THE COLLEGE OF ESTATE MANAGEMENT POSTAL COURSES Roof Structures and Finishes Contents © Introduction © Learning objectives ‘Design and selection of roof form and materials ‘© Classification «Factors affecting selection of a suitable structure + Examples of roof structures Pitched roof structures Flat roofs Special roof structures + Rooffinishes Selection of coverings Range of coverings © Fittings in roof structures Rooflights and patent glazing Fire vents and ventilators Gantry structures Rainwater goods © Some possible fi «| Summary 8.93 © The College of Estate Management 1995 8011THE COLLEGE OF ESTATE MANAGEMENT POSTAL COURSES Roof Structures and Finishes Introduction ‘This paper deals with those types of roof structures and their finishes which are applicable mainly to industrial and commercial type buildings Learning objectives Upon completion of this paper you should be able to: 1 2 Outline the considerations in the design and selection of roof forms and covering. List and comment upon the common and specialist types of roof structures used in industrial and commercial buildings. Identify the various types of roof coverings that could be used in industrial and commercial buildings, and comment upon the advantages and limitations of each ‘Understand the various design features and elements associated with roof structures for the above types of buildings. Appreciate the common problems experienced with roof coverings. 3 8011Roof Structures and Finishes 4 8011THE COLLEGE OF ESTATE MANAGEMENT POSTAL COURSES Roof Structures and Finishes Design and selection of roof form and materials The selection of the correct roof structure and covering is of paramount importance to the success of any building. Modern techniques and advances in material types have given the designer a vast selection of possible alternatives when specifying a roofing system. All these systems have their advantages and limitations so the critical appraisal of each becomes ever ‘more important. The functional requirements will vary according to the circumstances in which the buildings and roof structure and finishes are required to perform. The following is a list of the principal considerations ‘* Weather exclusion —a fundamental need to prevent climatic conditions causing discomfort to building occupiers and damage to the intemal fabric and contents. ‘¢ Structural stability ~ to sustain all wind, imposed and self-loads without failing in its structural integrity. Thermal capacity — to conserve heat during cold periods and prevent heat build-up from solar gain during warm periods. * Sound insulation — to provide adequate acoustic performance to prevent excessive noise gain internally from external noise sources and vice versa. ‘© Fire resistance - to provide an adequate fire barrier to contain an outbreak of fire within the area over which the roof is constructed. This is to prevent the fire spreading to adjacent, structures. © Aesthetics — to provide a finished appearance to a building (although flat roofs are often criticised for not meeting this requirement), © Functional needs of building user — such as rooflights for natural light; support of internal structures, such as cranes; heating system via solar panels.Roof Structures and Finishes Cost ~ a major consideration in any design decision. In addition to the initial cost of the structure and covering, you also need to consider maintenance costs and the life expectancy of the covering. In the late 1960s and early 1970s flat roofs appeared to be a very ‘economical solution. During that era, on average, flat roofs were 40 percent cheaper than pitched roofs. However, when one considers the cost of annual sweeping off of roofs, ‘emergency repairs to blisters and cracks and eventual replacement (in less than 15 years in some instances), a flat roof structure is not such an attractive proposition. FIGURE 1 Common roof shapes > Pitch roof Mansard Mono pitch Flat 6 8011Roof Structures and Finishes Classification Once the basic concept of the building has been decided, the designer has a wide range of possible roof structures to choose from. ‘The actual structural form can be classified in a number of ways, depending upon its How is it constructed? trusses: pitched roofs; flat roof: less than 10° roof pitch; specialist design: shells, inflatable roofs, tent structures. How is it designed? — two-dimensional or three-dimensional; = symmetrical or asymmetrical; — flat, less than 10° roof pitch; — varying pitches, eg a mansard roof; — inflatable structure. What materials are used? = steel; = concrete; ~ timber; - aluminium; — combination of mat Where it formed? = insitu (on site); = prefabricated (off site). construction, design, materials used or method of fabrication. A brief summary of these classifications follows. portal frames: wall and roof frame elements combined with a rigid joint between; 8011Roof Soructures and Finishes Factors affecting the selection of a suitable structure The size and plan shape of the building. Generally buildings which have a simple shape and are of limited width can be covered satisfactorily with a pitched roof, but where the plan shape is irregular, resulting in a good deal of cutting of the coverings at hips and valleys, a flat roof may be more suitable. ‘The type of building, its location and the nature of the activities carried on within. The latter will dictate the permitted column spacing and thereby affect the span. Generally the minimum span consistent with the requirements for a clear floor space will give the most economical construction. ‘The bearing capacity of the soil should be considered, in that, although short span construction is usually the cheapest, it may prove more economical to use wide spans and so reduce the number of column bases to a minimum, Special loading requirements such as heavy factory equipment which may be suspended from the roof framework, and other specific needs of the building owner. Services such as pipes and ducts may have to be accommodated within the thickness of the roof. A pitched roof offers an advantage in this respect, especially where it provides space for water cisterns and services and can also be used for storage. Rainwater discharge may be included under this heading. Natural lighting requirements may lead to the choi give the amount and quality of light needed for p: of a special roof form which will lar processes. Aesthetic considerations. Both external and internal appearance may be important and ‘may result in the choice of an expensive form of construction purely because of its visual effect. For example, where a group of buildings is to be erected the use of flat roofs will have a unifying effect, whilst pitched roofs would emphasise the individuality of the buildings. The planning requirements for the area would also need to be considered, Speedy completion may be essential and this would probably be best achieved by using a prefabricated roof structure. A comparison of initial costs and costs-in-use for the type under consideration. Costs: in-use include maintenance, eg painting, repairs and renewals, and heating, lighting and cleaning costs which may vary with the type of roof used. Thus when comparing the relative merits of steel and pre-cast concrete portal frames, one should take into account the fact that steel requires frequent painting to prevent corrosion. 8 8011Roof Structures and Finishes Examples of roof structures ‘A range of roof structures will now be analyzed by classifying into pitched, flat or a special category and then considering the materials used in the construction. Pitched roof structures 1 Timber (refer to Figure 2) The use of purpose-designed timber trusses is now common practice, as opposed to a purlin and rafter constructed roof of previous generations. Using stress-graded timber (see ‘Materials’ module), and based upon recommendations of the Timber Research and Development Association, a variety of economically designed trusses have been constructed capable of spanning up to 17.5m (Figure 3.) Inaddition to the standard timber sections, structures of laminated timber construction are available. These consist of thin layers of timber glued together to form a composite beam or portal frame. They provide a more economical solution for large spans than using solid timber. (Figure 4.) Timber has the advantage of being light in construction, aesthetically pleasing and with acceptable fire resistance when treated timbers are used. Eaves securing of trusses is to a wallplate, and wind bracing in the form of diagonal ties is required to end bays. 9 8011Roof Structures and Finishes FIGURE 2 Purlin and rafter roof construction Raters Ridge (100% 50mm @ 450 c's) . 1180 « 25mm) Parlin z 1150 75mm) Tiling \ battens (60x 25mm) Fett - underlay Strats every ath rater (75 Pam) Wau piave ‘Spine walt 8x %5m0m) ~ toevery Span (6; ‘port Main steel || meee weal at ‘PRODUCT GROUP 74 — | ‘Mineral steel - fire protection ‘omitted forclanty Treated softwood spacer batten Profiled ridge capping ‘Over purlin - profiled sheeting with liner panel Mineral woo! ro, —Minara! woo al, Minera eet SU 13 or 18| [PRODUCT GROUP 13 or 18 (Prsterbogrd rig lining — Profiled sheeting npn Spacer battens aid oper} ‘supported.on puri | (ieeteion an Vert by -tndsca grade —— t C platooadrd a - eta angle section ain steel pin Le partin ~ industrial rade plasterboard ele Mineral waa! rot PRODUCT GROUP 2A-— = z —— Sheeting sal | +E iain stee!- fire protection IL, 7) omiteat tor etary ‘Over purlin - profiled sheeting with plasterboard lining GENERAL NOTES GENERAL NOTES ate only @ few typical examples of industrial cladding systems available tothe specifier nd ore not intended to be comprehensive. a oe yp id comprises resilient and flexible minerel woo! rols 60mm thick, manufactured 7 & Fae enh and tangino They oe iaealy sulted to ightweight industrial root cladding syatems for bath 12g Oats inden punin plications. PRODUCT GROUP 13/5 similar in type and application but is ‘valle in a range of thicknesses. a ADUCT GROUP TA is » decoretive-faced mineral woo! insulation panel intended for use with metal 3d Crutoms and is equally suited to industrial wall cladding systerms. Bato on iS eRTING PROFILED ROOFS ~The system Mlustrated is one of many in which mineral wool UPGRADING Ee oorporated to upgrade the thermal performance whilst improving eppearance and insult er annass atthe seme time, The systems include ranges of components thet are capable woathertitns types and configurations of existing roof sheets. For further information contact the insulation product manufacturer concerned. Courtesy: Eurisol 29 8011Roof Structures and Finishes FIGURE 13 (continued) Profiled sheeting Capped fixing serew and Cold bridge spacce ‘Mineral woo! insulation “aid above hning board Decoratve-aced ‘mineral woo! slabs Industria! grade plasterboara Unde prt ning wih ‘or bre-cerment imng board insulation between purlins Capped txing serew and- ‘cold bridge spacer" Y Lovoss supports ‘Main supporting sections Decorative-faced mineral woo! sabe Cross-supports Simmer Support wires Main steel [a ross-support sections ‘Mineral woo! insulation rolls i “ain support sections Horizontal suspended ceiling A! For secon A see next page faysin grid ystenn Courtesy: Butisol 30 8011Roof Structures and Finishes FIGURE 13 (continued) (Profiled sheeting ‘Main stee! Mineral woo! rls, [PRODUCT GROUP 15, Jaia ‘between main support sections Plasterimineral fibre board ortile calling iling- View on AA Horizontal suspended c lay-in grid system ‘New profiled metal root ‘sheeting fixed to spacers ith seltseaiing, selPtapping ‘Mineral woot insulation rolls, PRODUCT GROUP 13 or 78, | laid between new and existing Light metalized or timber ‘spacers serewed to suport brackets es fetal support brackets fixed to existing purlingssith Solitapping sores Existing purlin ‘Existing hook-bott fixings fer undisturboo Existing profiled roof sheeting View on BB -} new profiled roof sheeting Selttapping serews C seitsapping screws ‘Suppor brackets spanning acrass sheeting corrugations Existing asbestos or metal rooting sheeting Flange of purlin Lt inerai woo insutation rolls, proper GROUP 13 or 18 Upgrading existing profiled roof-sheeting Courtesy: Burisol 31 8011Roof Structures and Finishes 5 Flat metal sheeting Copper, zinc or lead was used originally for flat roof coverings. In recent years aluminium and stainless steel flat roofing systems have also been developed. The construction of this type of work is of a specialist nature involving drips, rolls and welts. You should refer to the appropriate British Standard. FIGURE 14 Sheet metal roofing Felt Underlay — ‘Welted joint Transverse joints Fixing cleat Standing seam Wood roll Longitudinal joints 32 8011Roof Structures and Finishes 6 Fle le roofing systems Flexible roofing is the name given to a wide range of felts, asphalt, rubber or PVC roofing materials. The quality of the different systems can vary appreciably, so itis important to assess the performance of the system before making a selection. © Felts. During the last 20 years there have been substantial advances in the technology of roofing felts. (See the ‘Materials’ module.) Most felt manufacturers now produce a range of felts including, standard glass-fibre and polyester-reinforced high tensile felts. In addition to advances in felt, the bitumen used in the manufacture can now be modified with SBS (Styrene Butadine Styrene) or APP (Atactic Polypropylene) to form an elastomeric felt which is more flexible and has better performance characteristics than a standard bitumen. Felts can be laid in the traditional roll and pour method, or torch-on felts can be used where the bitumen adhesive is already bonded to the felt. The felt is laid down using a heat torch which fuses the bitumen to the base. A wide range of felt types is available for roof systems. These include vapour barriers and venting layers for intermediate layers, and finishing sheets in standard green or white mineral chippings, or sand facing that requires painting with a solar reflective coating, or the more prestigious copper, lead, aluminium or even stainless steel finished felts. Reference to manufacturers’ literature isa useful source of information for the systems and detailing associated with this system of roofing, © Asphalt. Most commonly this is a mastic asphalt made from limestone and bitumen. It is usually laid in two layers to a total thickness of 20 mm on an isolating layer of black sheeting felt or building paper. Attention to detail at upstands and eaves is important and provision for expansion joints should be incorporated into large areas. The asphalt should be reinforced with an asphalt fillet at angles and finished with a metal trim to eaves. The finish coating can be in a reflective white paint or a light spar chippings. © Rubber or PVC system. In recent years there has been an influx of single layer roofing systems from the Continent. ‘These are formed from either a rubber or polymer system of sheeting which can be secured to the building by means of edge fixings and securing pads spaced around the roof. The joints are welted together using either a chemical treatment or a hot torch. Special aluminium trims are made for flashings and collars for protruding pipes. 33 8011Roof Structures and Finishes roof structures Fittings Rooflights and patent glazing As the name implies, these are incorporated into the roof structure to provide natural light, and sometimes ventilation, to the area of the building below. Rooflights consist of askirting and atop, with ventilation louvres occasionally incorporated. into the sides of the skirting. The top can be either a glazed sheet or a PVC, glass fibre or polycarbonate dome, Single and double skin units are available. Patent glazing consists of a system of glazing bars and glass or polycarbonate sheet between, in either double or single skin, The glazing bars, which are predominantly in aluminium, are set on a timber or concrete skirting and designed to be self-draining. A common version of patent glazing used in industrial type building is a northlight detail where the roof is designed in bays, with northlights between each bay. ‘When using rooflights and/or patent glazing, one needs to consider security, solar gain problems, mechanism for opening vents where applicable, and upstand details, which ensure the roof is watertight. FIGURE 15 Courtesy: Ubbink 34 8011Roof Structures and Finishes FIGURE 15 (continued) Purilan universal UNV31 ISO ~~ Single lap nterfockng tes on 38% 25mm battens at 345mm (gauge, counterbatiens and 13mm Boaraing =~ Purilan universal UNV31L ISO {600 x-300 x 4mm slates on 38 x 25mm battens at 250mm gauge, ‘ounterbattens and Imm boarding Courtesy: Ubbink 35 8011Roof Structures and Finishes Courtes FIGURE 16 Flat roof windows : Ubbink 36 8011Roof Structures and Finishes FIGURE 17 ae pane Sinton \\\ \A\ Glazing bars @ aN N \ her ‘Sketch of northlight roof Profiled sheet rooting Patent glazing wn RHS stenchions at girder ends Ridge unit Profiled sheet Load flashing Insulation Patent glazing secured to glazing rails Valley gutter UB rafter Raking RHS lattice — girder Lead flashing, ‘Gutter straps Outline details 37 8011Roof Structures and Finishes FIGURE 17 (continued) Anodised or plastic _— Coated extruded ‘aluminium glazing bar Stainless stoet Ne ‘glazing bead Seren wire i ‘Neoprene gasket — Condensation channel Deep section for —— double glazing or = insulated cladding Glazing rai! Patent glazing - typical details 38 8011Roof Structures and Finishes Fire vents and ventilators These are units incorporated into the roof structure to provide ventilation but maintain the waterproof integrity of the roof. They achieve this by a system of louvres and covers which are designed to be self-draining. A fire vent is a specific type of vent which is incorporated over stairwells for automatic ventilation of smoke should a fire occur. FIGURE 18 Stairwell smoke ventilator Extruded aluminium lig trame Brushpile id'sea! ‘Bxthaded aluminium Electro-magnstic eye catch assembly Performance The unitis designed to operate on a fail-safe open system with selt-acting spring actuators arranged to ‘apply constant opening pressure on the ventilator li. The electro-magnetic pad catch assembly holds the lid closed until the electric current is switched off by the ire alarm or smoke detection system (2s required). A rremote control panel, placed in an accessible position, with Firemans’ break glass switch and voltage ‘ree contacts can be connected to the fire alarm or smoke detection system. Accessories include cord, ing and pole reset system for reclosing the ventilation lid following testing ar en alarm condition. Courtesy: HH Robertson (UK) Lid 39 8011Roof Structures and Finishes Gantry structures ‘These structures are incorporated into the roof to enable access for inspection and maintenance of the roof and associated structures, On large structures a gantry may be installed to provide a support for maintenance cradles to enable maintenance of elevation details. The consideration of future maintenance is an important Health and Safety requirement. Rainwater goods Consideration should be given to the catchment area and the pitch of the roof. In accordance with the recommendation of the Building Regulations, a maximum capacity of 75 mm per hour flow rate should be used as the basis of the calculations. The design of the system should be to minimise blockages, ensure easy cleaning and provide grids to all inlets. Weirs should be provided at the ends of valley gutters. Rainwater goods are obtainable in cast iron, PVC, aluminium, zinc and galvanised steel A variety of profiles including square, half-round, and ogee are available. Refer to the Building Regulations for calculation of gutter and downpipe sizes or, alternatively, most manufacturers produce their own design capacity tables. le finishes defects Some pos: As has been emphasised throughout this paper, there isa vast range of roof coverings, so careful selection is required to choose a system suitable for the application considered. A more detailed account of defects is given in the ‘Common Building Defects’ paper. However, the following notes are intended to give an appreciation of some common problems. As with other areas of construction, poor design and workmanship are contributory to many of the problems experienced, so careful consideration needs to be given to these aspects to reduce 2 Slates = delamination of the surface; ~ fixing failure; - chemical reaction on the slate surface in polluted environments. Clay and concrete tiles = delamination of the surface; — cracking of tiles and nibs; = mortar pointing failure. 40 8011Roof Structures and Finishes * Felts = degrading of felt; — blistering and ponding; — bitumen failure; — thermal movement causing bulging or splitting; — delamination of applied finishes; — fixing whilst damp. © Asphalt — thermal movement causing creasing and cracks; — blistering; = degrading of asphalt. © Metal sheeting = delamination of sandwich construction systems; ~ corrosion of sheeting and fixings; = chemical reaction with dissimilar metals; = discolouration and chalking of finishes; = condensation problems; — joint and flashing failure. This is not intended to be a comprehensive list of defects, but it does indicate common problems which can be experienced Summary This paper has looked at a variety of typical roof structures which could be used in industrial and commercial situations, and considered finishes which might be suitable. You are strongly urged to observe the construction and finishes used on a number of industrial or commercial roofs, and consider the criteria which the designer may have used in making the selection. 41 8011Roof Structures and Finishes REFERENCES CP3, Chapter V, Part 2, 1992, Wind Loads BS 6399, Part 3, 1988, Imposed Roof Loads BSCP 747, Felt in Roofing Building Regulations, Part H BS 6661 1986, Design, Construction and Maintenance of Single Skin Air Supported Structures. 42 8011