GOVERNMENT OF INDIA

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MINISTRY OF RAILWAYS
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Report
on
Self Supported
Roofing System
Report no.
no.RDSO/WKS/2015/3
April, 2015

Works Directorate
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Research Design and Standards Organization, Lucknow 226011.

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 Synopsis

The roofing of a structure not only protects the structure and its interiors from the outer

elements but also gives an aesthetic look to the structure. Steel roofing is generally more

economical for larger spaces in terms of maintenance and enhanced flexibility of space

utilization. With the invention of self-supporting structural elements as roof covering, it is

now possible to develop innovative shapes of roofs especially for industrial, sports & other

service buildings and public areas where long spans are desirable. Self supported structure

without trusses, purlins or ancillary supports have been developed by joining several

longitudinal self-supporting elements having an identical length and cross section and

abutting on a rigid horizontal superstructure.

This report covers the basic concepts of self supported roofing system, installation details,

advantage, disadvantage & material specifications. The report also covers cost benefit of

self supported roofing system on the basis of works carried out in the past by Central

Railway by providing self supported roofing system for New Station Building at LTT, CST

Mumbai and Matunga Workshop.

 INDEX

S.No. Description of Item Page No.

1. Roofing system 1
2. Requirement of roofing material 1
3. Metal roofing 1
4. Classification of metal roofing 2
5. Merits of self supported roofing system 3
6. Material and technology 3
7. Specification of galvalume sheet 4
8. Primary sheeting material 4
9. Present systems of self supported roofing 5
10. Hanging arrangement for light and fixures 17
11. Natural light 19
12. Ventilation 19
13. Conceptual plan of self supported roof for platform covering with 21
three tracks
14. Comparative analysis between A.C. sheet MS channel, 26
Precoated color MS tubular, Proflex systems, and Pre-
engineered structures
15. Case studies 28
16. Advantages of self supported roof 31
17. Recommendation 31
18. Pioneers in the field of self supported roofing systems in India 32
19. Annexure A & B 34-37
Introduction:- Self Supported Roofing system is a revolutionary system where roofing sheets do not
require intermediate support like purlins or trusses. The system comprises of profiled roofing sheets that
are directly fixed to the supporting structure at the sides and provide stability due to its curved shape. The
shape and size of roofing element is chosen to satisfy the general requirement of strength and stiffness,
lightness and economy, ease of handling and erection, proper seating and leak proof joints.

1. ROOFING SYSTEM:-

A Roof is the uppermost part of the building, provided as a structural covering, to create enclosed
space for habitants and to protect from rain, sun, wind etc.

A Roof consists of Structural element which supports Roof Coverings.

The Structural element may be trusses, portals, beams, slabs (with or without beams),
shells or domes.

The Roof Coverings may be A.C. Sheets. G.I. Sheets, Tiles or Slab Itself.

There are enormous varieties of Roofing Materials and their selection is done based on Price,
Availability, Durability, Appearance and regional considerations.

2. REQUIREMENT OF ROOFING MATERIAL:-

It should have adequate strength and stability to carry the dead and superimposed live loads.

It should effectively protect the habitants and building from sun, rain, wind etc and should be
durable.

It should be waterproof and have efficient drainage arrangement.

It should be fire resistant.

It should be aesthetically appealing.

3. METAL ROOFING:-
Nowadays Metal Roofing of aluminum-zinc alloys is replacing conventional AC/GI sheets as
being;

Fire-resistant qualities,

Longevity,

Light Weight,

Speed of installation,
Page 1 of 37

Low-maintenance,

Recyclable, predictable and reliable material and quality.

Metal roofing also lends itself well to many design elements currently used in todays
architecture. Hips, valleys, slope changes, transitions are all available to the designer.

4. CLASSIFICATION OF METAL ROOFING:-

For the purposes of Spanning Ability, metal roofing can be divided broadly into two categories.

Non Structural Roofing

Structural Roofing

4.1 NON STRUCTURAL METAL ROOFING:- Nonstructural roofing requires a continuous support or
closely spaced Purlins, Channels or Trusses

Page 2 of 37
 4.2 STRUCTURAL METAL ROOFING :-

Structural roofing can span the distance between the supporting roof purlins/Beam by
itself, similar to metal decking.

It is also called Self Supported Roofing.

Today, structural roofing is used in many industrial and commercial applications worldwide.

5. MERITS OF SELF SUPPORTED ROOFING SYSYTEM:-

Stability is ensured based on arch principle without Truss, Purlins or intermediate supports.

Can provide unobstructed clear span of 9 m to 30 m.

Roofing panels are mechanically seamed (Interlocked) and free from holes, nuts, bolt overlaps and
sealants, thereby ensuring almost zero maintenance.

Mechanical sealing ensures 100% Leak Proof Roofs.

Faster Execution and Errection (around 1500 sq. mtrs in 12 hrs).

No Bird nuisance and hence provides cleaner and more hygienic Building.

Distinguished Arch Shape and Flexibility of colors result in strong aesthetic appeal.

Upto 50% Economical compared to Conventional Roofing System.

6. MATERIAL AND TECHNOLOGY:-

There are different type of materials for the construction of roof frame and roof covering. Common
materials are metal/galvalume sheets, ferrocement, plastics and canvas.

Most common material for roof covering is High Quality, High Grade, Pre-Coated Galvalume Sheet
of Thickness 0.8 mm to 1.6 mm. Galvalume steel is the ideal material being flexible strong and
corrosion proof. It is aluminum-zinc alloy-coated steel sheets with 55% aluminum, 43.5% zinc and
1.5% silicon coating.

Page 3 of 37

GALVALUME is a flat rolled steel sheet coated with alloy of Aluminum
Aluminum, zinc and silicon,
silicon produced
by a continuous hot dip process.

It is four times more corrosion
rosion resistant than Galvanized steel in similar environmental conditions.

Grade 550 Steel used is known as High tensile steel with a minimum tensile strength of 550 MPA.

These
ese sheets have less tendency of fly off when a strong wind blows unlike other commercial
quality or low tensile steel.

7. SPECIFICATION OF GALVALUME SHEET

SHEET:-

BASE METAL Cold Rolled Structural Quality Steel In Coil Form,

Coil Width: 914 mm
STEEL GRADE GRADE D: 350 MPa Yield Strength. Min.
STEEL THICKNESS RANGE 0.8 mm To 1.60 mm (Base Metal Thickness)
AZ 150, 150 Gms./Sq. M. Alu-Zinc-silicon
silicon Coating (55% Al.
BARE GALVALUME COATING
43.5% Zn. and 1.5% silicon)
Top Side Suitable for Roll-Forming,
Forming, 20 microns total dry
thickness,
COLOUR COATING & TESTING
Bend Test method or ASTM D4 145-83
NCCA Standard T-Bend 145
METHODS
Back Side 12 microns total dry thickness, epoxy primer and
polyester wash-coat.
Thickness :0.8mm
0.8mm 0.9mm 1.0mm 1.1mm 1.6mm
WEIGHT PER SQ MTR.
Weight Kg/Sq Mtrs :10 11.1 12.5 13.9 20
COIL WEIGHT APP. 3.75 TONS (Length
Length of sheet 400 to 450 mtrs.)
ASTM A792 :Standard
Standard Specification for Steel Sheet, 55 %
STANDARD
Aluminum-Zinc Alloy-Coated
Coated by the Hot-Dip
Hot Process
Further technical details of galvalume sheet is provided in Technical data sheet as Annexure A

8. PRIMARY SHEETING MATERIAL

MATERIAL:-

Galvalume Sheets comes in Cold Roll Coils of width 0.914 m, length

ength varying from 400 to 450 m, each
roll weighing approx. 3.5 Tones. It is per-painted by PE-Color (Polyester Coated Aluminium) with
thickness varying from 15-20
20 microns
microns.

Page 4 of 37
9. SYSTEMS OF SELF SUPPORTED ROOFING:

Three prominent systems are prevalent as below.

1. PROFLEX ROOFING SYSTEM

2. KALZIP SYSTEM by KALZIP LTD.
3. SAFLOK 700 by SAFINTRA LTD.

9.1 PROFLEX ROOFING SYSTEM:

Proflex Roofing Solutions Technology uses high quality, high grade, pre-coated Galvalume Steel as the
basic raw material. The panel forming and installation is a complete on-site process. The Mobile panel
forming Units (roll-forming/panel fabrication equipment) along with crane, seaming and other
equipments are transported to project sites with required manpower, enabling panel forming &
installation. The process allows high-speed operations, thereby saving time.

The steel coils of the designed width, is fed into the Mobile panel forming Units. This Mobile panel
forming Unit equipment forms profiled panels having the desired finished width, length and curvature, in
two stages. The installation can start from one end of the building, and moving along the length of the
building, the process shall be completed. Roofing panels are installed over RCC gutter beam with
Anchor bolts or with Nut Bolts in case of Steel Beams at both ends. The RCC/steel sub-structure has to
be designed considering the arch reaction data with suitable load combinations.

9.1.1FABRICATION AND PANEL FORMATION:-

The Panel formation is done as per the required length and curvature at the site itself.

The Sheet from the roll is passed through a Hydraulic Profile machine (MIC Machine) to give it the
Trapezoidal shape and cut to the required length.

After the profiling, these panels are passed through another Hydraulic machine for Pre Curving as
per the design.

Fig: MIC Profiler machine Fig: Trapezoidal shape panels

Page 5 of 37
9.1.2 MECHANICAL SEALING:

Seaming is like 'zipping up' of a rolled metal peals together using a Mechanical Seaming machine.

Three roofing panels are mechanically seamed (Interlocked) at site along with the light fixtures
and hangers.

Panels are free from holes, nuts/bolts, overlaps and sealants which ensures almost zero
maintenance.

Fig: Mechanical Seaming Tool Fig: Sketch of Mechanical Seaming

9.1.3 EXECUTION AND ERRECTION

Pre Curving and assembly of Sheets are done at Site.

The process allows High Speed Erection of Roofing Sheets giving installation speed of around
1500 sq. m. in 12 hrs.

After Erection, it is bolted with the supporting structure by Self Splitting screws or Nuts & Bolts.

9.1.4 FIXING OF SHEETS WITH MAIN STRUCTURE

The Pre Curved Proflex Sheet, after launching is fixed at the supporting structure or eave with
self-splitting High Tensile Screws or Nuts & Bolts.

In case of single span, side/End Support with gutters for collection and disposal of rainwater is
needed.

In case of multiple spans the center support with gutter is required.

These supports with gutters can be RCC or Steel.

Page 6 of 37
9.1.5 SUPPORT ARRANGEMENT ON RCC:

Min. 450

Min. 450

Fig: RCC Gutter with Fixing Arrangements.

Page 7 of 37
Page 8 of 37
9.1.6 SUPPORT ARRANGEMENT ON STEEL:

Fig: Centre Steel Gutter with Runner Plates on both sides

Page 9 of 37
9.2 KALZIP SYSTEM:-

Kalzip is precision engineered, multi component aluminum standing seam roofing and wall cladding
system with adequate durability, good performance and low maintenance. It utilizes a range of
materials, finishes and shapes including curved and/or tapered, and any pitch from 1.5 upwards. The
systems low weight, durability, speed of construction and adaptability make it suitable for new build
and refurbishment projects.

A Kalzip roof can be anything from a simple single-skin solution to a sophisticated system that
incorporates integral components and accessories. Depending on the supporting structure and
individual application, the roof configuration can be adapted to suit the requirements of the building,
such as design, snow and wind loading, and performance targets.

9.2.1 KALZIP PROFILES:

The system incorporates a range of Kalzip aluminum standing seam profiles of different shapes and
sizes.

Page 10 of 37
9.2.3 KALZIP ROOF SYSTEM CONFIGRATION:-

Kalzip standing seam roof systems are available in a multitude of a configurations to cater for the most
of the architectural design and performance requirements.

Kalzip liner roof and Kalzip liner deck roof systems can be used for new build construction where speed
of installation on a project is of utmost importance. The Kalzip structural deck and Kalzip structural
cassette systems provide economical solutions for long span installations and eliminate the need for
purlins.

Kalzip roof constructions can also be modified to accommodate various acoustic performance
requirements, by incorporating other layers such as high density insulation, acoustic boards and
flexible membranes.

To complete the chosen Kalzip system, essential components and accessories, such as clips and
barrier pads, are required.

9.2.4 CLIPS & THERMAL BARRIER PADS:

Kalzip profiled sheets are secured to the substructure of a roof construction by the use of extruded
Kalzip aluminium (L) clips or Kalzip E clips along with polyamide thermal barrier pads. These clip offer
a fixing mechanism and the head of clip allow free movement of the external sheet during thermal
cycling, enabling the use of long sheet lengths. These clips lock into the small seam of the aluminum
profiles and are covered by the next profile, which is the large seam. Both these profiles are zipped to
create a friction-locked connection.

Kalzip E clips are steel reinforced polyamide clips designed to further enhance the overall Kalzip
system by improving its thermal, acoustic and movement performance. They offer a fixing mechanism
with no significant thermal bridging whilst still retaining structural capability similar to the extruded
aluminium (L) clip. The E clips also reduce the frictional forces generated during thermal cycling of the
external sheet and are recommended for use on roof areas with sheet lengths exceeding 40 meters.

Aluminum L clip with thermal barrier pad Polyamide E clip

Page 11 of 37
9.2.5 KALZIP SYSTEMS - Components and accessories
Kalzip components and accessories are specially designed to match the system components. The
system consists of liners decks and cassettes. Visible elements can be added to match the individual
hue/colour of the profiles or the surface of the profiled sheets to produce a harmony with the roof and
wall cladding surfaces.

Kalzip deck roof Kalzip structural cassette

9.2.6 KALZIP FLAT ROOF

Kalzip flat roof system is a single ply membrane system which offers complete versatility across all
kind of roofing applications. As an aluminum product, it combines strength with lightness, durability,
corrosion-resistant and essentially maintenance-free. The design of the Kalzip system enables quick
and easy installation. Roof sheets are concealed fixed to the substructure by means of non-
penetrative clips.

9.2.7 KALZIP LINER ROOF:

Kalzip liners are thermally insulated roofs made of high grade steel or aluminum. Standard finishes
include a galvanised, or white enamel finish to suit the internal application. The steel liner can be
both smooth curved and crimp curved to suit most of the requirements. The liner can also be
perforated to improve acoustic performance.

When used within the Kalzip liner roof system, the profile of the liner sheet will be determined by its
dimensional compatibility with the roof sheet and its thickness will be determined by the internal wind
pressure, the purlin centers, dead weight of the construction components and live load
considerations.

Page 12 of 37
 Liner roof system

9.2.8 KALZIP STRUCTURAL DECKS:

The Kalzip structural deck roof system provides an economical solution for long span installations and
eliminates the need for purlins. Kalzip structural decks are available as standard in high grade steel and
zinc aluminum alloy and is suitable for rafter span ranging from 5 to 8 meters. Standard finishes include
hot-dip galvanized, natural finish and white polyester coated on hot-dip galvanized substrate. Steel
provides the optimum in loading and spanning capability; whereas aluminum offers exceptional
durability in buildings with high humidity levels such as swimming pools.

When used within the Kalzip structural deck roof system the gauge and profile of the decking sheet is
determined by the rafter centers, all external roof loads, internal wind loads, service loads and the dead
weight of the construction components.

Structural deck roof system

Page 13 of 37
9.2.9 KALZIP STRUCTURAL CASSETTES:

Kalzip structural cassette system is suitable for wall applications. Kalzip structural trays are available as
standard in high grade steel or aluminum and are suitable for long span wall applications. With
structural trays, there is also a reduced requirement for structural steelwork. Once in position the
interior face of the tray provides a clean and pleasing internal appearance with no visible
fixings. Standard finishes include a galvanised finish or white polyester coated for a more aesthetically
pleasing appearance.

When used within the Kalzip liner-deck roof system the thickness and profile of the Kalzip structural
tray is determined by the purlin centers, all external roof loads, internal wind loads, the dead weight of
the construction components. The system has the unique advantages of on-site production where
continuous roll formed sheet lengths in excess of 150 meters are used to cover large spans.

Structural cassette roof system

Page 14 of 37
9.3 SAFLOK 700:

SAFLOK 700 is an angular interlocking triple pan, 4-rib profile. It is a concealed fix sheet profile
designed for very low pitched roofs. It is an angular interlocking standing seam trapezoidal rib pro le,
and is usually roll formed on mobile mills on the building site.

Because clips under the sheet hold it down, the sheet is not punctured with fasteners, and remains
completely watertight even at a very low slope. The securing clips are pre-fixed into the purlins and the
sheet is mechanically snapped onto the clip. As a concealed fix sheet can also expand and contract
over the clips as the temperature changes, this system is ideal for long spans on industrial, commercial
and retail buildings.

9.3.1 CLIPPING SYSTEM:-

The SAFLOK 700 clip incorporates a dual action component to positively hold down the male-female
joint on every third rib, and an anchor to clasp the two inner ribs. Every rib is therefore secured, making
it fully interlocking. It is essential that the male rib is directly engaged to the underside of the clip.

An Aluminum clip is a necessary when using Aluminum Material. However when using Aluminum clip
on Galvalume sheets, it is recommended to use an isolation tape to prevent the bridging of the two
dissimilar materials. The recommended tape is a Denso LDP 300 or similar. Should the two metals
have direct contact it will ultimately result in the manifestation of galvanic corrosion and the service life
of the Aluminum will be compromised.

Page 15 of 37
9.3.2 GENERAL SPECIFICATIONS:-

SAFLOK 700 can be ordered in any practical length as per customer requirements. However on site
rolling is done for span lengths in excess of 13 m. The minimum roof pitch when using SAFLOK 700 is
2 on steel and 3 on wood. SAFLOK 700 is suitable for light foot traffic only with 1.5kPa downward
pressure, 1.6kPa upward pressure and 0.75kPa for the side cladding, inward or outward.

The sheeting will be a double interlocking concealed fix SAFLOK 700 profile as manufactured by
Safintra Roofng, roll formed in continuous lengths from certified G550 steel or High Quality, High
Grade, Pre-Coated Galvalume Sheets.

9.3.3 STANDARD INSTALLATION:-

Sheets are always laid into the prevailing weather. The first sheet is laid on the leeward (downwind)
edge of the roof, with a female rib on the outermost edge.

Step 1
Fix the first SAFLOK-700 clips perpendicular to the gutter in a straight line on the edge first sheet to
ensure straightness. Care should be taken to ensure that the overlap is facing away from the prevailing
weather.
Step 2
Locate the first sheet above the clips ensuring that the overhang into the gutter is correct. Push
downwards on the SAFLOK-700 sheet until the decking is secured at every clip.

Page 16 of 37
 Step 3
Lap the next SAFLOK-700 clip over the top of the male rib.

Step 4
The holes on the existing and new clip will align and hook into place on the self locating tabs. Fasten
this section first and fix the remaining two holes as previously. Fasten all clips in this manner.

Step 5
Lay the next SAFLOK 700 sheet. Inspections should be made periodically to ensure the decking is
installed squarely. This can be done by comparing the coverage at the ridge and gutter line.

Step 6
Locate the next sheet above the clips ensuring that the overhang into the gutter is correct. Proceed as
from Step 2.

Note: During installation, clean the roof daily by removing all leftovers, pop rivets and unused fasteners
or any other debris. NEVER re-use a Saflok 700 clip.

10. HANGING ARRANGEMENT FOR LIGHT AND FIXURES:

Hanging arrangements for fixtures can be fixed during Mechanical Seaming of the panels.

These hanging arrangements are seamed in the pre-curved panels by seaming Tool at the
required Location.

These hangers are used for hanging lights and other fixtures with maximum point load upto 25
Kg each.

Page 17 of 37
Page 18 of 37
11. NATURAL LIGHT:-

For the Natural lighting, Proflex sheet Roof is fitted with 2mm Thick transparent Poly
Carbonate Sheets in the designed length and spacing.

Fixing is done by cutting the Proflex Sheet and fixing the Flat Polycarbonate sheets.

This arrangement makes the working area well lit during the daytime and helps saving
electricity cost.

12. VENTILATION:-

65cm dia Turbo Ventilators that are self-rotating, provided at top of Proflex Roof, which throws
out the hot air and keeps the covered are fully ventilated.

These ventilators do not require electricity.

Page 19 of 37
Page 20 of 37
13. SCHEMATIC DIAGRAM OF SELF SUPPORTED ROOF FOR PLATFORM COVERING WITH
THREE TRACKS:-

The conceptual plan of platform shelter covering three tracks using self supported profile sheets is
shown in adjoining figure. The provision of turbo ventilator is made to ensure proper ventilation inside
and perplex sheets has been provided to utilize day light. As proflex system is not suitable for
unsupported span more than 30 m, a modified system using nominal supporting structure i.e. I-
section & purlins is also suggested for spans more than 30 m. Provision of transparent solar panels
at the top will not only provide day light but also generate electricity for in-house use.

Schematic diagram for electrical fitting, seating space (individual benches below the support beam &
seats around the column), drainage, vending stalls, coach indication boards, signages & platform
display board is also shown in adjoining figures.

Page 21 of 37
Page 22 of 37
Page 23 of 37
CONCEPTUAL PLAN OF SEATING, DRINKING WATER BOOTHS AND VENDING STALLS

Page 24 of 37
CONCEPTUAL PLAN OF ELECTRICAL INSTALLATIONS, SIGNAGES AND DISPLAY BOARDS
Page 25 of 37
14. COMPARATIVE ANALYSIS BETWEEN A.C. SHEET MS CHANNEL, PRECOATED COLOR
MS TUBULAR, PROFLEX SYSTEMS, AND PRE-ENGINEERED STRUCTURES FOR 15 MTRS
CLEAR BUILDING SPAN.

SR. POINTS OF A.C.SHEET MS PRECOATED PROFLEX PREENGINEERED

NO. COMPARISON CHANNEL COLOR SYSTEMS STRUCTURES
MS TUBULAR

1. Cost Moderate Moderate Economical Costly

Effectiveness (Rs. 4500/Sq.mt (Rs. 4800/Sq.mt (Rs. 2500/Sq.mt (Rs. 5000/Sq.mt
approx.) approx.) approx.) approx.)

2. Fabrication & 1000 sqm takes 1000 sqm takes 1000 sqm takes 1 1000 sqm in 7 days
Installation 25 to 30 days 25 to 30 days Day
Speed

3. Enclosed Restrictions due Restrictions due Un obstructed Less obstructed

volume to use of to use of Trusses clear span as a Portal system
Trusses and and Steel frames facilitates larger
Steel frames enclosed volume

4. Leakage and Use of J-hooks Use of J-hooks No Punctures in Leak Proof as well
corrosion and Bolts in and Bolts in Roof, as Corrosion Free
Roofing makes it Roofing makes it therefore Leak in short Term
prone to leakage prone to leakage Proof
and corrosion and corrosion as well as
corrosion free

5. Maintenance Due to leakage Due to leakage Being leakage Required less

and corrosion, and corrosion, and corrosion maintenances in
roofing and roofing and inside proof, structure long run.
inside wall wall damage, requires little
damage, need to need to be maintenances in
be maintained maintained on long run
on yearly basis. yearly basis.

6. Height of High due to use High due to use Eliminating the Can reduce the
Structures of trusses. of trusses. use of truss can height of structure
reduce the overall by the use of portal
height of design
structure.

Page 26 of 37
SR. POINTS OF A.C.SHEET MS PRECOATED PROFLEX PREENGINEERED
NO. COMPARISON CHANNEL COLOR SYSTEMS STRUCTURES
MS TUBULAR

7. Lighting & Obstruction in Obstruction in Un -Obstructed Less obstructed

Illumination Natural and Natural and Natural and Natural and
artificial lighting artificial lighting artificial artificial lighting
Lighting

8. Ventilation & Temperature Temperature Un obstructed air Less obstructed air

Temperature consistency is consistency is not flow and superior Flow and superior
consistency not good. good. Obstruction temperature Temperature
Obstruction in in clear air flow consistency. Less consistency
clear air flow consumption of
electrical energy
due to
ventilation

9. Working Moderate Moderate Excellent Comfortable

Environment

10. Suitability for Well suited Well suited Well suited With limitation
provision of
Gantry (E.O.T.)

11. Aesthetic Average Average Aesthetically Aesthetically

Appearance pleasing due to pleasing
arch shape

Page 27 of 37
15. CASE STUDIES:

1st CASE STUDY: CONSTRUCTION OF NEW LTT STATION BUILDING (Span 15Mtrs, Length 150 Mtrs)

Central Railway Construction Organisation has successfully used the Self Supported Curved Metal Roofing
System in Public Place at New Station Building at LTT, CST Mumbai of size 150mtrx30 Mtrs. The Span of
Proflex Curved roof is 15 Mtrs (10 Spans).

COST COMPARISON: conventional roof with steel truss+ppgi sheet & proflex roof.
Cost of Conventional roof with Steel Truss and Pre painted GI Sheets:-

Total Area of Roofing - 4500 Sq.Mtrs.

Cost of Roofing with Steel Truss and Pre painted GI Sheets - Rs 6500/Sq.Mtrs.

Total Cost of Roofing - Rs 2,92,50,000
Cost of Proflex Curved roof: (Span 15 Mtrs, Thickness 0.90 mm):-

Total Area of Roofing in LTT - 4500 Sq. Mtrs.

Total Area of Roofing with curved profile - 5033 Sq. Mtrs.

Cost of Proflex Sheet Roofing - Rs 2304/ Sq. Mtrs

Cost of Proflex Roofing - Rs 1,15,96,000

Saving in cost: Rs 1,76,54,000 for the area of 4500Sq Mtrs. i.e. Rs 3923 per Sq. Mtrs. (65% Saving)

Page 28 of 37
2nd CASE STUDY: INTEGRATED DISASSEMBLY LIFTING AND INSPECTION SHED (IDLI SHED) AT
MATUNGA WORKSHOP (Span 19Mtrs, Length 135 Mtrs)

IDLI Shed has been constructed with 2 Pit Lines and Gantry Girder crane in Matunga Workshop. The size
of the shed is 19 Mtrs x135 Mtrs. Initially the shed was designed with Steel Truss and Pre Painted GI
sheets.

COST COMPARISON: CONVENTIONAL ROOF WITH STEEL TRUSS + PPGI SHEET & PROFLEX
ROOF.

Cost of Conventional roof with Steel Truss and Pre painted GI Sheets:-

Total Area of Roofing - 2565 Sq.Mtrs.

Cost of Roofing with Steel Truss and Pre painted GI Sheets
Rs. 7230/Sq.Mtrs.
Total Cost of Roofing - Rs. 1,85,44,850

Cost of Proflex Curved roof: (Span 19 Mtrs, Thickness 0.90 mm):-

Total Area of Roofing - 2565 Sq. Mtrs.

Total Area of Roofing with curved profile - 3027 Sq. Mtrs.

Cost of Proflex Sheet Roofing (1.2 mm) - Rs 2304/ Sq. Mtrs
Cost of Proflex Roofing - Rs 69,74,200/-

Saving in cost: Rs 1,15,70,750/- for the area of 2565 Sq Mtrs. i.e. Rs 4511 per Sq. Mtrs. ( 68% Saving)

Page 29 of 37
3rd CASE STUDY: PAINT SHOP AT MATUNGA WORKSHOP (Span 25 Mtrs, Length 48.8 Mtrs)

Paint Shop Shed of size 25 Mtrs x 48.8 Mtrs was Initially designed with Steel Trusses with two spans of
12.2 Mtrs each and Pre Painted GI sheets, but later changed to single span of 24.4 Mtrs with self supported
Proflex sheet roofing.

COST COMPARISON: CONVENTIONAL ROOF WITH STEEL TRUSS + PPGI SHEET & PROFLEX
ROOF.

Cost of Conventional roof with Steel Truss and Pre painted GI Sheets:-

Total Area of Roofing -1220 Sq.Mtrs.

Cost of Roofing with Steel Truss and Pre painted GI Sheets Rs. 5242/Sq.Mtrs.
Total Cost of Roofing - Rs. 63,96,250

Cost of Proflex Curved roof: (Span 25 Mtrs, Thickness 1.20 mm):-

Total Area of Roofing - 1220 Sq. Mtrs.

Total Area of Roofing with curved profile - 1403 Sq. Mtrs.

Cost of Proflex Sheet Roofing ( 1.2 mm) - Rs 2525/ Sq. Mtrs*
Cost of Proflex Roofing - Rs 35,42,575/-

Saving in cost: Rs 28,53,675/- for the area of 1220 Sq Mtrs. (span 25 m) i.e. Rs 2340 per Sq. Mtrs.
(52% Saving)

Page 30 of 37
16. ADVANTAGES OF SELF SUPPORTED ROOF:-

Central Railway Construction organization has used Self Supported Curved Roofing System
from Proflex with three different spans of 15mtrs, 19 Mtrs and 25 Mtrs successfully. Following
are the distinct advantages

Since it is a Self Supporting Roofing system Based on Arch Principle without Truss, Purlins or
Ancillary support, it is very economical compared to Conventional Roofing System. The
reduction in cost achieved for various spans is as under:

Sr. Span in Roofing Cost in Rs/Sq. Mtrs Saving % age

No. Mtrs Conventional Curved Proflex Saving
1 15 6500 2304 4196 65%
2 19 7230 2304 4926 68%
3 25 5242 2525 2717 52%

Faster Execution and Erection.

The Curved Proflex roof of LTT Station Complex ( 4500 Sq. Mtrs) was erected in 15 Days,

Shed at Matunga workshop ( 2774 Sq. Mtrs) was erected in 4 Days,

Curved roof of paint shop (1220 Sq. Mtrs) was erected in 3 days including on-site panel
formation and Installation of curved Roof.

Conventional Steel Truss roofing takes months for fabrication, erection and sheet fixing.

It gives fully leak proof roofs.

No Bird nuisance and hence provides cleaner and more hygienic Building.

Distinguished Arch Shape and Flexibility of colors result in strong aesthetic appeal.

17. RECOMMENDATION:-

Curved Metal Roofing system of Proflex is suitable for Workshops, Warehouses and covered
public places of span varying from 9 mtrs to 35 mtrs.

Installing Proflex Roofing system is a specialized job and can be done efficiently by the trained
and skilled staff from industry.

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18. A PIONEERS IN THE FIELD OF SELF SUPPORTED ROOFING SYSTEMS:

1. PROFLEX SYSTEMS
Division of M&B Engineering Limited
MB House, Stadium Road,
Ahmedabad - 380014
Cell # +91 9099002244
Tel: +91 079 26405563, +91 079 26405572,
Fax: +91 79 2656 1588
E-mail: [email protected]
Web: http://www.mbproflex.com

2. KALZIP LTD.
Haydock Lane, Haydock
St. Helens
WA11 9TY
Merseyside
United Kingdom
Tel: +44 1942 295 500
Fax: +44 1942 295 508
E-mail: [email protected]
Web: http:// www.kalzip.com/

3. SAFINTRA Roofing (India) Limited

Sultania House, 2nd Floor,
18 Subhash Road, Vile Parle (East),
Mumbai: 400057
Tel: +91 2242489696
Fax: +91 22 42489650
E-mail: [email protected]
Web: http://www.safintra.in

Page 32 of 37
4. MERCURY ENTERPRISES Ltd.
1, Karan Gharonda Society
Sainikwadi, Vadgaonsheri,
Pune - 411014
Cell # +91 9860191038, +91 9423251936
Tel: +91 20 27037391
Fax: +91 20 27037391
E-mail: [email protected]
Web: www.mercuryroof.com, www.mercuryroofing.com

5. KAILASH ROOFING
922, ITI Layout, Ring Road,
Papareddypalya, Nagarabhavi 2nd Stage,
Banglore - 560072
Tel: +91 80 23185345
Fax: +91 80 23186437
E-mail: [email protected]
Web: www.kailashroofing.com

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 Annexure A

A. CLASSIFICATION OF COVERING SHEET: The material is available based on the type of base
metal used and available in following trade names.

Commercial steel(CS)
Forming steel(FS)
Drawing steel(DS)
High temperature steel(HTS)
Structural steel(SS)

Structural steel (SS) is available in two grades namely 340 and 550

These products are available in several coating masses with coating designations as given below
Minimum Requirements
Coating Designation
Triple spot test Single spot test
Total both sides, g/m 2 Total both sides, g/m2
AZM 100 100 85
AZM 110 110 95
AZM 120 120 105
AZM 150 150 130
AZM 165 165 150
AZM 180 180 155
AZM 210 210 180
All coating weight tests have to be performed in accordance with the requirements stated in
specification ASTM A924/A924M.

B. CHEMICAL COMPOSITION:
The heat analysis of the base metal shall confirm to the requirements as shown below:

Composition, %-Heat Analysis Element, maximum, Unless Otherwise Shown

Designation C Mn P S Al Cu Ni Cr Mo V Cb TiB N B
CS Type 0.10 0.60 0.030 0.035 0.25 0.20 0.15 0.06 0.008 0.008 0.025
AC,D,E
CS Type 0.08 0.60 0.10 0.035 0.25 0.20 0.15 0.06 0.008 0.008 0.025
C C,D,E

FSC,G 0.02 0.50 0.020 0.030 0.25 0.20 0.15 0.06 0.008 0.008 0.025
to
0.10
DS D,E 0.06 0.50 0.020 0.025 0.10, 0.25 0.20 0.15 0.06 0.008 0.008 0.025
min
HTS C 0.02 0.60 0.040, 0.035 0.25 0.20 0.15 0.06 0.008 0.008 0.025
to min
0.15
Page 34 of 37
 Composition, %-Heat Analysis Element, maximum, Unless Otherwise Shown
Designation C Mn P S Cu Ni Cr Mo V Cb Ti4 NB
Structural Steel
Grade 33 [230] 0.20 1.35 0.04 0.040 0.25 0.20 0.15 0.06 0.008 0.008 0.025

Grade 37 [255] 0.20 1.35 0.10 0.040 0.25 0.20 0.15 0.06 0.008 0.008 0.025

Grade 40 [275] 0.25 1.35 0.10 0.040 0.25 0.20 0.15 0.06 0.008 0.008 0.025

Grade 50 Class1, 0.25 1.35 0.20 0.040 0.25 0.20 0.15 0.06 0.008 0.008 0.025
Class2, and Class4
[340 Class1, Class2,
and Class4]
Grade 60 [410] 0.25 1.35 0.20 0.040 0.25 0.20 0.15 0.06 0.008 0.008 0.025

Grade 70 [480] 0.25 1.35 0.20 0.040 0.25 0.20 0.15 0.06 0.008 0.008 0.025

Grade 80 [550] 0.20 1.35 0.04 0.040 0.25 0.20 0.15 0.06 0.008 0.015 0.025
Class1
Grade 80 [550] 0.02 1.35 0.05 0.020 0.25 0.20 0.15 0.06 0.10 0.10 0.15
Class2C
Grade 80 [550] 0.20 1.35 0.04 0.040 0.25 0.20 0.15 0.06 0.008 0.015 0.025
Class3

C. COATING COMPOSITION:
The 55% aluminum zinc alloy coating composition, by weight, is normally 55% aluminum, 1.6%
silicon and the balance zinc.

D. MECHANICAL PROPERTIES:
The structural steel sheet shall confirm to the mechanical property requirements as given below for
different grades.
Grade Yield Strength, min, MPa Tensile Strength, Elongation in 50mm,
min, MPa min, %
230 230 310 20
255 255 360 18
275 275 380 16
340 Class 1 340 450 12
340 Class 2 340 12
340 Class 4 340 410 12
410 410 480 10B
480 480 550 9B
550 Class 1C 550D 570
550 Class 2C,E 550D 570
550 Class 3 550D 570F 3
Page 35 of 37
 All tests for mechanical properties shall be conducted in accordance with ASTM standard
A924/924M.

E. BENDING PROPERTIES: Structural sheets are commonly bent by cold bending.

F. DIMENSIONS & PERMIABLE VARIATIONS: All the dimensions and permeable variations shall
comply with the requirements of specification ASTM A924/A924M

G. ORGANIC PAINT COATING SYSTEM:

Regular modified polyester with internal lubricant, 20 micron of top coat over
suitable for roll forming. 5 micron of primer.
7 micron of back coat over 5 micron primer

H. THICKNESS:
i) Basic material the thickness (BMT) = 1.00 MM
ii) Total Coated thickness (TCT) = 1.09 MM with a tolerance of -0/0.02 mm.

I. TESTING OF MATERIAL: The sheets shall be tested before use to check the following:
i) Thickness
ii) Tensile Strength
iii) Contents of Aluminium, Zinc and Silicon.
iv) Water tightness
The entire tests mentioned in ASTM codes like the tests given below should be done prior to the
installation of the roofing system.

SN PROPERTY METHOD TEST

1 TOP COAT THICKNESS (MICRONS) ECCA T1-1995
2 GLOSS AT 60 DEGREE ECCA T2-1995
3 PENCIL HARDNESS TEST ECCA T4-1995
4 IMPACT TEST (IN JOULES) ECCA T5-1995
5 SALT SPRAY TEST ECCA T8-1996
6 ADHESION TEST ( CROSS - HATCH ) NCCA II - 5
7 ERICHSEN CUPPING TEST ECCA T6
8 HUMIDITY TEST NCCA III - 6
9 T-BEND TEST (T=SUBSTRATE THICKNESS) ECCA T-7
10 SOLVENT RUB TEST
ECCA T-11
(methyl ethyl ketone - DOUBLE RUB)
11 CHEMICAL RESI. ( 5% NAOH, 5% H2SO4 ) ECCA T18-1995
12 MAX OPERATING TEMP. ECCA T-12

Page 36 of 37
 Annexure B

i) Layout of RCC Support Arrangement:-

750

ii) Layout of Steel Support Arrangement:-

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