friendly technical help
desk which is freely available to all Architects,
Consulting Engineers and Contractors to assist
all aspects of roof deck and liner tray design
The technical help desk is available on:
01244 892 199 or via roofdek@tatasteel.com
Shotton Works
Our Shotton operations take place in an
environmentally sensitive area. We are
surrounded by the Dee Estuary, which is
designated as a Special Area for Conservation,
Special Protection Area and Site of Special
Scientific Interest.
An area of man-made lagoons within our
boundary has similar environmental
designations, being a breeding ground for
Common Terns and an important reed bed
habitat, leading to our proud tradition of
co-existing with the natural world in this
special place without compromising
biodiversity.
Clearance and maintenance work is regularly
undertaken to ensure the lagoon areas are
preserved in optimum conditions and we
manage the open areas of our site to
maximise their potential as habitats to flora
and fauna, including a wide range of breeding
and migratory birds.
3
RoofDek Profile ranges

Shallow deck profile range

Developed to optimise the designer’s needs for
efficiency, aesthetics and structural performance

Structural RoofDek profile range

Tata Steel provides the designers needs for efficiency, aethestics and
structural performance by offering a comprehensive portfolio of
shallow RoofDek profiles.

Load/span figures
The tables are based on a total ‘Dead & Super’ imposed load of
1.50kN/m2, a line load of 2.00kN/m and a deflection limit of L/200. The
factor of safety used is 1.5 for live load and 1.35 for dead load. Where
actual design loads exceed these, the spans must be reduced. Subject
to satisfactory fixings, the decks will resist wind uplift to at least the D32s
value of 1.50kN/m2, and a deflection limit of L/90. Full load span tables
may be obtained from our website: www.tatasteelconstruction.com
or from our technical department.

Maximum cantilevers assume a 0.9kN point load on the end, with the
adjacent span being the single span as shown in the table. The end of
the cantilever must be stiffened with an angle flashing. Steel type is
taken as galvanised and coated at 280N/mm2.

Point and impact loads D35

Metal decking may mark if subjected to extreme point or impact load.
Where the sheet is required as an exposed soffit, a thicker gauge should
be considered if localised marking is not acceptable.

Curving
Self curving can induce stress marking in the sheet. The radius limits
suggested in the tables reduce the visible effect of this; however some
perceptible distortion may occur.
D46

D60

For material specification see page 13.

4
 RoofDek Profile ranges

Structural profile specifications

Profile Material Gauge and Weight Load/span Load/span Minimum Minimum Cantilever
finish maximum maximum self curve factory
single span double span curve
(mm) (kg/m2) (mm) (mm) (m) (mm) (mm)

Steel 0.70 Interior Liner & Galvatite® 6.67 1650* 1800 40 – 325

Steel 0.90 Interior Liner & Galvatite® 8.58 1875* 2300 45 – 375

D32s Steel 1.20 Interior Liner & Galvatite® 11.46 2100* 2800 50 – 450

Aluminium 0.90 Stucco 2.98 1075* 1500* 40 – 250

Aluminium 1.20 Mill 3.97 1250* 1900* 50 – 300

Steel 0.70 Interior Liner & Galvatite® 7.08 1803 2519 40 400 400

Steel 0.90 Interior Liner & Galvatite® 9.11 2114 2835 50 400 475

D35 Steel 1.20 Interior Liner & Galvatite® 12.16 2404 3224 60 – 575

Aluminium 0.90 Stucco 3.16 1311 1960 40 400 300

Aluminium 1.20 Mill 4.21 1525 2267 50 – 350

Steel 0.70 Interior Liner & Galvatite® 7.20 2433 3120 55 400 575

Steel 0.90 Interior Liner & Galvatite® 9.26 2708 3631 65 400 650

D46 Steel 1.20 Interior Liner & Galvatite® 12.37 2994 4015 75 – 725

Aluminium 0.90 Stucco 3.21 1762 2501 55 400 400

Aluminium 1.20 Mill 4.28 2051 2761 65 – 475

Steel 0.70 Interior Liner & Galvatite® 8.34 3022 3772 70 – 725

Steel 0.90 Interior Liner & Galvatite® 10.73 3348 4489 80 – 800

D60 Steel 1.20 Interior Liner & Galvatite® 14.32 3672 4923 85 – 875

Aluminium 0.90 Stucco 3.72 2300 3060 70 – 575

Aluminium 1.20 Mill 4.96 2542 3408 80 – 625

Notes *Span limited by 2kN/m line load.

1. RoofDek profiles are available with Colorcoat HPS 200 Ultra® pre-finished steel, however these load tables do not apply - please
contact us for load span data. Aluminium, other finishes and materials are available subject to minimum order quantity.
2. Calculations accord to Eurocode, however a fixings check is also required.
3. Load table is based on the deck bearing onto 100mm min. flange steel beam.
4. Load spans calculated to Eurocode 3 and 9.

01244 892 199 | www.tatasteelconstruction.com/roofdek 5

RoofDek Profile ranges

Deep deck profile range

Designed for exceptional strength and span capability
for all roofing types

Structural RoofDek profile range

Deep decks have exceptional strength and span capability, providing a
rugged structural platform for all roofing types. They are ideal for
D100
architecturally interesting large space buildings as they eliminate the
need for purlins, but are used in any situation where a strong solid base
for the roof is required.

Single ply roofs, metal standing seam, asphalt and bitumen roofs all use
deep RoofDek, and in recent years they have been the default choice
for green roofs, which impose a heavy dead load.

When specifying deep decks, designers frequently take advantage of D135

Tata Steel's free diaphragm design service to reduce or eliminate in
plane roof bracing.

Load/span figures
The tables are based on a total ‘Dead & Super’ imposed load of
1.50kN/m2, a line load of 2.00kN/m and a deflection limit of L/200. The
factor of safety used is 1.5 for live load and 1.35 for dead load. Where
actual design loads exceed these, the spans must be reduced. Subject D153
to satisfactory fixings, the decks will resist wind uplift to at least the
value of 1.50kN/m2, and a deflection limit of L/90. Full load span tables
may be obtained from our website: www.tatasteelconstruction.com
or from our technical department.

Sheet lengths – extended end laps

Sheet lengths in excess of 12 metres are not practical for installation on
site and may also be subject to delivery restrictions. Extended end laps D159
can be used to create a double span whilst keeping the deck length to
a minimum. If a deck length in excess of 12 metres is nevertheless
required, contact our Technical Department for assistance.

D200

D210

For material specification see page 13.

6
 RoofDek Profile ranges

Structural profile specifications

Profile Material Gauge and Weight Load/span Load/span Minimum Minimum Cantilever
finish maximum maximum self curve factory
single span double span curve
(mm) (kg/m2) (mm) (mm) (m) (mm) (mm)

Steel 0.70 Interior Liner & Galvatite® 9.64 4409 4696 110 – 1000

Steel 0.90 Interior Liner & Galvatite® 12.41 4788 5869 120 – 1150

D100 Steel 1.20 Interior Liner & Galvatite® 16.57 5245 7034 125 – 1250

Aluminium 0.90 Stucco 4.30 3298 3769 110 – 850

Aluminium 1.20 Mill 5.74 3642 4883 120 – 925

Steel 0.75 Interior Liner 9.49 4929 4506 150 – 1100

D135 Steel 0.88 Interior Liner 11.14 5511 5376 160 – 1200

Steel 1.25 Interior Liner 15.84 6164 7435 180 – 1350

Steel 0.75 Interior Liner 10.50 5162 4898 165 – 1250

D153 Steel 0.88 Interior Liner 12.33 5946 5865 175 – 1300

Steel 1.25 Interior Liner 17.54 6737 8150 195 – 1400

Steel 1.25 Interior Liner 19.19 7101 8595 220 – 1550

D159
Aluminium 1.50 Mill 7.97 5243 6559 200 – 1200

Steel 0.88 Interior Liner 13.81 5698 6405 260 – 1550

D200 Steel 1.25 Interior Liner 19.65 8403 9217 280 – 1800

Steel 1.50 Interior Liner 23.59 8947 10781 300 – 1900

D210 Steel 1.25 Galvatite® 16.24 7600 See note 4 250 – 1750

Notes
1. RoofDek profiles are available with Colorcoat HPS 200 Ultra® pre-finished steel, however these
load tables do not apply - please contact us for load span data. Aluminium, other finishes and
materials are available subject to minimum order quantity.
2. Calculations accord to Eurocode, however a fixings check is also required.
3. Load table is based on the deck bearing onto 100mm min. flange steel beam.
4. For maximum Load/Span in double span conditions, contact the technical department.
5. The Interior Liner colour on D135, D153 and D200 is RAL9002.

01244 892 199 | www.tatasteelconstruction.com/roofdek 7

RoofDek Liner trays

Liner tray profiles

Structural liner trays

Structural liner trays provide a neat planar inner surface, flat except for
the stiffening ribs. It is suitable for both roof and wall cladding
applications spanning across the main steels and omitting the need for HLT90/600
purlins or cladding rails.

HLT130/600

HLT145/600

For material specification see page 13.

8
 RoofDek Liner trays

Structural liner tray profile specifications

Profile Material Gauge and Weight Load/span Load/span Minimum Minimum Cantilever
finish maximum maximum self curve factory
single span double span curve
(mm) (kg/m2) (mm) (mm) (m) (mm) (mm)

Steel 0.75 Interior Liner 8.62 3100 3000 – – 700

HLT90/600 Steel 1.00 Interior Liner 11.49 3800 3900 – – 1150

Steel 1.25 Interior Liner 14.36 4100 4300 – – 1300

Steel 0.75 Interior Liner 9.57 4100 4100 – – 800

HLT130/600 Steel 1.00 Interior Liner 12.75 5100 5300 – – 1500

Steel 1.25 Interior Liner 15.95 5500 5900 – – 1700

Steel 0.75 Interior Liner 9.81 4300 4000 – – 650

HLT145/600 Steel 1.00 Interior Liner 13.08 5300 5600 – – 1450

Steel 1.25 Interior Liner 16.35 6000 6300 – – 1700

The colour of the Interior Liner on all HLT profiles is RAL 9002.

01244 892 199 | www.tatasteelconstruction.com/roofdek 9

RoofDek Acoustic profile ranges

Acoustic profiles

Acoustic RoofDek range

Tata Steel offers a range of tried and tested acoustic profiles which D46
achieve various sound absorption ratings from A–D. Please contact
Perforated
our technical department for more information.
10.7% of exposed area
13.0% of cover area
Acoustics
The decks illustrated on this page are available with perforated webs
to provide acoustic absorption. Two different open area percentage
figures are in general use and both are shown. The percentage of D60
exposed area is the open area divided by the exposed area of steel Perforated
following around the profiles. The percentage of cover area is the open
13.9% of exposed area
area divided by the plan area of the soffit. The perforating patterns are 19.6% of cover area
illustrated here.
4.5
D46, D60 and D100 use perforating
pattern 4546 60° D100
4.5mm holes at 6.3mm triangular 6.3 Perforated
centres. Pattern open area 46%. 13.3% of exposed area
21.1% of cover area
D159 uses perforating pattern 3327
3.3mm holes at 6.0mm triangular centres. 3.3
Pattern open area 27%. Fully perforated 60°
D135
deck may be available, please enquire if 6.0
required. Perforated
6.1% of exposed area
D135, D153 and D200 use perforating 10.0% of cover area
pattern P3L-S 3.0
3.0mm holes at 5.5mm square centres.
Pattern open area 23.5%. 5.5 D153
Perforated
6.2% of exposed area
11.0% of cover area

D159
Perforated
7.6% of exposed area
14.2% of cover area

D200
Perforated
5.0% of exposed area
10.0% of cover area

10
 RoofDek Acoustic profile ranges

Acoustic profile specifications

Profile Material Gauge and Weight Load/span Load/span Minimum Minimum Cantilever
finish maximum maximum self curve factory
single span double span curve
(mm) (kg/m2) (mm) (mm) (m) (mm) (mm)
Steel 0.70 Interior Liner & Galvatite® 6.49 1614 2152 55 400 475

Steel 0.90 Interior Liner & Galvatite® 8.35 2667 3003 65 400 550
D46
Steel 1.20 Interior Liner & Galvatite® 11.15 2959 3874 75 – 600
Perforated
Aluminium 0.90 Stucco 2.89 1202* 1602 55 400 325

Aluminium 1.20 Mill 3.86 2037 2441 65 – 400

Steel 0.70 Interior Liner & Galvatite® 7.25 1647 2196 70 – 600

Steel 0.90 Interior Liner & Galvatite® 9.33 2725 3425 80 – 675
D60
Steel 1.20 Interior Liner & Galvatite® 12.45 3621 4499 85 – 725
Perforated
Aluminium 0.90 Stucco 3.23 1232 1642 70 – 475

Aluminium 1.20 Mill 4.31 2123 2778 80 – 525

Steel 0.90 Interior Liner & Galvatite® 10.92 3574 4453 120 – 975

D100 Steel 1.20 Interior Liner & Galvatite® 14.58 5212 6066 125 – 1050

Perforated Aluminium 0.90 Stucco 3.79 1647 2196 110 – 700

Aluminium 1.20 Mill 5.05 3062 3733 120 – 775

Steel 0.75 Interior Liner 8.90 3150 3772 150 – 1000

D135
Steel 0.88 Interior Liner 10.46 4526 4626 160 – 1100
Perforated
Steel 1.25 Interior Liner 14.87 6142 6717 180 – 1200

Steel 0.75 Interior Liner 9.86 3421 4200 165 – 1100

D153
Steel 0.88 Interior Liner 11.58 5012 5150 175 – 1150
Perforated
Steel 1.25 Interior Liner 16.46 6730 7442 195 – 1250

D159 Steel 1.25 Interior Liner 17.80 7084 7853 220 – 1400

Perforated Aluminium 1.50 Mill 7.40 5222 5942 200 – 1100

Steel 0.88 Interior Liner 13.13 3583 4778 260 – 1200

D200
Steel 1.25 Interior Liner 18.67 7739 7890 280 – 1700
Perforated
Steel 1.50 Interior Liner 22.41 8945 9494 300 – 1800

Notes *Span limited by 2kN/m line load.

1. Aluminium profiles are subject to minimum order quantities.
2. Calculations accord to Eurocode, however a fixings check is also required.
3. Load table is based on the deck bearing onto 100mm min. flange steel beam.
4. The Interior Liner colour on D135, D153 & D200 is RAL 9002.

01244 892 199 | www.tatasteelconstruction.com/roofdek 11

RoofDek Acoustic profile ranges

Acoustic profiles

Acoustic structural liner tray

Tata Steel offers a range of acoustic liner trays which achieve a Class HLT90/600
A sound absorption rating. Structural Trays offer a wider flat soffit
Perforated
enabling a greater perforated area, achieving the best acoustic
18.8% of exposed area
absorption result. 18.8% of cover area

The percentage of exposed area is the open area divided by the

exposed area of steel following around the profiles. The percentage of
cover area is the open area divided by the plan area of the soffit. HLT130/600
The perforating pattern is P3 ZZ, illustrated below: Perforated
18.8% of exposed area
3.0 18.8% of cover area
3.0mm holes at 5.5mm square centres.
Pattern open area 23.5%.
5.5
HLT145/600
Perforated
18.8% of exposed area
18.8% of cover area

Acoustic profile specifications

Profile Material Gauge and Weight Load/span Load/span Minimum Minimum Cantilever
finish maximum maximum self curve factory
single span double span curve
(mm) (kg/m2) (mm) (mm) (m) (mm) (mm)

Steel 0.75 Interior Liner 7.52 3100 2900 – – 700

HLT90/600
Steel 1.00 Interior Liner 10.02 3400 3800 – – 1100
Perforated
Steel 1.25 Interior Liner 12.52 3700 4300 – – 1300

Steel 0.75 Interior Liner 8.47 4000 3900 – – 750

HLT130/600
Steel 1.00 Interior Liner 11.28 4900 5000 – – 1400
Perforated
Steel 1.25 Interior Liner 14.12 5300 5600 – – 1600

Steel 0.75 Interior Liner 8.72 4200 3700 – – 650

HLT145/600
Steel 1.00 Interior Liner 11.63 5200 5200 – – 1350
Perforated
Steel 1.25 Interior Liner 14.54 5700 5900 – – 1600

The colour of the Interior Liner on all HLT profiles is RAL 9002.

12
 RoofDek Technical Information

Technical information
Fire rating
All non-perforated deck sheets provide a fire rating of Class 1 to BS476:
Part 7 and Class 0 in accordance with current Building Regulations.

Fixing

Profile Main fixings at Main fixings Side lap

ridge and eaves (Intermediate) fixing
D32s every pitch every other pitch* not essential**
D35 –> D200 every pitch every pitch 450mm centres
D210 every pitch every pitch 350mm centres
HLT 130/600 4 per tray 4 per tray 450mm centres
D210 requires alignment cleats to prevent profile spread.
* Every other pitch is based on always starting with a fixing in the first pitch of every sheet, and a profile pitch of 200mm or less.
** Side lap fixing is not essential where using a fully supported under lap, otherwise it’s recommended to fix at 450mm centres.

Extended end laps

Sheet lengths in excess of 12 metres are not
practical for installation on-site and may also
be subject to delivery restrictions. Extended
end laps can be used to create a double span
whilst keeping the deck length to a minimum.
Load span data for double spanning
continuous sheet can conservatively be
applied, provided these rules are followed.
The end lap must extend into 10% of each span
and must be tail fixed by means of 5.5mm
diameter self drilling steel stitching screws
connecting each web (not the flange) of the
overlying profile, to the web of the underlying
profile, one fixing in each web (2 per pitch or
the sheet) at each end of the end lap.
The web is the inclined upright part of the
profile (as opposed to the horizontal flanges).
The deck is fixed to the support in the normal
way.
The web fixings must not be made through
perforated sections of webs. Extended laps are
not recommended for perforated profiles.

5.5mm diameter self drilling steel Every web is

stitching screws connecting each stitched at the
web end of the lap

Fixing to
Support

10% of
span

Total overlap
20% of span
10% of
span

Material specification
Galvanised steel: Interior liner (D159): Aluminium:
Tata Steel Galvatite®, hot dip zinc coated steel Tata Steel Galvatite®, hot dip zinc coated steel Stucco embossed or plain Aluminium.
EN 10326-S280GD+Z275. EN 10326-S320GD+ZA100 substrate, with Aluminium alloy to BS EN 485-1/2/3/4:1995.
Guaranteed minimum yield stress 280N/mm2. Colorcoat® Interior Liner 15 micron coating to Mill and stucco - grade 3005 H27.
Minimum zinc coating mass 275g/m2 total interior, colour: bright white. ARS coated - grade 3004 H44.
both sides. (Except D159 which uses
Interior liner (Tata Steel NL Profiles): RoofDek profiles are also available with
EN 10326-S320GD+Z275).
Tata Steel Galvatite®, hot dip zinc coated steel Colorcoat HPS200 Ultra® pre-finished steel.
Interior liner steel (standard decks): EN 10326-S320GD+ZMA100 substrate, with For further information please contact us.
Tata Steel Galvatite®, hot dip zinc coated steel Colorcoat® Interior Liner 15 micron coating to
EN 10326-S280+ZA80 substrate, with interior, colour: Hamlet (RAL 9002) for Tata
Colorcoat® Interior Liner 15 micron Steel Europe decks.
coating to interior, colour bright white.

01244 892 199 | www.tatasteelconstruction.com/roofdek 13

RoofDek Structural design

Structural design
Structural
Eurocode design
BS EN 1993 Eurocode 3: Design of steel
structures.
Part 1-3: Cold-formed thin gauge members
and sheeting.
BS EN 1999 Eurocode 9: Design of aluminium
structures.
Part 1-4: Cold-formed structural sheeting.
British Standards design
BS5950 Structural use of steelwork in building.
Part 6: Code of practice for design of light
gauge profiled steel sheeting.
Part 9: Code of practice for stressed skin
design.
Loading UK National Annex to Eurocode 1
Eurocode design Actions on structures
Calculate loading to BS EN 1991 Eurocode 1: Part 1-1: General actions – Densities,
Basis of design and actions on structures. self-weight, imposed loads for buildings
Part 1-1: BS EN 1991-1-1 General actions –
Table NA.7 – Imposed loads on roofs not
Densities, self-weight, imposed loads for accessible except for normal maintenance
buildings. and repair
Part 1-3: BS EN 1991-1-3 General actions – Roof slope, αk Qk
Snow loads. α degrees kN/m2 kN
α < 30º 0,6
Part 1-4: BS EN 1991-1-4 General actions –
30 º < α < 60º 0,6[(60 – α)/30] 0,9
Wind actions.
α >= 60º 0
British Standards design
Calculate loads to BS 6399. Span types
Part 2: 1997 Code of Practice for wind loads. Single span – one length of deck with a
support at each end.
Part 3: 1988 Code of Practice for imposed roof
loads (including snow and snow drifting). Double span – one length of deck with a
support at each end plus a support in the
Fragility middle.
Non-fragility requirements are determined by Multi span – The length of deck extends over
ACR(M)001:2000 Test For Fragility of Roofing more than 3 supports.
Assemblies (second edition).
Where the deck end laps, it must be lapped
over by at least 50mm. This does not provide
continuity – extended end laps are required
for continuity, please see previous page.

14
 RoofDek Diaphragm design

Diaphragm design
Function of diaphragm action Limitations Irregular roof plan
showing division into
• Transfers wind load from walls to brace • Diaphragm area must be surrounded by at diaphragms.
walls running perpendicular. least 3 braced walls.
• Replaces in plane roof bracing. • Deck must be fixed to the structure on all 4 C Vertical bracing
edges of diaphragm area.
Benefits Roof Light
• Removes visual clutter in the roof - popular To design we need: B
with architects • Drawings showing deck layout and braced
• Saves money by removing some of the steel walls. A D
elements. • Line loads at diaphragm edges.

Seam Fasteners Purlin

Rafter

Purlin/Rafter
connector

Sheet/Shear
connector fastener

Shear Connector

Edge Member Sheet Purlin

(Purlin) Fastener

Diaphragm analysis
program
We offer a free diaphragm design service.
The analysis assumes that the diaphragm area
is rectangular and braced on at least 3 sides.

At the time of publication, our analysis uses

BS EN 1993-1-3.

01244 892 199 | www.tatasteelconstruction.com/roofdek 15

RoofDek Tested acoustic systems

Acoustic systems
Sound absorption and reduction
Tata Steel has carried out a number of acoustic tests at Salford University which examines the sound absorption of the most popular acoustic
decks and trays in the range.

Absorption (αp)

D46 D60 D100 D159 HLT130/600

Frequency Open Filled Open Filled Open Filled Open Filled
(Hz) trough trough trough trough trough trough trough trough
125 0.95 1.00 0.90 1.00 0.95 1.00 0.95 1.00 1.00
250 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
500 1.00 0.95 1.00 1.00 1.00 1.00 1.00 1.00 1.00
1000 0.85 0.90 0.85 0.90 0.80 0.85 0.50 0.60 0.95
2000 0.50 0.60 0.50 0.60 0.50 0.60 0.30 0.55 0.85
4000 0.40 0.40 0.35 0.45 0.40 0.45 0.35 0.50 0.85

αw 0.55 0.60 0.50 0.60 0.55 0.60 0.40 0.60 0.95

CLASS D C D C D C D C A

PIR – for sound reduction Rain noise

• Kingspan insulation (SRL test report
C/00/5L/7950/1)
• Weighted Sound Reduction Index Rw =
27dB
• Mechanically fastened single ply membrane
system
• Kingspan Thermaroof TR26 (85mm)
• Polythene vapour control layer
• Tata Steel D60 0.7mm steel deck
PIR + Rubbertech – for sound
reduction
• Kingspan insulation (SRL test report
C/03/5L/0830/2).
• Weighted Sound Reduction Index Rw =
35dB.
• Mechanically fastened single ply membrane
system.
• Kingspan Thermaroof TR26 (85mm).
• Rubbertech R10 Acoustic Membrane.
• Polythene vapour control layer.
• Tata Steel D60 0.7mm steel deck.
Approved Document E, 2004
Amendment requires construction of new
school buildings to follow guidance provided
by Building Bulletin 93. BB 93 advises
designers to consider the effect of impact
noise from rain at an early stage of the roof
design in order to minimise disturbance
within the building.
What constitutes a problem level of rain noise
is subjective. Roof systems employing a
weatherproofing layer in full contact with
insulation, supported by a metal deck are not
usually problematic in practice. However for
more critical applications rain noise may be
reduced by the selective specification of the
insulation system, and to a lesser extent the
membrane, the fixing system, and the vapour
control layer.
Rain generated impact sound transmission is
measured by a test to Draft International
Standard ISO 140-18.
A tank positioned 3.5m above the test roof is
filled with water and consistently recharged.
The perforated base area, height and flow rate
are calibrated to ensure a rainfall intensity of
0.67 Lmin/m3 (40mm/h). Sound intensity
measurements are taken below the roof
construction in the frequency range of 50 Hz
to 5000 Hz.
Indicative sound level test results on D60
0.7mm deck are between 52 - 60dB.
The sound intensity level measures the
amount of sound being transmitted through
the roof and therefore the lower this figure is,
the better.
Further details, test reports and details of
other combinations are available from
Rockwool Limited and Kingspan Insulation
Limited respectively.

16
 RoofDek Tested acoustic systems

Sound reduction
RoofDek D60 typical acoustic build up
Fully bonded single ply membrane system

1.5mm thick PVC single ply membrane fully adhered

100mm thick Hardrock Dual Density SPA

2mm thick aluminium cored vapour control

50mm thick Hardrock Dual Density TFA layer

Tata Steel RoofDek D60 web perforated deck

• Absorption co-efficient (αw) = 0.55

• Absorption Class D
• Weighted sound reduction (Rw) = 39dB

Sound reduction
The acoustic performance of the profiled metal cladding construction CAUTION: The Predicted SRI values should be used only to provide
detailed below has been predicted using a computer programme guidance for preliminary design and/or appraisal of build construction
developed by the Department of Applied Acoustics at the University of systems. Laboratory measurements should still be used to provide
Salford under a research contract funded by the Metal Cladding and definitive acoustic data. For a project specific calculation contact
Roofing Manufacturers Association. Tata Steel Technical Department on 01244 892 199 or e-mail:
roofdek@tatasteel.com
Predicted sound reduction values (dB)
Construction details (typical)
Frequency 0.7 mm 0.9 mm 1.2 mm Weather sheet: Membrane thickness = 1.2mm
(Hz)
Insulation: Cavity width = 200mm
100 17.4 19.4 21.7
Insulation thickness = 200mm
125 19.2 21.2 23.7
Density = 80kg/m3.
160 21.8 24.0 26.5
Fixing spacing = 233mm
200 26.1 28.3 30.8
Purlin spacing = 4000mm
250 30.4 29.9 29.5
Type = SOFT
315 30.1 35.7 35.4
400 29.3 40.2 40.6 Liner Sheet: D100 Pitch = 233mm
500 22.4 39.2 45.1 Crown = 109mm
630 37.0 37.8 50.0 Valley = 63mm
800 45.3 31.2 48.6 Depth = 100mm
1000 56.4 45.3 47.2 Thickness = 0.7/0.9/1.2mm
1250 60.8 56.4 39.3
1600 59.9 67.0 56.7
2000 70.6 66.9 67.2
2500 75.5 76.6 74.9
3150 77.8 81.9 83.1
4000 86.4 85.1 88.8
5000 91.9 93.0 92.8

Weighted Rw 37.0 dB 40.5 dB 43.2 dB

01244 892 199 | www.tatasteelconstruction.com/roofdek 17

RoofDek Roof safety

Roof safety
Latchways have conducted numerous tests Thereafter Latchways Plc. strongly
using the Constant Force® Post in recommend that any annual inspection, re-
conjunction with Tata Steel RoofDek. certification or servicing of ManSafe products
The information below shows a typical be undertaken by a Latchways Registered
application of a Latchways Mansafe® system Installer.
with a Single Ply membrane roof. Only a Latchways Registered Installer will have
received the necessary Latchways training,
Installation, Annual Inspection have access to technical documentation and
and Certification original parts should replacement be
Only a Latchways Registered Installer is able to necessary.
design, supply, install and certify Latchways
ManSafe products. For further details please contact Latchways
directly on +44 (0) 1380 732700.

Profiles & widths

Base plate fixing centres†

Base plate Steel deck
fixing centres specification
459 D32S
459 D35
210 D46
210 D60
210 D100

The Single Ply Constant Force post is suitable for use with insulation thicknesses’ of 50 mm – 220 mm. The advice of the Single Ply The base plate fixing centres must line up with the crowns of
manufacturer should be sought when specifying all aspects of the vapour control layer, fasteners, waterproof covering and overall the steel deck.
roof construction. † Latchways reference to base plate fixing centres is defined as
All roofing components must be installed strictly in accordance with the manufacturers’ recommendations and specification. the width of the fixing points for the Latchways base plate.
The standard colour of the post is Dark Grey – RAL 7037. Other colours are available to order at additional cost subject to availability
and lead time. Contact Latchways technical department for further information. The post is not suitable for use within gutters or
areas where standing water occurs. Adequate falls for drainage must be provided within the finished roof construction.
The welding of the Single Ply membrane to the Constant Force post base plate must strictly follow the Single Ply manufacturer's
recommendations regarding application and working temperatures.

245mm

6,000 – 10,000mm 6,000 – 10,000mm

Weld Weld

Single Ply membrane

Protective plastic cap

Plastic toggle guide

Toggle bolt

18

Service and support
Tata Steel maintains a friendly technical help
desk which is freely available to all
Architects, Engineers and Contractors to
assist with all aspects of RoofDek and liner
tray design.
01244 892 199 | www.tatasteelconstruction.com/roofdek
Specification service
The Tata Steel RoofDek team are able to
provide a comprehensive Specification
Service. Assistance in creating NBS
specifications for RoofDek and trays can be
provided to ensure the correct deck or tray is
specificed for the right application.
Design calculations & diaphagm
design
To assist the specifier, the team are able to
provide design calculations for live, dead,
wind and snow drift loads and where required
diaphragn design calculations.
RoofDek Service and support
Analysis Software
RoofDek Analysis Software has been created
in partnership with leading international
developer CSC, best known for the very
widely-adopted Tedds structural design
software. With all calculations compliant with
Eurocodes, the package enables structural
engineers and designers to carry out full deck
analysis to achieve optimum design and cost
efficiencies.
To download the RoofDek software, visit
www.tatasteelconstruction.com/roofdek
19
RoofDek Sustainability
Sustainability
At Tata Steel, we are committed to making the
products society needs and to making them in
the safest and most responsible way possible.
CO2 is a by-product of the steel making
process and we have a well-developed
strategy to minimise our CO2 footprint. In fact,
over the last 40 years we have reduced the
energy needed to produce steel by 50%. And
we have set a target of reducing our CO2
emissions by a further 20% in the next ten
years.
Some of our savings in CO2 come from major
investments, like the recovery of waste gases
at our Port Talbot site. This investment of
£60m is already saving 297,000 tonnes of CO2
emissions annually. Other reductions have
come from smaller site-based initiatives such
as the zero-carbon scheme at our Shotton site.
Since starting this in 2005, the site has
reduced its CO2 footprint by more than 25%.
We are also investing in the future to realise a
major step-change in steel making with lower
20
CO2 emissions. We are a leading partner in the All Tata Steel manufacturing sites are certified
€59m ULCOS project which aims to cut the to ISO 14001, the international standard for
CO2 emissions from steel production by 50% environmental management systems. We also
by 2050. recognise the responsibility we have both up
and down our supply chains and we work to
The first phase of ULCOS involved research to
ensure that sustainable practices are adopted
evaluate a new generation of steel making
throughout by close co-operation with both
technologies, while the second phase will
suppliers and customers.
operate the most promising of these on a
demonstration plant. The pilot HIsarna For more information on our sustainability
furnace is operated by Tata Steel, in strategy, visit www.tatasteelconstruction.com/
cooperation with representatives from steel sustainability
plants across Europe and will demonstrate
technology for producing steel with up to
50% less CO2 emissions. This is potentially the
first step to the dawn of a new era in steel
making.
For Tata Steel, sustainability is not all about
CO2. There are initiatives ongoing across our
sites to reduce waste, minimise emissions and
contribute to our communities.
“We take our
responsibility as a
sustainable steel
producer very
seriously and have
taken a leading role
in reducing CO2
emissions across
the steel industry.”
Tata Steel’s Shotton site – now with 25% less CO2
emissions than in 2005.

Peacehaven
RoofDek D100 Case Study
Wastewater Treatment Works
Peacehaven, E. Sussex
Featuring the UK’s largest curved green roof
and covering an area equal to 2.5 football
pitches, Southern Water’s £300m, state-of-
the-art water treatment plant will service the
entire Brighton and Hove area. The roof
features over 18,000m2 of Tata Steel
RoofDek D100 and the Tata Steel C19 profile
on the walls, all in Olive Green, double-sided
Colorcoat HPS200 Ultra®.
Peacehaven Wastewater Treatment Works is
an environmental improvement scheme at
Lower Hoddern Farm in Peacehaven, East
Sussex, UK. The project will treat 95 million
litres (ML) of wastewater a day.
Designed to blend in with the landscape the
plant will treat wastewater generated from
Brighton and Hove, Rottingdean, Saltdean,
Telscombe, Woodingdean and Peacehaven
and is scheduled to be fully operational by
spring 2013.
01244 892 199 | www.tatasteelconstruction.com/roofdek
The biggest challenge on-site was logistics in
terms of transferring the thousands of tonnes
of substrate onto the roof and covering the
complete area using mobile tower cranes. To
overcome this issue, a series of conveyor belts
were used to transport the volume of material,
which was then raked to follow the curve of
the building.
The green roof has been installed over
18,000m2 of Tata Steel RoofDek D100 in Olive
Green double-sided 0.9mm Colorcoat HPS200
Ultra®.
Designed to accommodate the additional
loadings imposed by green roof construction,
RoofDek D100 features a 700mm cover width
and a 233.3mm pitch that provides a very
strong deck and offers excellent insulation
support. Its lightweight construction also
minimises the load on the building structure.
RoofDek Case Studies
“The metal deck single ply structure with
shear batten support overcame initial design
concerns,” explained Project Manager Paul
Webb.
The project involved a total envelope solution,
including walls featuring the Tata Steel C19
profile in Olive Green 0.7mm double-sided
Colorcoat HPS200 Ultra® in single and double
skin configurations. Colorcoat HPS200 Ultra® is
the most durable pre-finished steel on the
market.
Based upon a revolutionary coating system,
Colorcoat HPS200 Ultra® provides outstanding
colour and gloss retention, and corrosion
resistance even at the cut edge.
Double-sided Colorcoat HPS200 Ultra® is ideal
for the demanding internal environment at
Peacehaven Wastewater Treatment Works,
where the same unique formulation topcoat
and corrosion-resistant primer applied to the
reverse side provides a robust barrier on both
sides of the steel substrate.
21
RoofDek Case Studies

West Cheshire College

RoofDek D135 case study

Ellesmere Port Campus

and Chester Campus
West Cheshire College prides itself on its
standards of teaching and the courses it
provides. In order to enhance the learning
experience offered, it has committed to
building two new high-quality campuses.
Featuring ComFlor® composite floor decking
and RoofDek Structural Roof Decking, the
new facilities will improve vocational
opportunities for young people and extend
the range of opportunities for adults to
develop skills.

The Ellesmere Port Campus involves the

construction of a 19,500m2 new build art,
design and media, hospitality and catering
and hairdressing and beauty block. Running in
parallel, the Chester Campus construction
programme consists of a 6,000m2 state-of-the-
art science and technology teaching facility.
The main focus of both campuses is an
internal project court where vocational
students of different trades are able to work
alongside one another in building a house,
within the project court itself.

As part of the new build programme,

11,000m2 of ComFlor® 80 composite floor
decking was specified for both campuses.
Alongside this, 2,300m2 of RoofDek D135
structural metal roof decking was specified.

By offering a comprehensive range of steel

composite floor and roof decking systems, Tata
Steel were in the unique position of being able
to meet all of the roofing and flooring
requirements for the College project.

22
 RoofDek Case Studies

West Burton Power Station

HLT130/600 liner tray case study
CCGT Power Station, West Burton,
Nottinghamshire
EDF Energy's 1300MW Combined Cycle Gas
Turbine (CCGT) power station at West
Burton, Nottinghamshire, will meet the
needs of 1.5 million people. The project
features 40,000m2 of a Tata Steel Acoustic
Structural Liner Tray Built Up System, for
high sound reduction and absorption levels
in three giant turbine halls.

It is adjacent to EDF’s existing 2,000MW coal

fired power station and has been built using
advanced, yet proven technology to provide
an efficient and flexible power station to meet
future energy supply requirements and to
help reduce the intensity of the company’s
CO2 emissions from its electricity production.
A major construction project by any standard,
West Burton CCGT saw over 1000 individual
contractors working on site at the height of
the very complex build programme.
The project’s three 32m tall, steel-framed
turbine halls, each measuring 82m long x 35m
wide, feature a total of 40,000m2 of a Tata
Steel Acoustic Structural Liner Tray Built Up
System, installed by Hertel Technical Services.
The very stringent acoustic requirements were
fully met at West Burton, thanks to the wealth
of experience Tata Steel could bring to the
project, drawing on an excellent track record
in full acoustic systems at other CCGT power
station projects at Rye House, Hertfordshire
and Killlingholme, Lincolnshire.
The roof and wall constructions feature the
Tata Steel HLT130/600 0.75mm gauge
acoustic structural liner tray.
Forming the base of a roof and wall
construction incorporating two dense mineral
fibre insulation layers, HLT130/600’s inherent
properties greatly assisted sound reduction
and absorption, simultaneously controlling
noise breakout and reducing internal high and
low frequency noise levels in the three halls.
A sound reduction figure of 36dB was
achieved in each of the halls, significantly
reducing their acoustic impact in the
surrounding area.
The built up roofing and cladding system
included a rigid mineral fibre slab in the pans
of the HLT130/600 structural liner tray.
A further semi-rigid mineral fibre slab was
inserted above the tray flanges. This was
separated from the rigid insulation layer by a
flat 0.7mm galvanised steel sheet, helping to
provide vital mass in the built-up system
The external roofs feature the Panels and
Profiles R32 profile. The external walls are clad
in the C32 profile.
Both products have a 0.7mm Colorcoat
Prisma® Silver Metallic finish, plus a Denim
finish on the lower levels of C32. Versatile,
lightweight and strong, Colorcoat Prisma® is
an ideal choice when it comes to exposed
external environments like West Burton.
Offering outstanding UV resistance, Colorcoat
Prisma® gives first-class colour and gloss
retention, following comprehensive natural
weathering testing in a variety of contrasting
climates.

The R32 roof profile accommodates 800

metres of lightweight aluminium walkways,
complete with tubular handrails, with stainless
steel fixings to the Panels and Profiles sheets.
This facilitates easy servicing of 100 rooflights
and ventilators on each of the three roofs,
which also feature parapet walls in C32 on all
sides.

01244 892 199 | www.tatasteelconstruction.com/roofdek 23

www.tatasteelconstruction.com/roofdek

Trademarks of Tata Steel

Colorcoat, Colorcoat HPS200 Ultra, Colorcoat Prisma
and Galvatite are trademarks are registered
trademarks of Tata Steel UK Limited.

Care has been taken to ensure that the contents of

this publication are accurate, but Tata Steel Europe
Limited and its subsidiaries, (including Tata Steel UK
Limited), do not accept responsibility or liability for
errors or information that is found to be misleading.
Suggestions for, or descriptions of, the end use or
application of products or methods of working are
for information only and Tata Steel Europe Limited
and its subsidiaries accept no liability in respect
thereof.

Before using products or services supplied or

manufactured by Tata Steel Europe Limited and its
subsidiaries, customers should satisfy themselves as
to their suitability.

Printed with biodegradable vegetable inks on

material sourced from responsibly managed forests,
certified in accordance with the FSC. Contains 10%
recovered fibre, diverting waste from landfill.

Sales Contact Details

Tata Steel
Shotton
Deeside
Flintshire
CH5 2NH
United Kingdom
T: +44 (0) 1244 892 199
F: +44 (0) 1244 892 121
E: roofdek@tatasteel.com

Copyright 2016 Tata Steel UK Limited, Registered Office: 30 Millbank London SW1P 4WY, Registered in England No. 2280000

Language English UK 0716