Cladding Installation

Roong & Walling
Installation Manual
2012-2013
Roofing and Walling
Manual 2012-13 Edition
Date of Issue February, 2012
GENERAL NOTES TO READ BEFORE YOU USE THIS GUIDE
This Guide is the 2012-13 edition of the LYSAGHT Roofing & Walling
Manual, issued on February, 2012. BlueScope Steel and BlueScope
Lysaght may make changes to this Guide in its sole discretion. You
should check you are using the most up-to-date version of the Guide
before you start construction.
This Guide has been prepared for a range of roofing and walling
applications including water drainage systems, using products
manufactured or supplied by BlueScope Lysaght.
Conditions of Use
If you use this Guide, you acknowledge and agree that your use is
subject to the terms and conditions in this Guide. BlueScope Steel,
its agents, officers, employees, sub-contractors or consultants make
no representations, either expressed or implied, as to the suitability
of the information and data in this Guide for your particular purposes.
Its your responsibility to ensure the design you use is appropriate for
your needs, the products you have purchased, your site and structural
limitations and your building and construction capabilities.
Use of Genuine Materials

Structures in this Guide should only be built or constructed using
those genuine LYSAGHT or recommended third party products.
Except as otherwise provide in these terms, any warranties only apply
to you (if at all) if you use the recommended genuine LYSAGHT or
third party products and method of construction.
Check Delivery
It is important that you check all materials delivered to site against
your invoice before you use them in your building or construction to
ensure all components have arrived, are of the appropriate quality and
are ready for installation.
Limitation of Liability
By using this Guide, you accept the risks and responsibility for all
losses, damages, costs and other consequences resulting directly or
indirectly from using this Guide. To the maximum extent permitted
by law, BlueScope Lysaghts liability (whether arising under statute,
contract, tort (including negligence), equity or otherwise) to any
persons whatsoever in respect of anything done or not done, arising
directly or indirectly, by any such person in reliance, whether in whole
or in part, on this Guide, is limited, at BlueScope Lysaghts option, to:
(a)
in the case of goods, the repair of the goods, the

replacement of the goods or paying for the cost of repair or
replacement of the goods; or
(b)
in the case of services, the resupply of services or paying

for the cost of resupplying the services.
This publication is intended to be an aid for professional engineers

in design matters, and builders or roong contractors in relation to
construction and is not a substitute for professional judgement.
The information in this booklet is suitable for use only in areas where a
tropical cyclone is unlikely to occur as defined in AS/NZS 1170. 2:2002
Part 2: Structural Actions - Wind Actions (or if used outside Australia, to
the equivalent standard).
Information on cyclonic performance may be found in our Cyclonic Area
Design Manual which is available on-line at www.lysaght.com.
All erection and connection details to be made in accordance with the
relevant standard connection details drawing contained in this Guide.
We recommend you get professional advice to ensure your particular
needs are adequately met.
a) Before you commence construction:
b) you should check with your local government authority to see if any
form of prior permission or approval is required;
c) if you want to build or construct any attached structure, you should
seek advice from a suitably qualified engineer to verify the capacity of
your existing structure to withstand any additional load arising from the
attached structure. You should also check with your local government
authority to determine any specific requirements for the attachment to
existing structures;
d) you should check with your local workplace health and safety
authority to see what safety measures you need to put in place prior to
and during construction. It is the responsibility of the installer/erector
to ensure all local safe work practices are adhered to and the safety of
the whole site is maintained at all times.
To ensure maximum lifespan of your building, consult your nearest
BlueScope Lysaght branch for information regarding maintenance,
handling, storage and any other technical assistance you may require.
Terms and conditions of sale are available at local BlueScope Lysaght
sales ofces.
Published by BlueScope Lysaght Limited
BlueScope Lysaght Limited 2012
Lysaght Roofing and Walling Manual
Previously published as:
Lysaght Roofing & Walling Users Guide
Steel Roofing and Walling: Installation Manual, and
Using Lysaght Roofing and Walling
Product Descriptions
All descriptions, specications, illustrations, drawings, data,
dimensions and weights contained in catalogues, price lists, or
other advertising matter of BlueScope Lysaght or elsewhere are
approximations only. They are intended by BlueScope Lysaght to be a
general description for information and identication purposes and do
not create a sale by description. BlueScope Lysaght reserves the right
at any time to:
(a) manufacture and procure Goods with such minor modications from
its drawings and specications as it sees t; and
(b) alter specications shown in its promotional literature to reect
changes made after the date of such publication
LYSAGHT Roong and Walling Manual
2012-13 Edition
Contents
Introduction
PART A: DESIGN
Design preliminaries
2.1 Product selection
2.2 Materials and finishes
2.3 Support spacings
2.4 Maximum lengths of roofing
2.5 Low roof pitches
2.6 Wind forces on roofs
2.7 Codes and performance tests
2.8 Environmental conditions
2.9 Metal and timber compatibility
2.10 Transportation
2.11 Paint and COLORBOND finishes
2.12 Specifications - roofing
2.13 Specifications - walling
2.14 Maximum roof lengths for drainage
2
2
2
3
3
3
3
3
4
4, 5
4
4
6
7
8
PART B: INSTALLATION
27
General care, safety and handling

7.1 Safety
7.2 Care and storage before installation
7.3 Handling cladding on site
7.4 Walking on roofs
7.5 Marking out, cutting and drilling
7.6 Clean up
7.7 Warn other contractors
7.8 Strippable coatings
7.9 Sealants
7.10 Maintenance
27
27
27
27
27
27
28
28
28
29
30
Installing pierce-fixed cladding

8.1 General installation procedure
8.2 Side-lapping & positioning pierce-fixed sheets
8.3 Pierce-fixing on crests
8.4 Pierce-fixing on valleys (for walling only)
8.5 Pierce-fixing on side-laps
31
31
33
33
34
34
Fasteners
3.1 Materials for screws
3.2 Materials for nails
3.3 Materials for blind rivets
3.4 Materials for sealing washers
3.5 Identification of screws
3.6 Setting of screws
3.7 Quantity of fasteners and clips
3.8 Recommended fasteners and locations
9
9
9
9
9
10
10
11
11
Installing concealed-fixed cladding

9.1 Installing KLIP-LOK roofs
9.2 Installing KLIP-LOK walls
9.3 Installing EASYCLAD
9.4 Installing LONGLINE 305 roofs
9.5 Installing LONGLINE 305 walls
35
35
41
42
44
46
Curved, bent & tapered cladding

4.1 Spring-curved-ridge roof
4.2 Spring-arched roof
4.3 Spring-curved concave roofs
4.4 Pre-curved sheets
4.5 Capped bent ribbed roofs
4.6 Tapered roofing
16
16
17
18
18
19
19
Ends of sheets
10.1 Turn-ups
10.2 Turning-down
10.3 Blocking off rib cavities
10.4 End-lapping
10.5 Expansion
10.6 Roof overhang with edge stiffener
47
47
49
50
51
53
54
Insulation & skylights

5.1 Heat control
5.2 Condensation
5.3 Noise reduction
5.4 Insulation materials
5.5 Insulation thickness
5.6 Skylighting
20
20
21
22
22
23
23
Roof drainage
6.1 Introduction
6.2 Design of drainage (eaves-gutter system)
24
24
24
Flashings
11.1 Materials
11.2 Longitudinal flashings
11.3 Transverse flashings
11.4 Flashing at change of pitch
11.5 Flashing large roof penetrations
11.6 Flashing small roof penetrations
11.7 Flashing walls
11.8 Bushfire protection
55
55
55
56
58
59
61
62
64
References
65
Index
66
LYSAGHT Roong and Walling Manual
2012-13 Edition
Contemporary and traditional, residential or commercial: all are

accomplished with ease using LYSAGHT building products.
INTRODUCTION
1 Introduction
1
Introduction
Scope
Conditions of use
This book is a guide to the installation of steel roofing and

walling manufactured by BlueScope Lysaght. We intend that it
be used by all trades and professions involved with specifying
and applying the wide range of our products.
Where we recommend use of third party materials, ensure

you check the qualities and capabilities of those products
We refer only to genuine steel roofing and walling

manufactured by us and marketed under our brand names.
Our recommendations should only be used for our products
because they are based on comprehensive testing of our
profiles, base-metal-thicknesses (BMT) and material finishes.
Your suggestions
with the relevant manufacturer before use.
Please send your suggestions for improvements to this

manual to BlueScope Lysaght Research & Technology
PO Box 7121, Blacktown Business Centre, NSW 2148.
Further information on products and services

Specific product information
s WWWLYSAGHTCOM
We also have specific publications for all of our products, and

you should use them in conjunction with this manual.
s 9OURSUPPLIEROF,93!'(4 products
Cyclonic conditions
s "LUE3COPE,YSAGHT)NFORMATION3ERVICE
on 1800 641 417
)NGENERALTHISBOOKREFERSTONON CYCLONICCONDITIONS$ESIGN

INFORMATIONFORCYCLONICAREASISINOUR#YCLONIC!REA$ESIGN
Manual.
Warranties
For over 150 years we have consistently manufactured the
highest quality building products. The ,93!'(4 brand is
SYNONYMOUSWITH!USTRALIANBUILDING
Our continuing confidence in our products is shown in the
warranties we offer.
Our products are engineered to perform according to our
specifications only if they are used in the appropriate
conditions and installed to the recommendations in this
manual and our other publications.
Naturally, the warranties require specifiers and installers
to exercise due care in how the products are applied and
INSTALLEDANDARESUBJECTTOFINALUSEANDINSTALLATION!LSO
owners need to maintain the finished work.
We invite you to ask about the warranties applicable to your
proposed purchase, at your supplier of ,93!'(4 products.
Roong and Walling Installation Manual
2012-13 Edition
DESIGNDESIGN PRELIMINARIES
PART A: DESIGN
2
Design preliminaries
2.1 Product selection
When you design steel cladding into your building you
have a wide range of profiles from which to choose. Whilst
roofing and walling obviously have to keep out the weather,
they also have significant effects on the looks, cost and
durability of a building.
)FYOUAREUNSUREABOUTANYPRODUCTFEATURE, visit
www.lysaght.com, call our information line or seek advice from
the relevant specialists.
Other factors that affect selection are treated in Chapters
2 to 6.
Walls
The design of walling from a steel perspective is fairly
straightforward. Once you have made the aesthetic decision
of which profile to use, the main considerations are the
support spacings (Section 2.3), fixing details (Chapter 3) and
the details of flashing (Chapter 11).
Roofs
4HEREAREMANYFACTORSINDESIGNINGROOFSINCLUDING
s THESHAPEISTHEROOFTOBE@FLATORPITCHED
or curved?
s THESUPPORTINGSTRUCTUREANDSUPPORTSPACING
s THEWINDFORCESTHATTHEROOFMUSTSUSTAIN
s THEPITCHWHICHAFFECTSTHELOOKSTHEPROFILESABILITY
to efficiently carry rain to the gutters, and fixing
details;
s THERMALEXPANSIONOFLONGSHEETS#HAPTER
s THEATTRIBUTESOFOTHERMATERIALSUSEDINTHEROOF
design.
4HISBOOKDOESNTATTEMPTTOCOVERTHESTRUCTURALDESIGN
DETAILSOFSUPPORTSORAESTHETICSTHEREAREMANYOTHERTEXTS
AND!USTRALIAN3TANDARDSTHATCOVERTHEM
This chapter gives tables of recommended support spacings,
and the maximum roof length for pitch and rainfall intensity
for steel roofing products.
The appropriate design will depend on your particular needs
ANDCIRCUMSTANCES9OUSHOULDGETADVICEFROMTHERELEVANT
specialists where required.
2.2 Materials and finishes

Our most widely used cladding profiles are listed in Tables
2.12.1 and 2.13.1. They are available in #/,/2"/.$
prepainted steel, or in unpainted :).#!,5-% aluminium/zinc
alloy-coated steel.
#/,/2"/.$ pre-painted steel has either a aluminium/
zinc alloy-coated steel or stainless steel base metal, with a
range of organic coatings to cope with exposure to a range of
environments.
s #/,/2"/.$ is prepainted steel for exterior roofing and
WALLING)TISTHEMOSTWIDELYUSED
s #/,/2"/.$ -%4!,,)# is prepainted steel for superior
aesthetic qualities displaying a metallic sheen.
s #/,/2"/.$ 5,42! is prepainted steel for severe
coastal or industrial environments (generally within about
100 to 200 metres of the source).
s #/,/2"/.$ 34!).,%33 is prepainted stainless steel for
very severe coastal or industrial environments (generally
WITHINABOUTMETRESOFTHESOURCE )TISSUBJECTTO
availability and long lead times.
Check with your local BlueScope Lysaght office for availability
of profiles, materials, finishes, colours, accessories; and for
suitability of the product.
Tables 2.12.1 and 2.13.1 list general information for profile
selection. Refer to our publications on specific products
for detailed specifications. There are also publications on
:).#!,5-% steel and #/,/2"/.$ prepainted steel from
our information line (Page 1).
Typical material specifications

s :).#!,5-% aluminium/zinc alloy-coated steel complying
WITH!3-INIMUMYIELDSTRENGTHSARE'
-0A OR'-0A DEPENDINGONPROFILE
-INIMUMCOATINGMASSIS!:GM2 )
s #/,/2"/.$ is a pre-painted steel. The painting
COMPLIESWITH!3.:3ANDTHESTEELBASEISAN
ALUMINIUMZINCALLOY COATEDSTEELCOMPLYINGWITH!3
-INIMUMYIELDSTRENGTHSARE'-0A
OR'-0A DEPENDINGONPROFILE-INIMUMCOATING
MASSIS!:GM2)
s #/,/2"/.$5LTRAISAPRE PAINTEDSTEEL4HEPAINTING
COMPLIESWITH!3.:3ANDTHESTEELBASEISAN
2012-13 Edition
s #/,/2"/.$ Stainless is a pre-painted steel. The

PAINTINGCOMPLIESWITH!3.:3ANDTHESTEELBASEIS
ASTAINLESSSTEELCOMPLYINGWITH!)3)!34-4YPE
5.3.O3
2.3 Support spacings

The maximum recommended support spacings are shown in
Tables 2.13.1 and 2.14.1. They are based on data in accordance
WITH!3$ESIGNANDINSTALLATIONOFSHEETROOFAND
WALLCLADDING-ETALAND!3-ETHODSOFTESTING
sheet roof and wall claddingResistance to concentrated
loads.
The spacings in the tables are recommended to produce
adequate performance of claddings under concentrated
loading (incidental for maintenance).
For support spacings in wind conditions, refer to our
publications on specific products for wind pressure data.
)NALLCASESCLADDINGISFIXEDTOASUPPORTOFMMMINIMUM
BASEMETALTHICKNESS"-4 ANDMINIMUMYIELDSTRESSOF'
)FYOUWANTTOUSEMETALBATTENSTHINNERTHANMMSEEK
advice from our information line.
2.4 Maximum lengths of roofing

The valleys (or pans) of roofing have to carry water
TOTHEGUTTERS)FINHEAVYRAINTHEVALLEYSOVERFILL
water can flow into the roof through the side-laps
and flashings.
Factors affecting waterproof and drainage capacity of the laps
OFAPROFILEINCLUDE
s THEWIDTHANDDEPTHOFTHEVALLEYSORPANS
s THEPITCHOFTHEROOFRAINFLOWSFASTERONASTEEPER
pitch;
s RAINFALLINTENSITYFORTHEGEOGRAPHICALAREA
s THELENGTHOFTHEROOFFROMRIDGETOGUTTERAND
s PENETRATIONSTHATCAUSENEARBYVALLEYSTOCARRY
extra rain diverted from valleys obstructed by the
penetration (Figure 2.14.1).
The maximum recommended roof lengths for drainage for
each profile are given in Table 2.14.1 at the end of this chapter.
2.5 Low roof pitches

5NLESSTHEREISADEQUATEPOSITIVEFALLINAROOFTHEREIS
danger of ponding, which can lead to a reduced service life,
particularly in coastal areas.
!TLOWSLOPESSAYAROUNDIN SLOPEALLROOFSUPPORTS
must be in the one plane because slight variations can result
in zero or negative fall. This may occur even after completion
of the building as the result of settlement, timber warping or
shrinking, or extra loadings (like air conditioners).
Minimum recommended roof slopes are listed in Table
!SAGUIDEWHEREVERPOSSIBLEYOUSHOULDDESIGNFOR
AMINIMUMSLOPEOFIN 2OOFSLOPESLOWERTHANTHE
recommended minimum may be available subject to enquiry
and will be dependent upon the roof application and building
details. Lower roof slopes may require additional provisions
to be adhered to. Please call your nearest service centre for
advice.
2.6 Wind forces on roofs

Winds create considerable forces on both the topside and
the underside of roof cladding, and you must consider these
FORCESINTHEDESIGNANDFIXINGOFANYROOF4HEFORCESARE
s inward forces tending to collapse the roof cladding
inwards, caused by wind acting directly on the windward
side; and
s outward forces tending to lift the roof cladding from its
framing, and the entire roof structure from the rest of the
building. Outward forces can be caused both by uplift
from negative wind pressures, outside the building; and by
positive wind pressure inside the building.
'ENERALLYTHEGREATESTWINDFORCESIMPOSEDONROOFSAREDUE
to the outward forces. Because the dead weight of roofing
materials is relatively small, the outward forces must be
resisted by the roof fasteners.
)TISVERYIMPORTANTTHATTHEBATTENSANDROOFFRAMING
are adequately fixed to the rafters and walls, and that
under extreme conditions the wall framing is anchored to
the footings. Special anchoring provisions may apply in
cyclonic areas. Specialist advice should be sought in these
circumstances.
2.7 Codes and performance tests

!3SPECIFIESTHEDESIGNANDINSTALLATIONOFSHEET
metal roof and wall cladding. Our roofing profiles satisfy all the
requirements of this standard, including the ability of the roof
to resist outward forces and concentrated loads. The testing
ISPERFORMEDACCORDINGTO!3
2012-13 Edition
2 Design preliminaries
aluminium/zinc alloy-coated steel complying with

!3-INIMUMYIELDSTRENGTHSARE'-0A
OR'-0A DEPENDINGONPROFILE-INIMUMCOATING
MASSIS!:GM2)
Metal roofing products must comply with the performance

specifications, and be checked by stringent tests, in
accordance with the standard. Such tests have been carried
out on all our claddings and the results have been used in the
preparation of the fixing and installation recommendations in
this manual.
2.8 Environmental conditions

Coated steel products can be damaged by some environmental
conditions including industrial, agricultural, marine, intensive
animal farming, swimming pools or other aggressive
conditions.
)FANYOFOURPRODUCTSARETOBEUSEDINTHESECONDITIONS
or unusually corrosive environments, seek advice from our
information line (Page 1).
+EEPTHEPRODUCTDRYANDCLEAROFTHEGROUND)FSTACKEDOR
bundled product becomes wet for extended periods, separate
it, wipe it with a clean cloth and stack it to dry thoroughly.
2.9 Metal and timber compatibility

Contact with, or runoff from, some materials can damage
coated steel products. Buildings can also be susceptible to
condensation on inside surfaces.
The materials include certain metals, treated timbers and
chemicals.
s $ONTALLOWANYCONTACTOFCOATEDSTEELPRODUCTSWITH
INCOMPATIBLEMATERIALS4ABLE
s $ONTALLOWDISCHARGEOFRAINWATERFROMINCOMPATIBLE
MATERIALSONTOCOATEDSTEELPRODUCTS4ABLE
s MATERIALSSUBJECTTOCYCLESOFDRYNESSANDWETNESS
or which have excessive moisture content (such as
improperly-seasoned timber)
s WETANDDRYCONCRETE
s SOILS
s VEGETABLEMATTER
s CLEANINGAGENTSEGBRICKCLEANING
s ANYMATERIALWHICHWILLINHIBITNORMALEXPOSURETOTHE
atmosphere
2.10 Transportation
Because our roofing and walling is manufactured by
continuous processes, sheet lengths can be supplied up to
the limits of transport regulations, which vary from state to
state.
+, (3ISAVAILABLEINEXTRALONGLENGTHSVIAANON SITE
mobile rollformer. This service is available nationally, subject
to enquiry.
2.11 Paint and COLORBOND finishes

#/,/2"/.$ finishes can be damaged by some handling,
INSTALLATIONORMAINTENANCEACTIVITIES)FDAMAGEOCCURSTOTHE
#/,/2"/.$ pre-painted finish, refer to Technical Bulletin
TB-2, published by BlueScope Steel.
2EPLACEMENTOFSEVERELYDAMAGED#/,/2"/.$STEELSHOULD
consider that the replacement sheet may not match perfectly
due to the possible long term fading of the installed sheets
exposed to weathering.
9OUMAYOVERPAINTWHOLEROOFSANDPAINTACCESSORIESTO
match specific colours. The overpaint guidelines are also
discussed in Technical Bulletin TB-2.
s %NSURETHATSUPPORTINGMEMBERSARECOMPATIBLEWITH
the coated steel products or, alternatively, appropriately
coated.
)FTHEREAREDOUBTSABOUTTHECOMPATIBILITYOFOTHERPRODUCTS
being used, seek advice from our information line.
)NCOMPATIBLEMATERIALSINCLUDE
s
s
s
s
s
LEAD
COPPER
MONELMETAL
BARESTEEL
STAINLESSSTEELEXCEPTWITH#/,/2"/.$
stainless cladding)
s CARBONINPENCILSANDSOMERUBBERS
s GREENORSOMECHEMICALLY TREATEDTIMBER
LIKE##!ORTANALITHTREATMENTS
2012-13 Edition
YES
YES
YES
YES
NO
NO
YES
NO
NO
YES
NO
NO
YES
NO
NO

NO
NO
YES
NO
NO
YES
YES
YES
YES
ZINC
NO
NO
YES
NO
NO
YES
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
NO
COLORBOND, COLORBOND ULTRA,

COLORBOND STAINLESS
COLORBOND METALLIC
ACCESSORIES OR FASTENER OR (UPPER SURFACE)
YES
YES
NO
NO
NO
NO
NO
NO
NO
STAINLESS STEEL
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
( 1 ) MONEL - COPPER/NICKEL ALLOY

( 2 ) FOR FURTHER GUIDENCE REFER TO AS/NZS 3500.3: 2003
YES
YES
YES
GALVANISED
(ZINC COATED STEEL)
YES
NO
NO
ZINCALUME
YES
YES
YES
YES
YES
YES
YES
YES
YES
ZINC
UPPER CLADDING OR ROOF DRAINAGE SYSTEM MATERIAL
YES
NO
NO
YES
YES
YES
YES
YES
YES
YES
NO
NO
YES
YES
YES
YES
YES
YES
YES
NO
NO
YES
YES
YES
YES
YES
YES
COLORBOND , COLORBOND ULTRA,

COLORBOND STAINLESS STAINLESS STEEL
COLORBOND METALLIC
YES
YES
NO
YES
YES
NO
NO
NO
NO
COPPER &
COPPER ALLOYS(1)
YES
YES
NO
YES
YES
NO
NO
YES
YES
YES
YES
YES
YES
YES
YES
YES
NO
NO
ALUMINIUM ALLOYS
LEAD
NO
NO
NO
YES
NO
NO
NO
NO
NO
NO
NO
NO
NO
YES
NO
NO
NO
NO
LEAD
YES
YES
YES
YES
YES
YES
YES
NO
NO
GLAZED ROOF TILES,

GLASS & PLASTIC
COPPER &
COPPER ALLOYS(1)
YES
YES
YES
YES
ALUMINIUM ALLOYS
ACCEPTATIBILITY OF DRAINAGE FROM AN UPPER SURFACE TO A LOWER METAL SURFACE
ZINCALUME
GALVANISED (ZINC COATED STEEL)
ZINC
COLORBOND METALLIC
COLORBOND STAINLESS STEEL
STAINLESS STEEL
ALUMINIUM ALLOYS
COPPER & COPPER ALLOYS(1)
LEAD
LOWER ROOF DRAINAGE

SYSTEM MATERIAL
GALVANISED
(ZINC COATED STEEL)
YES
YES
YES
ZINCALUME
( 1 ) MONEL - COPPER/NICKEL ALLOY

( 2 ) FOR FURTHER GUIDENCE REFER TO AS/NZS 3500.3: 2003
ZINCALUME
GALVANISED (ZINC COATED STEEL)
ZINC
COLORBOND METALLIC
COLORBOND STAINLESS
STAINLESS STEEL
ALUMINIUM ALLOYS
COPPER & COPPER ALLOYS(1)
LEAD
ROOF DRAINAGE SYSTEM COMPONENTS

& ANY CLADDING MATERIAL
COMPATIBILITY OF DIRECT CONTACT BETWEEN METALS OR ALLOYS
2012-13 Edition
Table 2.9.1
!CCEPTABILITYOFDRAINAGEFROMUPPERSURFACEONTOALOWERMETALSURFACEANDDIRECTCONTACT
2.12 Specifications - roofing

Table 2.12.1
Specifications of roofing & walling profiles
Eaves Overhang3
CUSTOM ORB4
CUSTOM BLUE ORB4
FLATDEK5
FLATDEK II5
INTEGRITY 820
1500
1800
2100
200
600
1650
2050
2350
1750
2350
3000
2200
2800
3600
150
200
250
450
500
550
2600
3000
3300
3200
3450
3600
3850
3900
3900
150
200
250
1800
2100
2200
3050
200
250
500
600
2150
2500
3250
3550
300
400
KLIP-LOK 406
0.60
6.6
KLIP-LOK 700 HI-STRENGTH
KLIP-LOK CLASSIC 700
LONGLINE 305 (not tapered)

7
7
SPANDEK6
SPANRIB
TRIMDEK
2
See Section 2.5.
FLATDEK & FLATDEK II are Home Improvement profiles. Please refer to the brochures for more installation details..
Slope of 2 (1 in 30) is available subject to enquiry. Please refer to Section 2.5.
2012-13 Edition
2.13 Specifications - walling

Table 2.13.1
Specifications of profiles for walling only
Overhang
mm
EASY-CLAD
MINI ORB7
MULTICLAD
PANELRIB6
TRIMWALL
WALLCLAD
0.42
4.1
272
260
12
1000
1000
WEATHERBOARD
Roofing & Walling profiles
Walling profiles only
O
ES IS IS ES
Step
Spacing definitions
ES = End span
IS = Internal span
O = Overhang
Single span
2012-13 Edition
n/a
2.14 Maximum roof lengths for drainage
Table 2.14.1
Maximum roof lengths for
drainage measured from ridge to
gutter (m) Penetrations alter the
flow of water on a roof. Thus,
for design, you need to use an
effective roof length (Figure
2.14.1).
247
165
124
99
82
74
49
308
205
154
123
103
93
62
361
241
181
144
120
108
72
449
300
225
180
150
135
90
536
357
268
214
179
161
107
616
411
308
246
205
185
123
Figure 2.14.1
%XAMPLE OF CALCULATING EFFECTIVE ROOF
lengths where penetrations alter the
flow of water on a roof.
97
65
49
39
32
24
19
./4% ! SUITABLY QUALIFIED ENGINEER

is recommended for calculating/
checking roof design and flow
design.
LYSAGHT FLATDEK and FLATDEK II are recommended for home improvement use only (carports/verandahs) where
weathertightness is not of primary importance. Drainage figures are therefore not supplied.
SPANDEK with slope of 2 (1 in 30) is available subject to enquiry. Please refer to Section 2.5.
2012-13 Edition
DESIGNFASTENERS
3
Fasteners
When you select fasteners, you should consider the design life of the
structure, because the fasteners and the cladding material should have
similar life expectancies.
Fastener change to metric sizing

4HE!USTRALIANFASTENERINDUSTRYISMOVINGTOACHANGEINFASTENER
description that will bring it into line with international markets. This is an
on-going process as product requirements and design changes.
Traditionally self drilling fasteners have been described in gauge (outside
thread diameter), by tpi (threads per inch) and by length (mm). The new
changes will convert gauge to metric sizing (eg #12 is approx. M5.5)
3.1 Materials for screws

Screws are available in a variety of materials, finishes and colours
to match #/,/2"/.$ PREPAINTEDSTEELANDDESIGN9OUSHOULDUSE
SCREWSTO!3#LASSORBETTER !DDITIONALINFORMATIONON
fastener finishes is in the technical bulletin TB-16.
Table 3.1.1
3 Fasteners
Materials for screws
powder coated/painted
3.2 Materials for nails

Nails should be of galvanised steel. They are only used to fix the clips of
some concealed-fixed cladding to timber supports.
3.3 Materials for blind rivets

For #/,/2"/.$34!).,%33 use stainless steel blind rivets with
stainless steel mandrels; for '!,6!"/.$:).#!,5-% and
#/,/2"/.$ steels, use aluminium blind rivets. Blind rivets are used for
fixing flashings, accessories and side-laps.
3.4 Materials for sealing washers

Sealing washers used under the heads of screws on #/,/2"/.$
FINISHESMUSTBEMADEFROMMATERIALSTHATDONTHAVESIGNIFICANTLEVELSOF
CONDUCTIVECARBONBLACKPARTICULARLYINMARINEENVIRONMENTS5SE%0$-
washers, not neoprene.
2012-13 Edition
DESIGNFASTENERS
10
Shank
Screw length
Head
Sealing washer
3.5 Identification of screws

4HEFORMATOFTHENUMBERCODEIS
12
14
50
M6
11
50
Screw gauge
Thread pitch
(Thread outside
(threads per
diameter)
inch)
M refers to metric size
Shank protection
Overall length of the

screw measured from
under the head to the
tip of the drill point (mm)
&ASTENERSMUSTHAVEACOATINGSYSTEMTOMEET!3#LASS
OR!3#LASS
Ripple Teks!UTO4EKS, Teks$ESIGNER(EADS and RoofZips are
REGISTEREDTRADEMARKSOF)47"UILDEXANDARERECOMMENDEDFORSPECIFIC
applications. Other equivalent quality fasteners which comply to the
above standards are also recommended for use with ,93!'(4 roofing
and walling products.
Figure 3.5.1
Typical roofing screws
Where a screw penetrates roof sheeting (for fixing or stitching), a sealing

WASHERISRECOMMENDED4HESEALINGWASHERISTOBEAN%0$-NON
conductive rubber.
Table 3.5.1
Where a screw penetrates the rib of the sheeting (as for roofing), the 'top
thread section' feature is recommended to maximise resistance to water
penetration.
Typical features of screws
7LERO
,IEH
,I\EKSRLIEH
[MXLMRXIKVEXIH
QIXEP[EWLIV
,I\LIEH
[MXL)4(1WIEP
,I\EKSRLIEH
[MXLMRXIKVEXIH
QIXEP[EWLIV
,I\LIEH
[MXLRSWIEP
;EJIVLIEH
;EJIVLIEH
[MXLRSWIEP
(VMPP TSMRX
7IPJHVMPPMRKJSVQIXEP
Top Thread Section

VIWMWXERGIXS[EXIVTIRIXVEXMSR
Dwell Section
Shank Protection
6SSJ>MT
TSMRX
7IPJHVMPPMRKJSVXMQFIV
7TIGMEP WIPJWIEPMRK LIEH
6MTTPI>MTW
WGVI[LIEH[MXL
WIPJWIEPMRKLIEH
6MTTPI>MT
TSMRX
3.6 Setting of screws

Figure 3.6.1
)TISIMPORTANTTHATYOUSETSCREWSCORRECTLY
Fasteners with sealing washers should be tightened only until the washer
is gripped firmly enough to provide a weathertight seal. The fasteners
should not be over-tightened because this may split the sealing washer
or deform the sheet, either of which could lead to water penetration.
Take particular care when valley fixing because there is no flexibility with
the sheet hard against its support. Take particular care to ensure the
fastener is driven perpendicular to the sheeting to avoid deformation of
the washer.
2012-13 Edition
DESIGNFASTENERS
3.7 Quantity of fasteners and clips

KLIP-LOK 406, KLIP-LOK 700HS, KLIP-LOK CLASSIC 700
and LONGLINE 305
For number of clips, see equation at right.
For +,)0 ,/+ 406, there are 2 fasteners per clip.
For +,)0 ,/+() 342%.'4(AND+,)0 ,/+#,!33)#
there are 3 fasteners per clip.
For ,/.',).%, there is 1 fastener per clip.
11
Number of clips per job =

(Number of supports) x (Number of sheets +1)
for ,/.',).% 305 and +,)0 ,/+ 406, or
(Number of supports) x (Number of sheets)
for +,)0 ,/+(3AND+,)0 ,/+#,!33)#
Number of fasteners per job =
,/.',).% 305 = number of clips
+,)0 ,/+ 406 = number of clips x 2
+,)0 ,/+(3NUMBEROFCLIPSX
+,)0 ,/+#,!33)# 700 = number of clips x 3
Pierce-fixed profiles
For number of fasteners, see equation at right (n is the number
of fasteners per support, as shown in the diagrams for each cladding
product.
Number of fasteners per job (for pierced fixing) =

n x (Number of sheets) x (Number of supports)
Side-laps
3IDE LAPFASTENERSAREOFTENPLACEDATABOUTMMCENTRES
(See section 8.5)
Side-lap and accessory fastenings
The recommended fasteners and minimum specifications for a cladding

are detailed in the individual cladding brochure. The location of the
fasteners are detailed in the following diagrams for each cladding
product.
s5SEMMDIAMETERALUMINIUMSEALEDBLIND
rivets.
Fastener length with insulation, boards and packers
&ORALLOTHERPRODUCTSUSE
Where insulation (blankets or boards), foam packers or any other packer/

board where the cladding screw penetrates through to the support is
installed under cladding, you may need to increase the length of screws
depending on the density and thickness of the insulation, board or packer.
7HENTHESCREWISPROPERLYTIGHTENED3ECTION
s
INTO METALTHERESHOULDBEATLEASTTHREETHREADSPROTRUDINGPASTTHE
For -).)/2" and 0!.%,2)"
s 2OOF:IPS M6 -11 x 25 or
s - X$ESIGNER(EAD or
s (EX(EAD-ETAL4EKSWITHSEAL XOR
s 3EALEDBLINDRIVETSMMDIAMETERALUMINIUM
support you are fixing towhere rib fixing is done then the 'shank
protection' must not reach the support (Figure 3.8.1);
s
Shank protection
INTO TIMBERTHESCREWMUSTPENETRATETHETIMBERBYTHESAMEAMOUNT
that the recommended screw would do if there were no insulation, i.e.

same embedment.
s &ORDEEPINSULATIONBOARDORPACKERTHEAVAILABILITYOFASUITABLE
screw, with all the recommended features and minimum
SPECIFICATIONSWILLNEEDTOBEINVESTIGATED)TMAYBENECESSARYTO
increase the screw gauge accordingly or seek advice from the screw
manufacturer. Site trial of screw fixing may need to be conducted to
determine the suitability of the selected screw.
Steel support
Three threads
(minimum)
Figure 3.8.1
Setting screws correctly
Fixing to steel thicker than 3mm

5SEAPPROPRIATESELF DRILLINGSCREWSWITHANEXTENDEDDRILLPOINTOR
pre-drill hole and seek advice from the screw manufacturer on the
appropriate screw specifications.
2012-13 Edition
3 Fasteners
3.8 Recommended fasteners and locations
DESIGNFASTENERS
12
Table 3.8
'UIDETOESTIMATEFASTENERSANDCLIPSREQUIREDFORTYPICALINSTALLATION
Fastener & Clip Requirement Guide (per m2)

Cladding
profile
No. of fasteners
(or clips) per
sheet width
Sheet
Cover
Width
450
Maximum support spacings (mm)

1
600
900
1200
1500
1800
CUSTOM ORB
3
5
762
762
9
15
7
11
5
8
4
6
3
5
3
4
CUSTOM BLUE
ORB
3
5
762
762
9
15
7
11
5
8
4
6
3
5
3
4
EASYCLAD
300
INTEGRITY 820
820
KLIP-LOK 406
2
1 CLIP
406
406
6
3
5
2
4
2
3
1
KLIP-LOK 700
HI-STRENGTH
3
1 CLIP
700
700
5
2
4
1
3
1
3
1
KLIP-LOK
CLASSIC 700
3
1 CLIP
700
700
5
2
4
1
3
1
3
1
LONGLINE 305
(not tapered)
1
1 CLIP
305
305
4
4
3
3
2
2
2
2
MINI ORB
6
11
820
820
17
30
13
22
9
15
7
11
5
9
5
7
MULTICLAD
840
11
PANELRIB
4
8
850
850
11
21
8
16
6
10
4
8
4
6
3
5
SPANDEK
3
4
700
700
10
13
8
10
5
6
4
5
3
4
3
3
SPANRIB
820
TRIMDEK
762
12
TRIMWALL
762
12
WALLCLAD
3
5
762
762
9
15
7
11
5
8
4
6
3
5
3
4
Typical residential framing spacings.
2012-13 Edition
DESIGNFASTENERS
13
Table 3.8.1
'UIDETOFASTENERFIXINGANDLAYOUT
CUSTOM ORB, CUSTOM BLUE ORB (and WALLCLAD)
Crest: 3 fasteners
Crest: 5 fasteners
Side-lap
Pan/Valley: 3 fasteners
Side-lap
Width covered by x number of sheets (m)

Number of sheets
Coverage (m)
2.3
3.0
3.8 4.6
10 11 12 13 14
15
16
17
18
19
20
5.3 6.1 6.9 7.6 8.4 9.1 9.9 10.7 11.4 12.2 13.0 13.7 14.5 15.2
EASYCLAD
3 Fasteners
1 fastener

Number of sheets
Coverage (m)
0.9
1.2
1.5 1.8
10 11 12 13 14
15
16
17
18
19
20
2.1 2.4 2.7 3.0 3.3 3.6 3.9 4.2
4.5
4.8
5.1
5.4
5.7
6.0
15
16
17
18
19
20
INTEGRITY 820
Crest: 3 fasteners

Number of sheets
Coverage (m)
2.5
3.3
4.1 4.9
10 11 12 13 14
5.7 6.6 7.4 8.2 9.0 9.8 10.7 11.5 12.3 13.1 13.9 14.8 15.6 16.4
KLIP-LOK 700HS & KLIP-LOK CLASSIC 700
+,)0 ,/+() 342%.'4(
+,)0 ,/+#,!33)#
One clip and 3 fasteners
One clip and 3 fasteners

Sheet
Clip
Clip

Number of sheets
Coverage (m)
2.1
2.8
3.5 4.2
10 11 12 13 14
15
16
17
18
19
KEY
20
4.9 5.6 6.3 7.0 7.7 8.4 9.1 9.8 10.5 11.2 11.9 12.6 13.3 14.0
Fasteners per sheet

per support
2012-13 Edition
14
DESIGNFASTENERS
KLIP-LOK 406
1 clip, 2 fasteners
Clip
Clip
Number of sheets
Coverage (m)
1.2
1.6
2.0 2.4
10 11 12 13 14
15
16
17
18
19
20
2.8 3.2 3.7 4.1 4.5 4.9 5.3 5.7
6.1
6.5
6.9
7.3
7.7
8.1
LONGLINE 305 (not tapered)
1 clip, 1 fastener
Clip
Clip
Number of sheets
Coverage (m)
0.9
1.2
1.5 1.8
10 11 12 13 14
15
16
17
18
19
20
2.1 2.4 2.7 3.1 3.4 3.7 4.0 4.3
4.6
4.9
5.2
5.5
5.8
6.1
MINI ORB
Number of sheets
Coverage (m)
2.5
3.3
4.1 4.9
10 11 12 13 14
15
16
17
18
19
20
5.7 6.6 7.4 8.2 9.0 9.8 10.7 11.5 12.3 13.1 13.9 14.8 15.6 16.4
MULTICLAD

Number of sheets
Coverage (m)
2.5
3.4
4.2 5.0
10 11 12 13 14
15
16
17
18
19
KEY
20
5.9 6.7 7.6 8.4 9.2 10.1 10.9 11.8 12.6 13.4 14.3 15.1 16.0 16.8
Fasteners per sheet

per support
2012-13 Edition
DESIGNFASTENERS
15
PANELRIB
Pan: 4 fasteners
Side lap
Side lap
Pan: 8 fasteners
Number of sheets
Coverage (m)
2.6
3.4
4.3 5.1
10 11 12 13 14
15
16
17
18
19
20
6.0 6.8 7.7 8.5 9.4 10.2 11.1 11.9 12.8 13.6 14.5 15.3 16.2 17.0
SPANRIB
Crest: 3 fasteners

3
2.5
3.3
4.1 4.9
10 11 12 13 14
15
16
17
18
19
20
5.7 6.6 7.4 8.2 9.0 9.8 10.7 11.5 12.3 13.1 13.9 14.8 15.6 16.4
3 Fasteners
Number of sheets
Coverage (m)
SPANDEK
Crest: 3 fasteners
Crest: 4 fasteners
Side lap
Side lap

Number of sheets
Coverage (m)
2.1
2.8
3.5 4.2
10 11 12 13 14
15
16
17
18
19
20
4.9 5.6 6.3 7.0 7.7 8.4 9.1 9.8 10.5 11.2 11.9 12.6 13.3 14.0
TRIMDEK & TRIMWALL - (TRIMWALL pan fasten only)
Crest: 4 fasteners
Side lap

Number of sheets
Coverage (m)
2.3
3.0
3.8 4.6
10 11 12 13 14
15
16
17
18
19
20
5.3 6.1 6.9 7.6 8.4 9.1 9.9 10.7 11.4 12.2 13.0 13.7 14.5 15.2
WALLCLAD - (Valley/pan fasten only)
Side-lap
KEY
Side-lap
2012-13 Edition
Fasteners per sheet

per support
16
DESIGNCURVED, BENT AND TAPERED ROOFING
4
Curved, bent & tapered cladding
Curved sheets can be used for both roofing and walling applications.
Sheeting can be curved into either concave or convex shapes as
required.
Spring-cur
ved-ridge roof
Sheets straight except for
a curve near the ridge
Spring-ar
ched or
convex roof
Sheets curved in a radius
from eave to eave
!NEXCELLENTMETHODOFCLADDINGLOW SLOPEGABLEROOFSIS
to run continuous lengths of roofing from eave to eave,
across the full width of the roof. This gives a particularly neat
ANDATTRACTIVEROOF)TISALSOPOSSIBLETOSPRING CURVESHEETS
into a concave shape.
Spring-cur
ved concave roof
Sheets curved concavely in a radius
Pre-curved sheets
Sheets curved by machine before
installation
With the exception of +,)0 ,/+, the ridge capping is eliminated

in these roofs, thus avoiding any possibility of leakage along
the ridge. +,)0 ,/+ can be used similarly, but the ribs are cut
at the ridge and a metal cap is fitted over the cut.
Capped bent ribbed roofs

(for example KLIP-LOK)
Figure 4.1
Typical curved and bent applications
4.1 Spring-curved-ridge roof

Sheets in a spring-curved-ridge roof remain straight except
for a curve near the ridge.
The pans of +,)0 ,/+).4%'2)49,/.',).% and 42)-$%+ tend to
oilcan (minor waviness in the pan) when spring curved.
!PARTFROMNOTLOOKINGGOODANOILCANNEDPANMAYRETAINWATERWHICH
could lead to discolouration and/or deterioration of the sheet coating and
ALSOCONTRIBUTESTOTHERMALLYINDUCEDROOFNOISE)FSOMEOILCANNINGINTHE
pans is acceptable, these profiles can be spring-curved up to a maximum
SLOPEOFIN WITHTHESPACINGBETWEENTHEPURLINSATTHERIDGE
being slightly less than the internal span recommended for the profile
in Table 2.12.1.
Over the supports at the ridge, very slight crease marks may appear in the
PANSORVALLEYSWHENSUBJECTEDTOFOOTTRAFFIC4HEYDONTAFFECTSTRENGTH
and will usually not be seen from the ground.
NS
Only the sheet profiles recommended for spring-curving are shown in

Table 4.1.1.
NS
Spacing from
Table 4.1.1
NS
NS = Normal spacing
given in Table 2.3.1
NS
%ACHSHEETISFIRSTFIXEDTOONESIDEOFTHEROOFANDTHENPULLEDDOWNTO
be fixed to the other side. To minimise small laying errors, lay alternate
sheets from opposite sides of the roof.
Figure 4.1.1
Spring-curved-ridge roof
Side laps should be sealed with silicone sealant for the length
of the curve.
2012-13 Edition
17
Table 4.1.1
Minimum spacing of purlins at ridge for spring-curved-ridge roof (mm)
Rise
4.2 Spring-arched roof

Width
Sheets in a spring-arched (convex) roof are curved in a radius from eave

to eave. SPANDEK, LONGLINE 305, CUSTOM ORB and CUSTOM BLUE
ORB can be spring-curved for an arched roof. Table 4.2.1 shows the
acceptable radii.
The top face of all purlins must accurately follow and be tangential to the
radius of the arch. The radius of curvature can be calculated from the
formula in Figure 4.2.1.
Radius
2
Radius = Width + 4(Rise)

8 x Rise
Figure 4.2.1
Calculation of radius
Table 4.2.1
(Fluted)
(Tapered)
Seal length
measured on roof
At the crest of an arch the roof is flat, which is obviously below the
specified minimum roof pitch. Therefore side laps of shallow roof profile
as such as CUSTOM ORB, CUSTOM BLUE ORB and SPANDEK should
be sealed over the crest of the arch until there is sufficient pitch to give
adequate drainage (see Table 2.3.1). The length of seal is shown in Figure
4.2.2. Refer to Section 8.5 for side-lap fixing and Section 7.9 for sealant
application.
ius
Rad
Over the supports very slight crease marks may appear in the pans or
valleys when subjected to foot traffic. They dont affect strength and will
usually not be seen from the ground.
If end laps are necessary they should not be located at or near the
crest of the arch and each sheet length must span at least three purlin
spacings.
Profiles with wide pans manufactured from high tensile steel (such as
KLIP-LOK, SPANRIB and INTEGRITY 820) are susceptible to local buckling
of the pans and are therefore not recommended for spring-arched roofs.
Figure 4.2.2
Seal length for side laps on spring-arched roof
2012-13 Edition
4 Curved, bent & tapered
Recommended radii for convex spring-curving
18
4HESEPRODUCTSMAYBEMADESPECIALLYFROMSOFTSTEEL' TOMINIMISE
the problem.
%ACHSHEETISFIRSTFIXEDTOONESIDEOFTHEROOFANDTHENPULLEDDOWNTO
BEFIXEDTOTHEOTHERSIDE!LTERNATESHEETSARELAIDFROMOPPOSITESIDESOF
the roof.
4.3 Spring-curved concave roofs

Roofing can be spring-curved into concave shapes.
Table 4.3.1 shows the acceptable radii.
Table 4.3.1
Radii for spring curved concave roofs
Figure 4.3.1
Spring-curved concave roof
For fluted and tapered LONGLINE please contact your local Service
Centre for advice.
4.4 Pre-curved sheets

Pre-curving of #534/-",5%/2" and-).)/2" is available for various
APPLICATIONS WEDONTRECOMMENDPRE CURVINGFOROTHERPROFILES
Pre-curved corrugated roofing is popular for aesthetics (such as a
bullnosed verandah roof), or for function (such as a gutterless eave
design). #534/-",5%/2" can be curved to a small radius (300 to
400mm - local variations apply).
-).)/2" CANBECURVEDTOARADIUSTOASSMALLASMMTHOUGHITISNT
recommended for roofing.
Because of the spacing of curving rolls, there is usually a straight portion
at the end of the sheet beyond the curve (often 50 to 110mm for #534/-
",5%/2", and about 50mm for -).)/2" !LLOWFORTHISINYOURDESIGN
)TCANBETRIMMEDOFFIFNECESSARY
)FAPRE CURVEDSECTIONOFCLADDINGISTOBEJOINEDTOASTRAIGHTSECTIONITIS
recommended that you order the curved and straight sheets at the same
time, asking for them to be matched in production to ensure a quality endLAP%ND LAPTHESHEETSASDESCRIBEDIN3ECTION%ND LAPPING
Our #534/-",5%/2" and the -).)/2"PAGESOFTHE,93!'(4
Walling Products brochure gives more details on curving.
2012-13 Edition
19
4.5 Capped bent ribbed roofs

Tray cladding can be used in continuous lengths from eave to
eave by cutting the ribs and bending the pans at the ridgeline.
The same process is used on Mansard roofs. Caps are fitted over
the cut ribs, which open up when the pans are bent. Fitting the rib
caps can be time-consuming and care must be taken with sealing
to avoid any possibility of leakage.
The ribs must be cut squarely, with a metal cutting blade in a
power saw, set to the depth of the rib minus 2mm.
)NSOMESTATESPRESSEDSTEELCAPSMAYBEAVAILABLETOSUIT+,)0
LOK ribs, though the range of angles is limited. Caps can be
handmade to suit any angle from flat sheet.
+,)0 ,/+ is most frequently used for capped bent ribbed roofs,
but ,/.',).%42)-$%+ or even30!.$%+can be used. For
these four profiles the rib caps can be made from pieces of rib
PROFILECUTFROMASHORTLENGTHOFCLADDING!NEUTRAL CURESILICON
sealant should be used.
Figure 4.5.1
and on flanges.
Capped bent ribbed roof
Overlap
4.6 Tapered roofing

LONGLINE products
The ,/.',).%CLADDINGPRODUCTISAVAILABLEINCOVERWIDTHSOF
Underlap
s , /.',).% 305 - Wide flat pans, with a uniform cover width of

305mm.
Underlap
s & LUTED,/.',).% Flat panned profile with subtle concertina

type with longitudinal pan stiffeners with a uniform cover width of
300mm.
s 4 APERED,/.',).% - Concertina type stiffeners running
longitudinally in the pans varying from a subtle definition to a bold
definition. Cover width varying from a wide end of 305mm, down to
a narrow end of as low as 145mm.
Overlap
With combinations of fluted and tapered sheets, and/or with spring

curving, striking or special architectural effects can be achieved.
The tapered ,/.',).%RESULTSINAFANEFFECTONROOFS!LTERNATING
the arrangement of tapered sheets or the combination of tapers/
fluted or standard ,/.',).% 305 sheets will result in various
patterns and textures being achieved.
!LLTAPERSARELINEARTAPERS4HETAPERSAREMANUFACTUREDINTHE
STANDARDMODETERMEDONTHEPRODUCTIONLINEAS&/27!2$TAPER
or in the non-standard mode (termed on the production line as
2%6%23%TAPER
4HENORMALMANUFACTUREISh&/27!2$vANDUNLESSSPECIFIEDTHE
&/27!2$TAPERWILLBEPRODUCED
The orientation of installation of the sheets will govern as to which
end of the roof that laying can commence. On some projects the
choice of laying direction is important and thus the selection of the
correct direction of taper (Forward or Reverse) is vital.
For product range and availability and assistance on tapers, please
contact your nearest service centre.
Forward Taper
Standard width
(cover 305mm)
Fluted
(cover 300mm)
Narrow end with
dimension of
approx. 265mm
Narrow end with
dimension of
approx. 235mm
Narrow end with
dimension of
approx. 155mm
Figure 4.6.1
Tapered ,/.',).%
2012-13 Edition
4 Curved, bent & tapered
Reverse Taper
20
DESIGNINSULATION AND SKYLIGHTING
9OUOFTENCONSIDERINSULATINGABUILDINGTOREDUCE
s HEATINGFROMTHESUNINSUMMER
Insulation & skylights
s LOSSOFHEATFROMINSIDEINWINTER
s CONDENSATIONONTHEINSIDEOFTHEROOFINGANDWALLINGAND
s NOISEFROMRAINTHERMALEXPANSIONANDCONTRACTIONANDOTHER
sources.
5SUALLYWHENONEOFTHESEFOURISTREATEDTHEREISALSOABENEFICIALEFFECT
on the others.
9OUNEEDTOCOMPARETHEINITIALCOSTOFINSTALLINGINSULATIONWITHTHE
savings in costs of heating and cooling. There are also gains for the
environment when you save energy.
(" (OME)NSULATIONIN!USTRALIA 2ECOMMENDEDINSULATIONLEVEL
for all States thoroughly treats the subject, including comprehensive
tables of recommended thermal resistance (R values) for over 1000 towns
THROUGHOUT!USTRALIA
5.1 Heat control

)NSUMMERBUILDINGSGETHOTFROMTHESUNANDWEWANTTOCOOLTHEINSIDE
in winter we often heat the inside and want to avoid losing that heat.
&ACTORSINCONTROLLINGHEATINCLUDE
s THEORIENTATIONOFTHEBUILDINGRELATIVETOTHESUN
s EXTERNALSHADINGFROMTREESOROTHERBUILDINGS
s DESIGNOFTHEBUILDINGESPECIALLYVENTILATIONANDSEALING
at doors and windows;
s THECOLOURSANDSURFACEGLOSSOFTHECLADDING
4HEFIRSTTHREEFACTORSAREOUTSIDETHESCOPEOFTHISBOOK(EATIS
absorbed into a sheet on one side, and some of that absorbed heat is
re-radiated from the other side (Figure 5.1.1).
s ,IGHT COLOUREDORSHINYSURFACESDONTABSORBMUCHHEAT
and they radiate little.
s $ARK COLOUREDORDULLSURFACESABSORBALOTOFHEAT
ANDTHEYRADIATEALOT4HISDOESNTSTOPYOUUSINGDARKERCLADDINGS
because you can use reflective foil laminate under the cladding.
COLORBOND steel with THERMATECH technology

The next generation #/,/2"/.$ steel incorporates 4(%2-!4%#(
technology, which provides a new level of thermal protection by absorbing less
HEAT!VERAGEREDUCTIONINSOLARABSORPTIONACROSSALLSTANDARDCOLOURSIS
Now 14 of the 20 standard#/,/2"/.$STEELCOLOURSARE@MEDIUMTOLIGHT
UNDERTHE"!3)8COLOURCLASSIFICATIONWHICHMEANSREFLECTIVEFOILATTHEROOF
MAYNOTBEREQUIRED)TALSOMEANSADROPOFROOFINSULATION2RATINGMAYBE
applicable.
Figure 5.1.1
(EATTRANSMITTEDINTOABUILDING
New #/,/2"/.$C//,-!8 is specifically designed to reduce solar

absorbtion. Refer to your local branch for colour availability for these products.
2012-13 Edition
21
Table 5.1.1
!PPROXIMATETHERMALTRANSMISSIONFORCOMPARISONSONLY
ZINCALUME
COLORBOND
Coolmax (Whitehaven)
Classic Cream, Surfmist
Sandbank
Wilderness
Woodland Grey
Deep Ocean
25
40
2.0
9.0
2.0
7.0
22.5
37.1
59.7
91.2
101.4
108.2
26.6
43.8
70.3
106.9
118.7
126.6
0.9
1.5
2.4
3.6
4.0
4.3
3.8
6.1
9.6
14.4
15.9
16.9
0.6
1.1
1.7
2.5
2.8
3.0
2.7
4.3
6.9
10.3
11.3
12.0
Comparison of thermal performance

Table 5.1.1 shows thermal performances of different insulation systems by
showing the heat that may be expected through roofs of new materials.
Heat control methods

)NROOFSASIMPLEINEXPENSIVEANDVERYEFFECTIVEMETHODISTODRAPEA
membrane of reflective foil laminate over the supports before laying the
cladding. The laminate can also provide a vapour barrier to minimise
CONDENSATION)FTHEMEMBRANEISALLOWEDTODRAPETOMMBETWEEN
the supports the air space between the membrane and the roof cladding
will further improve heat insulation (Figure 5.1.2).
!DDITIONALHEATINSULATIONISOFTENACHIEVEDBYUSINGBULKINSULATION
blankets or batts (Figure 5.1.3).
Figure 5.1.2
Reflective foil laminate is simple, cheap and very
effective
The same principles apply to walls, though the foil is not draped.
5.2 Condensation
5 Insulation & skylighting
When the air in a building in contact with metal cladding is warmer than
the cladding, water vapour (moisture) in the air can condense on the
inside of the cladding.
Water vapour passes fairly freely through most building linings into the
ceiling and wall spaces where it may directly contact the cladding.
Condensation can lead to deterioration of building components and
STAININGOFCEILINGANDWALLS)FINSULATIONBLANKETSORBATTSAREWET
or even slightly dampened by condensation, its efficiency is reduced
markedly.
The amount of condensation depends upon the amount of water vapour
INTHEAIRANDTHISVARIESWITHCLIMATICCONDITIONS!CTIVITIESWITHINA
building can add substantially to the amount of water vapour, and typical
domestic situations include bathing, showering, cooking, washing
ANDDRYINGCLOTHESANDDISHESANDBREATHING)TISESSENTIALTOVENT
substantial amounts of water vapour to outside the building.
To minimise the risk of condensation on the underside of roofing, a
vapour barrier is often used to prevent contact of warm moist air with the
roofing reflective foil laminate is commonly used.
Figure 5.1.3
Typical roof insulation with foil and blanket
2012-13 Edition
22
To minimise the risk of condensation on the underside of

the laminate, the laminate must be draped between roof
supports so that the cold cladding is not in contact with the
laminate (except at the supports).
s INSULATIONPREVIOUSLYRECOMMENDEDTOOVERCOMERAIN
noise will also reduce the thermally induced clicking
noise.
5.4 Insulation materials

5.3 Noise reduction
Rain noise
To reduce rain noise on metal roofing, an insulation blanket
can be placed over the foil laminate described above, before
LAYINGTHEROOFING)TISIMPORTANTTHATTHELAMINATEISPULLED
tight enough to hold the blanket hard against the underside
of the roofing so as to dampen the rain-induced vibration
ATTHEPOINTOFIMPACT)FTHEBLANKETISNOTHARDAGAINSTTHE
roofing the noise reduction will not be as good.
&ORPURLINSPACINGSOVERMMFIRSTLAYWIREMESHOVER
the purlins, tighten and fix it, before laying the membrane.
Thermally-induced noise
Roofing expands and contracts due to temperature changes
in the cladding, and particularly rapid changes can be
CAUSEDBYPASSINGCLOUDSORASTRONGBREEZE&OREXAMPLEIF
a passing cloud suddenly shades the roof from the sun, the
CLADDINGTEMPERATURECOULDDROPABOUT#AFTERSECONDS
INSHADEANDABOUT#AFTERMINUTESINSHADE
Thermally-induced noise is caused by slipping at fasteners
where the roof expands relative to its supports. The slipping
is controlled by the friction between the roof and its
supports. When the static friction is overcome impulsively,
sounds are produced sometimes as loud as a pistol-shot
the higher the friction, the louder the sound. No damage
to the cladding or fasteners will occur.
Typical insulation materials are reflective foil laminates,

insulation blankets or batts made from fibreglass, and
boards made from polystyrene. Remember that the colour of
cladding also has a marked effect (Section 5.1).
Foil laminates
Foil laminates reflect heat and can double-up as a vapour
barrier to control condensation. Where they are used as
a vapour barrier the joints between successive strips are
overlapped about 100mm, and sealed with a tape impervious
to moisture.
Blankets and batts

Blankets and batts minimise heat convection and are
available with the laminate bonded to the fibreglass. They
are also effective in reducing noise.
)NSULATIONBLANKETSMUSTBEPROTECTEDFROMMOISTURE
particularly around the edges of the roof and even more
particularly at the bottom end of the cladding where
rainwater run-off can be blown back under a low-pitched
ROOF)FTHEBLANKETOVERHANGSTHEBOTTOMSUPPORTITMAY
even come into contact with water in the gutter, where
the insulation will absorb moisture and remain damp for
extended periods, thus leading to deterioration of the
coating on the underside of the roofing and reducing the
effectiveness of the insulation.
s CHOOSINGLIGHTCOLOUREDROOFING
)NSULATIONBLANKETSUPTOANOMINALTHICKNESSOFUPTOMM
for pierce-fixed cladding and +,)0 ,/+(3; and up to
50mm for +,)0 ,/+ and all other concealed-fixed profiles
will compress sufficiently over the roof supports to allow
normal procedures to be used for fixing.
For +,)0 ,/+#,!33)#in thicknesses between
75-100mm, seek advice from our technical support line.
(OWEVERYOUMAYNEEDTOINCREASETHELENGTHOFFASTENERS
slightly to allow for the thickness of the compressed blanket
between the cladding and support.
s VENTINGTHEROOFSPACE
Polystyrene boards
s INCLUDINGANEXPANSIONJOINT3ECTION
%XPANDEDANDEXTRUDEDPOLYSTYRENEISALSOUSEDFORTHE
same purposes as blankets and batts. The boards are
more rigid and relatively less compressible which demand
different fixing to that mentioned above. Seek advice from
manufacturers of polystyrene insulation.
4HENOISECANBEREDUCEDBY
s PLACINGAMATERIALWITHLOWCOEFFICIENTOFFRICTION
BETWEENTHEROOFINGANDITSSUPPORTSFOREXAMPLE06#
tape or strips of foil laminate);
s CHOOSINGSTEELSUPPORTSRATHERTHANTIMBERLOWER
coefficient of friction);
s BEINGCAREFULABOUTDESIGNDETAILSINVALLEYS
(where heat tends to be retained); and/or
s INSULATINGTHEROOFSPACETOREDUCETHETHERMAL
DIFFERENTIAL)NTROPICALAREASITMAYBEBETTERTOINSULATE
the ceiling rather than the roofing (which can also reduce
noise) by having the silver foil facing upwards towards the
roong, instead of downwards towards the ceiling.;
2012-13 Edition
23
5.5 Insulation thickness (glass wool)

Insulation blankets and batts can cause cladding to bow
out between the fasteners. To minimise this problem, the
maximum thickness of blankets and batts should be 100mm
for pierce-fixed cladding and KLIP-LOK 700HS and 50mm
for KLIP-LOK 406 and all LONGLINE 305. (Maximum density
12kg/m3.) For KLIP-LOK CLASSIC 700, in thicknesses between
75-100mm, seek advice from our technical support line.
For more dense glass wool and rock wool, and thicker
insulation, spacers are recommended.
5.6 Skylighting
One of the simplest methods of getting natural light through
a steel roof is the inclusion of translucent sheets which
match the steel profiles.
It is preferable to use profiled translucent cladding in single
widths so that they can overlap, and be supported by, the
steel cladding on both sides. It is also preferable to position
the lengths of translucent cladding at the top of a roof run
so the high end can lap under the capping or flashing and
the low end can overlap a steel sheet. This is because the
translucent cladding will readily overlap a steel sheet but the
reverse is difficult.
Building regulations require a safety mesh to be fitted under
translucent cladding.
Figure 5.6.1
Placement of translucent sheets pierce fixed decks
Steel
KL-Classic
Translucent
KL-Classic translucent sheet
KL-Classic
Figure 5.6.2
Placement of translucent sheets concealed fixed decks
5 Insulation & skylighting
Because of its greater thermal expansion, translucent

cladding should be fixed using oversized holes and sealing
washers recommended by the translucent cladding
manufacturer. When used with concealed fixed claddings,
ensure the fasteners do not penetrate the steel cladding.
There are translucent products available that easily
accommodate this and some translucent products have a
clip-fixing system to allow thermal movement. Dont exceed
the maximum support spacing specified by the translucent
cladding manufacturer.
Skylighting increases the transmission of solar heat.
Generally speaking, heat transmission is proportional
to light transmission, so the more sunlight that enters a
building the hotter it will be. Clear, uncoloured fibreglass has
good light transmission of about 65% but this means on a
typical summer day, with peak solar radiation of 850 W/m2,
transmission through a clear fibreglass skylight would be
about 550 W/m2.
Translucent fibreglass cladding is available to match
CUSTOM ORB, INTEGRITY 820, KLIP-LOK 406, KLIP-LOK
CLASSIC 700, KLIP-LOK 700HS, LONGLINE 305, SPANDEK
and TRIMDEK. Polycarbonate cladding is also available for
CUSTOM ORB and TRIMDEK.
Steel
2012-13 Edition
24
DESIGNROOF DRAINAGE
6.1 Introduction
Roof drainage
Roof drainage systems can be affected by a number of variables and must

be designed and detailed by a suitable qualified trade or professional. The
design of roof drainage aims to protect people, property and the building.
The designed drainage system must be installed under the supervision
of a qualified trade or professional. The steps of the design process are
illustrated below.
$ETERMINEAVERAGERECURRANCEINTERVAL!2)
2. Obtain rainfall intensity of site
3. Work out roof dimensions.
$ETERMINECATCHMENTAREAWITHSLOPE
$ETERMINEAREAFORPROPOSEDEAVESGUTTER
$ETERMINECATCHMENTAREAPERDOWNPIPE
$ETERMINENUMBEROFDOWNPIPESREQUIRED
$ETERMINELOCATIONOFDOWNPIPESANDHIGHPOINTS
#HECKCATCHMENTAREAFOREACHDOWNPIPE
$ETERMINEDOWNPIPESIZE
$ETERMINEOVERFLOWMEASURES
6.2 Design of drainage (eaves-gutter system)

The steps in the design process are for a perimeter drainage system
using the standard roll-formed rainwater products (gutters) installed at
THEBUILDINGEAVES$RAINAGESYSTEMSFORLARGERROOFSUSEBOXGUTTERSAT
the perimeter and internally. Box gutter systems are thoroughly treated in
!3.:3AND("
)TISASSUMEDTHATTHEEAVESGUTTERSWILLHAVEAGRADIENTOFOR
steeper.
$ECIDEONTHEAVERAGERECURRENCEINTERVAL!2) 7HERESIGNIFICANT
inconvenience or injury to people, or damage to property (including
CONTENTSOFABUILDING ISUNLIKELYAMINIMUM!2)CANBEYEARS
)FTHESECONDITIONSARELIKELYYEARSISRECOMMENDED
$ETERMINERAINFALLINTENSITYFORTHESITEFROM4ABLE-OREDATA
ISIN!3.:3"#!ORINOURLOCALREGIONAL2AINWATER
Solutions brochure.
3. Sketch a roof plan showing dimensions in plan view, pitch of roof,
layout of ridges and valleys and large roof penetrations.
4. Calculate the catchment area of the roof from the plan. To allow for
THESLOPEOFTHEROOFINCREASETHEPLANAREABYFOREVERYDEGREE
OFPITCHUPTO&ORPITCHESOVERREFERTO!3.:3
'ETTHEEFFECTIVECROSS SECTIONALAREAOFTHEGUTTERYOUINTENDTO
use from Table 6.2.2.
2012-13 Edition
DESIGNROOF DRAINAGE
5SINGTHECROSS SECTIONALAREAOFTHEGUTTERONTHEGRAPHIN&IGURE
6.2.2, determine the catchment area per downpipe.
25
Table 6.2.1
$ESIGNRAINFALLINTENSITIES
7. Calculate (as a first test) the minimum number of downpipes

REQUIREDFORTHESELECTEDGUTTERUSINGTHEEQUATION
Number of
Total catchment area of the roof

downpipes (min.) Catchment area (determined in 6)
Round the number of downpipes up to the next whole number.

8. On the plan, select locations for the downpipes and the high points
in the gutters. Where practical, the catchments for each downpipe
should be about equal in area.
When selecting the location of high points and downpipes,
consideration should also be given to proximity to high
concentrations of water flow (e.g. valley gutters, diversions around
large roof penetrations, dormers, etc.) More guidance is given in
!3.:3("AND"#!
Calculate the area of each catchment for each downpipe.
7ITHTHEAREAOFYOUREAVESGUTTERCHECKTHATTHECATCHMENTAREA
for each downpipe, calculated in Step 8, is equal to or less than the
catchment area shown by the graph.
)FACATCHMENTAREAISTOOBIGTHENYOUCAN
s)NCREASETHENUMBERANDSIZEOFDOWNPIPES
s2EPOSITIONTHEDOWNPIPESANDORTHEHIGHPOINTS
s#HOOSEAGUTTERWITHBIGGEREFFECTIVECROSS SECTIONALAREA
then repeat the above from Step 6.
$ECIDEONTHEDOWNPIPESIZE2ECOMMENDATIONSIN
!3.:3ONDOWNPIPESIZES!SANAPPROXIMATEGUIDE
the area of round pipes should be equal to the area of the gutter,
WHILSTTHEAREAOFSQUAREORRECTANGULARPIPESMAYBESMALLER
(Table 6.2.2).
Colonial
11. Consider measures to counter overflow of gutters into the

building. Consideration of overflow at high concentrations of
WATERFLOWMAYNEEDTOBEGIVEN'UIDANCEONTHISMATTERISGIVEN
IN.37$EPTOF&AIR4RADINGBULLETIN&4"*ANUARY
Half Round
& Flat back
)NSTALLGUTTERSWITHASUITABLEFALLTOAVOIDPONDINGANDTOALLOWWATER
to easily ow away. Steeper falls are preferred for prolonged life of
THEGUTTER-OREINFORMATIONCANBEFOUNDINOURPUBLICATION@7ATER
/VERmOW2ESIDENTIAL'UTTERS2EFERTOTHE"#!ANDTHE!USTRALIAN
Standards for more guidance.
Box gutter
Box gutter
Figure 6.1.1
Typical gutters
2012-13 Edition
6 Roof drainage
26
DESIGNROOF DRAINAGE
Figure 6.2.2
Figure 6.2.2
Cross-sectional
area of eaves gutters required for various
Cross-sectional area of eaves gutters required for various roof
ROOFCATCHMENTAREASWHEREGRADIENTOFGUTTERISAND
catchment areas (where gradient of gutter 1:500 and steeper).
STEEPER !DAPTEDFROM!3
(Adapted from AS 3500.3: 2003)
Example
Find the minimum catchment area for
each downpipe on a house in Forbes
using Quad Hi-front gutter.
METHOD
Using the gutter cross sectional area taken
from Table 6.2.2 (shown across the bottom of
the graph) draw a line upwards until it
intersects with the Design rainfall intensity
(Table 6.2.1). Draw a line at 90 to determine
the catchment area for each downpipe.
151 B.C.A.
5804 Table 6.2.2
Table 6.2.2
37
(Gradient 1:500 and steeper.)

(Gradient 1:500 or steeper )
Table 6.2.2
,93!'(4GUTTERAREAS
and downpipes
gradient
#
'UTTERDOWNPIPEANDACCESSORIYAVAILABILITYANDDETAILSMAY
VARYLOCALLY2EFERENCESHOULDBEMADETOTHELOCAL,93!'(4
Rainwater Solutions brochure for your area.
2012-13 Edition
CARE AND HANDLING
27
0!24").34!,,!4)/.
General care, safety and

handling
7.1 Safety
)TISCOMMONSENSETOWORKSAFELYPROTECTINGYOURSELFAND
workmates from accidents on the site. Safety includes the
practices you use; as well as personal protection of eyes and
skin from sunburn, and hearing from noise. Some sunscreens
contain titanatium oxides. These have been shown to break
down some paint compounds and these should be avoided.
Occupational health and safety laws enforce safe working
conditions in most locations. Laws in every state require you
to have fall protection which includes safety mesh, personal
harnesses and perimeter guardrails. We recommend that
you are fully aware of all local codes of safe practice and
you adhere strictly to all laws that apply to your site.
7.2 Care and storage before installation

Rain or condensation is easily drawn between the surfaces
of stacked sheets by capillary action, or they can be driven
in by wind. This trapped moisture cannot evaporate easily, so
it can cause deterioration of the coating which may lead to
reduced life-expectancy or poor appearance.
)FMATERIALSARENOTREQUIREDFORIMMEDIATEUSESTACKTHEM
NEATLYANDCLEAROFTHEGROUND)FLEFTINTHEOPENPROTECT
them with waterproof covers.
)FSTACKEDORBUNDLEDPRODUCTBECOMESWETSEPARATEIT
without delay, wipe it with a clean cloth and stack it to dry
thoroughly.
7.4 Walking on roofs

)TISIMPORTANTTHATYOUWALKONROOFINGCAREFULLYTOAVOID
damage to either the roofing or yourself.
'ENERALLYKEEPYOURWEIGHTEVENLYDISTRIBUTEDOVERTHESOLES
of both feet to avoid concentrating your weight on either
HEELSORTOES!LWAYSWEARSMOOTHSOFT SOLEDSHOESAVOID
ribbed soles that pick up and hold small stones, swarf and
other objects.
7HENYOUWALKPARALLELTOTHERIBS
s FORRIBBEDROOFINGWALKONATLEASTTWORIBSOR
corrugations (#534/-/2"#534/-",5%/2"
and 30!.$%+);
s FORPAN TYPEROOFING walk in the pans
(,/.',).%+,)0 ,/++,)0 ,/+(3,
+,)0 ,/+#,!33)#, 30!.2)"42)-$%+
).4%'2)49).
When you walk across the ribs, walk over or close to the
ROOFINGSUPPORTS5SUALLYOVERFASTENERLOCATIONS
"ECAREFULWHENMOVINGBETWEENSUPPORTS$ONOTWALKIN
the pan immediately adjacent to flashings or translucent
sheeting. Walk at least one pan away.
!LWAYSTAKEPARTICULARCAREWHENWALKINGONWETORNEWLY
laid sheets particularly on steeply pitched roofs.
)FTHEREWILLBEHEAVYFOOTTRAFFICONAROOFPROVIDEA
temporary walkway or working platform with consideration
of hand rails to minimise damage.
7.5 Marking out, cutting and drilling

7.3 Handling cladding on site
Marking out
On large building projects you can reduce handling time by

lifting bundles with a crane direct from the delivery truck
ONTOTHEROOFFRAME5SEASPREADERBARFORLONGSHEETS&OR
small to medium size projects, without mechanical handling
facilities, you can unload sheets by hand and pass them up
to the roof one at a time.
!PENCILOFANYCOLOURMAYBEUSEDEXCEPTBLACKOR
SO CALLEDLEADPENCILS$ONTUSEBLACKPENCILSTOMARK
roofing or walling because the graphite content can create
an electric cell when wet and thus cause deterioration of
THEFINISH9OUCANALSOUSEASTRINGLINEWITHCHALKDUSTORA
fine, felt-tipped marker.
(ANDLING3AFETY ,93!'(4 product may be sharp and heavy.

)TISRECOMMENDEDTHATHEAVY DUTYCUT RESISTANTGLOVESAND
appropriate manual handling techniques or a lifting plan be
used when handling material.
Cutting
(ANDLEMATERIALSCAREFULLYTOAVOIDDAMAGEDONTDRAG
materials over rough surfaces or each other; carry tools,
DONTDRAGTHEMPROTECTFROMSWARF
Where possible, you should minimise site-work by using

sheets cut to length in the factory.
For cutting thin metal on site, we recommend that you use a
power saw with a metal-cutting blade because it produces
fewer damaging hot metal particles and leaves less resultant
burr than does a carborundum disc.
!LTERNATIVECUTTINGTOOLSELECTRICSHEARSANDNIBBLERS ARE
also suitable however extra care with the straightness of the
cut may be required.
2012-13 Edition
7 Care & handling
28
CARE AND HANDLING
Cut materials over the ground and not over other materials
where hot particles can fall and cause damage to finishes
especially COLORBOND prepainted finishes. It is best to
have the exterior colour finish of a COLORBOND prepainted
sheet facing down, however you must then protect the paint
finish from scratching by your work supports.
If you have to cut materials near sheets already installed,
mask them or direct the stream of hot particles away.
Reciprocating nibblers are also widely used in the roofing
trade, and they produce an excellent cut.
The resulting small, sharp scraps can rust and damage
finishes; and they can cause personal injury. Take special
care to collect these scraps.
Making holes
Holes are often made by drilling or cutting by hole saw or
jig saw. Mask the area around the hole to protect paint from
damage by swarf.
7.6 Clean up
Swarf (metal scraps and/or abrasive particles resulting
from cutting and drilling) left on the surfaces of materials
will cause rust stains which can lead to reduced life of the
material.
7.7 Warn other contractors

Many stains arising from swarf do so, not from the work
of roofing-installers, but from other contractors working
on the job. Similarly, problems can arise from contact with
incompatible materials, like copper piping or chemically
treated timber. Acid cleaning of bricks can also be a
problem. Remember to warn them to walk on pans, not on
the ribs. Architects and builders need to be aware of all
this, and warn contractors accordingly.
7.8 Strippable coatings

To provide temporary protection during production, handling
and transport, some COLORBOND steel products are
coated with a plastic. This coating peels off easily when
new, but it has a relatively short life, especially in sunlight.
If you dont remove this coating at the time of installation,
you may find it very hard to remove later on.
Please dispose of the plastic in an environmentally
responsible manner.
s 3WEEPORHOSEALLMETALLICSWARFANDOTHERDEBRISFROM
roof areas and gutters at the end of each day and at the
completion of the installation. Failure to do so can lead
to blockages of water flow or surface staining (such as
when the metal particles rust).
s )FSWARFHASBECOMESTUCKONAFINISHITCANBEREMOVED
Take great care not to remove the paint or the metal
coatings.
s &ORCRITICALAPPLICATIONSINSPECTTHEJOBTWOWEEKSAFTER
completion, when rain or condensation will have caused
any remaining swarf to rust, and thus highlight affected
areas.
2012-13 Edition
7.9 Sealants
Recommended sealants
Neutral-cure silicone sealants have been successfully used
with the range of steel finishes on our roofing and walling;
and on flashings, cappings, and gutters made from the same
materials as the cladding.
.EUTRAL CURESILICONESEALANTS
s HAVEGOODADHESIONTOTHECLEANSURFACEOFALLOUR
roofing and walling;
s AREWATERRESISTANTANDNON CORROSIVE
s ARERESISTANTTOEXTREMESOFHEATANDCOLDWHILERETAINING
good flexibility;
s EXCELLENTGAPFILLERS
s PROVIDEHIGHRESISTANCETOULTRA VIOLETRAYSSUNLIGHT AND
s HAVEALONGSERVICELIFE
s 4HEYARE./4ADHESIVES
)TISIMPORTANTTHATONLYNEUTRAL CURESILICONEBEUSEDWITH
sheet steel. Other silicone sealants, often have a vinegar or
ammonia smell, and give off aggressive by-products during
curing which are detrimental to sheet steel.
)FINDOUBTLOOKFORAMESSAGEONTHESEALANTPACKAGELIKE
Suitable for use with galvanised and :).#!,5-% steel
products.
Cleaning surfaces
For effective bonding, all surfaces must be clean, dry and
free from contaminants such as old sealant or oil.
Mineral turpentine is suitable for cleaning the surfaces but
care must be taken to completely remove all residual solvent
with a clean dry cloth. White spirits is an alternative.
seal. To ensure complete sealant cure, the width of sealant

in a lap should not exceed 25mm when compressed (Figure
7.8.1).
Applying sealant
!LWAYSAPPLYTHEBEADOFSEALANTINACONTINUOUSLINEALONG
the centreline of the fastener holes. This ensures that, when
compressed, the sealant positively seals the fastener.
Be careful not to entrap air when applying sealant.
%SPECIALLYDONTPLACEARINGOFSEALANTAROUNDFASTENER
holes because entrapped air compresses during tightening
of fasteners, and may blow a channel through the sealant,
which could prevent the fastener from being sealed.
Fasteners
5SESOLIDORSEALEDFASTENERSEGSCREWSANDBLINDPOP
rivets), otherwise you have to apply sealant to the hollow
centre of open pop rivets.
To preserve the life of your cladding, is very important that
fastener materials are compatible with the cladding
3ECTION
Procedure
4HEPREFERREDPROCEDUREFORLAPFABRICATIONIS
!SSEMBLECLAMPANDDRILL
2. Separate components and remove drilling debris;
3. Clean joint surfaces as recommended above;
!PPLYBEADS OFSEALANT
5. Relocate components and fix;
%XTERNALLYSEALEACHFASTENERIFHOLLOWBLINDRIVETSARE
used.
To prevent premature curing (which causes poor bonding),
finish the joint as soon as practical after applying the beads
Sealant must be applied on the same day as the surface is

cleaned.
Joint strength
*OINTSSEALEDWITHSEALANTSHOULDBEMECHANICALLYFIXEDFOR
strength. Spacing of the fixing will depend upon the type of
joint to be sealed. Fasteners in joints of simple seams (flat
sheet steel joints) should generally be no further apart than
50mm. Fasteners in joints with profiled roofing (e.g. side
lap joints) can be spaced further apart. The spacing of the
fasteners shall be based on good and accepted industry
practices to ensure suitable bonding of the sealant to the
mating surfaces.
The sealant does not require significant adhesive strength
in itself, but it must bond positively to all the surfaces it is to
29
Figure 7.8.1
Typical joints with sealant
25mm nominal.
Sealant
Figure 7.8.1.1
Typical crest with sealant
2012-13 Edition
7 Care & handling
CARE AND HANDLING
30
CARE AND HANDLING
OFSEALANT4HEMANUFACTURERSSPECIFIEDSEALANTOPENTIMES
should be followed.
Sealant clean up
With practice you will be able to judge the size of beads thus
avoiding squeeze-out and the subsequent need to clean up.
5NCUREDSEALANTCANBEREMOVEDWITHACLEANDRYRAGAND
any excess then removed with a cloth lightly dampened with
MINERALTURPENTINEORWHITESPIRITS%XCESSCUREDSEALANTIS
best removed with a plastic spatula to avoid damage to the
surface finish of the metal.
!VOIDANYUNNECESSARYSMEARINGOFSEALANTONSURFACES
intended for painting as silicone can affect adhesion of
paint. Smeared sealant may be treated by lightly abrading
the area with a non-metallic scouring medium.
7.10 Maintenance
Factors that most affect the long life of a roof (or wall) are
original design, the environment of the installation, and the
maintenance of the installation. Maintenance is probably the
biggest factor.
-AINTENANCEINCLUDES
s 2EGULARINSPECTIONFORPROBLEMSBEFORETHEYBECOME
major corrosion sites;
s 2EGULARWASHINGDOWNESPECIALLYNEARCOASTALOR
industrial influences;
s 2EMOVALOFLEAVESANDOTHERDEBRISFROMGUTTERS
downpipes, leaf-guards, slots, holes and other overflow
devices;
Maintenance of COLORBOND pre-painted steel

The paint system on #/,/2"/.$ steel sheet is very
durable. Simple maintenance of the finish enhances its life
and maintains attractiveness for longer periods.
Where the paint finish is naturally washed by rainwater
(roofs, for example) there is usually no additional
MAINTENANCENEEDED(OWEVERAREASTOBEWASHEDINCLUDE
soffits, wall cladding under eaves, garage doors, and the
underside of eave gutters.
Washing should be done at least every six months and more
frequently in coastal areas where sea spray is prevalent,
and in areas where high levels of industrial fallout occur.
!VOIDACCUMULATIONOFSALTYDEPOSITSORINDUSTRIALDIRT
%STABLISHAREGULARROUTINEFORWASHING#/,/2"/.$
prepainted steel products. Often garage doors can be
washed with clean water at the same time as your car is
BEINGWASHED'UTTERINGANDEAVESCANBEHOSEDDOWN
when windows are being cleaned. Walls can be hosed down
(if water restrictions permit) while watering the garden.
7HEREREGULARMAINTENANCEDOESNTREMOVEALLTHEDIRT
wash the surface with a mild solution of pure soap or nonABRASIVENON IONICKITCHENDETERGENTINWARMWATER5SEA
sponge, soft cloth or soft bristle nylon brush; be gentle to
prevent shiny spots. Thoroughly rinse off the detergent with
clean water.
Never use abrasive or solvent cleaners (like turps, petrol,
kerosene and paint thinners) on#/,/2"/.$ steel
surfaces. For advice on grease, oil or deposits not removed
BYSOAPORDETERGENTCONTACTOUR)NFORMATION3ERVICE
s +EEPWALLSFREEOFSOILCONCRETEANDDEBRISNEAR
the ground;
s $ONTOVERSPRAYPESTICIDE
2012-13 Edition
INSTALLATIONPIERCE-FIXING
31
8
Installing pierce-fixed
cladding
9OUCANPLACESCREWSTHROUGHTHECRESTSORINTHEPANSVALLEYS
however, to maximise watertightness, always place roof screws
through the crests. For walling, you may fix through either the crest
or valley/pan (Figure 8.1).
8 Pierce-fixing
Pierce-fixing is the method of fixing sheets using fasteners which

pass through the sheet. This is different from the alternative method
CALLEDCONCEALED FIXING#HAPTER 4HEMETHODOFFIXINGYOUUSEIS
determined by the cladding profile you are using.
Figure 8.1
#RESTANDVALLEYFIXING#534/-/2"
!LWAYSDRIVETHESCREWSPERPENDICULARTOTHECLADDINGANDINTHE
centre of the corrugation or rib.
The following procedures are described for roofs, but the same
general principles apply to walls.
8.1 General installation procedure

Check flatness, slope and overhang
"EFORESTARTINGWORKENSURETHAT
s THESUPPORTSFORYOURCLADDINGARETRULYINTHESAMEPLANE
s THEMINIMUMROOFSLOPESCONFORMTO3ECTION
(Low-roof-pitches); and
s THEOVERHANGSOFSHEETSFROMTHETOPANDBOTTOMSUPPORTS
DONTEXCEEDTHOSEIN4ABLEAND4ABLEWHILST
also overhanging a minimum of 50mm into gutters.
Make any necessary adjustments before you start laying sheets,
because they will be difficult or impossible to rectify later.
Orient sheets before lifting

For maximum weathertightness, start laying sheets from the end
of the building that will be in the lee of the worst-anticipated or
prevailing weather (Figure 8.1.1).
Figure 8.1.1
Lay sheets towards prevailing weather
)TISMUCHEASIERANDSAFERTOTURNSHEETSONTHEGROUNDTHANUPON
the roof. Before lifting sheets on to the roof, check that they are the
correct way up and the overlapping side is towards the edge of the
roof from which installation will start.
Place bundles of sheets over or near firm supports, not at mid span
of roof members.
2012-13 Edition
32
Position first sheet

With particular care, position the first sheet before fixing to ensure
that it is correctly located in relation to other parts of the building.
#HECKTHATTHESHEET
s ISALIGNEDWITHTHEEND WALLORITSBARGEORFASCIA
bearing in mind the type of flashing or capping
treatment to be used; and
s ALIGNSCORRECTLYATITSENDSINRELATIONTOTHEGUTTER
and ridge (or parapet or transverse wall). Roof sheets
should overhang a minimum of 50mm into gutters.
Fix the sheet as described later in this chapter.
Position other sheets

!FTERFIXINGTHEFIRSTSHEETINPOSITIONALIGNTHEFOLLOWINGSHEETS
USING
s THELONGEDGEOFTHEPREVIOUSSHEETAND
s AMEASUREMENTFROMTHEENDOFTHESHEETTOTHEFASCIAOR
PURLINATTHEGUTTER)TISIMPORTANTTHATYOUKEEPTHEGUTTER
end of all sheets in a straight line.
&IXTHESHEETBYEITHER
s FIXINGEACHSHEETCOMPLETELYBEFORELAYINGTHENEXTOR
s FIXTHESHEETSUFFICIENTLYTOENSUREITCANTMOVECOMPLETE
laying all sheets, then return to place all the intermediate
fasteners later.
Check alignment occasionally

Occasionally check that the sheets are still parallel with the first
sheet, by taking two measurements across the width of the fixed
cladding (Figure 8.1.2).
Figure 8.1.2
!TABOUTHALFWAYTHROUGHTHEJOBPERFORMASIMILARCHECKBUTTAKE
the measurements from the finishing line to aim for the final sheet
TOBEPARALLELWITHTHEENDOFTHEROOF)FTHEMEASUREMENTSARENOT
close enough, lay subsequent sheets very slightly out of parallel to
GRADUALLYCORRECTTHEERRORBY
s PROPERLYALIGNANDFIXALAPTHEN
s FIXTHEOTHEREDGEOFTHESHEETPLACINGTHEFASTENERSSLIGHTLY
closer or further from where they would normally be if there
WASNOERROR'RADUALLYCORRECTTHEERRORBYPLACINGTHE
fasteners in such a way as to slowly bring the sheets back
into correct alignment.)
2012-13 Edition
33
8.2 Side-lapping & positioning pierce-fixed sheets

To prevent moisture being drawn into laps by capillary action, the
edges of sheets are slightly modified. #534/-/2" and #534/-
",5%/2" have the edges of the sheet over-curved, other products
like 30!.$%+42)-$%+).4%'2)49 820 and30!.2)" all have
FLUTESFORMEDINTOTHEUNDERLAPPINGRIB)TISIMPORTANTTHATSHEETS
be lapped correctly. This means there should only be one overlap/
underlap - double lapping is not recommended. (Figure 8.2.1)
8 Pierce-fixing
!FTERFIXINGTHEFIRSTSHEETPLACETHENEXTANDSUBSEQUENT SHEET

with its side lap snugly over the previous sheet (Figure 8.2.1).
Secure the sheet firmly in place until each end of the sheet has
been fixed.
9OUCANDOTHISEASILYBY
s ALIGNTHEBOTTOMEDGEACCURATELYBYAMEASUREMENTFROM
the end of the sheet to the fascia or purlin at the gutter;
s CLAMPTHELAPWITHAPAIROFVICEGRIPS&IGURE
s ATTHETOPOFTHESHEETNESTLETHESIDELAPSNUGLYCHECK
alignment, and fix the sheet with a fastener.
Figure 8.2.1
Crest fixing
8.3 Pierce-fixing on crests
Figure 8.2.2
#RESTFIXINGISRECOMMENDEDFORROOFSMADEFROM
Clamp one end of the sheet whilst fixing the other

end.
s
s
s
s
s
s
#534/-/2"
#534/-",5%/2"
30!.$%+
42)-$%+
).4%'2)49820
30!.2)"
Crest fixing may also be used for these products when they are
used as walling.
2012-13 Edition
34
8.4 Pierce-fixing on valleys (for walling only)

Wall fasteners may be placed on the crests, but they are usually
PLACEDINTHEVALLEYOFWALLCLADDINGBECAUSE
s THEYARELESSCONSPICUOUSANDDONTBREAKTHEAESTHETIC
lines of the steel cladding;
s THEREISNORISKOFTHEPROFILEBEINGDEFORMEDBECAUSETHE
fastener is placed through the cladding where it rests flat
against its support (Figure 8.4.1); and
Figure 8.4.1
Typical valley fixing (for walls only)
s WATERPENETRATIONISNOTAPROBLEM
(OWEVERWHENVALLEY FIXEDTHECLADDINGNEEDSASIDE LAPFASTENER
INALLLAPSATEACHSUPPORT9OUWILLFINDITMOREECONOMICALIN
labour, time and cost of fasteners to use a crest fastener at each
side lap in place of the lap fastener and adjacent valley fastener
(Figure 8.4.2).
8.5 Pierce-fixing on side-laps

Where roofing is installed according to the support spacings shown
in Tables 2.12.1 and/or 2.13.1, side-lap fasteners are generally not
required.
Figure 8.4.2
!LTERNATIVEVALLEYPANFIXINGWITHCRESTFIXINGATSIDE
laps (for walls only)
9OUMAYNEEDTOUSESIDE LAPFASTENERSWHERETHECLADDINGIS
laid a little out of alignment, where the weather resistance of a
joint is questionable, at the end of overhangs, where insulation
RESULTSINTHELAPOPENINGORFORANYNUMBEROFREASONS$ECIDEON
the number of side-lap fasteners by what looks effective in each
individual case.
The side-laps of shallow roof profiles on curved roofs (convex and
concave) would be considered to have reduced weather resistance,
and especially over the crest of the roof due to inadequate drainage
FROMINSUFFICIENTSLOPE)TISCOMMONINDUSTRYPRACTICETOPROVIDE
side-lap fastening over the curved roof and in particular over the
crest region where sealant is used.
4YPICALPRACTICEISTOSPACETHESIDE LAPFASTENERSATMM
maximum.
For cyclonic regions where resistance against flying debris is
required the maximum recommended spacing of side-lap fasteners
is 600mm.
Where valley fasteners are used (walling), you need side-lap
FASTENERSALONGEACHLAPATEACHSUPPORT!LTERNATIVELYACREST
fastener may be used at each side-lap, in place of the side-lap
fastener and adjacent valley fastener (as mentioned above in
Section 8.4).
Side-lap fasteners are located in the centre of the crest of the
overlapping rib (Figures 8.4.1 and 8.4.2)
2012-13 Edition
INSTALLATIONCONCEALED-FIXING
35
9
Installing concealed-fixed
cladding
Concealed-fixing is the method of fixing sheets using fasteners

WHICHDONOTPASSTHROUGHTHESHEET)NSTEADTHECLADDINGISHELDIN
place with clips. This is different from the alternative method called
pierce-fixing (Chapter 8). The method of fixing you use is determined
by the cladding profile you are using.
#ONCEALED FIXINGISUSEDFOR
+,)0 ,/+() 342%.'4(
+,)0 ,/+#,!33)#
+,)0 ,/+
%!39#,!$
,/.',).%
9 Concealed-fixing
s
s
s
s
s
Very steep pitches

To prevent concealed-fixed cladding from sliding downward in the
fixing clips, on very steep pitches, you should pierce-fix through
each sheet under the flashing or capping, along the top of the
sheets, but not less than 25mm from the ends of a sheet.
Direction of laying
9.1 Installing KLIP-LOK roofs
KLIP-LOK CLASSIC clip

(For KLIP-LOK CLASSIC 700)
5SETHESAMEGENERALPROCEDUREDESCRIBEDIN3ECTION'ENERAL
INSTALLATIONPROCEDURE (OWEVERATTHESTARTOFINSTALLING+,)0
,/++,)0 ,/+#,!33)#+, #,!33)# or +,)0 ,/+
() 342%.'4(+, (3 a row of clips is fixed to the supports
before the first sheet is located over them and locked in position.
Clips
+,)0 ,/+(3 use KL-700HS clips.
+,)0 ,/+#,!33)# use KL-#,!33)# clips.
For+,)0 ,/+ use KL-65 clips.
The orientation of the clips is important because they are not
SYMMETRICAL&IGURE
The fixing holes are pre-punched. On KL65 clips you can use the
dimples to locate other fasteners where a fastener breaks or a
timber support splits.
!STHEREAREDIFFERENCESININSTALLATIONPROCEDURESEACHTYPEOF
+,)0 ,/+ will be presented separately.
Figure 9.1.1
+,)0 ,/+CLIPS
2012-13 Edition
36
1. KLIP-LOK 700 HI-STRENGTH Preparation

!SDESCRIBEDIN'ENERALINSTALLATIONPROCEDURE3ECTION
s CHECKFLATNESSSLOPEANDOVERHANG
s ORIENTTHESHEETSBEFORELIFTING.OTETHEOVERLAPPING
rib is towards the end of the building where you start
&IGURE
s #HECKTHATTHEOVERHANGOFTHESHEETSFROMTHECLIPS
at both eaves and ridge, is not less than the minimum
in Table 2.12.1.
Sheet 3
Sheet 2
Prevailing weather
Sheet 1
Direction of laying
Figure 9.1.1
s 4HEFIRSTANDTHELASTSUPPORTSANDCLIPSSHOULDBEAT
least 75mm from each end of the sheet to keep
maximum holding power.

Consider which end of the building is best to start from. For
maximum weather-tightness, start laying sheets from the end
of the building that will be downwind of the worst-anticipated
ORPREVAILINGWEATHER&IGURE
)TISMUCHEASIERANDSAFERTOTURNSHEETSONTHEGROUNDTHAN
up on the roof. Before lifting sheets on to the roof, check
that they are the correct way up and the overlapping side is
towards the edge of the roof from which installation will start.
Place bundles of sheets over or near rm supports, not at mid
span of roof members.
Starting method 1. Cut the 1st clip 25mm from the centre of
the second tower (as shown). The first tower on the cut clip
LOCATESINTHESTRIBOFTHEFIRSTSHEET&IGURE
Figure 9.1.2
Alternative methods for rst clips
Starting method 2. The first tower on the first clip locates in

THEFIRSTRIBOFTHEFIRSTSHEET&IGURE 4HECLIPFIXESTHE
edge of the first sheet, but you must fix two clips at the start.
Steps for installation

1 Lay and x wire mesh to the supports and glass wool
insulation in accordance with the appropriate building
requirements.
2 Position the rst clips on each support by placing onto the
SUPPORTNEARESTTHEROOFEDGE&IGURE
3 Fix the rst clip on the support so they point in the
DIRECTIONOFLAYING%NSURETHECLIPISDEGREESTOTHE
edge of the sheet.
!
LIGNTHECLIPSUSINGASTRINGLINEORTHElRSTSHEETASA
straight edge) to align the clips as you x a clip to each
support working towards the high end of the roof.
$
RIVEHEX HEADSCREWSTHROUGHTHETOPOFTHECLIPINTOTHE
support.
Figure 9.1.3
Fix the rst row of clips. Fix the next (and subsequent)
clips and sheets
6 Work along the edge of the roof ensuring it aligns
correctly at its ends in relation to the gutter and ridge (or
parapet or transverse wall).
7 Position the rst sheet so that it overhangs the desired
AMOUNTUSUALLYMM TOTHEGUTTER)TISIMPORTANTTO
ensure this rst sheet is placed square to adjacent
EDGES&IGURE
2012-13 Edition
% NGAGETHESHEETWITHCLIPSUSINGVERTICALFOOTPRESSURE
ONALLTHERIBSOVEREACHCLIP&IGURE
& IXTHENEXTROWOFCLIPSONETOEACHSUPPORTWITHTHE
SLOTSANDTABSENGAGED"ESURETHECLIPISDEGREESTO
the edge of the sheet.
37
Overlapping
rib
!
SBEFOREPLACETHENEXTSHEETOVERITSCLIPSENSURINGYOU
also engage the edge of the preceding sheet.
Underlapping rib
!
CCURATELYPOSITIONTHESHEETSOTHATITOVERHANGSTHE
DESIREDAMOUNTINTOTHEGUTTER)TISIMPORTANTTHATYOU
keep the gutter-end of all sheets in a straight line.
& ULLYENGAGETHETWOSHEETSALONGTHEOVERLAPPINGRIB9OU
can do this by walking along the full length of the sheet
with one foot in the centre pan of the previous sheet and
the other foot applying vertical pressure to the top of the
INTERLOCKINGRIBSATREGULARINTERVALS)TISIMPORTANTTHAT
YOUDONTWALKINTHEUNSUPPORTEDPANBESIDETHEOVERLAP
&IGURE
Figure 9.1.4
Placing the rst sheet
9 Concealed-fixing
13 Similarly, engage all the clips by applying vertical foot

pressure to the top of the other two ribs over each clip.
)TISESSENTIALTHATTHESHEETSINTERLOCKCOMPLETELY)TIS
important that your weight is fully on the sheet you are
installing.

Occasionally check that the sheets are still parallel with the
rst sheet, by taking two measurements across the width of
the xed sheeting.
!TABOUTHALFWAYTHROUGHTHEJOBPERFORMASIMILARCHECK
but take the measurements from the nishing line to aim for
THElNALSHEETTOBEPARALLELWITHTHEENDOFTHEROOF)FTHE
measurements are not close enough, lay subsequent sheets
very slightly out of parallel to gradually correct the error.
&IGURE 4OALLOWTHISTOHAPPENmATTENTHETABSONTHE
base of subsequent clipsthe slot in the clip will allow the
clips to be xed out of standard pitch.
Fix the last sheet

)FTHElNALSPACEISLESSTHANTHEFULLWIDTHOFASHEETYOU
can cut a sheet along its length and shorten the clips as
APPROPRIATE)TISDESIRABLETOlXTHESHEETATONEEND
Don't step in this pan

until ribs are engaged
Figure 9.1.5
Engaging the lapping ribs
Installing translucent sheets with

cladding should be xed using oversized holes and sealing
washers recommended by the cladding manufacturer. When
used with concealed xed claddings, ensure the fasteners
do not penetrate the steel cladding. There are translucent
products available that easily accommodate this.
.OTE$ONTEXCEEDTHEMAXIMUMSUPPORTSPACINGSPECIlEDBYTHE
TRANSLUCENTCLADDINGMANUFACTURER5SEOFTRANSLUSCENTSHEETING
may result in lower limit state capacities.
Purlin
Fixed sheets
Later checks =
Early checks =
Later checks =
Start
Finish
Early checks =
Figure 9.1.6
2012-13 Edition
38
2. KLIP-LOK CLASSIC 700 Preparation
Sheet 3
Sheet 2
"EFORESTARTINGWORKENSURETHAT
Sheet 1
s 4 HESUPPORTSFORYOURCLADDINGARETRULYINTHESAMEPLANE
this is critical if the roof slope is ) 5
Prevailing weather
s 4 HEMINIMUMROOFSLOPESCONFORMTOOURRECOMMENDATIONS
and
Figure 9.1.7
s 4 HEOVERHANGSOFSHEETSFROMTHETOPANDBOTTOMSUPPORTS
DONTEXCEEDOURRECOMMENDATIONS
KLIP-LOK CLASSIC: Starting method

Standard flashing
First sheet
s 4 HElRSTANDLASTSUPPORTSANDCLIPSSHOULDBEATLEASTMM
from each end of the sheet to keep maximum holding power.
Make any necessary adjustments before you start laying
sheets, because they will be difcult to rectify later.
Direction of laying
Second clip
Wire mesh
First clip
Figure 9.1.8
Alternative methods for rst clips

Consider which end of the building is best to start from. For
maximum weather-tightness, start laying sheets from the end of
the building that will be downwind of the worst-anticipated or
PREVAILINGWEATHER&IGURE
)TISMUCHEASIERANDSAFERTOTURNSHEETSONTHEGROUNDTHANUP
on the roof. Before lifting sheets on to the roof, check that they
are the correct way up and the overlapping side is towards the
edge of the roof from which installation will start.
Stringline
Place bundles of sheets over or near rm supports, not at mid

Steps for installation
Purlins
Clips
Use a string-line to align

first row of clips. It is critical to
ensure first row is aligned correctly.
1 Lay and x wire mesh to the supports in accordance with

the appropriate building requirements.
2 Place the glass wool insulation.
3 Position the rst clips on each support by placing onto the
SUPPORTNEARESTTHEROOFEDGE&IGURE
4 Fix the rst clip on the support so they point in the direction
OFLAYING%NSURETHECLIPISDEGREESTOTHEEDGEOFTHE
sheet.
!
LIGNTHECLIPSUSINGASTRINGLINE&IGURE ORTHElRST
sheet as a straight edge to align the clips as you x a clip to
each support working towards the high end of the roof.
Figure 9.1.9
Use a stringline to ensure rst row of clips is aligned. Fix
rst row of clips.
Underlapping
rib
$
RIVEHEX HEADSCREWSTHROUGHTHETOPOFTHECLIPINTOTHE
support.
7 Work along the edge of the roof, ensuring it aligns correctly
at its ends in relation to the gutter and ridge or parapet or
TRANSVERSEWALL&IGURE
8 Position the rst sheet so that it overhangs the desired
AMOUNTMINIMUMMM TOTHEGUTTER)TISIMPORTANTTO
ensure this rst sheet is placed square to adjacent edges.
&IGURE
Overlapping
rib
Gutter edge
KLIP-LOK CLASSIC
Figure 9.1.10
Placing the rst sheet
2012-13 Edition
39
%NGAGE THE SHEET WITH CLIPS USING VERTICAL FOOT PRESSURE ON

ALL THE RIBS OVER EACH CLIP &IGURE
10 Fix each next row of clips one to each support by
engaging the front of the clip assembly onto the underlap
rib of the preceeding sheet engaging the spur of the clip
TO THE LEADING EDGE OF THE PREVIOUS SHEET &IGURES
"E SURE THE CLIP IS AT TO THE EDGE OF THE SHEET
11 Repeat engaging the sheet with clips using vertical foot
pressure on all the ribs over each clip.
13 Similarly, engage all the clips by applying vertical foot

pressure to the top of the other two ribs over each clip.
KLIP-LOK CLASSIC
Second and subsequent clips
are installed with the male clip
overlapping the underlap rib of the
previous sheet.
Figure 9.1.11
Fix the next (and subsequent) clips and sheets
Next clip assembly

Previous clip assembly
)T IS ESSENTIAL THAT THE SHEETS INTERLOCK COMPLETELY )T IS

important that your weight is fully on the sheet you are
installing.
Spur
Purlin
Occasionally check that the sheets are still parallel with the
rst sheet, by taking two measurements across the width of
the xed sheeting.
9 Concealed-fixing
&ULLY ENGAGE THE TWO SHEETS ALONG THE OVERLAPPING RIB 9OU
can do this by walking along the full length of the sheet
with one foot in the centre pan of the previous sheet and
the other foot applying vertical pressure to the top of the
INTERLOCKING RIBS AT REGULAR INTERVALS )T IS RECOMMENDED
THAT YOU DONT WALK IN THE UNSUPPORTED PAN BESIDE THE
UNDERLAPPING RIB &IGURE
Sheet
Figure 9.1.12
Engaging the next clip to the rst sheet
!T ABOUT HALF WAY THROUGH THE JOB PERFORM A SIMILAR CHECK

but take the measurements from the nishing line to aim for
THE lNAL SHEET TO BE PARALLEL WITH THE END OF THE ROOF )F THE
measurements are not close enough, lay subsequent sheets
very slightly out of parallel to gradually correct the error.
&IGURE
Fix the last sheet
Overlapping rib
Installing translucent sheets with KLIP-LOK CLASSIC 700
Underlapping rib
Figure 9.1.13
Fixed sheets
Purlin
Early checks =
Later checks =
Early checks =
Later checks =
Start

cladding should be xed and sealed using screws and
washers recommended by the cladding manufacturer. When
used with concealed xed claddings, ensure the fasteners
do not penetrate the steel cladding. There are translucent
products available that easily accommodate this.
Finish
)F THE lNAL SPACE IS LESS THAN THE FULL WIDTH OF A SHEET YOU
can cut a sheet along its length and shorten the clips as
APPROPRIATE )T IS DESIRABLE TO lX THE SHEET AT ONE END
Figure 9.1.14
2012-13 Edition
40
3. KLIP-LOK 406 Preparation

Before starting work ensure that:
s #
HECKTHATTHETOPFACESOFALLPURLINSORBATTENSARELYING
in one plane, this is critical for shallow slope roofs.
s 4 HEMINIMUMROOFSLOPESCONFORMTOOUR
RECOMMENDATIONSAND
Figure 9.1.15
s 4 HEOVERHANGSOFSHEETSFROMTHETOPANDBOTTOM
SUPPORTSDONTEXCEEDOURRECOMMENDATIONS
s 4 HElRSTANDLASTSUPPORTSANDCLIPSSHOULDBEATLEAST
MMFROMEACHENDOFTHESHEETTOKEEPMAXIMUM
holding power.
s-AKESPOTCHECKSFORTHEALIGNMENTOFSHEETSDURING
LAYINGTOCONTROLFANNINGORCREEPSHEETSMM
COVERAGE 4ORECTIFYALIGNMENTSHEETSMAYBEADJUSTED
MMBYPULLINGTHECLIPAWAYORPUSHINGTOWARDSTHE
sheet while fastening the clip.
Figure 9.1.16
3TARTINGMETHODFOR+,
s&ORVERYSTEEPROOFORVERTICALWALLAPPLICATIONSAPOSITIVE
fastener (screw or bolt) is required in each sheet length to
PREVENTMOVEMENTDOWNTHEFASTENINGCLIPS4HISISBEST
positioned under or through the ashing or capping at the
top end.
sKLIP-LOK 406 can be fastened over insulation wool
BLANKETSUPTOMMTHICKWHENTHEBLANKETISDRAPED
over supports before installation of clips.
Figure 9.1.17
Orient the sheets correctly before installation on clips.
s3HEETSSHOULDPROJECTAMINIMUMMMINTOTHEGUTTER
line.
!CCURATEALIGNMENTENSURESEFlCIENTLOCKINGOFSHEETS
ANDCLIPS#ONVERSELYMISALIGNMENTCANINTERFEREWITHTHE
LOCKINGACTIONPARTICULARLYONCLOSESUPPORTCENTRES-AKE
ANYNECESSARYADJUSTMENTSBEFOREYOUSTARTLAYINGSHEETS
BECAUSETHEYWILLBEDIFlCULTTORECTIFYLATER
Steps for Installation

Step 1
7HENLIFTINGSHEETLENGTHSONTOTHEROOFFRAMEREADYFOR
INSTALLATIONMAKESUREALLSHEETSHAVETHEOVERLAPPINGRIBS
FACINGTOWARDSTHESIDEWHEREFASTENINGISTOCOMMENCE
&IGURE
Figure 9.1.18
Position the first sheet of the run of clips
POSITIONINGTHECENTRERIBlRSTANDENGAGETHECENTREAND
OVERLAPPINGRIBSONTOALLCLIPSBYFOOTPRESSURE&IG
4HElRSTRUNOFCLIPSMUSTBELOCATEDANDFASTENEDONE
to each support, so that they will correctly engage in the
OVERLAPPINGANDCENTRERIBSOFTHElRSTSHEETWHENITIS
LOCATEDANDLOCKEDOVERTHEM4ODOTHISFASTENCLIPSTOTHE
PURLINSATEACHENDOFTHESHEETHAVINGPOSITIONEDTHEMSO
THATTHElRSTSHEETWILLBEINCORRECTRELATIONTOOTHERBUILDING
ELEMENTS!LIGNANDFASTENTHEREMAINDEROFTHElRSTRUNOF
CLIPSUSINGASTRINGLINEORTHElRSTSHEETASASTRAIGHTEDGE
Step 2
0OSITIONTHElRSTSHEETLONGITUDINALLYINRELATIONTOGUTTER
overhang and locate it over the fastened run of clips,
Figure 9.1.19
Position the next row of clips over the underlapping
rib of the first sheet and fix clip to supports.
2012-13 Edition
41
Step 3
)Nstall subsequent sheets by following Steps 3 and 4 and
Position and fasten the next run of clips, one to each support,
with the short return leg of the clip over the underlapping rib
OFTHEINSTALLEDSHEET&IGURE
make periodic checks that the installed sheets are aligned

with the roof perimeter.
)FTHECLIPFOULSONEOFTHESPURSSPACEDALONGTHEOUTERFREE
edge of the underlapping rib, the spur can be attened with a
blow from a rubber mallet to allow the clip to seat down over
the rib.
)FTHESPACELEFTBETWEENTHELASTFULLSHEETANDTHEFASCIAOR
parapet is more than a half sheet width, a sheet can be cut
longitudinally, leaving the centre rib complete. This partial
sheet can be fully clipped onto a row of clips as for a full
SHEETBEFOREINSTALLINGTHECAPPINGORmASHING)FTHESPACE
left between the last full sheet and the fascia or parapet is
less than a half sheet width, it can be covered by the capping
ORmASHING)NTHISCASETHELASTSHEETSHOULDBESECUREDBY
cutting sheet in halves and fastening the underlapping rib at
EACHPURLINWITHAHALFSHEET&IGURES
Step 5
3IMILARLYAHALFCLIPMAYALSOBEUSEDIFREQUIRED)NTHIS
case, where a partial sheet of less than two ribs is used, it is
necessary to turn up the lip along the edge of the cut sheet.
Figure 9.1.20
This can then be covered by the capping or ashing.
9 Concealed-fixing
Lay the next row of sheeting over the next row of clips.
Step 4
Place the second sheet over the second run of clips, again
POSITIONINGTHECENTRERIBlRST!STRINGLINESTRETCHEDACROSS
the bottom alignment of the sheets can be used to check that
THEENDSOFTHESHEETSAREINLINE&IGURE
Fully engage the interlocking ribs and the centre rib over
EACHCLIP&IGURE
This can be achieved by walking along the full length of the
sheet being installed with one foot in the tray next to the
overlapping rib and the other foot applying pressure to the
top of the interlocking ribs at regular intervals.
Figure 9.1.22
+,)0 ,/+
Placing last sheet where half a sheet will fit
!LSOAPPLYFOOTPRESSURETOTHETOPOFTHECENTRERIBOVEREACH
clip. For complete interlocking, which is essential, the spurs
of KLIP-LOK 406 along the underlapping rib must be fully
engaged in the shoulder of the overlapping rib.
Figure 9.1.23
+,)0 ,/+
0LACINGLASTSHEETWHEREHALFASHEETWONTFIT
9.2 Installing KLIP-LOK walls

Figure 9.1.21
!DISTINCThCLICKvWILLBEHEARDASTHEINTERLOCKINGRIBSFULLY
engage.
When engaging KLIP-LOK 406 interlocking ribs, stand only on
the sheet being installed, that is the overlapping sheet, and
not on the preceding sheet.
)NWALLINGAPPLICATIONSHORIZONTALPRESSUREWILLNEEDTO
BEAPPLIEDLOCALLYTOTHESHEETSTOENGAGETHERIBS5SE
body pressure (torso, hand or foot) or use a rubber mallet
if required. Care should be exercised due to the potential
instability of of the temporary worker access equipment.
To prevent +,)0 ,/+ from sliding downward in the fixing
clips, you should pierce-fix through each sheet under the
flashing or capping, along the top of the sheets.
2012-13 Edition
42
9.3 Installing Easyclad

9OUCANUSE %!39#,!$FORWALLSSOFFITLININGSORCEILINGS5SEA
similar installation procedure for all.
%!39#,!$ (2 pans per sheet) are pierce-fixed through the
underlapping edge of each sheet. The fasteners in one sheet are
concealed by the leading edge of the next. For the last sheet, a trim
channel is used.
)FYOUAREUSING%!39#,!$ with the ribs horizontal, start installing
from the bottom of the wall so that the joints between panels tend
TOSHEDWATER&IGURE
CD39
9OUCANUSEEITHEROFTWOMETHODSTOFIXTHEFIRSTPANELA#$TRIM
CHANNELOR#$STARTINGCLIPS
Trim channel
Start method 1 Using a trim channel on walls

Trim
channel
Support
Support
With particular care, fix a trim channel at each support.

Be careful to locate it correctly in relation to other parts of the
building (see Section 8.1 Position first sheet).
s 5SETRIMCHANNEL#$WITH%!39#,!$.
Easyclad panel
The first%!39#,!$ panel is held in place by fitting it into the fixed

TRIMCHANNEL&IGURE
Recommended
fastening
Figure 9.3.1
5SINGATRIMCHANNELTOSTART
Start method 2 Using clips on walls

With particular care, fix starting clips at each support. Be careful to
locate them correctly in relation to other parts of the building (see
Section 8.1 Position first sheet).
CD40 Starting clip
(OOKTHELIPOFAN%!39#,!$ SHEETUNDERTHESECLIPS&IGURE
Support
EASYCLAD panel
Figure 9.3.2
5SINGACLIPTOSTART
2012-13 Edition
43
Fixing EASYCLAD panels

Locate the first panel either in its trim channel or under the clips
(depending on the start method you used).
Indentations to
locate screws
Fix the underlapping side of the panel, to each support, through

the flat edge, with the recommended fastener (Chapter 3). The
indentations along the edge help you locate the fasteners (Figure

Figure 9.3.3
Fit subsequent panels by hooking the lip of your next sheet under
the folded-back edge of the previous panel before fixing in the
SAMEWAYASBEFORE&IGURE
9 Concealed-fixing
)NDENTSONEDGEOFSHEETHELPTOLOCATE
screws
Figure 9.3.4
Starting for subsequent sheets
5SUALLYTHELAST%!39#,!$ panel will have to be cut in width to suit

THEBUILDING4HEPANELMAYREQUIREEXPOSEDPIERCE FIXING)FYOU
USEATRIMCHANNELATTHEENDOFTHE%!39#,!$WALLINGPOSITIONIT
ANDPIERCE FIXWITHTHELASTPANEL&IGURE
Support
Panel
fastening
Last panel cut to width
Pierce fixing
in valley
Trim channel
Figure: 9.3.5
5SINGTRIMCHANNELTOFINISH
Support
Weather side
Inside
Figure 9.3.6
Start external walls from the bottom
2012-13 Edition
44
9.4 Installing LONGLINE 305 roofs

For ,/.',).% (standard width, fluted or tapered) use the same
GENERALPROCEDUREDESCRIBEDIN3ECTION'ENERALINSTALLATION
PROCEDURE (OWEVERATTHESTARTOFINSTALLING,/.',).%, a row
of clips is fixed to the supports before the first sheet is located over
them and locked in position.
Preparation
Before starting, check that the supports on which your sheeting
will rest are in the same plane; that the pitch and overhangs
conform to the minimum specifications.
Figure 9.4.1
,/.',).% clips

Consider which end of the building is best to start from. So that
side laps are protected, we recommend that you start laying
sheets from the end of the building that will be in the lee of the
worst anticipated or prevailing weather.
)TISMUCHEASIERANDSAFERTOTURNSHEETSONTHEGROUNDTHANUP
on the roof. Before lifting sheets on to the roof, check that they are
the correct way up and the overlapping side is towards the edge of
the roof from which installation will start.
Place bundles of sheets over or near firm supports, not at mid
Prepare clips
Cut all starting/finishing clips and discard the unwanted pieces.
&IGURE
Fix the first row of clips

With particular care, determine the location of the first sheet and
mark the edge of the sheet on the purlins.
Figure 9.4.2
Placing first sheet
&IXTHEFIRSTSTARTINGCLIPONTHEPURLIN5SINGASTRINGLINEORTHE
first sheet as a straight edge) fix the other starting clips for the first
sheet on each purlin.
Place the first sheet

,OCATETHEFIRSTSHEETOVERTHEFIXEDSTARTINGCLIPS&IGURE
5SINGAMEASUREMENTFROMTHEGUTTER ENDOFTHESHEETTOTHE
fascia or purlin, position the sheet so that it overhangs the
desired amount into the gutter.
When setting the first sheet, remember that it is important you
keep the gutter-end of all sheets at a constant distance from the
edge of the gutter or fascia.
"ENDTHETABOFALLCLIPSOVERTHERIB&IGURE
Fix the next (and subsequent) clips and sheets

5SINGTHERIBCLOSINGTOOLSQUASHTHEMALERIBOFTHEFIRST
(previous) sheet at each purlin where the top fixing clips will fit
&IGURE
Figure 9.4.3
Tab bending for start/finish clips
2. Place top fixing clips over each squashed male rib and fix to the
PURLINS&IGURE 7ITHAFELT TIPPEDPENMAKEASMALLMARK
in the pan to enable you to locate the clips in the later locking
OPERATIONWITHTHEBUTTONPUNCH&IGURE
2012-13 Edition
45
3. Place the next sheet over the edge of the preceding sheet
&IGURE
!CCURATELYPOSITIONTHESHEETSOTHATITOVERHANGSTHE
desired amount into the gutter.
4. Fully engage the sheet with the clips, using foot pressure on
THERIBSOVEREACHCLIP9OUCANDOTHISBYWALKINGALONGTHE
full length of the sheet with one foot in the tray next to the
overlapping rib and the other foot applying pressure to the
top of the interlocking ribs at regular intervals.
Check alignment periodically

Check that sheets are still parallel with the first sheet.
Place the last sheet

!SSESSHOWTHELASTSHEETWILLFITINRELATIONTOTHEFASCIA
Fix a cut starting/finishing clip to the purlins.
Figure 9.4.4
Flatten rib for top fixing clips
9 Concealed-fixing
Place the last sheet over the finishing clips, and bend the tab of
all clips over the rib. (Similar to the steps used in the first sheet.
&IGURES
Lock all ribs

!LLLAPPEDRIBSMUSTBELOCKEDALONGTHEIRLENGTHBYBUTTON
punching at the clips, and if necessary between the clips TYPICALLYATMMCENTRETOCENTRE&IGURE 0UNCHINGTOA
string line guide stretched across the sheeting is recommended
as random punching mars the appearance of the finished work.
9OUMUSTBUTTON PUNCHTHROUGHTHEHOLEINEACHTOPFIXINGCLIP
you locate the clip with the pen mark made previously. When
operating the punching tool, stand on the pan of the overlapping
sheet to ensure that the sheets are fully engaged.
Contact your nearest Service Centre for advice on buttonpunching either side of the clip.
Note:
!SANALTERNATIVETOTHE3TARTING&INISHINGCLIPTHETOPFIXING
clip is often used in this situation. The female rib of the first
sheet will need to be squashed in a similar manner to the
male rib to allow the top fixing clip to be installed. The rib can
be squashed using the rib closing tool.
Figure 9.4.5
Placing subsequent sheets
30 mm
Rib
must touch
Figure 9.4.6
Lock all ribs with button punch
2012-13 Edition
46
INSTALLATIONENDS OF SHEETS
Alternative Start/Finish with SHEERLINE gutter as fascia

The following installation is an alternative approach used on
some commercial and residential roofs where SHEERLINE
gutter is to be fitted as a longitudinal barge fascia.
Starting/finishing clip
(with upstand removed)
Prepare clips
Cut all start/finishing clips and discard the unwanted piece.
&IGURE
Figure 9.4.7
Installation
Consider which end of the building is best to start from.
1 Position the starting/nishing clips on each support by
placing onto the support nearest the gutter fascia.
Gutter return lip
2 The turned down tab under the starting/nishing clip

is used to position the overhang of the clips. On timber
purlins an additional screw or nail is driven through the
HOLEINTHETABINTOTHEPURLINS&IGURE
3 Position the rst sheet by locating the female rib under
the tab on the upstand of the starting/nishing clips after
locating the sheet longitudinally for gutter overhang
etc. Then secure the sheet by folding the pre-bent clip
UPSTANDSDOWNOVERTHEFEMALERIB&IGURE
)FTHETRAYTURN UPATTHEHIGHENDOFTHESHEETINGISTOBE
ush-stop ended, this should be done before positioning
the sheets and allow an extra 50mm on the sheet length.
Figure 9.4.8
Starting/Finishing clip
Blind rivet
used a shown at start of
ROOFWHEN3(%%2,).%GUTTER
required as fascia (use a blind rivets or wafer head screws
TOFASTENTHERETURNLEGOFTHE3(%%2,).%GUTTER
4 Similarly for the starting/nishing clips at the end of the

roof area, and install the last sheet in a similar fashion.
&IGURE
Blind rivet
Figure 9.4.9
Starting/Finishing clip used as shown at nish of
ROOFWHEN3(%%2,).%GUTTERREQUIREDASFASCIA
9.5 Installing LONGLINE 305 walls

)NWALLINGAPPLICATIONSHORIZONTALPRESSUREWILLNEEDTO
BEAPPLIEDLOCALLYTOTHESHEETSTOENGAGETHERIBS5SE
body pressure (torso, hand or foot) or use a rubber mallet
if required. Care should be exercised due to the potential
instability of of the temporary worker access equipment.
4OPREVENT,/.',).%FROMSLIDINGDOWNWARDINTHEFIXING
clips, you should pierce-fix through each sheet under the
flashing or capping, along the top of the sheets.
2012-13 Edition
47
10
Ends of sheets
This chapter describes how you can treat the ends of
sheets to maximise waterproofing, or to stop vermin
entering.
CUSTOM ORB
10.1 Turn-ups
!TTHEHIGHENDOFROOFINGWINDCANDRIVEWATERUPHILL
under the flashing or capping, into a building. To minimise
this problem, you turn up the valleys (or pans) at the high
end of roofing.
(The process is called turning-up or stop-ending).
!LLROOFINGONSLOPESBELOWIN SHOULDBETURNED
up.
Figure 10.1.2
Turn-up tools are available for all our roofing profiles
EXCEPT#534/-/2" and ,/.',).% when it is
tapered (Figure 10.1.1 on the next page).
$URINGTHETURN UPOPERATIONCARESHOULDBEEXERCISEDTO
prevent tearing or puncturing the steel sheets.
9OUCANTURN UPSHEETSBEFOREORAFTERTHEYAREFIXEDON
THEROOF)FYOUDOTHELATTERYOUMUSTHAVESUFFICIENT
clearance for the turn-up tool at the top end of the sheets
(about 50mm).
Turning-up CUSTOM ORB

Figure 10.1.3
Turning-up (42)-$%+ shown)
With pliers, multi-grips or a shifting spanner closed down

to approximately 2mm, grip the valley corrugations 20mm
in from the end of the sheet and turn up as far as possible
(Figure 10.1.2). Be careful not to tear the sheet.
Turning-up TRIMDEK and SPANDEK

Slide the turn-up tool onto the end of the sheet as far as it
WILLGO(OLDINGTHETOOLAGAINSTTHEENDOFTHESHEETPULL
THEHANDLETOTURNUPTHETRAYABOUT&IGURE
Turning-up KLIP-LOK
9OUGETTHEBESTRESULTSBYFIRSTCUTTINGOFFTHECORNEROFTHE
DOWN POINTINGLEGOFEACHFEMALERIB$OTHISBEFOREYOU
place the sheets on the roof.
-ups
ted turn
Comple
Figure 10.1.4
+,)0 ,/+ tool ready for turn-up
s 7ITHTHEHINGEDTURN UPTOOLOPENPOSITIONTHETOOLON
the sheet with the locating pins hard against the end of
the sheet.
s (OLDTHEHANDLESTOGETHERTOCLAMPTHETOOLONTOTHE
TRAYANDPULLTHEMTOTURN UPTHETRAY&IGURE
10.1.4).
2012-13 Edition
9 Concealed-fixing
Turning-up #534/-/2"
48
TRIMDEK
Turn-up &
turn-down
Turn
down
Turn
up
KLIP-LOK 406
LONGLINE 305
Turn-up &
turn-down
SPANDEK
Turn
up
Figure 10.1.1
INTEGRITY 820
or SPANRIB
Turn-up &
turn-down
KLIP-LOK 700 HI-STRENGTH &

Turn-up and turn-down tools
Flush turning-up KLIP-LOK 406

)NNORMALTURNING UPOF+,)0 ,/+, the tops of the ribs protrude
past the turned up tray. Consequently the turn-ups cannot be
positioned hard against a fascia or wall, or the ends of the
sheets on either side of the ridge cannot be butted together. This
is usually of no consequence because the turn-up is completely
COVEREDBYAFLASHINGORCAPPING(OWEVERIFYOUWANTTHERIBS
not to protrude past the turn-up, you can make a flush turn-up.
9OUNEEDANEXTRAMMINSHEETLENGTHFORFLUSHTURN UPS
40
mm
1. Cut the top of each rib before turning-up the pans (Figure
10.1.5). Turn-up the pans as described before.
2. Position the backing tool (if available) in the tray and hold it
hard against the turn-up with a foot.
7ITHARUBBERMALLETFOLDTHEPROTRUDING@EARSFLUSHAGAINST
the backing tool.
'Ear' flattened
Turning-up LONGLINE 305
Flush turn-ups are usually used on ,/.',).%. Cut off a
portion of the female rib for at least 50mm. For a flush turn-up,
you also need to cut the crown of the centre rib for at least
50mm.
'Ear' awaiting
flattening
Figure 10.1.5
5SINGTHEBACKINGTOOLFORFLUSHTURN UPON
+,)0 ,/+'steel shown)
2012-13 Edition
50
50
49
(OLDINGTHEENDOFTHETOOLAGAINSTTHEENDOFTHESHEETPULLTHEHANDLEUP
)FTURNING UPFLUSHFOLDTHEPROTRUDING@EARSFLUSHAGAINSTTHETURN UP
tool with a rubber mallet (Figure 10.1.6).
mm
9OUNEEDANEXTRAMMINSHEETLENGTHFORFLUSHTURN UPS
mm
Part of rib
removed
90
Fold 'ears' against tool

for a flush turn-up
Figure 10.1.6
10.2 Turning-down
Figure 10.2.1
Turning-down the gutter end
(42)-$%+ shown)
When wide tray sheeting is used on roof slopes below 1 in 5 (10) the end
of the trays at the low end of the sheeting should be turned down slightly
WITHATURN DOWNTOOL!TTHELOWENDOFROOFINGWINDORCAPILLARYACTION
can cause water to run back up the underside of the flat trays of the
sheeting. The process is called turning-down (or lipping).
4URN DOWNTOOLSAREAVAILABLEFOR42)-$%++,)0 ,/++,)0 ,/+
() 342%.'4(,/.',).%).4%'2)49AND30!.2)"
$URINGTHETURN DOWNOPERATIONCARESHOULDBEEXERCISEDTOPREVENT
tearing or puncturing the steel sheets.
20
Turning-down is usually done after the sheeting is fixed on the roof,

provided there is no obstruction to the operation of the turn-down tool.
s 0USHTHETURN DOWNTOOLOVERTHEENDOFTHETRAYASFARASITWILLGO
Figure 10.2.2
s (OLDTHETOOLHARDAGAINSTTHEENDOFTHETRAYANDPUSHTHEHANDLETO
FORMATURN DOWNABOUT
Turning-down the gutter end

(,/.',).% shown)
2012-13 Edition
10 Ends of sheets
Turning up ,/.',).%
50
Sheet-ends on low slopes and overlaps

For claddings laid on slopes of 5 degrees or less, the underlap lip of the
under-sheet may require to be cut back on the corner at the downhill end
of the sheet, to block capillary action (Figure 10.2.3).
This may be required where the return lip of the underlapping sheet
nests snugly with the overlapping sheet without a gap, or where there is
interference with the down-turning of the valley.
5mm
minimum
5mm
minimum
Cut back corner
Figure 10.2.3
Cut 30!.$%+ on low slopes.
10.3 Blocking off rib cavities

$USTINSECTSBIRDSRODENTSANDWIND DRIVENRAINCANENTERABUILDING
through the cavities under ribs. To minimise these problems the cavities
can be blocked off. The blocking off could be achieved by the use of infill
STRIPSORWHEREAVAILABLEBYRIBSTOP ENDS)NSOMEREGIONSTHERIBSTOP
ENDSFOR+,)0 ,/+MAYBEAVAILABLE
Fitting KLIP-LOK 406 rib end-stops during sheet installation
s
n
top tte
d s to ba ly)
n
E d on
e 6
ten 40
fas (KL-
Figure 10.3.1
Fitting rib end-stops during installation of
sheets
Fix the rib end-stops to the side of the eaves support after the
+,)0 ,/+CLIPHASBEENSECUREDINPOSITION!LIGNTHERIBEND STOPSWITH
the upstands of the fixing clips (Figure 10.3.1).
Fitting KLIP-LOK 406 rib end-stops after sheet installation

"ENDTHEFLATOFTHEEND STOPS0USHANEND STOPINTOTHESPACEUNDER
each rib until the flat is wedged firmly between the underside of the
cladding and support (Figure 10.3.2).
Infill strips
Closed-cell, foam-plastic infill strips are available to match the top or
bottom profile of our roof claddings.
!TTHELOWERENDOFCLADDINGTHESTRIPISSANDWICHEDUNDERTHEROOF
cladding. Similarly, at the upper end, the strip is sandwiched between
topside of the roofing and the underside of the flashing or capping
(Figure 10.3.3).
Figure 10.3.2
Fitting rib end-stops to +,)0 ,/+after
installation of sheets
$ONTUSEINFILLSTRIPSTHATCANABSORBWATERBECAUSERETAINEDMOISTURE
CANLEADTODETERIORATIONOFTHESHEETCOATING!VOIDUSINGINFILLSTRIPS
made from, or treated with, flammable materials, particularly in areas
prone to bushfire (Section 11.8).
7HEREROOFPITCHESAREBELOWIN YOUSHOULDINCORPORATEINFILL
strips to maximise resistance to water entry.
Figure 10.3.3
Profiled closed-cell infill at eaves
2012-13 Edition
51
10.4 End-lapping
Because our roofing and walling is manufactured by continuous
processes, sheet lengths can be supplied up to the limits of transport
regulations which are frequently long enough to cover roofs without endlapping the sheets.
)FYOUCONTEMPLATEUSINGSHEETSTHATARESHORTERTHANTHEFULLSPANAND
END LAPTHEMYOUNEEDTOCONSIDER
s THEROOFSLOPEBECAUSEITAFFECTSTHEAMOUNTOFEND LAP
(see Table 10.4.1);
s THEMETHODOFFIXINGOFTHECLADDINGTOITSSUPPORTSBECAUSEIT
AFFECTSTHEMAXIMUMLENGTHOFSHEETSEE3ECTION %XPANSION
joints and Table 10.5.2).
s 4REATPURLINSPACINGSATLAPSANDEXPANSIONJOINTSAS%ND3PANS
Table 10.4.1
%ND LAPS
Fixing methods for end laps

(a)
Pierce-fixed
through crest
See Table 10.4
.1
(b)
Pierce-fixed
through valley/pan
See Table 10.4.1

Fastened clip
on support
2 fasteners per tray

self-drilling screws
with EPDM
sealing washer
s 0IERCE FIXEDSHEETS
Position the lap centrally over the support; and the fastening secures
both the lap and the cladding. For roofing (Figure 10.4.1a) position the
crest fasteners as detailed in Table 3.8.1, and for walling (Figure 10.4.1b)
position the valley/pan fasteners as detailed in Table 3.8.1. For cladding
with two fastener patterns, use the pattern with the greater number of
fasteners (e.g. for #534/-/2" use 5 fasteners/sheet/support pattern)
s #ONCEALED FIXEDSHEETS
The lap should be positioned just clear, and on the high side of the
support (Figure 10.4.1c). This will allow normal concealed fastening
at the support and thus allow thermal movement to occur at the clip.
The lap is secured with pierce fasteners through the pan/valley. For
alternative lapping of concealed-fixed cladding, by fixing through the
valley/pan directly into the support (similarly to that detailed for walling
above) please contact your nearest BlueScope Lysaght service centre for
advice.
(c)
Concealed-fixed
Figure 10.4.1
Fixing at end laps
2012-13 Edition
10 Ends of sheets
See Table 10.4.1
52
To make the end-lapping of +,)0 ,/+ EASIERREMOVEFORTHELENGTH

of the lap, the down-turn of the underlapping ribs of the upper and lower
sheets in each sheet run (Figure 10.4.2). The cut-back ribs are covered
by the sheets of the next sheet run and provide an added stitch screw
through the side of the ribs.
For ,/.',).%end-lapping the undersheet (lower sheet) ribs will have

to be slightly squashed at the lap and for the length of the lap to allow
the oversheet (upper sheet) to nest snugly. The rib closing tool may be
suitable to squash the ribs. To make end-lapping easier, remove the
down-turn of the under-lapping rib of the lower sheets for the length of
the lap.
+,)0 ,/+(3+,)0 ,/+#,!33)#are not recommended to be endLAPPED)NSTEADANEXPANSIONJOINTMUSTBEUSED2EFERTO3ECTION
BELOW )DEALLYLONGLENGTHSHEETSFROMAMOBILEROLLFORMERSHOULDBEUSED
WHEREPOSSIBLE+, (3 ASTHISELIMINATESTHENEEDFOREND LAPPING
*
*
4
* Downturn of male rib removed

for length of lap
Figure 10.4.2
Remove down-turn of male rib when end-lapping
+,)0 ,/+
Order of laying
For profiles other than ,/.',).%, lay each run of sheets in turn from
lower to upper before moving on to the next run. For ,/.',).%5, lay
all lower run of sheets first, then lay the upper sheets (Figure 10.4.3).
End laps in pitches less than 15 degrees

%NDLAPSINROOFSOFLESSTHANIN SLOPESHOULDBESEALEDWITHA
sealant.
Upper
4
1
Spacing of supports at end-laps

For the maximum spacing between purlins, either side of an end lap in
a roof, use the spacing given for end spans (terminology and spacing in
Table 2.12.1).
Lower
Profiles other than LONGLINE 305
Upper
5
1
Lower
LONGLINE 305
Figure 10.4.3
5SETWORUNSOFSEALANT&IGURE
Laying sequence for end-lapped sheets
s ONERUNOFSEALANTATTHELOWENDOFTHELAPTOPREVENTMOISTURE
being drawn in by capillary action);
s THEOTHERRUNATTHEHIGHENDTOPREVENTCONDENSATIONFROM
running down the underside of the top sheet and entering the lap).
When the sheets are lapped together and fixed, the compressed sealant
should just appear at the end of the lap.
1. With the top sheet upside down, extrude a 3mm bead
of sealant across the underside of this sheet about 25mm from the
end.
2. Position the bottom sheet, then extrude a 3mm bead of sealant across
the top of the sheet to encapsulate the cut end of the underlapping
sheet.
3. Turn the top sheet over and fit it in place.
The side-lap between sheets of roofing has a cavity to prevent capillary
action between adjacent sheet runs (Section 8.2).
)TISIMPORTANTTHATEXCESSSEALANTEXTRUDEDFROMANEND LAPDOESNOT
enter this cavity because, if it does, moisture that may have entered the
side lap will not be able to drain unimpeded down the roof slope.
Figure 10.4.4
Sealing end-laps on very low pitched roofs
2012-13 Edition
53
10.5 Expansion
Background on thermal expansion
!LLMETALSEXPANDANDCONTRACTWITHCHANGESINTEMPERATURE!LTHOUGH
steel is by far the least affected of all the metals commonly used for roof
and wall cladding, the changes in length experienced in very long runs of
roofing are significant.
Table 10.5.1
Thermal expansion and contraction of steel
cladding
On a clear hot summer day, with no wind, the steel temperature in roof
CLADDINGCANREACHAPPROXIMATELY#IN#/,/2"/.$352&-)34, #
in plain :).#!,5-%ANDMORETHAN#IN#/,/2"/.$ .)'(43+9.
%XAMPLESOFTHETHERMALCHANGESINLENGTHSOFSTEELCLADDINGTHATWOULD
result from various temperature changes in the steel are shown in Table
10.5.1.
The actual expansion or contraction between the end of a sheet and the
last support would only be a fraction of the figures shown because the
movement in the length of fixed cladding would normally take place from
the centre towards each end of the sheet. The movement at each end is
thus only half the total expansion or contraction.
Transverse thermal expansion poses no problems in ribbed cladding
because each rib absorbs some transverse movement.
Maximum distance between top & bottom rows

of fasteners on a sheet, before expansion joint is
needed
/pans
Sheeting
turned down
Baffle flashing.
Notch over
ribs & fasten to
underlapping
sheet
Added protection
if required
250 mm
minimum overlap
Depth of
sheeting
plus
15 mm
Trays turned up
25 mm min.
clearance
300 mm
Figure 10.5.1
%XPANSIONJOINTDETAIL
Expansion joints
Thermal expansion effects are mitigated by slight bending of fastener
shanks, thermal movement of the building structure, and slight flexing of
THEPURLINSWHERETHEYARENOTRESTRAINEDBYCLEATSORBRIDGING (OWEVER
for very long runs of roofing, you should include an expansion joint to
overcome linear thermal expansion.
Table 10.5.2 shows the maximum distance between the top and bottom
ROWSOFFASTENERSONAPIERCE FIXEDSHEET&OR,/.',).%INDISTANCESOF
GREATERTHANMPLEASECONTACTYOUR3ERVICE#ENTREFORADVICE)FTHE
total length of two sheets pierce-fixed through the lap, or a single sheet
exceeds this distance, then an expansion joint is needed. There should be
no more than one pierce-fixed end-lap between expansion joints.
!NEXPANSIONJOINTINVOLVESOVERLAPPINGTHEENDSOFTHEUPPERSHEETS
over the ends of the lower sheetsbut with a clearance between them
ABOUTMM !TYPICALOVERLAPISMMTHISOVERLAPISNOTTHESAMEAS
the overhang in Table 2.13.1 which does not apply to expansion joints).
The clearance is usually created by having all the purlins for the roofing
on the high side of the joint, higher than the roofing on the low side of
THEJOINT!NEXTRAPURLINISNEEDEDATTHEJOINT!BAFFLEFLASHINGPROVIDES
weatherproofing. See Figure 10.5.1.
Where there is a risk of high winds, or the ribs result in a large opening,
you may need protection, such as extra flashing or the inclusion of
closed-cell foam infill strips.
2012-13 Edition
10 Ends of sheets
Table 10.5.2
54
INSTALLATIONFLASHINGS
Overhang
10.6 Roof overhang with edge stiffener

For the stiffened overhangs listed in Table 2.12.1, you need to stiffen the
gutter ends of the roofing.
Our 3(%%2,).% gutter, fixed through the return lip to the underside of
roofing at 200mm centres will provide the required stiffening.
!LTERNATIVELYYOUCANUSEAXXMMGALVANISED:).#!,5-%
steel angle fixed at 200mm centres to the underside of the roofing about
50mm from the end.
50mm nominal
Sheerline gutter fixed to underside of roofing

(200 mm centres)
rhan
Ove
nal
omi
n
0mm
Galvanised or ZINCALUME
steel angle 50x50x1.2mm
fixed to underside of roofing
(200mm centres).
Gutter may be fixed to angle.
Figure 10.6.1
Methods of stiffening roof overhangs
2012-13 Edition
11
Flashings
55
Flashings and cappings are strips of metal formed to weatherproof the

edges of roofing and walling.
For the purposes of this chapter, only the term flashing is used.
The following sections should be considered as a guide only.
&ORACOMPREHENSIVEACCOUNTOFFLASHINGGUIDELINESREFERTO("
3IMILARMETHODSOFFLASHINGAREUSEDFORDIFFERENTCLADDING PROFILES9OU
can adapt the principles to suit your application.
)NALLCASESITISIMPORTANTTOHAVEAMPLECOVERPROVIDEDBYTHEFLASHING
and proper turn-up of the cladding underneath.
"ECAREFULWHENMOVINGBETWEENSUPPORTS$ONOTWALKINTHEPAN
immediately adjacent to flashings or translucent sheeting. Walk at least
one pan away.
BlueScope Lysaght has a range of standard flashings. We can also
supply custom flashings to your requirements ask your local service
centre for details.
11.1 Materials
)TISVERYIMPORTANTTHATFLASHINGSBEMADEFROMMATERIALSTHATARE
compatible with the cladding (Section 2.10).
Lead flashing is not recommended, however it will usually be retained
WHENRE ROOFINGBECAUSEITISUSUALLYCEMENTEDINTOTHESTRUCTURE)N
THESECASES
s THEREMUSTBEABARRIERBETWEENTHELEADFLASHINGANDTHE
CLADDINGEITHERAPLASTICSTRIPSUCHASPOLYTHENEDAMPCOURSE OR
paint.
&LASHINGSSHOULDCONFORMTO!3.:3ANDBECOMPATIBLEWITH
the cladding (Section 2.10).
Materials for flashings are available in :).#!,5-% or #/,/2"/.$
finishes.
11.2 Longitudinal flashings

Longitudinal flashings run parallel to the pans or valleys, and are made to
suit the cladding profile (Figure 11.2.1). They should have an edge turneddown to dip into the pan or valley.
Flashing Cover
The minimum recommended cover of longitudinal flashings over cladding
SHOULDBEASFOLLOWSASTAKENFROM("
Pierce fixed roof sheet
#ONCEALEDFIXEDROOFSHEET
150mm min.
)NTOFULLPAN
(2/3 pan covered)
Figure 11.2.1
Typical longitudinal flashings
2012-13 Edition
10 Ends of sheets
s THETOPSURFACEOFTHELEADFLASHINGMUSTBEPAINTEDWITHAGOOD
quality exterior paint system (to limit contamination with lead
compounds in water running off the flashing); and
56
Every 4th rib (minimum)
11.3 Transverse flashings

Transverse flashings run across the pans or valleys (Figure
11.3.1). They usually have a stiffening lip, along the lower edge,
which is turned-down to dip into the pan or valley. To maximise
weatherproofing, the bent lip is fashioned to fit the profile.
The turn-down for transverse flashings for #534/-/2" and
#534/-",5%/2" can be fashioned to fit the profile by either
notching or scribing to match the corrugations, or lightly dressed
into the valleys. The type of fashioning (if any) depends upon profile
shape and the type of material used to flash. Fashioning is preferred
for low-slope roofs.
Every 3rd rib

(minimum)
The turn-down for transverse flashings for wide panned cladding is

always notched or scribed to fit over the ribs.
Flashing Cover
BlueScope Lysaght produces a range of standard flashings (hip,
barge, apron). To increase weathertightness, BlueScope Lysaght
recommends you maximise the overlap between flashings and
claddings.
Fixing of Flashings
Longitudinal flashings shall be fastened at maximum 500mm
centres. Transverse flashings shall be fastened in accordance with
(" ASDETAILEDBELOW
Profile
Recommended Fixing Spacing (min.)
#534/-/2"#534/-",5%/2"%VERYTHRIB
).4%'2)49
%VERYRIB
+,)0 ,/+
%VERYRIB
+,)0 ,/+()'(342%.'4(
%VERYRIB
+,)0 ,/+#,!33)#
%VERYRIB
,/.',).%
%VERYRIB
30!.$%+
%VERYRDRIB
42)-$%+
%VERYRIB
Every rib
Figure 11.3.1
Typical transverse flashings
The above fastener spacing relates to the stitching of flashings to

SHEETING)TDOESNOTCONSTITUTETHEMINIMUMNUMBEROFFASTENERS
required to fix the sheeting to purlins.
Notching tools
(AND OPERATEDNOTCHINGTOOLSCUTONENOTCHATATIME%ACHTOOL
matches only one cladding profile. There are two types of tool; their
use depends on whether or not the edge of the flashing has first
been bent down (Figure 11.3.2).
Table 11.3.1
Notching tools
KLIP-LOK 406
SPANDEK, TRIMDEK
Others subject to inquiry.
Flashings provide the essential weatherproofing at the

edges, and they sharpen the image of the finished job.
2012-13 Edition
57
Using notching tools

!FTERTHECLADDINGISFIXEDANDTHETURN UPSFINISHEDPROCEED
as follows.
s 0LACEAFLASHINGWITHTHENOTCH EDGERESTINGONTHERIBS
s ,OCATEYOURNOTCHINGTOOLOVERARIBWITHTHENOTCHINGHEADAGAINST
the flashing.
VERTICAL TOOL4HEBODYLOCATESALONGTHERIB
HORIZONTAL TOOLTHELUGSONTHEUNDERSIDELOCATESONTOPOFTHERIB
s 2AISETHEHANDLETOOPENTHETOOLAND
VERTICAL TOOL:
lift the flashing into the mouth of the tool;
HORIZONTAL TOOL: slide the mouth of the tool over the edge of the
flashing as far as it will go.
s 0USHDOWNONTHEHANDLETOPERFORMTHENOTCHING
s 2EPEATFORALLRIBSCHECKINGINEACHCASETHATTHEFLASHINGISCORRECTLY
positioned.
Figure 11.3.2
5SINGNOTCHINGTOOLS
s )FYOUAREUSINGAHORIZONTALTOOLBENDDOWNTHETONGUESBETWEENTHE
notches over a suitable straight edge (such as a piece of timber).
Notching with tinsnips

)FNOTCHINGTOOLSARENOTAVAILABLEFLASHINGSCANBENOTCHEDTOTHERIB
profile with tinsnips (Figure 11.3.3). The procedure is sometimes known as
SCRIBING!FTERTHECLADDINGISFIXEDANDTHETURN UPSFINISHEDPROCEEDAS
follows.
s 0LACETHEFLASHINGWITHTHETURNED DOWNEDGERESTING
on the ribs.
s -ARKOUTTHENOTCHINGUSINGATEMPLATEPOSITIONEDOVER
each rib.
s #UTTHENOTCHESWITHTINSNIPS
Fasteners for transverse flashings

9OUMUSTPROPERLYFIXBOTHFLASHINGSANDTHEENDSOFALLSHEETS
Where the cladding is pierce-fixed through crests, and the position of
the purlin allows it, the fasteners used to fix the sheets, may also fix the
flashings.
Figure 11.3.3
5SINGATEMPLATETOMARKOUTFORNOTCHINGWITH
tinsnips
On all other installations, pierce-fix your flashing to the ribs or crests of

the sheets.
2012-13 Edition
11 Flashings
This procedure is also used for hip cappings.
58
Joining flashings
The overlaps of transverse flashings should be sealed with a
recommended sealant and fastened. Before finally positioning and fixing
the lap, turn over the top piece and apply a 3mm bead of sealant across
the flashing, about 12mm from the end.
11.4 Flashing at change of pitch
Figure 11.4.1
Typical flashing at changes of pitch
2012-13 Edition
59
11.5 Flashing large roof penetrations

Penetrations through ribbed cladding block the valleys (or pans), and
THUSAFFECTTHEFREEFLOWOFRAINWATERDOWNAROOF!LLFLASHINGSHAVETO
weatherproof the cladding but on the uphill side of large penetrations,
they also have to channel rainwater sideways into valleys that run
unobstructed to the eaves.
&OURMETHODSAREDESCRIBEDHERE)NALLMETHODSTHEENDSOFCUTRIBSMAY
be closed off with caps on the outside of the rib, or with plugs inside the
ribs. Plugs must be used on side-laps to allow the anti-capillary cavity to
drain.
Note: For masonry construction, Building Code Australia (BCA) requires
the use of Damp Proof Course (DPC) to ensure weatherproong. For
acceptable methods see BCA section on weatherproong masonry.
Support framing
Wherever one or more of the sheet ribs are cut, you must provide framing
to support the cut ends of the roof cladding each side of the penetration.
Existing flashing
Figure 11.5.1
&LASHINGMETHOD(EADGUTTER
)FYOUHAVETORE USELEADFLASHINGSTHATAREBUILTINTOTHESTRUCTURE
special protection is needed (Section 11.1).
Method 1: Head gutter and apron flashings

This is often the simplest method, and commonly used for existing
protrusions (Figure 11.5.1).
Method 2: Flat tray and sleeve
11 Flashings
To avoid fitting and sealing end caps to all the sheet ribs on the low
side of the penetration, an apron flashing can be fitted to the sleeve and
sealed to the tray each side.
Figure 11.5.2
&LASHINGMETHOD&LATTRAYANDSLEEVE
2012-13 Edition
60
Method 3: Tray gutter for steeper roofs

)FTHEROOFPITCHISMORETHANSAYIN YOUCUTTHEROOFCLADDING
sufficiently high above the penetration to allow a tray gutter to raise
rainwater over the top of the sheet ribs and divert it around the
penetration (Figure 11.5.3).
Figure 11.5.3
&LASHINGMETHOD
Tray gutter for steeper roofs
Method 4: Penetration close to ridge capping

)FAROOFPENETRATIONISCLOSETOARIDGECAPPINGORFLASHINGABOVETHE
penetration), you can fit a simple flat tray, on top of the roofing, so that it
extends from under the capping down to a sleeve around the penetration.
Figure 11.5.4
&LASHINGMETHOD
Penetrations close to ridge capping

2012-13 Edition
61
11.6 Flashing small roof penetrations

!FLANGEDCYLINDRICALSLEEVEISAFAIRLYSIMPLEMETHODOFFLASHINGAROUND
small penetrations (such as pipe penetrations) which fit between the
ribs of a roof sheet, or penetrate only a single rib.
Two methods are described here. Wherever roofing is cut, you must
consider providing extra support for the roofing above and below the
penetration. Where one or more of the sheet ribs are cut, you must
provide framing to support at the cut ends of the roof cladding each
side of the penetration.
Method 1: Tapered metal skirt and sleeve

This method uses parts custom-fabricated from metal. There is no
positive seal between inside the building and the outside atmosphere
(Figure 11.6.1).
Method 2: Sleeve
This is often the simplest method (Figure 11.6.2). Flexible flanged
sleeves can be bought for flashing around penetrations of at least
350mm diameter. They overcome the problem of capping and sealing
THEOPENENDSOFCUTRIBS!SLEEVEISCOMMONLYUSEDTHOUGHSILICONE
sealant has a wider operating temperature range and is available in a
wider range of colours.
Figure 11.6.1
Small penetration with metal skirt and sleeve
The flange around the base of the sleeve can be contoured by hand to
match the cladding profile before it is sealed and fixed to the cladding.
Be careful not to dam any valleys or pans so that rainwater can drain
freely from the high side of the roof penetration. Moisture held in
such areas can cause deterioration of the sheet coating, reduced life
expectancy or poor appearance.
Where damming of any valley or tray is unavoidable, due to the size of
the pipe penetration, treat the installation as a large penetration
(Section 11.5).
Figure 11.6.2
Small penetration with sleeve
$EKTITE sleeve illustrated)
!LLCOPPERPIPEPENETRATIONSTHROUGH:).#!,5-% or #/,/2"/.$
steel cladding must be physically and electrically isolated from the
CLADDING4HISCANBEDONEBYUSINGASLEEVEOF06#POLYTHENEOR
similar plastic that is also ultra-violet stable.
2012-13 Edition
11 Flashings
Copper penetrations
62
11.7 Flashing walls

Cladding is usually installed with the profile running vertically or
horizontally, though sheets have been laid diagonallythe choice is
aesthetic.
Wind can drive rain hard against wall flashings, so it is important that you
pay attention to the detailing of flashings around windows, doors,
re-entrant and external corners, to ensure you get a watertight building.
9OUALSOWANTANEATAPPEARANCE
We make wall flashings for some wall claddings (like %!39#,!$
and -).)/2") which are sometimes called trims. Where these are not
suitable, custom-made flashings can be easily produced following the
general principles described in this section.
Walling profile running horizontally

s )TISUSUALTOLAYTHEFIRSTSHEETATTHEBOTTOMOFAWALLANDWORK
UPWARDSTOWARDSTHEEAVES9OUWANTTHEWINDOWANDDOORFLASHINGS
to fit properly into the valleys, so you should locate the first sheet
relative to the heads and sills of doors and windows. Thus, you first
have to decide where the cladding will eventually be located at the
heads of doorways and at the heads and sills of windows before you
place the first sheet.
s 7HEREPOSSIBLESELECTTHEVERTICALSIZEOFWINDOWSSOTHATTHE
flashings at both heads and sills will coincide neatly with the pitch of
your profile (Figure 11.7.1).
s "ESURETHATTHECRESTSOFTHEPROFILEALIGNWITHEACHOTHERON
adjacent walls, either side of a cornerthis ensures that horizontal
flashings fit properly into all valleys.
s 7HEREVALLEYSCREATEAVOIDATFLASHINGSUSECLOSED CELLFOAMPLASTIC
infill (Figure 10.3.3).
s 7HEREWIND DRIVENRAINCANBEEXPECTEDTURNBACKTHEEDGESOF
flashing to restrict water movement past the flashing.
Figure 11.7.1
4YPICALHEADERANDSILLFLASHINGPROFILERUNNING
horizontally (elevation)
2012-13 Edition
63
Figure 11.7.3
4YPICALFLASHINGATWINDOWANDDOORJAMBSPROFILE
running horizontally
Figure 11.7.2
4YPICALCORNERFLASHINGSPROFILERUNNING
horizontally (plan view)
2012-13 Edition
11 Flashings
64
Walling profile running vertically

Flashings are generally easier on jobs where the profile runs vertically
(Figures 11.7.4 and 11.7.5).
Figure 11.7.4
4YPICALHEADERANDSILLFLASHINGPROFILERUNNING
vertically (elevation).
Figure 11.7.5
4YPICALCORNERFLASHINGSPROFILERUNNING
VERTICALLYPLAN *AMBFLASHINGSFOLLOWSAME
principle.
11.8 Bushfire protection

!3 SETSOUTREQUIREMENTSFORTHEDESIGNANDCONSTRUCTIONOF
BUILDINGSINBUSHFIRE PRONEAREAS)TCALLSFORFLASHINGSTOBEBEDDEDON
fire resistant insulation material.
Be sure that flashings fit closely. Transverse flashings should be notched
or scribed (Figures 11.3.1 and 11.8.1)
Figure 11.8.1
Typical protection from sparks at ridge
2012-13 Edition
65
References
Australian Standards
BlueScope Lysaght
!3.:33TRUCTURALDESIGNACTIONS 0ERMANENT
imposed and other actions
!MONGSTTHEPUBLICATIONSOF"LUE3COPE3TEEL
the following are particularly appropriate.
!3.:33TRUCTURALDESIGNACTIONS 7INDACTIONS
!3.:33TRUCTURALDESIGNACTIONS 3NOWAND
ice actions
Technical bulletins (General)
!33TRUCTURALDESIGNACTIONS %ARTHQUAKE
ACTIONSIN!USTRALIA
TB-2 Overpainting and restoration of #/,/2"/.$

prepainted steel sheet
!3.:33TEELSHEETANDSTRIP(OT DIPPEDZINC
coated or aluminium/zinc-coated
TB-4 Maintenance of #/,/2"/.$ prepainted steel roofing
!3.:3$ESIGNANDINSTALLATIONOFSHEETROOFAND
wall claddingMetal
!3.:33PECIFICATIONFORRAINWATERGOODS
accessories and fasteners Metal shape or sheet
rainwater goods, and metal accessories and fasteners
4" 3TEELROOFINGANDWALLINGPRODUCTS3ELECTIONGUIDE
TB-5 Swarf staining of steel roofing and walling profiles

TB-8 Flashing materials for :).#!,5-% & #/,/2"/.$
steel sheet
4" 'ENERALGUIDETOGOODPRACTICEINTHEUSEOFSTEEL
roofing and walling products
!3.:33TEELNAILS-ETRICSERIES
TB-15 Recommended steel gutter systems
!3.:30REFINISHEDPREPAINTEDSHEETMETAL
products for interior/exterior building applications
Performance requirements
4" &ASTENERSFORROOFINGANDWALLINGPRODUCT3ELECTION
guide
TB-17 Selection guide for galvanised steel purlin products
!30LUMBINGANDDRAINAGE3TORMWATER
drainage
!33ELF DRILLINGSCREWSFORTHEBUILDINGAND
CONSTRUCTIONINDUSTRIES 'ENERALREQUIREMENTSAND
mechanical properties
Technical bulletins (Corrosion)
!3#ONSTRUCTIONOFBUILDINGSINBUSHFIRE PRONE
areas
CTB-8 Building applications
!32ESISTANCETOWINDPRESSURESFORNON
cyclone regions
CTB-10 Roof penetrations

CTB-11 Condensation
#4" $ISSIMILARMETALS
CTB-13 Contact with timber
!37INDLOADSFORHOUSING
#4" !CIDCLEANINGBRICKWORK
!3.:30LASTICROOFANDWALLCLADDINGMATERIALS
#4" )MMERSION
(")NSTALLATIONCODEFORMETALROOFANDWALLCLADDING
CTB-17 Following trades
("(OMEINSULATIONIN!USTRALIA
CTB-18 Painting lead flashing
("'UIDELINESFORTHEDESIGNOFSTRUCTURESINSNOW
areas
The full range of TBs and CTBs are available for
DOWNLOADFROMOURWEBSITEWWWLYSAGHTCOM
2012-13 Edition
11 Flashings
!3-ETHODSOFTESTINGSHEETROOFANDWALL
claddingResistance to concentrated loads
#4" 'ENERALINTRODUCTION
INDEX
66
Index
E
A
alignment of roofing
concealed-fixed 35
pierced-fixed 31
!USTRALIAN3TANDARDS
!54/4%+ (see screws) 10
B
blocking rib cavities 50
bullnosed (see pre-curved roofs) 18
bushfire protection 64
C
cappings. See flashings
care of products 27
clean up 28
clips
for %!39#,!$ 42
for +,)0 ,/+ 35
for ,/.',).% 44
required quantities 12
coatings, strippable 28
#/,/2"/.$ 2
and painting 4
avoiding rust stains 28
compatibility of materials 4, 5
drainage table 6
concealed-fixing. See installation
condensation 21
crest fixing 33
CURVING 3EEROOFCURVED
cutting cladding 27
cyclonic
anchoring footings 3
conditions 1
D
$EKTITEFLASHINGS
design 2
roof drainage 24
roofs 2
walls 2
dissimilar metals. See compatibility of
materials
DOWNPIPESIZE 3EEROOFDRAINAGE
downpipe size
DRAINAGEOFROOFS 3EEROOFDRAINAGE
design
effective roof lengths for drainage 8

end-lapping 51
expansion 53
fixing methods 51
low pitches 52
order of laying sheets 52
spacing of supports 52
ends of sheets 47
blocking rib cavities 50
end-lapping 51
overhang, stiffened 54
TURN DOWNS
turn-ups 47
environmental conditions 4
expansion 53
expansion joints 53
F
FASTENERS
features table 10
for accessories 11
for #534/-",5%/2" 13
for #534/-/2" 13
for %!39#,!$ 13
for insulation 11
for ).4%'2)49 13
for +,)0 ,/+ 13, 14
for ,/.',).% 14
for -).)/2" 14
for -5,4)#,!$ 14
for 0!.%,2)" 15
for side-laps 11
for 30!.$%+ 15
for 30!.2)" 15
for thicker steels 11
for transverse flashings 55
for 42)-$%+ 15
for 42)-7!,, 15
for 7!,,#,!$#534/-/2"
identification 10
NAILS
MATERIALS
quantity required 11, 12
RIVETSSEALING
screws, setting tightness 10
SEALINGWASHERS
WASHERSSEALING
finishes 2
flashings 55
at change of roof pitch 58
at copper penetrations 61
ATLARGEPENETRATIONS
at small penetrations 61
sleeve 61
longitudinal 55
materials 55
notching 58
notching tools 56, 57
notching with tinsnips 57
transverse 56
walls 62
G
gutters
areas 26
typical types 25
H
handling products 27
heat control 20
holes 28
I
incompatibility. See compatibility of
materials
infill strips 50
information 1
installation
alignment of roofing 32, 38
concealed-fixing 35
%!39#,!$42
+,)0 ,/+ on walls 41
+,)0 ,/+ 35
,/.',).% 44
pierce-fixed 31
crest fixing 33
procedure 31
side-laps 33, 34
valley fixing 34
insulation
fastener length 11
heat 20
materials 22
noise 22
thickness limitations 23
2012-13 Edition
67
INDEX
lengths
roofing 3
roofing drainage 8
transportation 4
lifting roofing 31
rainfall intensities table 25

references 65
rivets. See fasteners
roof
alignment of sheets 32
curved 16
TAPEREDROOFING
technical bulletins 65
testing performance 3
thermal transmission (heat control)
20
4(%2-!4%#( technology 20
translucent cladding. See skylighting.
transportation 4
trims (see flashings, walls) 62
TURN DOWNS
turn-ups 47
bullnosed (pre-curved roofs) 18

CAPPEDBENTRIBBED
pre-curved 18
spring-arched 17
spring-curved 18
spring-curved-ridge 16
M
maintenance 30
marking out 27
materials
cladding specifications 2
FORFASTENERS
for flashings 55
for insulation 22
design 2
drainage
design 24
downpipe locating 24, 25
downpipe size 25, 26
gutter areas & downpipes 26
gutter types 25
maximum roof lengths 8
rainfall intensities 25
N
nails. See fasteners
noise reduction 22
notching. See flashings
lengths (maximum) 3
roofing drainage 8
transportation 4
P
pencils for marking out 27
performance tests 3
pierce-fixing. See installation
pitches of roofs 3
products
profiles 6
selection 2
profiles of claddings 6, 7
pitches 3
TAPERED
walking on 27
wind forces 3
rust stains
avoiding 28
warn other contractors 28
V
valley fixing 34
W
walking on roofs 27
wall flashings 62
walls, design 2
warranties 1
WASHERSSEALING
wind forces 3
Z
:).#!,5-% 2
ZIP SEE2//&:)02)00,%:)0 10
S
quantities of clips & fasteners 11, 12
2012-13 Edition
References & Index
safety 27
guard rails 27
lifting roofing 31
walking on roofs 27
screws. See also fasteners
setting tightness 10
SEALANTUSE
SEALANTS
SEALINGWASHERS
selection of products 2
silicone sealant. See sealants
skylighting 23
solvents 30
spacing specifications 6
specifications
for profiles (tables) 6
materials 2
storage of products 27
strippable coatings 28
support spacings 3
NOTES
2012-13 Edition
Product Descriptions
All descriptions, specications, illustrations, drawings, data, dimensions and weights contained
this catalogue, all technical literature and websites containing information from BlueScope
Lysaght are approximations only.
They are intended by BlueScope Lysaght to be a general description for information and
identication purposes and do not create a sale by description. BlueScope Lysaght reserves the
right at any time to:
(a) supply Goods with such minor modications from its drawings and specications as it sees t;
and
(b) alter specications shown in its promotional literature to reect changes made after the date
of such publication.
Disclaimer, warranties and limitation of liability

This publication is intended to be an aid for all trades and professionals involved with specifying and
installing Lysaght products and not to be a substitute for professional judgement.
Terms and conditions of sale available at local BlueScope Lysaght sales offices.
Except to the extent to which liability may not lawfully be excluded or limited, BlueScope Steel
Limited will not be under or incur any liability to you for any direct or indirect loss or damage
(including, without limitation, consequential loss or damage such as loss of profit or anticipated
profit, loss of use, damage to goodwill and loss due to delay) however caused (including, without
limitation, breach of contract, negligence and/or breach of statute), which you may suffer or incur
in connection with this publication.
Copyright BlueScope Steel Limited March 2, 2012
Technical enquires: steeldirect@bluescopesteel.com or call 1800 641 417
www.lysaght.com
Please check the latest information which is always available at www.lysaght.com
LYSAGHT is a registered trademark of BlueScope Steel Limited, ABN 16 000 011 058. The LYSAGHT range of products is exclusively
made by BlueScope Steel Limited trading as BlueScope Lysaght. Printed by PM 1.5K 3/12

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Roong & Walling

Roofing and Walling

Manual 2012-13 Edition

Date of Issue February, 2012

GENERAL NOTES TO READ BEFORE YOU USE THIS GUIDE

Use of Genuine Materials

in the case of goods, the repair of the goods, the

in the case of services, the resupply of services or paying

This publication is intended to be an aid for professional engineers

LYSAGHT Roong and Walling Manual

General care, safety and handling

Installing pierce-fixed cladding

Installing concealed-fixed cladding

Curved, bent & tapered cladding

Insulation & skylights

LYSAGHT Roong and Walling Manual

Contemporary and traditional, residential or commercial: all are

This book is a guide to the installation of steel roofing and

Where we recommend use of third party materials, ensure

We refer only to genuine steel roofing and walling

with the relevant manufacturer before use.

Please send your suggestions for improvements to this

Further information on products and services

We also have specific publications for all of our products, and

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Roong and Walling Installation Manual

Roong and Walling Installation Manual

2.2 Materials and finishes

Typical material specifications

s #/,/2"/.$ Stainless is a pre-painted steel. The

2.3 Support spacings

2.4 Maximum lengths of roofing

Roong and Walling Installation Manual

2.5 Low roof pitches

2.6 Wind forces on roofs

2.7 Codes and performance tests

aluminium/zinc alloy-coated steel complying with

Metal roofing products must comply with the performance

2.8 Environmental conditions

2.9 Metal and timber compatibility

2.11 Paint and COLORBOND finishes

Roong and Walling Installation Manual

Roong and Walling Installation Manual

COLORBOND, COLORBOND ULTRA,

ACCESSORIES OR FASTENER OR (UPPER SURFACE)

( 1 ) MONEL - COPPER/NICKEL ALLOY

UPPER CLADDING OR ROOF DRAINAGE SYSTEM MATERIAL

COLORBOND , COLORBOND ULTRA,

GLAZED ROOF TILES,

ACCEPTATIBILITY OF DRAINAGE FROM AN UPPER SURFACE TO A LOWER METAL SURFACE

LOWER ROOF DRAINAGE

( 1 ) MONEL - COPPER/NICKEL ALLOY

ROOF DRAINAGE SYSTEM COMPONENTS

COMPATIBILITY OF DIRECT CONTACT BETWEEN METALS OR ALLOYS

2.12 Specifications - roofing

CUSTOM BLUE ORB4

KLIP-LOK 700 HI-STRENGTH

KLIP-LOK CLASSIC 700

LONGLINE 305 (not tapered)

See Section 2.5.

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