06-Self Supporting Roofing System-Umeshlavingia

06-Self Supporting Roofing System
Bio data of Mr. Umesh Lavingia

Education:
B.Engg. [Civil] , M. Engg. [Civil Str.] I.I.Sc.
Professional:
M.I.E., M.GICEA, Registered Valuer, Chairman for
Structural Engineering
Committee at GICEA, Ahmedabad.
Educational Activities: Prof. CEPT University, 2000-2007
Guide for the thesis at SBST CEPT University for
Masters Programme.
Guide for the thesis at Nirma University for Masters
Programme.
Examiner at various universities and institutions.
Professional Activities: Managing Director, Lavingia Consultants Pvt. Ltd., a
consulting engineering
with completion of 1500 projects including Large
School Project at Nairobi,
Kenya and Apartment building in London, U.K.
Director, Lavingia Communication Pvt. Ltd.,
Digital display system design
And development company.
Managing trustee:
Centre, Ahmedabad.
Arbitrator :
and Institutes.
Lectures:
at L.D.Collage of
Shree Gordhandas Patel Diagnostic and Research

In various cases of Civil Engineering works of Court
1. Polymer Concrete to the teachers of Engineering Collage

Engineering at Ahmedabad.
2. PERT /CPM technique to the professional body of

engineers organised by
Hydrabad based institute.
Seminar Document- REDECON 2010
3. Automatic Roofing Machine Technology at Seminar of

Advance Construction
Materials at CEPT University, Ahmedabad.
4.
Waste in Construction , Lecture on Engineers day 2005,
School of Building
Science and Technology, CEPT University.
5. Pre Engineering Buildings at the Gujarat Institute of Civil
Engineers & Architects,
Ahmedabad.
6. Number of Seminars on Earthquake affected structure
and its restructuring.
Self Supporting Roofing System

Development:
Efficient and judicious utilisation of materials and manpower in the quest
of modern life style of the society leads us for the introduction of
development which are caused due to the research and development
done by the people.
Structural supporting system is evolved out of the experimentation by
human race on the study and understanding of the behavioural pattern of
the natural elements and requirement as per the need of that day.
Historically if we observe then we can find number of examples of
supporting systems with arch action and folded plate action which has
been used in many ancient monuments. The advantages of these two
shapes had been well understood and applied in the various style for
covering and supporting many structures.
During the war time in the desert there was an acute need for
development of the system which is totally full proof against the dust and
natural forces. The new system should have a process of execution which
is absolutely fast and versatile in nature for its applicability in various
adverse conditions.
Meanwhile it has been observed that arched shape steel structure is most
suitable under the required conditions. With research and development
the army has evolved a system of utilising the steel plate to form a
required shape with additional crimping in it to have better strength and
span covering.
Self supporting Roofing System is the innovation of war time requirement
where seamless roofing structure is created from the steel plate giving
system which does not require intermediate supporting like Trusses ,
Purlins etc. This system gives rise to an elegant and pleasant structural
covering to various structures.
Structural behaviour of arch action and folded plate action is used in
formation of the profile development from the steel plate which is utilised
for the development of the skin for covering as roofing system. Seaming
technique is used to combine various elements of the developed skin
structure. Modern methodology of material lifting and fixing is also

applied to place the developed system in its proper place.
The whole technology is designed and developed in such a way that the
complete process of development of skin structure and its erection and
fixing is done at the site with utmost speed and accuracy which give rise
to an absolute elegant covering system with cost effectiveness.
Process:
FABRICATION AND INSTALLATION PROCESS:
The Two feet profile [TFP] roll-forming equipment forms a profile

having a finished width of approx 605 mm. The TFP roll-forming
equipment has 2 sets of rollers. Once the desired material is fed in
coil form, a straight panel of the required length is formed through
the 1st set of rollers and cut by a guillotine shear blade. This
straight panel is then fed into the 2nd set of rollers, which forms the
horizontal & vertical stiffening members, giving the panel a
curvature of the desired radius (as per the Design & Engineering of
the Arch Configuration). These curved panels are then placed on the
ground for further process. The profiling is done to the accuracy of a
2-4% tolerance in the Centre Rise.
This roll-forming equipment shall be placed inside the factory shop

floor of a predetermined size for an efficient manufacturing and
manoeuvring of panels (this shall depend on the size of an
individual panel & working area requirement). This equipment
requires a flat, levelled and a solid-compacted surface so that it can
be properly aligned. Hence the building contractor shall cooperate
with roofing system provider and their Project / Site Engineers.
There will be a labour force of approximately 25-30 people involved

in the manufacturing process, depending on the length & weight of
the panel. This involves all the activities pertaining to the
manufacturing of the TFP panels.
Once the panels are fabricated and placed on the ground, they are
taken up for inter-connection with each other. These panels are
placed on top of each other, side ways, so that they fit into their
male-female formation.
Metal hooks / hangers to suspend light fixtures / cable trays / ducts

/ point loads, etc., will be placed at their (PREDETERMINED)
locations before the panels are placed on top of each other. Each of
these hooks / hangers has a load bearing capacity of approx. 20- 25
kgs. Point load (however, this shall depend on the final thickness of
the material that has been chosen). It is mandatory for the lay-out
to be predetermined and to be spelt out to roofing systems
Engineers where such provisions are necessary. It would not be
possible to provide such requirements once the profile is seamed.
The male-female formation is crimped together using mechanical

seaming machines, which imposes a load of approximately 5 tons to
insure the seaming is of the required rigidity. These panels are
connected in sets of 3 panels each, depending on the lifting capacity
of the crane & other relevant factors. Each set of 3 panels is called a
PICK. After seaming, a clear epoxy lacquer is applied on the inner

side of the panel ends (6-wide band). This forms a protective layer
between the surface of panels and concrete beam to avoid direct
contact and prevent any kind of damage to the material.
Roofing Profile, the TFP, is installed over concrete gutter-beams.
The RCC sub-structure has to be designed considering the arch
reaction data & load combinations given by roofing system provider.
It shall be within the purview of the Consulting Engineer to ensure
the structure is designed to cater to the adverse load conditions.
There is also a system for the gutter in steel form. This is applied
with the help of
forming the gutter out of steel plate supported on steel
structural system and it is
fixed in the same fashion with self priming screws on it.
ACCESSORIES:
Accessories like ventilators and skylights can be provided with

Systems' Roofing at the crown/ridge only by making cut outs in the
roofing panel. Cut out can be provided at every 10th panel (i.e. 20
ft) in case of TFP in the longitudinal direction of the building.
The size of ventilator is 24 diameter and its capacity is 2200 CFM.

As thumb rule calculations, you can provide one ventilator for every
100 Sq. mtrs area.
Skylights are of 2 mm polycarbonate material. 2 x 7 is std. This

can be worked out in other sizes as per requirement in the multiple
of above dimentioning.
The roofing system provider will provide and ensure the following:
The line, level and the alignment of the slope-beam along the entire
length will be checked by Engineer after the concreting. No plaster
on the slope of the beam will be allowed. Contractor will be given
the guidance by roofing system provider to ensure the work is as
required. In case of any flaw, the Consulting Engineers office should
be referred for the ways the rectification is to be carried out.
Before erection, a Schmidt Hammer test of the concrete will be

carried out to ensure that the anchor bolts could be securely fixed
on the support. The scheme of Roll Forming, Fabrication and
Seaming on the ground will be finalized by roof system provider
with respect to their operation, storing of raw materials, movement
of cranes, assembly of the panels, etc.
The installation process has to be carried out from inside the

building from the shop floor. In this case, a hard-compacted & a
levelled floor are is required, where the crane shall be placed &
moved along the length of the building as the installation is carried
out. The installation shall start from one end of the building in one
bay, and moving along the length of the building, the process shall
be completed. The second bay shall be completed by following the
same process.
Each PICK of panels will be lifted with the crane using a spreader
bar and a sling evenly placed to ensure no distortion of the panel
takes place during lifting and placing. The crane shall hold / support
the PICK of panels till the alignment is done and completed using a
plumb & a water tube, and is bolted into the beam. To ensure these
panels dont shift from their alignment, they shall be tied up with a
guy rope to hold them in place. They will be supported with this
rope till enough panels are installed to form a square, i.e., till the
length and span are of an equal dimension.
The junction of the panels to the gutter beam shall be made using
either 2-3 anchor bolts of the desired size on each end of the panel
(depending on the stability requirement as derived from the Design
calculations). GI anchor Bolts of required sizes and type, with 2.5
inches G.I vicer & neoprene washers would be provided as
determined by the analysis during Design.
The installation process shall not be carried out in case of

unfavourable weather conditions like rain and / or in case when the
wind-speed is higher than 22 km/hour.
After all the panels are in place and installed, the same epoxy
lacquer is applied at the junction of the panels to the beam where it
has been bolted to form a protective layer on the bolts and the
holes underneath.
After installation of the TFP panels, because of the profile design,

trapezoidal voids are created between the gutter-beam and the panel
corrugation. These voids will then be covered by a flashing, fabricated
from the same sheeting material, or brick mortar. These voids shall be
covered to make the system water-tight.
Material usage:
The panel to be structurally strong to withstand loads as required by the

relevant building codes. These roofing panels to be manufactured from
superior quality, structural grade steel as per the specifications.
Base metal :
Steel Grade:
Cold rolled structural quality steel in the coil form.

Grade D ; 350 MPA Yst. Min.
Standard :
ASTM A792, Steel Sheet, Aluminium-Zinc alloy coated by
hot dip process.

Bare Galvalume coating: AZ 150, 150gms/sq.m. Alu-zinc coating [55%
Al. & 45%Zn.]
Coil width:
914 mm, Tolerance: -0.02 to +0.02mm
Normally material used in this cases is imported galvalume of thickness

varying between 0.70 mm to 1.6 mm, depending on the span. Apart from
the well-known inherent strengths as compared to the conventional G.I.
Sheets, Galvalume withstands continuous and intermittent exposure to
temperatures of up to 600 F, without discolouration and up to 120 F
without heavy oxidation and scaling.
Galvalume steel reflects twice as much heat and light as galvanised steel
and acts as a heat shield in roofing. This make galvalume an ideal
material for energy efficient buildings. During summer, it makes building
cooler by efficiently reflecting away sunlight and reducing the amount of
heat transmitted in to the building. Likewise it makes building warmer in
the winter by reflecting inside heat from underside of the roof back into
the building .
This good thermal reflectivity translates into Energy savings for the
building.
Structural Behaviour:
Structural behavioural pattern needs to be understood very correctly in
this case, otherwise some times wrong interpretation of forces and not
providing proper and simple structural elements leads to failure.
The roofing system provider gives per running meter loading due to the
various kind of forces generated because of dead load, live load, wind
load from different direction etc.
It is absolutely necessary for the designer of the structure to interpret
these loading as per the codal requirement of load combinations and
provide the structure to withstand all these load combinations. Failure to
understand cause the failure of the supporting system and damage to the
human beings also.
Comparative analysis with other systems.

Sr. Points of
No. Compariso
n
A.C.Sheet
MS
Precoated
color
Pre
Engineering
Self
Supporting
Structure.
MS tubuler
Structures.
Roofing
System
@ 5 mts.
c/c
@ 5.5 mts.
c/c
@ 8 mts. c/c
@ 6 mts. c/c
Costly
Long term
moderate.
Support
Spacing.
Cost
Economical Moderate
effectivene
ss
Fabrication
&
installation
speed.
1000 sq.
mts.
Normally
takes 25 to
30 days.
1000 sq.
mts.
Normally
takes 25 to
30 days.
1000 sq. mts.

Normally
takes @ 7
days.
2000 sq. mts.

Normally
takes @ 1
day.
Enclosed
volume
Restriction
due to
Trusses &
steel frame.
Restriction
due to
Trusses &
steel frame.
Less
obstructions
because of
the Portal
system.
Unobstructed
clear span
facilitates
larger
encl.volume.
Leakage
and
corrosion.
Use of J
hooks &
bolts make
it prone to
leakage &
corrosion @
30%chance
s.
Use of J
hooks &
bolts make
it prone to
leakage &
corrosion @
30%chances
.
Leak proof as
well as
corrosion free
@ 10 %
chances.
Leak proof as
well as
corrosion free
@0%
chances
Maintenanc Due to
e
leakage &
corrosion in
roofing
require to
maintain
Due to
leakage &
corrosion in
roofing
require to
maintain
Require less
maintenance
i.e. in @ 10
years.
No
Maintenance
in the long
run.
yearly.
yearly.
Height of
the
structure.
Height can
be
restricted
due to
trusses.
Height can
be restricted
due to
trusses.
Can reduce
height of
overall
structure due
to use of
Portal frames.
Elimination of
truss can
reduce height
of over all
structure.
Lighting
and
Illuminatio
n.
Obstruction
in natural
and
artificial
lights.
Obstruction
in natural
and artificial
lights.
Less
obstructed
natural and
artificial
lights.
Unobstructed
natural and
artificial
lights.
Ventilation
and
temperatur
e
consistency
.
Temperatur
e
consistency
is not good.
Obstruction
in clear air
flow.
Temperature
consistency
is not good.
Obstruction
in clear air
flow
Less
obstructed air
flow and
superior
temperature
consistency.
Unobstructed
air flow,
superior
temp.
consistency &
less
consumption
due to proper
ventilation.
10
Working
Use of
Moderate
Environme asbestos
nt.
sheet is not
recommend
ed.
Comfortable.
Excellent.
11
Suitability
in case of
Gantry
[E.O.T.]
Well
Recommen Recommend Not
ded
ed.
recommended suitability.
12
Aesthetic
Appearanc
e.
Average.
Average.
Good and
appealing.
Beautiful due
to arch shape
& colors.
Indicative costing:
Presently approximate indicative costing for this kind of system of roof
covering can be considered as under.
Span up to 15 mts. : @ Rs. 1250/= per sq. mts of laid area.
Span up to 20 mts.: @ Rs. 1400/= per sq. mts. of laid area.
Span up to 25 mts.: @ Rs. 1600/= per sq. mts. of laid area.
The whole system is fast, elegant, economical and versatile in nature
which give a solution which is absolutely eye pleasing and long lasting
without any trouble in its life span with numerous advantages.

06-Self Supporting Roofing System-Umeshlavingia

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06-Self Supporting Roofing System

Bio data of Mr. Umesh Lavingia

B.Engg. [Civil] , M. Engg. [Civil Str.] I.I.Sc.

Shree Gordhandas Patel Diagnostic and Research

1. Polymer Concrete to the teachers of Engineering Collage

2. PERT /CPM technique to the professional body of

Seminar Document- REDECON 2010