STANDARD SPECIFICATION NO.

KPC-A-07 Sheet
REVISION 1

STANDARD SPECIFICATION NO: KPC-A-07

STANDARD SPECIFICATION FOR

ROOF AND WALL CLADDING

FOR

PT KALTIM PRIMA COAL PROJECT

AT EAST KALIMANTAN, INDONESIA

Revision 0 1

D a t e 19/4/89 15/6/89

Prepared by S.S-J J.W

Checked by

Contracts
Approved
Approved By
Project Mgr.

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STANDARD SPECIFICATION NO. KPC-A-07 Sheet
REVISION 1

TABLE OF CONTENTS

Page No.

1.0 GENERAL 3

1.1 Scope of Work 3

1.2 Standards 3
1.3 Shop Drawings 3
1.4 Guarantee 4
1.5 Storage 4

2.0 MATERIALS 4
2.1 Cladding 4
2.2 Transulucent Cladding 4
2.3 Single Skin Cladding 5
2.4 Fixings 5
2.5 Sealant 5
2.6 Insulation 6
2.7 Acoustic Cladding Construction 6

3.0 WORKMANSHIP 7

3.1 Installatin 7
3.2 Protection 7
3.3 Disimilar Metals 7
3.4 Insulation 7
3.5 Flashings and Cappings 8
3.6 Penetration 8

4.0 RAINWATER GOODS 8

4.1 Gutters 9
4.2 Downpipes 9

5.0 PARAPET CAPPING 10

6.0 PARAPET SIDE FLASHING 10

7.0 DESIGN OF LOUVRES AND VENTILATORS 10

7.1 Design Capacity 10

7.2 Wind Loads 10
7.3 Construction 10

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1.0 GENERAL

1.1 SCOPE OF WORK

The Contractor shall design all fastening systems and

supply and install roof and wall insulation and
cladding, fascia and awning cladding, flashings,
trimming, guttering and downpipes as shown on the
Drawings and necessary for the completion of the work.

The whole of the work shall be detailed and installed

by the Manufacturer of the cladding or a firm licensed
by the Manufacturer.

The cladding and fastening system shall be designed to

resist the wind loads as specified.

1.2 STANDARDS

All materials and workmanship shall comply with the

latest editions and amendments of the relevant
Australian Standards, including but not limited to the
following:

AS1170 Rules of Minimum Design Loads on Structures

AS1273 UPVC Downpipe and Fittings for Rainwater
AS1397 Sheet Steel and Strip - Hot Dipped Zinc Coated
or Aluminium/Zine Coated
AS1445 Hot Dipped Zinc Coated or Aluminium/Zinc
Coated Sheet Steel - 76mm Pitch Corrugated
AS1562 Design and Installation of Metal Roofing
AS1903 Reflective Foil Laminate
AS1904 Code of Practice for Installation for
Reflective Roil Laminate in Buildings
AS2179 Metal Rainwater Goods - Specification
AS2180 Selection and Installation of Metal Rainwater
Goods - Code of Practice
AS2376 Plastic Building Sheets

H H Robertson - Erection Manual for Single Skin

Sheeting

1.3 SHOP DRAWINGS

Prior to fabrication, shop drawings and manufacturer's

installation leterature for the cladding system,
including but not limited to the following, shall be
submitted for approval:

- sheet layout, location and schedules

- flashings layout, location and schedules
- trims layout, location and schedules

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- method and type of fixings

- isolation and imcompatible materials,
detailing, location and type
- acoustic batt type, layout and schedules
- sealants, types and locations
- gutters, downpipes, bracket types and locations
- birdproofing and sealing
- batten layout, location and schedule

1.4 GUARANTEE

The cladding system shall be guaranteed against

failure through faulty materials and/or workmanship
for a period of five years form the date of Practical
Completion.

1.5 STORAGE

It shall be the responsibility of the Contractor to

ensure that all items delivered to site are:

(a) packed, delivered and unloaded in such a manner

as to avoid damage.

(b) inspected ondelviery for damage and/or defects

and if found to be defective shall be rejectd.

2.0 MATERIALS

2.1 CLADDING AND TRIM MATERIALS

(a) Cladding for Buildings

Roof and wall cladding for buildings shall be

Inverted Box Rib Five (IBR5) by H H Robertson
coated with "Hot Melt Versacor" when used in
the marine environment and coated with
"Stypoclad" when used onshore.

(b) Cladding for all Conveyors

Cladding for the conveyors shall be COR-RIB 12

by H H Robertson caoted with "Hot Melt
Versacor" for the marine enviroment and coated
with "Stypoclad" when used onshore.

For both items (a) and (b) an approved equivalent may

be used.

(c) Fascia gutters shall be 1.6mm base metal

thickness steel sheeting, coated with the

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compatible coating from (a) or (b) for the

particular location, complete with fixings.

(d) Box gutters shall be formed from 1.6mm base

metal thickness steel sheeting of shapes and
sizes as required, with protective coating
compatible to (a) or (b).

(e) Downpipes shall be 1.6mm base metal thickness

of steel sheeting in sizes required with with
protective coating compatible to (a) or (b).

2.2 TRANSLUCENT CLADDING

Translucent cladding shall be "Alysynite Everlite R79"

series 2400 or approved equal translucent sheeting of
profile to match cladding in either 2.1 (a) or (b).
The colour shall be nominated by the Engineer. Screws
and fixings shall be as recommended by the
manufacturers of the sheeting.

2.3 SINGLE SKIN CLADDING

All roof, fascia and awning cladding shall be in

"Robertson Stypoclad" pre-finished sheet steel
I-BR5/BR5 or approved equal, with guttering downpipes,
flashings, cappings, birdproofing and trims in similar
materials.

Where pre-finished materials cannot be used, the

metalwork shall be galvanised and painted to match the
pre-finished materials.

2.4 FIXINGS

Screw fixings complete with stainless steel and

neoprene washers shall be stainless as recommended by
the cladding manufacturer. The heads of large visible
fixings, such as hexagonal head screws in cladding
shall be colour matched to sheeting, either by
painting or by Deutsher Tonex plastic caps.

Side lap stiches and fixings for flashings and trims

shall be stainless steel self tapping screws with
neoprene washers.

2.5 SEALANT

Sealant shall be an approved brand, clear alcohol

curing silicone as recommended by the cladding
manufacturer.

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All flashings and cappings shall be set out and fixed

to allow for thermal movement of themselves and the
sheeting.

2.6 INSULATION

(a) Foil Insulation

Refelective thermal insulation shall be

fibreglass bonded core sheeted both sides with
aluminium foil, "Sisalation - 450", or equal
approved.

(b) Blanket/Batt Insulation

Blanket/Batt thermal insulation shall be 50mm

thick glass fibre doublt foil faced.bcked
insulaiton of thermal conductance not greater
o o
than 0.043 w/m at 20 , ACI Building Blanket or
equal approved.

2.7 ACOUSTIC CLADDING CONSTRUCTION

The acoustic cladding systems shall consit of

fibreglas sanwiched between an external sheet of steel
and an internal sheet of aluminium. the acoustic
cladding system shall be fixed to the outside of both
purlins and girts.

(a) External Steel Sheet to Acoustic Cladding

The external steel sheet to Acoustic Cladding

shall be Lysaght's Kliplock 0.6mm T.C.T. or
approved equal.

(b) Internal Aluminium Sheet

The internal aluminium sheet for both roofs and

walls shall be Comalco V Rib Profile VS700 or
approved equal with a base metal thicknes of
0.7mm. The internal aluminium sheet shall be
fully perforated to Metal Perforators Catalogue
No. 1810 or an approved equivalent. Hoel size
shall be 4.75mm nominal with a minimum 16.6%
open area. The internal aluminium sheet shall
be clear anodized.

(c) Fibreglass

The fibreglass shall be a minimum 50mm thick

3
layer of 32 kg/m density material. the
fibreglass batts shall be fully enclosed and

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sealed in a plastic enclosure. Teh maximum

dimensions of each plastic enclosure shall not
exceed 2000mm square. All batts shall be
designed to be installed uncut. Vacant sections
shall be left as necessary to avoid cutting.
(d) Plastic Enclosure Material

The plastic enclusere material used to fully

enclose the fibreglass shall be fifty (50)
micron thick Dupont Nylar polyester or an
approved equivalent.

3.0 WORKMANSHIP

3.1 INSTALLATIONS

Cladding shall be installed by tradesmen skilled and

experienced in the type specified and ina ccordance
with the manufacturer's instrucitons.

Carry out all necessary operations for the

satisfactory performance of the roof, including
cutting at junctions, trimmings around penetrations
and flashings etc.

Sheets shall be pre-cut in single lengths for each

slope and laid on each slope, working towards the
highest prevailing wind. Turn pans down into gutters
and up at top of slope, at ridges and ventilators and
outehr abutments.

3.2 PROTECTION

The coating shall remain undamged after the material

is installed. Damaged material shall be replaced with
new at the Contractor's expense.

Fillings, drillswarf, offcuts and scrap shall be

cleared away form work daily. Paricular care shall be
taken to prevent staining of the work byu rusting
rubbish. Attend on all other trades in this regard.

3.3 DISIMILAR METALS

Incompatible metals shall be separated from one

another by insulating seprators or neoprene, bitumous
filt, heavy bitumous paint or isolation tape.

3.4 INSULATION

Blanket/Batt insulation shall be laid over purlins,

with joints tight butted, and supported on "Cyclone

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Insulation Support Mesh" stretched tight and fixed to

purlins.

Elsewhere as shown Sisalation 450 shall be draped over

purlins and/or girts with maximum 150mm laps.

3.5 FLASHINGS AND CAPPINGS

Unless other wise detailed, flashings and cappings

across slopes shall lap 200mm down slope, with edge
scribed and folded into pans; flashings and cappings
on slope shall lap across one rib with edge turned
down to pan; veritcal edges of cappings and flashings
shasll lap 100mm. Joints in cappings and flashings
shall be sealed and lapped 100mm.

All flashings and capppings shall be set out and fixed

to allow for thermal movement fo themselves and the
sheeting.

Fix flashing and cappings to ribs of sheeting with

stainless steel screws and neoprene washers. Fixings
shall be at 500mm centres on slope and at 200mm
centres transversely. Fix elsewhere as required to
neatly and permanently secure the work.

All exposed rib ends shall be closed by matching

purpose made end caps, securely fixed, or by other
approved means.

Provide all flashings and cappings necessary to

waterproof the roof, and all other trims necessary to
fully bird.insect proof and neatly finish the roofs.

3.6 PENETRATION

Flash up to all a large penetrations through cladding

in 0.8mm base thickness matching colourbond iwth 200mm
lap to roofing wiht interrupted ribs closed off, and
all joints ealed and double rivetted. Flashings shall
turn 150mm up the penetrating member, to allow for
100mm lap by overflashing, and shall have 10mm
clearance. Overflashings shall be formed with the
penetrating members.

Flash all pipe penetrations with DEktite EPDM tyupe

flashings in accordance with the manufacturer's
recommendations.

4.0 RAINWATER GOODS

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All rainwater goods shall be fabricated as specified

earlier and detailed on the Drawings. All brackets
and support components shall be painted matching
colours.

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4.1 GUTTERS

(a) Fascia Gutters

Gutters shall be provided as shown, joined as

recommended by the manufacturer and supported
on purpose made brackets.

Expansion joints whre shown, shall be formed by

stop ending the gutter and saddle flashing over
the tow stop ends and leaving 10-20mm gap
between the ends of gutters.

Minimum falls to eaves gutters shall be 1:300

with locations of high points as required.

(b) Box Gutters

Purpose made box gutters shall be provided as

detailed. Expansion joints where shown, shall
be formed by stop ending the gutter and saddle
flashing over the two stop ends and leaving
10-20mm gap between the ends of gutters.

Provide 400 x 400 x 100 deept sumps to box

gutter at each down pipe as shown complete with
75 x 50mm overflow spouts set 50 down from top
of gutter.

Minimum fall to box gutters shall be 1:150 with

top flanges of gutters remaining level and
sides increasing in height to outlet.

4.2 DOWNPIPES

Pipes shall be positioned as shown, with seams at

back. Join with clip joints entered 75mm, sealed and
rivetted. Do not connect downpipe to gutter po. Form
o
all bends at 45 to horizontal unless otherwise shown.

Brackets shall be 25 x 3.0 m.s hot dip galvanised and

painted to match downpipes, located at ever joint and
elsewhere to be at 1500 centres maximum. Brackets
shall clamp behind downpipes with M6 plumbers's bolts
and be fixed to structure with two galvanised M8
fittings each.

Connect downpipes to underground stormwater pipes as

detailed.

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Provide 50mm dia. brass screw cleaning eye soldered to

front of each downpipe located 1000 above adjacent
ground level.

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5.0 PARAPET CAPPING

Provide 0.8mm base metal thickness prefinished parapet

capping to brick walls as detailed. Capping is to be
spring fixed to 25 x 2.0mm galvanisied clips fixed to
brickwork at 600 centres maximum.

No direct mechanical fixing of capping to parapet will

be permitted. Provide expanison joints at 6 metres
maximum.

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