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Hardrock Dual Density PDF
Hardrock Dual Density PDF
B
Hardrock Dual Density Boards – J42:425, J41:425 CI/SfB (47) Rm1 (M2)
February 2005 (replaces June 2004 issue)
UKAS UKAS
QUALITY ENVIRONMENTAL
MANAGEMENT MANAGEMENT
003 003
ASSESSMENT OF PRODUCTS FOR CONSTRUCTION
Standards and approvals Hardrock Dual Density Roofing Boards offer a high level of fire
safety. When tested under new EU linings fire classification
Rockwool Hardrock Dual Density Roofing Boards comply
system – for non combustibility to EN ISO 1182, and/or Gross
with the requirements of BS EN 13162: 2001, ‘Thermal
calorific value to EN ISO 1716 – Tissue faced products achieve
Insulation products for buildings Factory made mineral
the best A1 classification.
wool (MW) products specification.’
Factory Mutual
Based on fire testing to BS 476 Part 21: 1987 using standard
Hardrock Dual Density (Tissue faced) roofing boards are roofing components, Rockwool Hardrock Dual Density
Factory Mutual approved for Class 1 insulated steel deck Boards provide 60 minutes fire resistance, for both integrity
constructions. Approval Report No. J.I. 3015604. and insulation, when insulating a profiled steel deck roof.
The construction included a mechanically fastened single
Environment ply membrane – LPCB reference number 022a/01.
Rockwool products rely on trapped air for their thermal Details of the test construction and component materials
properties, which has neither ozone depleting nor global are available on request from the Rockwool Technical
warming potential. Sales Department.
Sound absorption
Sound reflection is often a problem experienced in
buildings such as manufacturing plants, convention and
sports halls. The use of Hardrock Dual Density Roofing
Hardrock Dual Density
Boards in conjunction with perforated steel decking
(Tissue Faced) Roofing Board
provides sound absorption within the building, thereby
Dimensional stability improving the environment for work and leisure.
2
Acoustic continued Rain Noise
Impact noise from rain must be considered at an early part
1.5 mm single ply membrane in the roof design, due to the fact that this can significantly
mechanically fastened increase the indoor noise level. Approved Document E –
150 mm single thickness Resistance to the passage of sound, 2004 Addition, requires
Hardrock Dual Density (tissue faced) Roofing Board the construction of new school buildings to meet
appropriate acoustic standards. Building Bulletin 93
outlines the methods of compliance. This includes a
requirement to minimise the noise of rainfall on
lightweight roofs and whilst no limit is set, methods of
control must be included and justified to Building Control.
U Values
The following examples
indicate typical U values
attained using Hardrock
Dual Density Roofing
Boards in combination with
mechanically fastened
single ply and built up
membrane systems.
19mm timber deck with 150mm dense concrete 150mm dense concrete Troughed steel decking
12.5mm plasterboard and deck and 50mm screed deck and 50mm screed without underlining
skim fixed to timber joists with 16mm plaster finish with suspended 12.5mm
plasterboard ceiling
* Calculations assume that insulation and membrane are of the telescopic type.
Calculations for individual constructions can be requested from the Rockwool Technical Sales Department on 0871 222 1780.
3
Hardrock Dual Density: Tissue faced boards
Hardrock Dual Density Roofing Boards are suitable for most Additional ballast may be needed for areas which are
types of roof deck. The glass tissue face of Hardrock Dual subjected to greater wind uplift, such as perimeters. This
Density (Tissue Faced) Roofing Board significantly reduces should be confirmed by the membrane manufacturer. The
bitumen uptake and ensures an excellent bond between the maximum combined weight of ballast and external loading
applied to the insulation board should not exceed 360 kg/m2.
first layer of membrane and the insulation.
Walkway routes, where required, should be established
Hardrock TFA is tissue faced top and bottom for use with
prior to laying the single ply membrane and be formed from
acoustic perforated profiled steel decks.
50 mm thick precast concrete paving slabs on purpose-made
Typical specifications and compatible support pads (Minimum 150 mm diameter).
1 Hardrock Dual Density (Tissue faced) Roofing Board Walkways to be fully supported by a load-spreading layer
with mechanically fastened single layer membranes applied between the insulation and the membrane.
The roof insulation is to be Rockwool Hardrock Dual Density
(Tissue faced) Roofing Board, as supplied by Rockwool The advice of the membrane manufacturer should be
Limited, Pencoed, Bridgend, CF35 6NY. sought when specifying all aspects of the vapour control
layer, fasteners, waterproof covering, fleece filter/cushion
The board size is to be: 2000 × 1200 mm or 2000 × 600 mm × layer, and construction of walkways.
.......... mm* thick.
3 Hardrock Dual Density (Tissue faced) Roofing Board
The boards are to be laid strictly in accordance with the with built-up high performance bituminous membranes
manufacturer’s recommendations, staggered, tightly
The roof insulation is to be Rockwool Hardrock Dual Density
butt-jointed and mechanically fastened through the vapour
(Tissue faced) Roofing Board as supplied by Rockwool
control layer to the deck. Walkways to be fully supported by
Limited, Pencoed, Bridgend, CF35 6NY.
a load spreading layer applied between the insulation and
the membrane. The board size is to be: 2000 × 600 × .......... mm* thick.
The advice of the membrane manufacturer should be sought The boards are to be laid strictly in accordance with the
when specifying all aspects of the vapour control layer, manufacturer’s recommendations, staggered, tightly
fasteners, waterproof covering and construction of walkways. butt-jointed and either fully bonded in hot bitumen or
mechanically fastened through the vapour control layer to
the deck.
The membrane must be bonded in accordance with
BS 8217: 1994. A ventilating sheet (3G) is not required.
The board size is to be: 2000 × 1200 or 2000 × 600 mm × 20mm thick two coat mastic asphalt roofing is to be applied
.......... mm* thick. over the sheathing felt / Hardrock Dual Density (Tissue
faced) Roofing Board in accordance with the appropriate
The boards are to be loose laid directly onto the vapour
Permanite Asphalt specification.
control layer, strictly in accordance with manufacturer’s
recommendations, staggered and tightly butt jointed. A project dedicated mastic asphalt waterproofing system
specification can be obtained directly from Permanite
The single ply membrane followed by a fleece filter/cushion
Asphalt Technical Services (Tel: 01629 582213.
layer should both be loose laid and installed over the
Fax 01629 583375. email: apd.tech@permanite.com).
insulation in accordance with the membrane
manufacturer’s recommendations.
4
Hardrock Dual Density: Cut to Falls
F E
• precision manufacture and supply to order
• site advisory service prior to and during installation. G D
C D E F F
G E C
Pre-cut Mitres F D deflector overlay
board
The use of factory made pre-cut mitres reduces site cutting E pre-cut valley mitre
C boards (see detail)
requirements and ensures accurate installation. D
pre-cut hip mitre boards
C (see detail)
U values
Consideration should be given as to whether an average or a
Typical Rockwool layout plan using Hardrock Dual Density Single Layer Cut to Falls system
minimum U value is required for the particular roof.
However, as a result of the tapered thickness of the Gutter runs and additional Cut to Falls systems
insulation, determining the overall U value for a particular A Hardrock Dual Density ‘Cut to Falls’ system can also be
roof requires a series of calculations. A full thermal provided for level gutters or other similar constructions.
calculation analysis is available on request. Even where existing falls are available and uniform
Hardrock Dual Density is used, a ‘Cut to Falls’ scheme may
A Cut to Falls system will normally enhance the thermal be required at certain locations on the roof to improve
performance of the roof in excess of Building Regulations drainage .The effectiveness of Cut to Falls gutters is
requirements. restricted to the available height created by the main roof
or other design considerations.
Cut to Falls pre-cut mitred
Achieved design fall
Deflector overlay boards boards at hip
Where practical, it is recommended that the minimum Deflector Overlay Boards are available to reduce the risk of
achieved design fall should be 1:60, with an enhanced water ponding behind rooflights, plant rooms and other
gradient of 1:40 at critical drainage points, such as gutters roofline obstructions.
or outlets.
Cricket overlay systems
Fixing Cricket Overlay Systems are used to improve drainage
Boards are delivered to site individually marked with a between rainwater outlets by introducing cross-falls where
positional code corresponding to the detailed layout none currently exist, as for example on a flat roof with falls
drawing provided. in one direction only.
The board layout should strictly follow that shown on the Cut to Falls pre-cut mitred
Typical specification boards at valley
drawing, and to avoid error it is advisable to place each
board in position temporarily prior to attachment. 5 Hardrock Dual Density Roofing Board cut to falls for
use with mechanically fastened single ply membranes or
The boards are either fully bonded to the vapour control
built-up high performance membranes
layer with hot bitumen or mechanically fastened through
The roof insulation is to be Rockwool Hardrock Dual Density
the vapour control layer to the deck. (see Design
Roofing Board Cut to Falls (Ref: CTF 1234), as manufactured
Considerations, page 6.)
by Rockwool Ltd, Pencoed, Bridgend, CF35 6NY. Minimum
thickness (.... mm)*, rising to a maximum thickness of
Good roofing design (.... mm)* with falls 1:60.
Flat roofs may include a variety of obstructions such as
The boards are to be laid strictly in accordance with the
rooflights, concrete plinths and air-handling units, where Use of Deflector Overlay Board
design drawings provided, Cut to Falls guidance notes and where the roof fall is obstructed
ponding water may collect unless correctly detailed.
manufacturer’s recommendations. by rooflight
Standing water may also occur at roof edges, held back by * insert as appropriate
the extra thickness of roofing membrane, or where outlets
are positioned at some distance from each other. The Cut to Falls specification should now be completed with the
appropriate clauses from specification 1 or 3 (page 4), together with
Where such situations arise, Rockwool offers various the selected membrane description.
solutions, by means of additional design features, which
also benefit the long term performance of the overall
roofing system.
5
Hardrock Dual Density: Design Considerations
Note: For 50 mm thick boards, the maximum trough width Mechanical fastening of insulation
is one and a half times the board thickness. (i.e. 75 mm)
1 Single ply mechanically fixed membrane systems
30 and 40 mm boards may not be cantilevered.
Where the complete roofing system is mechanically
fastened (for example single ply), Rockwool Limited
recommends that a minimum of one mechanical fastener is
used per board (or part thereof) to locate and secure the
boards during installation (see diagram opposite).
The tests conclude that for both the field area and the edge
region of flat roofs, sufficient stability is achieved when
using one fastener. For the corner region of flat roofs
external suction and internal pressure forces of up to 3.5
kN/m2 must be expected. However, it is universal practice in
such vulnerable areas to increase the number of membrane
Free spanning capability fasteners per m2, and also to reduce the distance between
For spanning, the minimum board thickness is equal to the the rows of fasteners.
maximum trough width divided by 3.
2 Fully bonded membrane system
Where installed trough widths exceed the maximum Where the membrane is fully bonded to the insulation Fastener with stress plate
spanning capability of the Hardrock Dual Density board, surface (e.g. with bitumen or adhesive) the number of support thread
provision must be made to provide full support for the mechanical fasteners per board should be determined by
insulation. windloading calculations conducted by the membrane
manufacturer.
single ply membrane
Factory Mutual
2000 mm
min. clear span For Factory Mutual specifications, standard Hardrock Dual
3
Density Roofing Board should be fixed in accordance with
the specification for Class 1 steel deck constructions and in
accordance with the F.M. Guide and appropriate F.M. data
sheets. Additionally, the insulation boards should be 600 mm
clear span mechanically fixed in accordance with the FM
Pre-securement Requirements. Further advice is available
Location of mechanical fastener
Note that the span to be measured is across the clear width of the from the Rockwool Technical Helpline Services Department. for securing Hardrock Dual
trough, and not from centre to centre of the crowns.
Density Board to metal, concrete
Vapour control layer and timber decks. (See
Additional roof loads mechanical fastening of
The need for a vapour control layer with Hardrock Dual
Plant and machinery insulation).
Density Roofing Boards should be calculated in accordance
Wherever possible, any roof-mounted plant, such as air
with BS 5250: 1989 and with reference to BS 6229: 2003
handling and refrigeration units, should be positioned on
(Code of Practice for Flat Roofs with Continuously
independent upstands bearing directly onto the substrate.
Supported Coverings).
Where this is not possible, and the equipment is to be placed
directly onto the finished roof, further protection to spread Flat roof design
the load on the Hardrock Dual Density Roofing Board may be
The roof construction and design should comply with BS
required. In such cases advice should be sought from the
6229:2003 (Code of practice for flat roofs with continuous
Rockwool Technical Helpline Services Department and the
supported coverings).
membrane manufacturer.
6
Hardrock Dual Density: Sitework
Installation
General
Hardrock Dual Density Roofing Boards should be laid with
staggered joints wherever possible and tightly butted to avoid
gaps. Ensure that the dense layer is used on the upper side
towards the membrane. This is clearly marked on the boards
as ‘This way up’.
Water absorption
Rockwool consists of randomly orientated water-repellent
fibres. Wetting will therefore only occur in proximity to its
surface.
Working platform
Under no circumstances may the finished roof be used as
a working platform without adequate protection being
provided.
7
Preparation work for refurbishment
Unless the existing roof finish is known to be sound and
watertight, and the type and condition of the surface
suitable for bonding or mechanical fixing of Hardrock Dual
Density Roofing Board, all previously applied finishes and, if
necessary, insulation layers should first of all be removed. It
is recommended that the specifier/contractor checks the
existing levels to ensure that the falls are correct.
Rockwool Hardrock Dual Density Roofing Boards are fully Health and safety
palletised and wrapped in a polythene shroud for protection
during transit and for short term protection if stored outside. Current HSE ‘CHIP’ Regulations and EU directive 97/69/EC
For longer term protection the pallets should be stored under confirm the safety of Rockwool mineral wool; Rockwool
a secure waterproof covering. Hardrock Dual Density should fibres are not classified as a possible human carcinogen.
be stacked no more than 2 pallets high for safety. The maximum exposure limit for mineral wool is 5mg/m3,
Where craning of pallets to roof level is required, the use of 8 hour time-weighted average.
a pallet fork attachment is recommended A Material Safety Data Sheet is available from the Rockwool
Marketing Services Department to assist in the preparation
Rockwool Rock Roller Trolley of risk assessments, as required by the Control of Substances
To facilitate fast and easy movement of the Hardrock Dual Hazardous to Health Regulations (COSHH).
Density Roofing Boards from the loading area to the point
i
of installation on the roof deck, Rockwool Limited have Technical Sales Helpline
developed a purpose made ‘trolley’ (see page 7). Each Rock
Technical advice relating to Hardrock Dual Density
Roller comes complete with operating instructions, which
Roofing Boards is available from the Rockwool
should be followed by the roofing contractor.
Technical Sales Department on 0871 222 1780. Rockwool Limited reserves the right
to alter or amend the specification of
Specify SPRA products without notice as our policy
is one of constant improvement.
The Single Ply Roofing Association (SPRA) represents
The information contained in this
membrane manufacturers, associated component
data sheet is believed to be correct
manufacturers and specialist subcontractors and aims to at the date of publication. Whilst
ensure the delivery of best value single ply roofing systems, Rockwool will endeavour to keep its
through a quality assured partnership. publications up to date, readers will
appreciate that between publications
By specifying products and specialist installation by SPRA there may be pertinent changes in the
law, or other developments affecting
Manufacturer, Associate and Contractor members you can
the accuracy of the information
be assured that all parties meet strict quality criteria. contained in this data sheet.
Compliance with these criteria and with the Code of
The applications shown do not
Conduct is assessed at application, by annual audit and by
necessarily represent an exhaustive
random spot checks. list of applications for Hardrock Dual
Density. Rockwool Limited does not
For further information, and to obtain copies of the SPRA accept responsibility for the
Design Guide and other documents, go to www.spra.co.uk consequences of using Hardrock Dual
or call 0115 914 4445 Density in applications different from
those described above. Expert advice
should be sought where such different
applications are contemplated, or
where the extent of any listed
application is in doubt.
Associate Member
Rockwool Limited
Pencoed. Bridgend. cf35 6ny
e info@rockwool.co.uk
www.rockwool.co.uk