Steel Roofing & Walling

Manual of Content

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GRS Manual 01/19 v1
Table of Content

Chapter 1: Introduction 1
Chapter 2: Sheet Selection 2-4
Chapter 3: General Care & Handling 5
Chapter 4: Installation Procedure 6 - 20
Chapter 5: Flashings 21 - 23
Chapter 6: Rib-Cap on Bent continues sheeting 24
Chapter 7: Cranking and Bullnosing Sheet 24
Chapter 8: Curved Sheeting 25
Chapter 9: Sprung Curved sheeting 25
Chapter 10: Translucent Sheeting 25 - 26
Chapter 11: Insulation 27 - 29
Chapter 12: Rainwater Run-off 30
Chapter 13: Gutter Capacity 30
Chapter 14: Downpipe Capacity 30
Chapter 15: Hail Guards 31
Chapter 16: Condensation 31 - 32
Chapter 17: Sealants 32
Chapter 18: Roof fixing- what to do 33
Chapter 19: Roof fixing- what not to do 34
1. Introduction

Total Roofing Solutions From GRS SANS 10400 - The application of the National Building
Global Roofing Solutions (GRS) is a division of Consolidat- Regulations.
ed Steel Industries, registered in South Africa, and
consisting of two leading South African roofing material GRS roofing/cladding products are engineered to
manufacturer Brownbuilt Metal Sections (established in perform as specified if installed and fastened in accor-
1964) and HH Robertson (established in 1958) together dance with the recommendations in this and other
with Helm Engineering a specialist flashing and vent relevant literature.
manufactures and RVI a specialist smoke and fire ventila-
tor and blinds for sun controller installer. Making it one of In general, the recommendations in this manual are for
the largest independent metal roofing companies in South wind conditions designed for an ultimate uplift load of
Africa. All are household names for the manufacture of 1.6kN/m². For information on cyclonic wind conditions
commercial and industrial steel roof covering and wall consult your nearest GRS office.
cladding profiles (concealed fix and pierced fix), and steel
floor decking profiles. A glance at the content page will indicate the range of
topics included as a result of trade surveys. The manual is
This Roofing and Walling Installation Manual has been structured so that information on a particular product can
prepared as a general reference to the correct installation be obtained without the necessity to search from cover to
of the Global Roofing Solutions wide range of metal cover.
roofing and cladding profiles.
Recommendations such as those contained in Chapter 5,
It is stressed that the detail applies only to metal roofing "Flashing and Capping" are based on standard roofing
and/or walling manufactured by GRS and marketed under trade practices and demonstrate the various GRS profiles
their specific brand names. and provide a weatherproof roof. The success of these
systems obviously rely on good workmanship and materials.
Recommendations are based on comprehensive testing of
specific GRS profiles, thicknesses and finishes and should GRS is confident that the manual will prove useful to
only be used for the nominated products as indicated. the professions and trades concerned with the specifi-
cation and application of the wide range of GRS metal
The Manual supplements the detailed recommendations roofing and cladding profiles available to the building
and procedures provided in individual product literature, and construction industry. As innovation is always to
which should also be consulted as appropriate. Other the fore in the roofing trade, GRS would be pleased to
references which may need to be consulted, depending receive comments and suggestions for the improve-
on the purpose include the latest additions of: ment of this manual.

SANS 10237: "Code of Practice - Roof and Slide Clad-

ding", SANS 0160: Basis of structual design and actions
for building and industrial structures.

1
2. Sheet Selection

2.1 Product Range Data

GRS range of steel roofing and cladding includes the For selected profiles, metals like stainless steel,
profiles listed in Table 2.1 and are available in various aluminium and copper are available. However, loadspan
finishes: tables differ from Table 2.1. Consult your nearest GRS
office.
A) Galvanised
B) Pre-painted finishes
Table 2.1 lists general information to enable profile
C) 55% Aluminium Zinc Alloy coated material
selection. Please refer to individual product literature
D) Aluminium Mill Finish
for detailed specifications.
E) Aluminium pre-painted finishes

Table 2.1 Roof and Wall Sheeting Specification

Profile Thickness kg/m² Cover Sheet Recommended Recommended Support Centres Roof cantilever
including width Dept Min Roof Slope Roofs Walls Gutter fixed to
coating mm mm Unstiffened
every pan. Max sheet
mm Internal End Internal length 13m

Brownbuilt406 ® 0.58 8.16 406 48 10 1800 1500 2700 200 450

0.8 10.26 Refer 2700 2400 3000 300 600
drainage table

Klip-Lok 406 ® 0.5 5.84 406 41 20 2000 1700 180 400

0.58 6.78 Refer 2500 2100 260 600
0.47 5.31 drainage table 1900 1600 150 350
0.53 5.98 2300 1900 180 400

Klip-Lok 700 ® 0.5 5.5 700 41 20 2000 1700 180 400

0.58 6.6 Refer 2500 2100 260 600
0.47 5.1 drainage table 1900 1600 150 350
0.53 5.7 2300 1900 180 400

Klip-Tite ® 0.5 5.5 700 41 20 2000 1700 180 400

0.58 6.6 Refer 2500 2100 260 600
0.47 5.1 drainage table 1900 1600 150 350
0.53 5.7 2300 2100 180 400

Zip-Tek 420 ® 0.58 6.63 420 69 10 2500 1900

0.55 6.0 Refer 2300 1900
0.53 5.8 drainage table 2300

IBR 890 0.5 5.42 890 37 5° for sheet 2200 2100 3100 270
0.58 6.28 lengths up to 30m, 2600 2300 3400 300
0.47 4.92 7.5° for sheet 2100 2000 3100 270
0.53 5.75 lengths above 3 0 m 2600 2300 3400 300

IBR 686 0.5 (FH) 5.48 686 37 5° for sheet 1800 1700 2750 350
0.58 6.36 lengths up to 30m, 2100 1800 2950 450
0.8 8.77 7.5° for sheet 2500 2300 3600 550
0.47 lengths above 30m 1800 1700 2750 350
0.53 2100 1800 2950 450

Nu-Rib 0.5 (FH) 4.93 762 28.6 7.5° for sheet 1550 1300 2200 400
0.58 5.72 lengths up to 30m, 1650 1400 2350 450
0.8 7.89 10° for sheet 1900 1600 2750 550
0.47 4.61 lengths above 30m 1550 1300 2200 400
0.53 5.22 1650 1400 2350 450

Corrugated 10.5 0.5 (FH) 4.93 792 17.5 7.5° for sheet 1100 900 1500 200
0.58 5.72 lengths up to 30m, 1100 900 1500 200
0.8 7.89 10° for sheet 1350 1200 1800 250
0.47 4.61 lengths above 30m 1200 900 2200 200
0.53 5.22 1700 1300 2400 250

2
Concealed Fix Roof Sheeting & Cladding

Note:
At 1:50 (1°) slope, all roof supports must be in the same plane as
slight variations can result in a zero or negative fall. This may
even occur after completion of the building as a result of timber
warping, shrinkage or from settlement. Where it is possible it is
wise to design for a minimum of 1:30 (2°) slope to insure a positive
fall and avoid any danger of "ponding" which can lead to a
reduced service life, particularly in coastal areas. The maximum
support spacings listed in Table 2.1 are based on the ability of
Klip-Lok 406® sheeting to withstand wind loads applicable to enclosed buildings
situated in average suburban or industrial areas with sheeting
A concealed fix profile with a unique double interlocking side fastened as per Chapter 4. These wind loads, also concentrated
lap makes this profile a very fast installing roof sheet. This loads, are determined in accordance with SANS 10237 "Code of
Practice Roof and Side Cladding".
profile is ideally suited to low roof pitches. Manufactured
from certified high yield steel or special grade aluminium For details of support spacings for conditions other than shown in
tables refer to individual product literature.
making it lighter and stronger.

Pierced Fix Roof

Sheeting & Cladding
Klip-Tite®
A rigid profile with improved properties providing improved
clipping and wind-uplift resistance through it's unique shape
and transverse stiffeners.

IBR 890
A trapezoidal profile wider than conventional sheets to
reduce the number of side laps and speed up
installation. Manufactured from certified high yield steel
making it lighter and stronger.
Zip-Tek 420
A deep trough concealed-fix standing seam profile suited for
low pitch roofs and is manufacturered from commercial
quality mild steel or Aluminium.
38mm

IBR 686
The trapezoidal flute design still offers the optimum
strength, mass and load span characteristics compared
to alternative profiles.
m
20.6m

Brownbuilt® 60.5m
m
A concealed-fix standing seam roofing which is fixed with 190.5m
m
m
concealed clips (no holes are made in the sheet) and is 28.6m 130mm
762mm
especially suited for low roof pitches. Manufactured from
commercial quality mild steel, aluminium and copper. Nu-Rib 762
This economical profile effectively bridges the gap between
corrugated and IBR profiles.

tions)
orruga
2m m/10 (c
17.5m
m
7 6
Klip-Lok 700®
Similar to Klip-Lok 406 but wider. The sheet is even Corrugated 10.5
faster to install yielding greater savings. The profile is Corrugated 10.5 has a tranquil appearance, it is relatively
ideally suited to low roof pitches. Manufactured from light, easy to handle and provides an economical coverage
certified high yield steel making it lighter and stronger. per unit mass.

3
2.2 Wind Forces on Roofs wind uplift forces and concentrated loads with an
Winds create considerable forces on both the upper appropriate factor of safety. The Code provides that
surfaces and the underside of a roof. These forces the compliance of metal roofing products with the
may take the form of positive or negative pressure and performance specifications shall be checked by
must be considered in the design and fixing of a roof. stringent proof tests, carried out in accordance with a
Generally the greatest wind forces imposed on roofs procedure which is laid down in the Code. Such proof
are due to suction (negative pressure) tending to lift the tests have been carried out on all GRS roof claddings
roof cladding from its framing and the entire roof struc- and the results have been used in the preparation of
ture from its supports. As the dead weight of roofing the fastening and installation recommendations in this
materials is relatively small, the suction forces must be manual.
resisted by the roof fasteners. It is equally important
that the battens and roof framing be adequately 2.4 Maintenance Procedures.
fastened to the rafters and walls, and that under As with any product, care and the attention during
extreme conditions the wall framing be anchored to the service is well repaid by extending service life.
footings. Regular cleaning of surfaces by hosing and the remov-
al of accumulated debris such as leaves, dirt, pollution
When overhangs are used, the combined effect of fallout etc., will help prevent the setting up of localised
push underneath and pull from above needs to be areas where accelerated corrosion might occur. In
calculated and allowed for in the spacing of purlin particular accumulations of wind-borne salty and
centres. This will apply to overhangs at eaves and corrosive deposits, i.e. under eaves overhangs, in
barges. coastal and industrial localities can have a particularly
aggressive effect on steel sheeting. On the other hand,
being fairly soluble, these salty deposits are readily
removed by a gentle hosing with clean water. It may be
advisable to provide permanent protective coating to
underside of overhangs.

2.5 Run-off Water

Run off from a pre-painted finish, polycarbonate or
inert material will accelerate corrosion on a galvanised
surface below. If the water is allowed to drip rather than
2.3 Codes and Performance Tests flow this situation is exaggerated which will show spot
SANS 10237 - "Code of Practice Roof and Side corrosion. Typical inert roof materials are, aluminium,
Cladding", lays down the performance standards slate, pre-painted sheets, fibreglass acrylic, glass and
which any metal roofing medium must satisfy. GRS polycarbonate. Also see table 2.2
roofing profiles satisfy all the requirements of this
standard. These include the ability of the roof to resist

Table 2.2: Acceptability Of Drainage From An Upper To Lower Surface

Upper surface Fibre

Galv Al/Zn+ Stainless Slate & Glass &
Galv +paint Al/Zn paint Al Copper Lead cement & Glazed
steel Plastic
Cement tiles (PV Panels)
Lower surface tiles

Galvanized Yes No No No No No No Yes Yes No No

Galv+paint Yes Yes Yes Yes Yes No No Yes Yes Yes Yes
Al/Zn Yes Yes Yes Yes Yes Yes No No Yes Yes Yes
Al/Zn +paint Yes Yes Yes Yes Yes Yes No No Yes Yes Yes
Aluminium Yes Yes Yes Yes Yes Yes No No Yes Yes Yes
Stainless steel Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Copper Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Zinc Yes No No No Yes Yes No No

4
3. General Care & Handling

3.1 Care and Storage Prior to Installation This produces less hot metal particals and burrs as
GRS roof and wall sheeting is normally transported to site opposed to carborundum discs. Metal particles on the
in strapped bundles. Bundles should be neatly stacked roof sheeting are detrimental to the life of the roof and
clear of the ground and if left in the open should be protect- leave unsightly red rust patches.
ed from rain and moisture with waterproof covers and
adequate ventilation. Note: Cut sheets to be deburred and coloured sheets to
be touched up.
ON NO ACCOUNT SHOULD SHEETING IN
ANY SURFACE FINISH, THAT IS BUNDLED OR
NESTED IN STACKS, BE ALLOWED TO GET WET. 3.5 Cleaning up
Normal installation procedures for roofing and flashing
Rain or condensation is easily drawn between the using self-drilling screws, drills, saws or angle grinders
surfaces of nested sheets by capillary action or driven in will usually deposit metallic particles onto the roof area.
by wind action, and as this trapped moisture cannot These metallic particles and all other debris including,
evaporate normally it can cause deterioration of the rivet shanks, nails, screws, nuts, cuttings, swarf, etc.
coating (i.e. White Rust) which may lead to a reduced should be swept from the roof sheeting , flashings and
life expectancy or poor appearance. If packs become gutters as soon as possible, certainly at the end of each
wet the sheets should be separated without delay and day's work and particularly on completion of the roof
the surface moisture removed with a clean cloth. The installation. Corrosion and possible failure of the
sheets should then be stacked so that air circulation pre-painted or galvanised coating may take place when
completes the drying process. iron, lead or copper based materials are allowed to
remain in contact with the coated surfaces subject to moist
3.2 Handling on Site or condensation conditions.
On large building projects handling time can be
reduced by lifting sheet bundles, by crane, direct from
the delivery truck onto the roof frame. A spreader beam 3.6 55% Aluminium Zinc Alloy Coated Steel
and fabric slings should be used to support the sheets Soft shoes and gloves should be worn when handling
while lifting. Sheets should be spread out in small this material to avoid discoloration caused by oily
bundles on roof frame to prevent overloading, and residue from the human body.
strapped to purlins to prevent them being lifted by wind.
Where mechanical handling facilities are not available,
sheets have to be unloaded by hand and passed up to
the roof one at a time.

To preserve the surface finish, sheets should be handled

with care. Do not slide sheets over rough surfaces or over
each other and do not drag tools, scaffold poles, etc. over
laid sheets.

3.3 Walking on Roof Sheeting

When walking along a length of roof sheeting walk in the
pans of Klip-Lok®, Klip-Tite®, Brownbuilt®, IBR and on
at least two corrugations of corrugated sheeting. When
walking across the length of roof sheeting walk over or
close to the purlins. Generally keep load evenly distrib-
uted over the soles of both feet and try not to concen-
trate load on heel or toe. Always wear soft soled shoes
when walking on roof sheeting. Sheets taken freshly
from packs may have the residue of rolling fluid on the
surface and care should be exercised when walking
over newly laid sheets until the fluid has evaporated.

3.4 Cutting sheets on Site

If it is necessary to cut sheets on site, care should be
taken to avoid cutting over other sheeting. Hot particles
cause damage to finishes (especially pre-painted
finishes). Use a power saw with cold cutting blades.

5
4. Installation procedure

4.1 General Procedure 4.2.1 Side-Lapping IBR 686 & 890 and
The installer must ensure that the steel structure is Nu-Rib
suitable for installation of sheeting. Particular attention
should be paid to squareness of structure and align-
ment of purlins and girts, which should be in the the
same plane and that purlin rotation is limited to the
guidelines stipulated in SAISC Red Book. When lifting
sheets onto the roof frame ready to commence laying When placing and locating each sheet the side lap over
and fastening, care should be taken to make sure all the previous sheet should be held firmly in place until
sheets are the correct way up and all have the overlap- each end of the sheet has been fastened. This can be
ping side towards the edge of the roof from which simply and easily achieved by clamping the lapped
installation should commence. Otherwise sheets will sheets with a pair of vice grips.
have to be turned over or turned end for end. Sheet
bundles should be placed over or near trusses and not
at mid-span of purlins. The first sheet should be
positioned with particular care before fastening, to
ensure that it lies straight and square and is correctly
located in relation to other building elements:

a) Transversely in relation to the barge fascia or side-wall,

bearing in mind the type of flashing or capping treatment
The procedure is to place the sheet being installed into
to be used.
position and lapped with the previous sheet as shown
b) Longitudinally in relation to the gutter and ridge or
above. The sheet is then located for "longitudinal align-
parapet or transverse wall. Roof sheets should overhang
ment and with the lap snugly nested the vice grips are
about 50 mm into gutters.
clamped onto one end, preferably the high end of the
lap as shown.
When the first sheet is fastened into position a string
line can be stretched across the lower end of the roof
This holds the lap in place at one end of the sheets while
alignment. The line and first sheet then become
the lap on the other end is snugly nested and the
locators for quick placing and aligning of subsequent
sheet fastened. The vice grips also holds the sheet in
sheets. However, periodic checks should be made
longitudinal alignment during fastening.
during the installation of each roof area, by measuring
across the width of the fastened sheeting, at the top
Each sheet should be fully fastened before proceeding
and again and the bottom of the sheet run. This is to
to the next sheet. The fastening sequence should be
ensure that any tendency to creep or fan is controlled.
from the centre of the sheet towards the sides. The
At some stage, say half-way, a measurement should
side lap with the preceding sheet should be fastened
also be made from both the top and bottom of the
last.
fastened sheeting to the far side or finishing line of the
roof area. This is to check that the fastened sheeting is
Pierced fastening may be achieved by the use of screws
parallel to the finishing line. If the building is not square
located in the crest or valley (cladding only) of the sheet
then tapered flashing is required. Fanning or stretching
corrugations or flute. See Tables 4.1, 4.2.1 and 4.2.2 for
of the sheet is not permitted to allow for a building that
recommended screws and nails.
is not square.
4.2.2 Crest Fastening
Fastening through the crest of the corrugations or flutes is
recommended for Corrugated and IBR roofing and can also
be used on cladding applications. The fasteners should be
positioned in the centre of a corrugation or flute and must be
driven perpendicular to the support.

4.2 Pierced Fastening

The pierce fastened Corrugated sheet has a one and a
half corrugation side lap, whereas IBR has a one flute
side lap as shown in the following illustrations.

IBR to timber support

6
4. Installation procedure

4.2.3 Valley Fastening (cladding only) 4.2.5 Pierced Fasteners

The method of pierced fastening through the valley The recommended fasteners listed in Table 4.2.1 have
between corrugations or flutes of Corrugated or IBR is been designed for pierced fastening GRS IBR and
recommended for wall cladding only. Corrugated roofing and cladding products to timber or
steel supports. GRS recommends that fasteners be
Fasteners located in the valley of wall sheeting are less selected having regard to the design life of the struc-
conspicuous and do not break the clean neat line of ture. Specifiers must take care to specify fasteners of
modern steel cladding. Valley fasteners are also tight- at least similar life expectancy to the cladding material
ened on an area of sheeting hard against the support
so there is no risk of the profile being deformed. How- Fasteners should be tightened only until the washer is
ever, valley fastened Corrugated and IBR require a gripped firmly enough to provide a weatherproof seal.
side lap fastener in each lap at each support and at The fasteners should not be overtightened as this will
midspan for fastener frequency and location - see squash the rubbers out under the washers head or
Table 4.1 deform the sheet. All holes for fasteners should be drilled
and not punched.Swarf and metal dust shall be removed
Valley fastening is not recommended for roofing before fixings and washers are positioned. In the case of
application of Corrugated or IBR. pre-coated sheeting, sheets should not be drilled in
packs, drilling in packs causes hot swart and metal dust to
Typical Valley Fastener Detail with Lap Fastener be trapped between the sheets and to embed into the
Over Support at Side Lap (side cladding only) surface coatings, which could cause corrosion of the
sheet after it has been installed.

Underdriven Correctly Driven Overdriven

4.2.6 Fastener selection and frequency

Table 4.1 shows the recommended number of
fasteners per sheet, at each support, and their location
across the sheet for both crest and valley fastening.
This frequency of fastening is to meet the conditions
and support spacing listed for Table 2.1. The frequency
4.2.4 Side Lap Fasteners
of side lap fasteners is also given here. When select-
Lap fastening (stitching) between supports is recom-
ing fasteners, one should consider the class of fasten-
mended to hold the side laps of roof and wall sheet-
ers used, thereby ensuring the life expectancy of the
ing firmly together and maintain a completely water-
fasteners is at least similar to that of the cladding.
proof joint. This applies particularly to roof sheeting
Refer to SANS1273: Fasteners for roof and wall cover-
which may be subjected to occasional roof traffic and to
ings (based on AS3566 and IS09223) Table 4.2.2 on
wall sheeting when installed over maximum spans.
page 9 lists the corrosion resistance classes and desig-
nations for fastener selection. Table 4.2.4 on page 9
indicates the compatibility of materials in direct
contact.

Fastener length for sheet & insulation

Where insulation is installed between purlin and sheet-
ing, the length of screws should be increased depending
on the compressed thickness and density of the insulation.
Maximum spacing of side lap fasteners should be 600mm
centres for roof sheeting. For side-cladding it should be on For metal purlins - The drill point and 3 threads
the girt and midway between girts. Side lap stitching at should at least protrude past the support but the shank
maximum 500mm centres is required for fire resistance protection must not reach the support.
rating at 30 minutes.
For Timber purlins - The screw should penetrate the
Side lap stitching on polycarbonate is essential. Use timber by the same depth recommended as if there
peel rivet & bonded EPDM washer. was no insulation (45mm).
7
Table 4.1 fastener frequency and location

1. Introduction

Table 4.2.1 pierced-fix sheeting fasteners

( 50 mm long for Nu-Rib only )

8
Table 4.2.2 classification, coating thickness and
designation of corrosion resistance

Table 4.2.3 Concealed-Fix sheeting Fasteners

Klip-Lok 406, Klip-Lok 700, Klip-Tite and Brownbuilt fixed to Cold Rolled Steel 1 to 4,5mm thick

Tapered wafer head screws

Zap No. 14 -20 x 16mm long PH3 No1
reduced drill point

timber purlins

Note: Where insulation is installed between the purlin and the sheeting, the length of screws increase depending on the compressed thickness and density of the insulation.
For steel purlins at least 3 screw threads should protrude past the support. For timber purlins the screw should penetrate the purlin by the same depth recommended as
if there was no insulation. Where Fiberglass insulation blankets in excess of 50mm is used over purlin, refer to Table.11.1 on page 27 for fixing details.

Table 4.2.4 Compatibility Of Materials In Direct Contact

Upper surface
Galv Al/Zn+ Stainless Unseasoned
Galv +paint Al/Zn paint Al Copper Lead
steel or wet timber
Lower surface

Galvanized Yes Yes Yes Yes No No No No No

Galv+paint Yes Yes Yes Yes Yes No No No No
Al/Zn Yes Yes Yes Yes Yes No No No No
Al/Zn +paint Yes Yes Yes Yes Yes No No No No
Aluminium Yes Yes Yes Yes Yes No No No No
Stainless steel No No No No No Yes No No No

Al/Zn=Aluminium/zinc
9
 4. Installation procedure

4.3 Concealed Fastening one located each end of the clip in the holes provided.
For Zip-Tek installation details refer to GRS Klip-Lok®, Extra dimples are provided for secondary fastening in
Klip-Tite® and Brownbuilt® concealed fix profiles follow case a fastener breaks, a timber support splits or for
the same general installation procedure as described in additional fasteners in areas where the wind loading
Chapter 4.1, except at commencement of installation a exceeds 1.6kN/m². Also, where additional fasteners are
row of fastening clips are positioned and fastened to required in the case of thick insulation blankets (refer p27).
the supports before the first sheet can be located over
them and locked in position. As there are major differ- Installation Procedures
ences in the clipping assembly and locking of Klip-Lok® Read in conjunction with chapters on stop ending, Flash-
and Klip-Tite® the installation of each is described ings and Bullnosing before commencing sheet instal-
separately on page 14. lation.

Fastener Length for Sheet & Insulation Before commencing also ensure that end-spans, inter-
Where insulation is installed between purlin and sheeting, nal spans and cantilevers are not exceeding the maxi-
the length of screws should be increased depending on mums allowed. (See Table 2.1) Also ensure that hip &
the compressed thickness and density of the insula- valley supports have been installed (see below). Also
tion. see how fixing clips are cut to fix rake-cut sheets.

For metal purlins - The drill point and 3 threads

should at least protrude past the support.

For Timber purlins - The screw should penetrate

the timber by the same depth recommended as if
there was no insulation (45mm).

4.3.1 Klip-Lok & Klip-Tite Installation

KL65 clips are used for concealed fastening Klip-Lok 406®.

These clips are asymmetric having a short downturn on the
interlocking rib upstand and a long downturn on the centre
rib upstand. The KL 700 Plus clips or the KL 700 clips are
used for concealed fastening Klip-Lok 700® & Klip-Tite ®.
These clips have three upstands for fixing the male rib and Plan View
the two centre ribs of the Klip-Lok 700® & Klip-Tite® sheet. This principle applies to both timber and steel structures.

Note:
Recommended Fasteners for Concealed
At rake-cut edges (hips & valley gutters) care should be
Fix Products taken that every rib is securely fixed down in this area
(Refer to TABLE 4.2.3) with pieces cut from standard fixing clips.

Fastening Clips Steps 1 to 5 illustrates Klip-Lok 406. The procedure for

The KL 65 and KL 700/ KL 700 Plus clips are fastened to the Klip-Lok 700 and Klip-Tite is the same. Read in conjuntion
top of the support with two and three fasteners respectively, with page 13, procedure for engaging side-laps.

10
4. Installation procedure

STEP 1
As described in the general procedures (Chapter 4.1),
when lifting sheet lengths onto the roof frame, ready for
installation, make sure all the sheets have overlapping
female rib facing towards the side where fastening is to
commence. The first run of KL65 or KL700 clips have
to be located and fastened one to each support so that
they will correctly engage in the female and centre ribs Note: Step in this pan, not on the male rib.
of the first sheet when it is located over them. To do
this, fasten clips to the purlins at each end of the sheet,
having positioned them so that the first sheet will be in If the clip falls on one of the spurs spaced along the
correct relation to other building elements. Align and outer free edge of the male rib, the spur should be
fasten the remainder of the first run of clips using a flattened with a blow from a rubber mallet to allow the
string line or the first sheet as a straight edge. The clip to seat down over the rib.
Interlocking Rib upstand side of the clip must be on the
outside edge of the roof supports and clips must be
square to the sheeting. When laying Bullnose or Rib
cap sheets please refer to Chapters 6 or 7 before
proceeding. Fix positive if there are no flashings.

STEP 4
Place the second sheet over the second run of clips
STEP 2 with the female rib overlapping the male rib of the first
Locate the first sheet over the fastened run of clips, having preceding sheet and the centre rib upstand of the clips.
positioned it longitudinally in relation to gutter overhang and Create a spur with a pair of pliers at end of sheet as
then fully engage on clips with foot pressure applied to the indicated in sketch above and with a rubber mallet,
centre and female ribs over each clip. close the female rib before engaging. A string line
stretched across the bottom alignment of sheets can
be used to check that the end of the sheets are in line.
The string line must be at a higher level than the depth
of the profile to ensure that it is not pushed away when
the sheet is positioned. Only then fully engage the
interlocking ribs and the centre rib over each clip. One
foot should be in the tray next to the overlapping female
rib and the other foot applying pressure to the top of the
interlocking ribs at regular intervals. Also apply foot
pressure to the top of the centre rib over each clip. See
sketch for Klip-Lok 406® & 700® & Klip-Tite® on page
13. When engaging side lap, always walk from one end
to the other (bullnose sheets walk from bullnose).
STEP 3 Never walk from both ends to the centre.
Position the next run of clips, one to each support, with the
interlocking ribs upstand of the clips engaged over the male
rib of the installed sheet. Do not step on the male rib. Step in
the end pan and fasten the clip at the centre rib first, then
fasten the clip at the male rib. Do not push or pull clips as
they will not engage properly into the sheet.

11
4. Installation procedure

For complete interlocking, which is essential, the spurs

of the underlapping male rib must be fully engaged in
the shoulder of the overlapping female rib. A distinct
"click" will be heard as the spurs along the edge of the
male rib snap into the shoulder along the female rib.

When engaging Klip-Lok® & Klip-Tite® interlocking

ribs, stand only on the sheet being installed. That is
the overlapping sheet - not on the preceding sheet.

Install subsequent sheets by following steps 3 and 4

and make periodic checks for parallel as described in
general procedure (Chapter 4.1)

If no spur is visible, create one with a pair of pliers 20

mm from the end of the sheet and close the female rib
± 300 mm before engaging.

STEP 5
If the space left between the last full sheet and fascia or
parapet is more than a half sheet width, a sheet can be
cut longitudinally leaving the centre rib complete, and
this part of the sheet can be fully engaged onto a row of
clips as for a full sheet.

If the space left between the last full sheet and fascia or
parapet is not a full sheet width, the last sheet needs to
be cut and a dry pan formed along the full length of the
sheet. This is achieved by measuring the width that the
last sheet has to cover, adding 40mm to the measured
width, cut the sheet at that point over its full length and
bend the sheet up to form a dry pan. This part of the
sheet can be fully engaged onto a row of clips as for a
full sheet.

12
4. Installation procedure

Procedure for engaging side-laps Installing KL700 Clip (on insulation

For insulation blankets thicker than 50mm, additional blanket up to 50mm thick)
measures must be employed - see table on page 29
1. Stand with a foot in the centre of the male rib's pan & over
the purlin to compress the insulation blanket.
2. Position the KL700 clip correctly over the male rib of
sheet and directly over the purlin. If any spur of the sheet
occurs where the KL700 clips are to be fitted these should
be flattened beforehand.
3. While still standing in the sheet's pan, also stand on the
KL700 clip as indicated, and while keeping it in the correct
position fix the centre screw first. Then fix the screw at the
sheet before fixing the outer screw.
"Use an extension piece for"
"the PH2 bit so that the drill's chuck
is always above the sheet 's rib."

Note: The same principles will apply when fitting

the clip with rigid board insulation or without insulation.

Engaging Sidelap
Note: Engage centre ribs of sheet to the clip first before Installing KL700-Plus clip (on insulation
engaging the side lap. blanket exceeding 50mm in thickness)

The extended base of the KL700-Plus clip has locating

holes to ease installation and resulting in more accurate
installation. The extended base eliminates insulation bulge
and should thus be used with insulation blankets exceeding
50mm in thickness.

1. Stand with a foot in the centre of the male rib’s pan and
over the purlin to compress the insulation blanket.
2. Position the KL700-Plus clip correctly over the male rib of
sheet and directly over the purlin. If any spur of the sheet
occurs where the KL700-Plus clips are to be fitted these
should be flattend beforehand.
3. While still standing in the sheets pan, also stand on the
KL700-Plus clip as indicated, and while keeping it in
correct position fix the screw at the sheet first and then
follow the sequence of fixing screws as indicated in the
table “Number of fasteners for KL700 - Plus clip”
on page 14, ensuring that the insulation blanket is
straightened-out during fixing.
4. Place the next KL700-Plus clip over the male of the
previously installed sheet whilst ensuring that the locating
holes of the two KL700-Plus clips line up. The locating
holes will ensure to follow a 700 module installation. Stand
with one foot in the male pan of the installed sheet and
other foot next to the centre rib of the clip and fix screws
in sequence as per paragraph 3.

13
4. Installation procedure

Number of fasteners for KL700-Plus Clip

The suggested fastener sizes as shown are recommended
for 1mm to 4.5mm cold rolled purlins.

Klip-Tite TM Klip-Lok 700 TM

Wafer Tek #10 - 16 x 16 lg Wafer Tek #10 - 16 x 16 lg

N/A
No Insulation

Wafer Tek #10 - 16 x 16 lg Wafer Tek #10 - 16 x 16 lg

Radiant Barriers
(Heat reflective N/A
Foil/ Laminate)

Wafer Tek #10 - 16 x 22 lg Wafer Tek #10 - 16 x 22 lg

50mm thick
Insulation Blanket N/A
12kg/m3

Wafer Tek #10 - 16 x 22 lg Wafer Tek #12 - 14 x 65 lg Note:

Fix Packer
down first with
75mm thick 2/ #12 x85 lg
Insulation Blanket Wafer Teks per
packer
12kg/m3 Packer ± 600mm from
Fasteners 25mm thick x end & ± 1250
Sequence 75mm wide x centres
2450 lg

Wafer Tek #10 - 16 x 22 lg Wafer Tek #12 - 14 x 65 lg Note:

Fix Packer
down first with
100mm thick 2/ #12 x85 lg
Insulation Blanket Wafer Teks per
3 packer
12kg/m Packer ± 600mm from
25mm thick x end & ± 1250
Fasteners 75mm wide x centres
Sequence 2450 lg

Wafer Tek #10 - 16 x 45 lg Wafer Tek #12 - 14 x 65 lg Note:

Fix Packer
down first with
115mm thick 2/ #12 x85 lg
Insulation Blanket Wafer Teks per
3 packer
12kg/m Packer ± 600mm from
30mm thick x end & ± 1250
Fasteners 75mm wide x centres
Sequence 2450 lg

Wafer Tek #10 - 16 x 45 lg Wafer Tek #12 - 14 x 85 lg Note:

Fix Packer
down first with
135mm thick 2/ #12 x85 lg
Insulation Blanket Wafer Teks per
packer
12kg/m3 Packer ± 600mm from
40mm thick x end & ± 1250
Fasteners 75mm wide x centres
Sequence 2450 lg

Note:
1. Above do not apply where insulation density exceeds 12kg/m 3.
2. Fasteners to be correct specification and length to allow at least 3 threads to protrude below the steel purlin.
3. The above does not apply when light steel frame purlins with thickness of less than 1mm are used.

14
4. Installation procedure

Ensure matching
locating holes

15
4. Installation procedure

4.3.2 BROWNBUILT® STEP 2

Three types of clips are used for the concealed fastening of A run of duplex clips, one to each support, is now
Brownbuilt® sheeting. A starting clip, a duplex clip and a positioned over the male rib of the installed sheet and
finishing clip. fastened to the supports with appropriate recommend-
ed fasteners. Before these clips can be positioned the
turnover along the top of the male rib of the sheeting
Duplex Clip has to be locally flattened with a rib closing tool.
D2

Rib Closing Sequence

Starting Clip
D1

Finishing Clip
S3
Clips for 2nd and successive sheets

Recommended Fasteners for Brownbuilt®

Clips (Refer to Table 4.2.3)

Installation Procedures
Read in conjunction with Chapters on Stop ending,
Flashings and Bullnosing before commencing sheet-
ing.

STEP 1 STEP 3
As described in the general procedures (Chapter 4.1) Place the next sheet in position by locating the female
when lifting sheet lengths onto the roof frame ready for rib over the overlapping male rib of the preceding
installation, make sure all the sheets have the overlap- sheet and the fastened clips. When placing the sheet
ping female rib facing towards the side where the check the longitudinal location using a string line
fastening is to commence. stretched across the bottom alignment of the sheeting.
Install subsequent sheets by following steps 2 and 3
and make periodic checks for parallel as described
in general procedures (Chapter 4.1). It is recom-
mended that periodic checks are made at intervals of
every sixth sheet.

STEP 4
If the last sheet in the roof is a full width sheet a finish-
ing clip can be positioned and fastened to each
support before placing the last sheet. The narrow
portion of the clip upstand is then folded down over the
male rib after the last sheet has been positioned.
The first run of starting clips have to be located with the
upstand side to the outer edge of each support so that
they will correctly engage in the centre rib of the first
sheet when it is located over them. Care must be taken
in aligning and fastening of the first line of clips in
relation to other building elements - using a string line
or the first sheet as a straight edge. Once the first sheet
is in place the outside leg of the starting clip must bent
down over the female rib of the sheet.

16
4. Installation procedure

STEP 5 Button Punching Location and Frequency

When all the sheeting is assembled in position and For spans between supports spaced up to 1300 mm
engaged with the fastened clips, the overlapping ribs button punching should be applied 150 mm. Each side
are locked together by using a button punching tool. of the duplex clips. For spans over 1300 mm an additional
button punch is required at mid-span. Button punching for
wind loading exceeding an uplift of 1.6kN/m², please
contact GRS.

Suspended Sheeting
Brownbuilt sheeting are also used as economical roof
and ceiling combinations for canopies, shop veran-
dahs, link corridors and suspended roofs. Sheeting is
laid in the opposite direction to the normal, commencing
with the male rib at the verge.

Fixing is accomplished with H.9 clip assemblies on

EVERY rib of the sheeting and holes for the 6mm
T-Bolts should be punched from the top and NOT
DRILLED. It is essential that the toe of at least one purlin
should face in the opposite direction to the others to
prevent movement of the sheeting.

Brownbuit 406 sheeting as suspended roof/-

ceiling
The overlapping female rib must be pressed down
firmly onto the underlapping male rib before applying
the button punch.

Note: The direction of the button punch as shown in above to

ensure the indentation is formed on the female side below the
end of the male rib.

4.3.3 Concealed Fastened Cladding

Klip-Lok® and Klip-Tite® are not suited for side
The spacing of punching along each interlocking rib
cladding. Brownbuilt® profiles however, may be used
should not exceed 900 mm and hot rolled purlin H9 clip
as walling or even on very steep roof pitches, and used
assembly on every rib must be kept clear of the support
as such, it should have at least one pierced-fix fastener
to avoid punching over a clip. Do NOT punch over clips.
through each pan to prevent its gravitational movement
down the fastening clips. This fastener can be located
Punching to a string line guide stretched across the
into the top support under the flashing along the top of
sheeting is recommended as with random punching,
the sheeting.
the appearance of the finished work can be marred.
The direction of Button Punching is extremely import-
ant as the indentation needs to be formed on the 4.4 Stop-ending
female side below the end of the male rib, see sketch All GRS roofing profiles, should be stopended at the
above. high end, regardless of slope, to ensure that water,
wind driven beneath the flashing will not drain into the
It is important that the Button Punch is set correctly and building.
should be checked at least once a day while in use.

17
4. Installation procedure

The stop-ending/turn-up operation should be carried Brownbuilt Stop-Ending Procedure

out before the sheets are placed in position - this applies Flush stop-ends are generally used with Brownbuilt®
especially where head/parapet walls occur - although it roofing, a tool is supplied for this purpose. Stop-ending
can be done after installation if sufficient clearance is is usually carried out on the ground before installing
left at the top end of the sheets for operation of the the sheets on the roof structure.
turn-up tool.
Prior to the folding of the pan of the sheet, it is essen-
Corrugated Iron tial to remove the overlap portion of the female rib for
Corrugated Iron requires vice-grips or a shifting spanner, at least 50 mm in length. For a flush stop-end the
closed down to 2 mm. Grip valley 20mm in from end of crown of the centre rib must also be cut for 50 mm from
sheet and turn up as far as possible. Rake cut sheets ie: the end to enable the formed ears to be folded flush
hips, can be stop ended with a shifting spanner or vice against the turned up tray. This is done with a rubber
grips in the same manner as straight sheets. mallet while holding the stop-ending tool behind the
turned up pan.

When using the Brownbuilt® stop-ending tool it is

important that the tool is pushed home over the ends
of sheets before the tool is raised through an Arc of
90°.

Klip-Lok®/Klip-Tite® Stop-Ending Procedure

If stop-ending is to be carried out after the installation
of sheets the corner of the turn down of the female rib
must be cut off. Do not use the Klip-Lok 406® stop-enders
tool for the Klip-Lok 700®/ Klip-Tite® profile because the
pan width varies.
Note: For Brownbuilt, an extra 50 mm should be allowed
Where rake cut sheets at hips have to be stop-ended, on the sheet length for flush stop-ending"
care must be taken to bend up full width of pan. This is
best done by using vice-grips to bend pan up full depth
of sheet.
Stop Ending at a Rake
A stop end needs to be formed at a hip. This is best
done by using vice grips with jaws to bend the pan up to
the depth of the profile. Where the sheets are rake
cut at valley gutters, lipping should be effected over the
full width of the pan.

4.5 Lipping
Regardless of roof slope, all concealed fix profiles roofing
pans must be turned down through an arc of 20° at the low
end of the sheet. This lipping ensures that rainwater
drains off the end of the sheeting and does not run
back up the underside of the flat pans by capillary or wind
action. The mouth of the appropriate lipping tool
(Klip-Lok®, Klip-Tite® or Brownbuilt®) is positioned over
the end of the pan and push on as far as it will go. The tool
is held hard against the end of the pan while the handle is
swung through an arc of about 20° to form a lip on the end
of the sheet.

18
4. Installation procedure

The lipping operation is usually carried out after the sheeting

is fastened on the roof before Brownbuilt gutters are fixed.

Brownbuilt (end laps are not recommended)

Sheets can also be rolled and cranked on site in
lengths that make it unnecessary to end-lap. End
lapping negates the concealed fixed concept and no
water tightness guarantee can be given. However, the
following procedure should be adopted should
end-laps be required.

The first sheet is fixed in the normal manner. Before

fixing second sheet the down-turn on the male rib of
the sheet should be cut off for a distance of 300 mm.
Fix both sheets to purlin with D2 duplex clip. The
4.6 End Lapping turn-down of the female rib of the third sheet must be
cut off for a distance of 300 mm before fixing as per
IBR, Nu-Rib & Corrugated
sheet one. Sheet four is cut and fixed as sheet two. All
Statistics show that the most corrosion takes place at
subsequent sheets are fixed as shown here.
the endlap and that it should be avoided wherever
possible.
All end-laps should be sealed with two runs of a
recommended sealant.
Should it be necessary for transport or other reasons to
end-lap pierced-fix sheeting, the following procedure
should be adopted. Lay each run of sheets in turn from
bottom to top before moving onto the next run.

Numbers show sheet laying sequence

Butyl strip

19
4. Installation procedure

4.7 Recommended Table 4.8 Coefficient of Expansion

Step-lap / Expansion Detail

The clip fixing systems for Brownbuilt®, Kip-Lok® and

Klip-Tite® allow for expansion and contraction, making
it possible to utilise lengths restricted only by handling.
Should an expansion joint be required in the structure
the sheets should be treated in the following manner.
An expansion joint can be provided at an end lap by
raising all the purlins or supports for the roof sheeting
on the high side of the lap to form a step 20 mm higher
than the depth of the sheeting. The roof sheeting then
overlap a minimum of 200 mm at the step and appropri-
ate weatherproofing is provided. An extra purlin or
support will be required at the step. Transverse expan- 5. Flashing
sion joints are not necessary for the thermal movement
in ribbed sheeting as each rib profile allows some
transverse movement. The coefficients of expansion Method of flashing for the range of GRS roof and wall
for various materials are given in Table 4.7 on the next sheeting are similar and the following details, with
page. appropriate variations, would apply to all profiles.
Flashings are available in Galvanised, pre-painted
steel, 55% Aluminium Zinc Alloy coated steel,
Aluminium or Copper. Flashing dimensions should be
generous with ample cover width over roof sheeting
and ample turn-up behind counter flashings. End
lapping to be a minimum of 150 mm. For concealed-fix
sheeting, no direct perforations should be made for
fixings.

5.1 Longitudinal Flashings

Longitudinal flashings for Brownbuilt®, Klip-Lok® and
Klip-Tite® should have a turn-down edge located
into the pan of the roof sheeting and of a depth to suit the
sheet profile. IBR and Corrugated flashings have
standard bends along edges with closer pieces where
required.

Brownbuilt®, Klip-Lok® & Klip-Tite® flashings should

be fixed using S1 or S10 brackets to ensure that no
holes are made directly through the sheet.

4.8 Expansion
An appreciation of the amount of expansion that
occurs in metal roofs may be gained from the arbitrary
example. A 15 m steel sheet expands 12 mm for a
temperature variation of 65°C. The actual expansion
movement between the end of a sheet and the last
support would be less than the figures shown because
the movement in a length of fastened sheeting would
normally take place from a point one-third down the
slope of the roof towards each end of the sheet. The
movement at the top of the sheet is then a third of the
expansion and contraction upwards and two thirds
downwards.
20
5. Flashing

5.2 Transverse Flashing Alternatively two sheet-wide closers are available for
Transverse flashings for Klip-Lok® & Klip-Tite® are Klip-Lok 406® or one sheet-wide closer for Klip-Lok
usually notched out and turned along their lower edge 700®/Klip-Tite®.
to match the sheet profile. This provides a baffle
against wind-borne moisture penetrating below the Headwall Flashing for Klip-Lok/Klip-Tite
flashings. Notched flashings should be fixed with S1 or (a similar principle would apply for Ridge & Apex flashings)
S10 brackets. No direct perforations are allowed for
concealed fix sheeting.
Pop rivet or preferably use stitching screws, a minimum
of 50mm away from the narrow flute. For this application
the minimum thickness for flashing is 0,8mm.

Transverse flashing for IBR sheeting have stiffening bends

along the outer edges with pre-notched, one sheet width,
Barge Flashing closer pieces underneath to ensure weather proofing.

Notching tools are available to notch-out single rib

profiles to match Klip-Lok®/Klip-Tite® and Brown-
built®.

/ Klip-Tite

After the sheeting has been fastened and the pans

turned up, the flashings are placed in position with the Transverse flashings for Corrugated usually have a
turned down edge on top of the ribs. Locate the notch- stiffening bend along the lower edge. To ensure
ing tool over a sheet rib with the notching head against weather proofing this should be lightly dressed into the
the turn down. Raise the handle to open the tool and lift valleys.
the turned down edge of the flashing into the mouth of
the tool. Push down on the handle to notch the rib
profile out of the turn down in line with the rib. Raise the
handle, lift the turned down edge sufficiently to relocate
the tool on the next rib ready to notch, while retaining
the flashings in its correct position. Repeat on each
sheet rib along the full length of the flashing. Ensure
clearance is maintained on both sides of each notch/-
cut-out to prevent scratching of the sheeting. Change of Pitch Flashing (Apron flashing)

21
5. Flashing

Flashing lightly dressed with ball-pen hammer

fastened to the ribs at the frequency shown in Table
5.1.

Transverse flashings for Brownbuilt, Klip-Tite and

Klip-Lok are fixed in conjunction with S1 or S10 brack-
ets at the frequency shown in Table 5.1. See table
4.2.2 & 4.2.3 for recommended fasteners.

Sliding brackets are to be used for sheet lengths longer 5.4 Flashings around Roof Protrusions
than 30 meters for Steel sheets and 20 meters for On low pitched roofs, any protrusions through ribbed
Aluminium sheets. Alternatively a 2-piece Expansion sheeting large enough to block or restrict flow of one or
Ridge cap can be used. more of the sheet drainage channels will require
special attention to the flashing around the protrusion.
This is to divert run-off from the blocked or restricted
channels and can be achieved by fitting a head gutter
across the high side. Run-off from the blocked chan-
nels is then discharged into clear channels either side
of the protrusion. The sheets on the high side of the
protrusion to a width of a full number of sheets are
lifted over three purlins to a height of the rib of the
sheet plus 25 mm by placing Z section pieces of
various depth on top of purlins. Taper flashings are
then fixed to either side to close the gap. (This detail is
only used on non-handed sheets like IBR and Nu-Rib)
Sliding Bracket
If the distance from the back of the protrusion to the
Fix sliding brackets to centre ribs only, not on side lap.
apex of the roof is less than 3,5 m then back flashing
must be used.

Taper Flashing

Two piece Expansion Ridge

Table 5.1 Fastener Frequency for Taper Flashing

Transverse Flashing

Klip-Tite® All centre Ribs

5.5 Pipe Penetration

Flashing around small pipe penetrations, which fit
between the ribs of a roof sheet and allows free flow of
water to ensure drainage or penetrate only single rib, is
5.3 Fastening Frequency for Transverse fairly simple. This requires a flanged cylindrical sleeve
Flashings fastened and sealed to the roof sheeting around a
Where possible, transverse flashings over IBR and Corru- clearance hole and the pipe penetration. The sleeve is
gated should be fastened in common with the sheeting with covered by a tapered skirt sealed and fastened to the
the normal sheet fasteners into the top purlin or support. pipe and there should be clearance between the skirt
Where the location of the top support does not permit pierce and sleeve and between the sleeve and pipe. This is to
fastening with the sheet fasteners, the flashing should be allow for thermal movement of the roof sheeting.

22
5. Flashing

If the roof penetration can be located close to the apex

of the roof, another alternative is to fit a simple flat
cover flash on top of the sheeting extending from
under the Ridge or Apex flashing down to a sleeve
around the penetration.

Support Framing

Where a pipe penetrates through the rib of a sheet is Wherever a roof penetration requires one or more of
best flashed using flexible neoprene flanged sleeve the sheet ribs to be cut, framing must be provided to
which can be obtained for flashings around penetra- support the cut ends of the roof sheeting each side of
tions up to 300 mm diameter. The flange around the the penetration.
base of the sleeve can be contoured by hand to match
the sheeting profile before it is sealed and fastened to
the sheeting. This allows drainage of run-off down the
trays or valleys each side of the penetration. The
sleeve tapers up from the flange to a watertight fit
around the penetration. When using these neoprene
sleeves care must be taken not to dam off any valleys
or trays which would prevent water draining around
them from the high side of the roof penetration. Mois-
ture retention in such areas can cause deterioration of
the sheet coating which may lead to a reduced life
expectancy.

Back Flash

23
6. Rib Cap-Bent Continues 7. Cranking and Bullnosing Sheet
Sheeting

On double-pitch roofs Klip-Lok and Brownbuilt can be It is possible to crank or bullnose Klip-Tite®, Klip-Lok®,
used in continuous lengths from eave to eave by cutting Brownbuilt®, IBR and Corrugated to a minimum radius of
the ribs and bending the pans at the ridge line. Bend 450 mm. Bullnose or cranking is achieved by stamping in a
must be done over a straight edge. Caps are then fitted series of indentations across the pan and up the side of the
and sealed over the cut ribs. This method provides a ribs at set distances, to give a "washboard" pattern to the
roof with very neat appearance with continuous pans sheet. The distance between the indentations determines
and unbroken rib-lines over the ridge and down each the radius of the curve. The cranking of sheets imparts
side of the roof slope. However, fitting the rib-caps is greater rigidity and renders them less tolerant of misaligned
time consuming and care must be taken with sealing to supports. If cranked sheets are forced to follow badly
avoid any possibility of leakage. Care should be taken aligned purlins or girts, sheet laps may not nest neatly,
to ensure that the ribs of each sheet are cut at 90° to causing poor appearance or loss of waterproofing. The
the longitudinal axis of the sheet. The ribs are easily cut steelwork therefore, has to be squarely aligned, be straight
with a metal cutting blade, in a power saw, set to the rib and true, with minimal deflection.
depth minus 2 mm. Any excess sealant must be
removed the day after applying.
Installation Procedures

Pierced Fix
For handling reasons IBR and Corrugated bullnosed
sheets are often supplied in short lengths allowing for an
end lap near the end of a roof. When this technique is
employed, it is ABSOLUTELY ESSENTIAL that each
This detail is not recommended for a ridge
detail with sheets longer than 30m either
run of bullnosed and straight sheets are end lapped
side. Sheets longer than 30m install sliding Ridge cap progressively across the width of the roof so they can be
brackets. (20m for Aluminium)
kept in alignment. This applies to all profiles. See laying
sequence below.

Apply approved sealer inside ends

and along buttom of cap. Place in
position over open pit.

Laying sequence for

IBR and Corrugated

Concealed Fix
When bullnosed sheets are installed it is important that the
indentations of adjacent sheets are aligned properly to
ensure side lap interlocking. This is best achieved by
narrowing the male rib for the full arc length of the bullnose
prior to installation.

24
8. Curved Sheeting

Curving of all GRS sheets, can be achieved by extend-

ing the distance between the indentations across the
sheet - effectively increasing the radius. Brownbuilt®,
Klip-Lok® & Klip-Tite® can be curved on site resulting
in limitations governed only by handling. IBR & Corru-
gated has to be transported by road and is limited to a
maximum cord height of 2m and sheet length of 12m.

9. Sprung Curved Sheeting

Convex
The Brownbuilt profile, the Klip-Lok & Klip-Tite® profiles,
IBR and Corrugated can be sprung curved in single
lengths over an arched roof, provided the radius of the Concave
arch is not less than the minimum listed for each sheet Brownbuilt®, Klip-Lok 406® (not KL700® & Klip-Tite®), IBR
profile in the Table 9.1 and Corrugated sheets can also be sprung to a minimum
radii shown in Table 9.2 for concave roof applications.
Table 9.2 - Concave

Note: Whenever sheets are sprung slight crease marks

may appear in the pans. Increased radii reduces this effect.
The same applies for a thicker sheet. In general, the
narrower the sheet the less marks appear in the pan.

10. Translucent Sheeting

Two translucent materials are available for GRS sheet-

ing. Glass Reinforced Plastic - GRP(Fibreglass) or,
Polycarbonate Resin. For availability refer Table 10.1
Regardless of reduced purlin spacing, avoid foot traffic
Where sheets are sprung curved, the cover width of on translucent sheets. If single-width translucent
the sheets tends to increase due to the curvature. For sheets are used, supported both sides by steel sheets,
concealed fix this needs to be controlled by bending purlin spacing need not be adjusted. More than one
the male rib upright to ensure that the original cover translucent sheet adjacent to one another, requires
width is not exceeded. This is done before the clip is substantially reduced purlin spacing see Table 10.1.
located over the male rib. Polycarbonate is available in single width sheets

25
10. Translucent Sheeting

except Klip-Lok 406 which is only available in a double It is preferable to position the lengths of translucent
width of 812mm (2 x Cover width of 406mm). GRS sheeting at the top of a roof run so that the top end is
offers Polycarbonate colours in Clear or Opal as a under the headwall or ridge flashing and the low end
standard. overlaps the steel sheet. Due to translucent sheeting
being thicker than steel, it will readily overlap the steel
sheet but the reverse is difficult. This is especially the
case with Klip-Lok sheeting. Because of its greater
thermal expansion, translucent sheeting for pierce-fix
(IBR) should be fixed using oversized holes and washers
as recommended by the translucent sheeting manufac-
turer. With conceal-fix sheeting, care should be taken
not to perforate the steel sheeting. Refer to drawing
below for Klip-Lok translucent fixing detail. There are
various methods of fixing translucent sheets in tandem
with conceal-fix sheeting. All these methods are in
conflict with the concealed-fix concept as the nature of
the material requires it be pierced. It would therefore be
excluded from any guarantees.

NB: All holes in polycarbonate to be 10mm diameter.

Two strips of Butylseal

26
11. Insulation

To reduce the transmission of heat from solar radia-

tion into a building, insulation can easily be incorporat-
ed in the roof system during installation of the roof sheet-
ing. For Concealed fix sheeting, fixing clips need to be
stabilised depending on the type of insulation used to
eliminate rocking. There are basically three types of
insulation, these being:

1. Reflective Foil Laminate/BubbleFoil

Foil laminate as an insulation acts to reduce the
transmission of heat from solar radiation into a build-
ing by reflection. To be able to insulate effectively, it is
necessary to allow an air space between the top face 3. Rigid Foam Insulation
of the laminate and the under side of the roof sheet. Rigid foam panel sandwiched between surfaces of
The foil laminate is easily incorporated into the roof aluminium foil, mill finish or white lacquered.
system during the installation of the roof sheeting by Installation is normally over purlins together with the
firstly installing straining wires over the top of the roof sheeting. Insulation boards are placed over purlins
purlins from apex to eave. The foil laminate is then laid with ends butt-jointed on purlins.
over the straining wires from apex to eave and tempo-
rarily fixed to top and bottom purlins. Permanent fixing Pierced-Fix Sheeting
is achieved with fixing of roof sheets. For Pierced-fixed sheets, the sheets are placed on top
of boards and fixed through sheet and board into
purlins with fixing screws of adequate length to pene-
trate sheet and board.

Concealed-fix sheeting
The density of typical polystyrene and polyisocyanurate
boards used in the industry allows the concealed fix clip to
be pressed into the board during fastening, even when
power tools are set to the lowest torque setting. Compres-
sion and creep resistance testing showed that both insula-
tion boards exhibit creep behaviour with no indication that
the creep process will discontinue or abate over time. The
fixing method will thus differ depending on the length of the
sheet.

a) Use 150mm x 0.8mm thick galvanised steel strip over the

entire length of the purlin for insulation thicknesses and
sheet lengths as indicated.
2. Fibreglass/Laminated Foil or Mineral-wool
Resin bonded fibreglass wool with a laminate of
either Kraft Aluminium Foil (or colour coated foil) of Insulation (mm) Sheet length (m)
various thicknesses is a high quality insulation mate-
rial that can be easily fixed in a similar manner to the
20 15
reflective foil laminate as described in 1 as above. For
concealed fix sheeting, blankets thicker than 50mm 25 17
may require additional measures to be taken, see table 30 20
11.1 on p29. 40 30
50 35
Note: For insulation material thicker than 50mm, the
clips may need to be elevated with 'packers' to facilitate When the sheet length exceeds the length indicated
the sheets to clip in, and to prevent the rocking of clips. (see above table) then U-spacers are to be used for
Refer to table 11.1 the balance of the length at the sheets ends.

27
11. Insulation

b) Use 1.6mm thick u-spacers pressed through the

insulation board directly under the fasteners to bear
hard onto the top of the purlin to stabilise the
concealed-fix for all insulation board thicknesses and
sheet lengths exceeding values given in paragraph (a)

1,6 thk.

28
11. Insulation

KLIP-LOK 406 & 700

KLIP-LOK 406 & 700

29
12. Rainwater Run-off

The rainwater run-off capacity of roof sheeting is a Table 13.1 Gutter Sizes For Various Rain-
limitation on the total length of a sheet run that must be fall Intensities & Roof Catchment Areas
considered in roof design and construction. As a Per Downpipe
guide, Table 12.1 lists the maximum recommended
length of roof run for various GRS sheet profiles at the
roof slopes and rainfall intensities shown. The roof
run is the total length of roof sheeting draining rainwater
in one direction including any end laps, expansion
joints or steps that may be presented in the roof.

13. Gutter Capacity

The gutter cross-sectional area given in Table 13.1 are

provided for guidance only. Where more design detail
is required, the South African Steel Construction Hand-
book Section 11 should be consulted.

Table 12.1 Maximum Roof Run (in metres) for Roof

Slopes & Rainfall Intensities (providing that the free
flow of water is not restricted)

Note: Gutter Freeboard

To allow for irregularity of the water surface and as a margin
of safety, it is recommended that a freeboard of 10% of the
maximum flow depth be allowed, with overall minimum
freeboard value of 40mm. For regions where hail occurs
frequently the freeboard should be increased to 15% with a
minimum of 50mm.
Table 13.1 lists a selection of roof catchment areas that
are drained by one downpipe and shows the cross Eaves gutters should have a fall towards the outlets 1
sectional area of gutter required for a range of rainfall in 500 and internal box gutters a fall of 1 in 200. If for
intensities. The roof catchment area for each downpipe is some design or other consideration, gutters are
the length of the roof run (ridge to gutter), multiplied by the installed without a fall, ponding will result and this
spacing between downpipes. Table 13.2 is an extract could reduce the life of the gutter. In such situations the
from the South African Steel Construction Handbook gutter should be cleaned out regularly. With high front-
and shows rainfall intensities for selected localities, ed eaves fascia gutters, care should be taken to
related to 5 minutes duration storms and a return interval prevent overflow from the back of the gutter into the
of 50 years. It is suggested that for design purposes the building, in the event of a blocked downpipe. This can
following five minute duration rainfall intensities be adopt- be done by providing drainage slots along the front of
ed for gutter and downpipe design, assuming a 20 year the gutter. Alternatively the outer vertical leg can be
return storm. lower to create an overflow.
Summer rainfall region : 200mm/hr
Year-round rainfall region: 150mm/hr
Winter rainfall region: 100mm/hr

30
14. Downpipe Capacity

The cross-section of a downpipe from an eaves gutter level than the inner vertical leg of the gutter. This will
should be 65mm² for each square metre of roof area help where an outlet has become restricted. Where
draining into the downpipe. The cross-section of a eaves gutters are not concealed it is advisable to
downpipe from an internal box gutter should be 100 design the gutter with the outer vertical leg lower than
mm² for each square metre of roof area draining into the inner leg. This will allow a natural flow of water in
the downpipe. case of hail or leaf build-up. If this cannot be achieved,
consideration should be given to the provision of
Table 13.2 Design Rainfall Intensities overflows at a lower level than the inner vertical leg of
5-Minutes Duration the gutter as described above. It may be useful to
consult the SAISC Red Book under the heading "Drain-
age", which could provide some assistance in the
design of hail guards.

16. Condensation

To minimize the risk of condensation under roof sheeting

a vapour barrier should be provide on the underside to
prevent contact with moist air. The reflective foil
laminate which provides heat insulation under the roof
However, the minimum cross-section of any downpipe sheeting can serve a dual function as a vapour barrier
should be at least half that of the gutter from which it simply by sealing the overlaps with a moisture impervi-
drains. It is good practice to provide drainage sumps at ous adhesive tape.
downpipe connections to gutters or at least have
funnels at the head of each downpipe, particularly for The laps should be about 1O mm and kept in close
internal box gutters. Where possible downpipes should contact when positioning the laminate so the tape can
be spaced at no more than 18 m centres. be readily applied. The laminate must be allowed to
drape between roof supports so the cold temperatures
of the roof sheeting will not be transmitted to the
laminate by contact. If this were to happen condensa-
tion could form on the underside of the laminate.

15. Hail Guards Condensation under roof sheeting occurs when the
sheeting becomes colder than the air in contact with it
and water vapour in the air condenses on the sheet. It is
Hail guards are generally installed as: somewhat unpredictable and many types of buildings
are subject to the problem. On a cool, clear night, roof
1. Hail protection sheeting will radiate heat into the atmosphere until the
2. Protection against leaf build-up and wind temperature of the sheeting drops below that of the
blown garbage. surrounding air, sometimes by as much as 5°C. The
3. Outlet protection. sheeting can continue to radiate heat and remain colder
than the air in contact until it is subjected to, and warmed
Although hail guards will not provide for every eventual- by, radiation from the sun. During this time the water
ity, good design can help to prevent restricting vapour in the air will continue to condense on the
free-flow of water. This is especially true for gutters underside. The amount of condensation will depend on
concealed behind parapet walls. Hail guards should for the amount of water vapour in the air and this varies with
instance never be installed under the overhang of climatic conditions. Activities within a building can add
roof-sheeting as hail build-up in this area could present substantially to the amount of water vapour in the air.
problems with ingress of water into the building. It In a house this applies to bathing (particularly show-
should rather attempt to retain the hail on top of the ering), cooking, washing machines, clothes dryers,
sheet. Where possible, consideration must be given to dishwashers and even the presence of people. Mois-
providing overflows (pipes through the wall) at a lower ture will pass fairly freely through most ceiling linings

31
16. Condensation

into the ceiling space where it may directly contact the

roof sheeting.

In addition to the obvious problems of water dripping

from the roof or ceiling and staining of the ceiling and
walls, condensation can lead to deterioration of
inaccessible building components. Also, if bulk insula-
tion is wet or even slightly dampened by condensation
its efficiency will be drastically reduced.

If condensation occurs in a building it is both difficult and

costly to eradicate so it is wise to take precautionary
measures during design and construction. To avoid
condensation in a roof, moist air must be prevented from
contacting the underside of the sheeting. The inclusion of
insulation wool between the reflective foil laminate and
roof sheeting, will further exclude the intrusion of moist air.
It will also further insulate the laminate from the cold
sheeting during condensation conditions.

17. Sealants

It is important that the correct sealant is used and the

manner in which it is applied is correct as this is the
means by which the roof is made waterproof. There
are a number of sealants on the market of which the
most commonly used in the roofing industry are
Silicone and Butyl. Both Silicone and Butyl are avail-
able in 300 ml cartridges. Butyl is also available in
ribbon or strip form - 8 x 3 mm and 5 mm dia. It must be
noted that only Silicone sealants that are acetic acid
free must be used on galvanised surfaces. This is due
to the fact wet conditions during the early stages of
sealant cure can promote a corrosive situation. The
above-mentioned sealants are suitable for use with
galvanised, colour coated, aluminium, stainless steel,
copper, polycarbonate and fibreglass. It is important
that when using any sealant that the surfaces to which
it is to be applied must be clean and dry.

Please note that whilst all care has been taken to

ensure the accuracy of data in this publication, no
responsibility can be accepted by GRS for any errors
or omissions.

32
 18. Roof Fixing - What To Do

How to ensure you maximize the life of your roof when

installing Steel Roofing. To maximise the life of your roof
observe the following Do's and Don'ts.

WHAT TO DO

Care and storage: Use of sealants:

• Material should be stored dry at all times, therefore • Use butyl or neutral cure silicone rubber sealants
cover stack with a tarp and stack sheets or bundles - butyl is also available in ribbon or strip form
clear of the ground to avoid material getting wet. - Neutral cure silicone rubber- sealantd should conform to
the following
• Should material get wet, unpack wet sheets to a) Good adhesion to the clean surface of roof sheeting.
allow drying. Use a clean cloth to remove surface b) Water resistance and non-corrosive to the sheeting.
moisture, and stack in such a way that air circulation c) Resistance to extremes of heat and cold while
completes the drying process. retaining good flexibility.
d) Provide high resistance to ultra-violet rays (sunlight)
Walking on Roof Sheeting: and have a long service life.
Clean soft-soled shoes should be worn. Dunlop • Mineral turpentine is suitable for cleaning only the
Volley shoes are recommended for use when surfaces to be adhered and remove all residual
installing and inspecting roof sheets. solvent with a dry cloth. While spirits such as Shell
X-55 can also be used to clean the surfaces to be
• Keep weight evenly distributed over the soles of the sealed.
feet, as new sheets may be slippery.
• Walk on purlin lines wherever possible. Swarf removal:
• Remove all metal scraps, pop rivet mandrels and
Compatibility: excess fasteners from the roof at least daily to
• Always use coated steel purlins and girts to avoid avoid rust stains.
any ZINCALUME® steel or pre-painted steel • When cleaning up after having installed roof sheets
contact with bare steel or treated timber. clean out the gutters, ensuring not to leave metal
tailings.
Bending:
Bending of pre-painted steel should preferably be Brick cleaning:
done without the use of a lubricant. • Ensure that brickwork that sits above / adjacent to
a section of roof is cleaned before roof and gutter
Cutting sheets on site: installation.
• use metal blades rather than carborundum
discs/angle grinders as they produce fewer Following Trades:
damaging hot metal particles, leaving fewer burrs • Pipes and other penetrations made from copper or
on the cut sheet. GRS recommends the use of lead must be post painted to prevent the deposition
cold cutting saws such as the Makita 4130 unit or of metallic copper ions upon the roof surface. Failure
an equivalent saw with appropriate blade. to comply with this requirement will result in the
accelerated corrosion of the roof sheet.
Fasteners and accessories: • Any mortar/concrete should be removed
• All screws should have rubber sealing washers. immediately from the roof sheets.
Rubber washers should be EPDM quality or the
equivalent and be free of carbon fillers. Detergents & Cleaners:
• Buy fasteners that are as durable as the roof • Only non-ionic detergent or "kitchen" detergent are
sheeting you have purchased and that comply with recommended for cleaning of roof sheets. (A soft
class AS.3566 Class 3. (AS3566 is a performance cloth, mop or soft nylon bristle brush may be used.)
based standard that specifies a minimum coating
thickness for fasteners to be used in benign (Class 1) to
severe marine (Class 4) environments.)

33
 19. Roof Fixing - What Not To Do

How to ensure you maximise the life of your roof when

installing Steel Roofing. To maximise the life of your
roof observe the following Do's and Don'ts.

WHAT NOT TO DO

Care and storage: Surface damage:

• Store packs of sheets in the open. • Touch up paint is not recommended to repair
surface scratches on pre-painted steel. The
Cutting sheets on site: different weathering pattern of touch up paint will
• Cutting should not be carried out on top of other lead to an inconsistent colour across the sheet's
roof sheets. surface. It is recommended that severely
damaged sheets be replaced.
Roof Fixing Battens: • If the pre-painted steel sheet is only scratched
• Do not use copper/chrome/arsenic (CCA) treated back to the metallic coating, leave the scratch bare
timber battens/purlins as perforation of the roof as the sacrificial properties of Zinc will protect the
sheet can occur. Separate CCA treated battens surface from corrosion.
from roofing sheets with appropriate barrier such • If the sheet is scratched back to the cold rolled
as insulation paper. metal base and the scratch is greater than 2mm
wide, sacrificial protection will be reduced and
those sheets should be replaced.
Compatibility:
• Lead and copper are not compatible with pre
painted steel or ZINCALUME® steel products. Following Trades:
Do not mount roof air conditioning units on CCA
treated timber. Also do not place CCA treated
Bending: timber or green hardwood dunnage on roof
• Do not use kerosene or distillate on pre-painted sheets.
steel as they soften the paint film.
Detergents & Cleaners:
Use of sealants: • Never use abrasive or solvent type cleaners
• Do not use acetic acid based sealants. While being (turpentine, petrol, kerosene, paint thinners) on
ideal for use with other materials they liberate pre-painted steel/ ZINCALUME® / galvanised
aggressive by-products during curing which is steel surfaces.
detrimental to sheet steel. These often have a • Never use wire brushes, steel wool, sponge
vinegar or ammonia smell. scourers to clean the roof sheet.

Swarf removal: Solar Panels

• Do not leave metal articles on the roof.
• Do not install PV panels on unpainted galvanised
Brick cleaning: sheeting as the contaminated waste run-off from
• Do not allow brick cleaning fluids to spray onto or the glass or plastic top surface will lead to
flow across sheeting and into gutters. This can accellerated spot corosion of the sheeting
lead to premature failure of the paint and corrosion - refer table: 2.2
of the metal.

Fasteners and accessories:

• Do not use galvanised steel ridge cap flashing or
gutters with a ZINCALUME® steel or pre-painted
steel roof. The galvanised steel will need to be
replaced at an earlier interval.
• Do not use stainless steel screws, galvanised
washers, cadmium plated screws or other type of
screw that doesn't comply with AS 3356 Class
three with ZINCALUME® steel or pre-painted steel
as this will lead to premature failure of the roof sheet.

34
NOTES

35
GRS Isando
Tel: +27 (0) 11 898 2900
Klip-Tite
GRS Bloemfontein
Tel: +27 (0) 51 432 3724

GRS Cape Town Klip-Lok

Tel: +27 (0) 21 521 1900

GRS Durban
Tel: +27 (0) 31 538 0940
Klip-Lok
GRS East London
Tel: +27 (0) 43 731 1895

GRS Nelspruit Brownbuilt

Tel: +27 (0) 13 492 0746

GRS Mosselbay
Tel: +27 (0) 44 695 0014 Zip-Tek
GRS Polokwane
Tel: +27 (0) 51 293 0313

GRS Port Elizabeth Zip-Tek

Tel: +27 (0) 41 486 1270

GRS Rustenburg
Tel: +27 (0) 14 596 6121 IBR
GRS Upington
Tel: +27 (0) 54 332 1656
IBR
GRS Exports
Tel: +27 (0) 11 898 2900

GRS Botswana Corrugated

Tel: + (00) 267 310 5761

GRS Ghana
Tel: +27 (0) 11 898 2976
Nu-Rib
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Tel: + (00) 266 2231 2244

GRS Mozambique BR7

Tel: + (00) 258 8230 50506

GRS Namibia +(00)

Windhoek
Keetmanshoop
+264 61 26 3890
+264 81 143 7067
Bond-Lok
Ondangwa +264 81 166 4341
Swakopmund Bay +264 81 165 7925

GRS Zambia +(00) QC Flooring

Kitwe +260 21 225 1315
Lusaka +260 96 749 5541

GRS Zimbabwe Bond-Dek

Tel: + (00) 263 477 4699