SA Roofing Jan / Feb 2016 | Issue: 76 by Trademax Publications

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JAN / FEB 2016 ISSUE: 76

SA R36 EACH INCL. / R360 PER ANNUM INCL.

JANUARY / FEBRUARY 2016

ISSUE: 76

EDITOR’S COMMENTS...................................................................................................... 2 CONTRIBUTORS................................................................................................................. 4 CMA AWARDS................................................................................................................. 6-7

Trademax Publications

SAFETY EQUIPMENT..................................................................................................... 8-9

SA Roofing

COVER STORY............................................................................................................. 10-13

Tel: 0861 SA ROOF (0861 727 663) Fax: 0866 991 346 Email: info@trademax.co.za www.trademax.co.za

OVER-ROOFING.......................................................................................................... 15-16 STAINLESS STEEL ROOFING................................................................................... 18-21 LOW-COST CEILINGS............................................................................................... 22-26

Postnet Suite 241 Private Bag X103 N1 City

GUTTERS........................................................................................................................28-30 ALUMINIUM.................................................................................................................. 32-34

7463

ARCHED TRUSS SYSTEM..........................................................................................36-37 CEILINGS & ACOUSTIC INSULATION................................................................38-39

PUBLISHER:

INDUSTRY NEWS............................................................................................................. 40

Billy Perrin 082 266 6976 billy@trademax.co.za EDITOR: Celéste Perrin editor@trademax.co.za

ADVERTISING: Jacqui Marsh jacqui@trademax.co.za LAYOUT & DESIGN: Craig Patterson craig@trademax.co.za SUBSCRIPTIONS: Belinda Thwesha belinda@trademax.co.za DISCLAIMER

The views expressed herein are not necessarily those of Trademax Publications. Although we have done our best to ensure the accuracy of our content, neither Trademax Publications nor SA Roofing magazine will be held liable for any views expressed or information disseminated, in editorial content or advertisements, in this issue.

8 15 JAN/FEB 2016

EDITOR’S COMMENTS

Our work is cut out for us

I have a feeling that 2016 is going to be a better year than 2015 was.

o, not because it couldn’t possibly get any worse, because evidently it can. (Are you also overwhelmed by the barrage of negative forecasts on, well, almost everything that impacts industry and consumers alike?) I have a feeling that we’re in for better days because we’re damned tough and we’re going to work our way out of these doldrums. At least, that’s what I think the ‘old schoolers’ will do. And I’m one of them. I’m ashamedly technologically challenged. Don’t ask me how wireless connections work, or how to pin a terist (what is that, anyway?). The first time I saw the phrase ‘IM’ I tried to correct its spelling by inserting an apostrophe. I still forget that LOL does not mean ‘lots of laughs.’ To be frank, I thought only birds made tweeting sounds. I don’t understand how my mother’s phone transports her UK holiday photos to me without paying for a stamp. And now I hear about talking cars that park themselves! I don’t know whether to be excited or scared – are the robots finally taking over? The building industry has always been at the forefront of innovation, and the latest marvel I’ve learnt about is VDC – Virtual Design and Construction. Apparently it obliterates communication obstacles between design, engineering, construction and client, moving projects from 2D legacy workflows into virtual realities even before a stone is turned.

It sounds amazing and is undoubtedly a very far cry from hand drawings from the 1990s – especially since this virtual environment is in the ‘cloud,’ can incorporate thousands of imagined structures, and can get 3D printed to scaled models of unprecedented detail. I’m so happy to leave the technological advances to the smart guys, and I’m so happy that there are so many smart people out there who, by doing what they do in their comfort zone, improve my comfort zone. Unfortunately I have to keep my head out of any sort of cloud; and, coming back to the poor state of affairs that impact our industry, I suspect many oldschoolers will follow a work ethic of applying some creative thinking but mainly hard work to weather the economic storm and come out of it for the better. That’s where SA Roofing can help. We are here to serve you, to help you say what you need to say to both your trade counterparts and your prospects. But let’s work together and work smarter, not necessarily harder. If we can do that, despite a slow start to 2016 for many, this might just be a great year. Welcome to the January/February 2016 issue of SA Roofing. Please send your questions, feedback and smart ideas to my inbox via: editor@trademax.co.za. And remember, we resume our monthly circulation with the next edition, being our March 2016 issue. Celéste

DWFCOLL 9017/1

Time takes a toll on most things, not stainless steel

Offering finishes from mirror to brown patina, in stainless steel you’ll find beauty, strength and versatility. So you’ll know that stainless steel doesn’t have to be bright to be brilliant.

Stainless Steel. It’s Simply Brilliant. Call 011 883 0119 or see sassda.co.za. Your complete stainless information source.

CONTRIBUTORS

Contributors GUS BEHN Gus Behn, CEO of Longspan Gutters (Pty) Ltd., joined the family-owned business in June 1994 after gaining extensive work experience that honed the skills he would need to eventually steer the company. After graduating from Maritzburg College in KwaZulu-Natal in 1988, he completed 18 months of national service in the South African Air Force. A 3-year career in real estate followed – first handling commercial leases in the Durban area, and then selling residential properties in the Pietermaritzburg surrounds. When he left the property game, Behn started working for Gilbey’s as a sales representative over the KZN Midlands area. He completed his stint with the company as one of their top sales performers. Although he joined Longspan Gutters at the insistence of and with much support from his father, it was at the bottom of the corporate ladder – Behn found himself installing gutters at all hours of the day and in all sorts of weather. However, the invaluable product and industry knowledge he gained soon equipped him to move into sales, and as time passed he took on more and more management duties. Today he is at the corporate helm (the Longspan Group comprises five companies) and especially proud that Longspan Gutters is widely regarded as a leading specialist rainwater goods provider in Southern Africa, offering so much more than just gutters.

GEORGE MATHEWS George E. Mathews is currently enrolled in his Bachelor’s degree studies at the UNISA’s Sunnyside campus in Pretoria. He also works as a consultant to the following organizations: North West University’s Centre for Research and Continued Education (CRCED - Pretoria), HVAC International (Pty.) Ltd., and TEMM International (Pty.) Ltd. In addition to the research paper “Proposed Installation of a Low-Cost Ceiling System in Low-Cost Housing” featured in this issue of SA Roofing, he has co-authored (together with Professor Edward H. Mathews profiled below) the paper “A Mobile Design Application for Energy Efficient Buildings,” among several others.

PROF EDWARD MATHEWS Professor Edward H. Mathews holds a PhD degree in Mechanical Engineering and is the head of the North West University’s Centre for Research and Continued Education (CRED) in Pretoria. In addition, he consults for HVAC International (Pty.) Ltd., and TEMM International (Pty.) Ltd.

Upcoming Events THATCHERS ASSOCIATION OF SA (TASA) 10TH ANNIVERSARY + LAUNCH OF TASA’S “GUIDE TO THATCH CONSTRUCTION IN SOUTH AFRICA” 23 APRIL 2016 | FOREVER HOTEL, CENTURION Email admin@sa-thatchers.co.za for more info or visit www.sa-thatchers.co.za

HOUSING FOR AFRICA CONFERENCE AND TOTALLY CONCRETE EXPO 9 - 11 MAY 2016 | GALLAGHER CONVENTION CENTRE, MIDRAND, JHB Visit www.totallyconcrete.co.za and www.construction-week.com for more info

AFSA INTERNATIONAL ALUMINIUM CONFERENCE & EXHIBITION 16 – 18 MARCH 2016 LAGOON BEACH HOTEL, CAPE TOWN Visit www.afsa-aluminium-conference.co.za for more info

WOODEX FOR AFRICA 9 - 11 MAY 2016 | GALLAGHER CONVENTION CENTRE, MIDRAND, JHB Visit www.woodexforafrica.com for more info

CAPE CONSTRUCTION CONFERENCE & TRADE EXPO 11 – 12 AUGUST 2016 | CTICC, CAPE TOWN Visit www.cape-construction.co.za for more info

INTERBUILD AFRICA 2016 (CO-LOCATED SHOWS: GLASS EXPO AFRICA, PLUMBDRAIN AFRICA, ECOAFRIBUILD AND HARDEX AFRICA) 17 – 20 AUGUST 2016, EXPO CENTRE NASREC, JHB Visit www.interbuild.co.za for more info NEW! WOOD WORLD SOUTH AFRICA (RUNNING ALONGSIDE INTERBUILD AFRICA 2016 IN HALL 5) Visit www.woodworldsa.co.za for more info

JAN/FEB 2016

C M A AWA R DS

Substantial increase in CMA Awards for Excellence entries The 2016 Concrete Manufacturers Association NPC, (CMA) Awards for Excellence competition has drawn a bumper crop of entries, which at 123 is almost double the 77 submissions entered during the last competition.

Coral Beach Estate, East London, roofed with Coverland’s Cupola roof tile.

mages and entry details of the competition’s six categories can be found in the Awards entry book which has been published electronically on the CMA’s website www.cma.org.za. The book provides a valuable reference document on some of the country’s most prestigious construction projects using precast concrete. Chairperson of the Awards committee, Monique Eggebeen, said the standard of this year’s submissions was high and in some cases extremely so. “It is quite clear from this year’s entry submissions that the use of precast concrete is growing rapidly across diverse applications, offering ease of installation as well as high standards of finish and durability.”

“First staged in 1985, the Awards have since become the undoubted highlight of the precast concrete industry’s calendar. They provide an excellent vehicle for southern African designers and project developers to establish themselves as trendsetters across several disciplines, and in doing so, to gain national recognition. The CMA is justifiably proud of the superior attributes of precast concrete which, once again, are evident in this year’s competition – attributes which are certainly on a par with those of our global compatriots.”

JAN/FEB 2016

“This year’s entry categories comprised the following: Aesthetics Commercial; Aesthetics Residential; Community Upliftment; Technical Excellence; Innovation and, for projects older than 10 years, Precast for Life,” explained Eggebeen. As anticipated, Aesthetics Commercial attracted by far the most entries, reeling in an impressive 50 projects. Submission numbers in the other categories were as follows: Aesthetics Residential - 12; Community Upliftment - 9; Technical Excellence - 26; Innovation - 15; and 10 entries in the Precast for Life category. Some entries were entered for two or more categories, which means that one project could win more than one award. Entries closed on 16 October 2015 and the judging took place on 23 November at the Johannesburg offices of PPC Cement, the main sponsor of this year’s event. The five judges, all leading professionals in the field of construction, were: landscape architect, Antoinette de Beer; architect, Hugh Fraser; civil engineer, Malcolm Pautz; civil engineer, Abe Thela; and quantity surveyor, Bert van der Heever. A possible six trophies, one for each category, and up to three commendation awards can be made in each category, providing the judges consider the entries to be worthy of an award. The results of the competition will be announced at a gala dinner ceremony at Summer Place in Johannesburg on 23 April 2016. Eggebeen concluded by saying that the CMA is extremely grateful to this year’s sponsors, without whom the awards could not have taken place. They are PPC (main sponsor), AfriSam, BASF, Chryso, and Lafarge.

C M A AWA R DS

CATEGORIES

AWARDS CATEGORY: AESTHETICS COMMERCIAL PROJECT: CORAL BEACH ESTATE, EAST LONDON Cupola Kalahari Farmhouse tiles and fittings manufactured by Coverland were used to roof Ocean Villas at Coral Beach Estate in East London. The strong deep-rolled Cupola profile roof tile, with its bold curves, lends an unmistakable Mediterranean character to the development. The tiles complement the earthy tones of the other houses and blend in neatly with the verdant vegetation.

PROFESSIONAL TEAM ARCHITECT: Geringer Architects QUANTITY SURVEYOR: Martin Walters MAIN CONTRACTOR: Rapid Trade 31 MANUFACTURER OF PRECAST CONCRETE ELEMENTS: Coverland

SOUTH AFRICA’S MOST ATTRACTIVE ROOF FASCIA SYSTEM

15 YEAR

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IDEAL DIY PRODUCTS www.roofbuddy.co.za

Call John: 082 452 1240 or email: roofbuddy@telkomsa.net

S A F E T Y EQ U I P M E NT

Understanding fall

restraint and fall arrest The term ‘fall protection’ is commonly regarded as a single concept that covers the entire spectrum of protection for workers who operate near fall hazards. However, there are multiple facets of fall protection, under different scenarios, that call for different applications. Hein Stapelberg, co-owner of Fall Protection Works, shares more.

With his lanyard at maximum extension, the person pictured here cannot physically fall over the edge – he is sufficiently restrained by his equipment.

THE EXTENT OF FALL PROTECTION In many instances, when people think of ‘fall protection,’ they tend to consider it as one topic that covers the complete range of protection systems for workers who operate near fall hazards. Usually, this is imagined in the form of a full-body harness and shock-absorbing lanyards. However, there are various aspects to fall protection that translate into various different applications and scenarios, and it is important to draw the necessary distinctions. Two safety techniques that appear very similar to most people, but warrant a more thorough understanding of what they entail, are fall restraints and fall arrests. In simple terms: • A fall restraint system is a preventative system that keeps workers away from the fall hazard, while • A fall arrest system allows workers to reach a hazard, from where it protects them if they should fall.

FALL RESTRAINT Fall restraint systems are most applicable in situations where workers have to do their duties near a fall hazard but don’t have to access a position that would directly expose them to the fall hazard. The restraint system, when correctly installed and applied, physically holds the worker back from the dangerous fall risk area. By eliminating the risk, the system prevents a fall from occurring.

Examples of scenarios where a restraint system should be in place include: Where maintenance work is being done near the edge of a building (e.g. gutters), and working in an area near a fragile work surface (e.g. near a skylight that may not be able to sustain a person’s weight).

CONSIDERATIONS WHEN FITTING FALL RESTRAINTS When fitting fall restraint systems, a number of factors must be taken into account for optimal safety: • The design of the restraint system should limit the user’s access to the fall risk at all times, while providing sufficient access to the areas where work needs to be done. • Rigorous testing should be done to ensure that the equipment the worker will be using can sufficiently support his/her weight as well as handle the forces involved in restraining them. • Fall restraint lanyards that exceed the correct operational length compromise the restraint capabilities and could lead to damage or injury. It is imperative that the lanyard used in a fall restraint system be of the correct length so as to prevent the user from inadvertently accessing the fall risk area.

JAN/FEB 2016

Fall arrest systems differ from fall restraint systems in that they allow a greater degree of freedom of movement for users to conduct their duties. This allows them to work in locations that would otherwise be inaccessible, but thereby also presents a greater potential for falling. However, in the event of a fall, the arrest system allows a worker to be safely stopped, and from there they can be rescued. In summary, whereas fall restraints keep workers a safe distance from the fall hazard, a fall arrest system allows the worker to conduct work in a direct fall risk position. Worker safety should be paramount to any operation or project, but even more so when working at height due to the increased risk of falling. Consult a qualified industry professional if you have questions about safety equipment or programmes.

Working in a position where he could fall from, the person pictured here is using a fall arrest system to ensure that, in the event of a fall, his fall will be arrested.

For more information, send an email to the author at hein@fallprotectionworks.com.

S A F E T Y EQ U I P M E NT

FALL ARREST

COV E R S TO RY

Clotan Steel. A partner you know you can trust. When it comes to roofing, there is too much at stake not to get it right. The reliability of the manufacturer you choose to do business with is pivotal. You need to choose a name you KNOW you can trust. When you read about Clotan Steel’s humble beginnings, the team’s drive and the hard work put in to bring them to where they are today, you know this company has been thoroughly tried, tested – and trusted. Here they share some of their insights and beliefs, and more of what makes them such a world-class outfit.

JAN/FEB 2016

COV E R S TO RY

“We live in an age defined by haste; we demand instant access to information, food, transport and communication – driven by our intense desire for instant gratification. By our very nature, when we want something, we want it now, and we’ll usually settle for an added bit of flair and panache to keep things vaguely interesting while we slave sheepishly ahead. Mostly, our affinity towards a particular product, company or service usually aligns snugly with the speed at which we will be able to gratify that very need. Yet, and you may nod in silent agreement, the things we value most in life are almost all based on mainly one thing: Trust – and trust develops over time, and comes mostly hard earned. It is exactly the trust we place in something that makes us treasure it as if it were a priceless commodity.

JAN/FEB 2016

THE QUESTION OF TRUST It is certainly no different when it comes to the construction industry. The skylines of our major cities are being adorned with spectacular and modern designs that relentlessly push the boundaries of design, yet the one common element that remains consistent and ever present is the use of steel. Steel is that solid, unwavering ol’ workhorse – the platform that is trusted to repeatedly shape colourful dreams into exquisite realities. At Clotan Steel, the philosophy of trust and reliability is fully engrained into every aspect of our operations and every product that leaves our premises.

COV E R S TO RY For more than 30 years our focus has been to form treasured and respected relationships with every potential stakeholder in our business – whether a small merchant in the vast wilderness of the DRC or a developer in central Cape Town. Delivering a solid sales experience every time someone crosses our threshold, the pride and passion that made this company the envy of its competitors is then further manifested in the quality products we deliver.

- allowing architects to design a very low-pitched roof without the constant threat of ‘puddling.’

CRAFT-LOCK® MORE THAN PROVES ITS METTLE

Recent demands for improved energy consumption are also no challenge for the product, since uniquely patented solar clips will fit the profile like a glove and will house just about any photovoltaic panel without jeopardizing the structural integrity of the roofing system.

Our flagship product is the Craft-Lock ® concealed fix system – a product that has been known and trusted for many years as the only, original concealed fix system that can consistently perform under severe weather and atmospheric conditions. The robust design of the profile makes it ideal for demanding site conditions where increased purlin spacing is required. The unique interlocking mechanism of two adjoining sheets makes it virtually impossible to unclip – a phenomenon that has been the Achilles heel of many of the profile’s closest competitors. Craft-Lock ® has successfully been tested to withstand negative loads of up to 3kN/m², the unique fixing method allowing it to maintain a positive fix method without piercing the roof surface. This ingenious approach allows for superior resistance against even the most violent of wind storms.

The recently upgraded roll-forming mills have by and large kept their small and versatile character, making accessibility to tightly spaced sites a dream to work with. Virtually as a given, the product can effortlessly be roll-formed on site by a small but well trained crew, literally within minutes after arriving on site.

It is exactly these unique, tried and tested features that recently made Craft-Lock ® the product of choice on the prestigious Mall of Africa project in Waterfall, Midrand – South Africa’s flagship retail development of this kind.

LIGHTWEIGHT STEEL ADDS EVEN MORE However, it is not only Craft-Lock ® that will continue to perform amicably on Waterfall’s latest and proudest addition: Almost 30,000m² of lightweight steel frames provide the framework and skeleton for the modern ETICS cladding system that adorns the majority of the façades around the Mall.

The 41mm-deep trough that forms in the broad flute of the Craft-Lock ® profile has a water carrying capacity of approximately 29 litres/m² surface on a roof pitch as low as 1˚

JAN/FEB 2016

COV E R S TO RY Lightweight steel frames and building methods have grown tremendously in popularity over the recent past, due to the lightweight but remarkably strong design capabilities of the 0.8mm ISQ550 steel. Once again, the reliability of steel, coupled with the speedy erection process, combines beautifully to achieve astounding results – with minimal waste and effort on site.

IT’S ALSO ABOUT PEOPLE Clotan Steel’s highly trained and experienced technical support staff played an integral role in the design stages of this project, as they do on all developments we encounter. Meticulous scrutiny of drawings allows us to compile complete and accurate cutting lists and flashing detailing, taking the effort away from the professional team. Lightweight steel designs are quickly converted into CAD files and can literally start roll-forming within hours of leaving the design table. For more than three decades, Clotan Steel has provided consistent and reliable service and products. That will not change as the company continues to earn the trust and peace of mind that one seeks in these tough and volatile conditions that dictate the construction industry.”

FOR MORE INFORMATION AND TO CONTACT CLOTAN STEEL: Tel: (016) 986 8000 E-mail: info@clotansteel.co.za Website: www.clotansteel.co.za

JAN/FEB 2016

Ash & Lacy Building Systems

Ashgrid

OvER-ROOfing SyStEM ‘Raising the Bar’ in roof refurbishment. MiniMiSES RiSK • Eliminates costly disruption to trade. • Dramatically improves health & safety for contractor & occupants of the building. • Eliminates consequential damage to property due to inclement weather & falling debris.

EASy & EffiCiEnt tO inStALL • Ideal for over-roofing. • Easy and safe insertion of brackets. • Patented “Twist & Lock” application. • Fewer components • Fast installation times. • Brackets are easily repositioned if required.

EnERgy EffiCiEnt • Easily achieve prescribed r-values of SANS10400 XA. • Creates a defined structural cavity to accomodate insulation. • Prevents compression of insulation allowing it to perform to specification. • Improves overall energy efficiency of building.

PROvEn QUALity • Manufactured & tested to international standards BS EN ISO 9001: 2000 & UKAS accredited

StRUCtURALLy SUPERiOR • Safe-Loc™ spigots - fast, secure and safe bar joints • New high performance brackets with deeper ribs. • No requirement for anti-sway brackets below 250mm construction depth • Allows continuous load transfer throughout the bar run • Deep ribbed bar, ensuring optimum fixing efficiency for the top sheet • High fixing torque and increased pull-out strengths achieved • Non-combustible

E: dion.marsh@ashandlacy.com M: +27+83 215 1782 O: +27+21+782 0255

www.ashandlacy.co.za

Ashgrid has Pick n Pay covered

OV E R- ROO F I N G

When a prominent Pick n Pay Hyper building looked like it was going to need a complete roof replacement, the property management team had serious concerns about the process and sought a better option. The Ashgrid over-roofing system provided an ideal solution.

he Pick n Pay Hyper building in Ottery, Cape Town, is a well known landmark to most Capetonians and a hive of activity seven days a week. The building is managed by Redefine Properties who recently had the unenviable challenge of having to attend to the roof, which over the years had begun presenting more and more water ingress problems. Redefine Properties and Pick n Pay had concerns regarding the risks associated with conventional roof replacement. They were particularly apprehensive when it came to public health and safety, the costly disruption to trade, inclement weather, and the potential for damage to property and stock that can occur when removing an existing roof covering.

JAN/FEB 2016

CASE STUDY: Pick n Pay Hypermarket, Ottery, Cape Town CLIENT: Redefine Properties Limited PROJECT MANAGEMENT: Slabber Fick & Associates Quantity Surveyors CONTRACTOR: Chartwell Roofing (Pty) Ltd (Cape) OVER-ROOFING SYSTEM: AshgridTM

OV E R- ROO F I N G

Three different heights of Ashgrid Systems were specified to eliminate the existing steps in the roof, namely 85mm, 135mm and 190mm. The existing roof covering and flashings were left in position, thereby providing an excellent work surface for the contractor, Chartwell Roofing. The Ashgrid bars and brackets were assembled on the roof prior to installation, as the unique patented ‘twist & lock’ technology of the system allowed for the brackets to be easily re-spaced along the bars to accommodate the profiles of the existing roof covering. The pre-assembled brackets and bars were then fixed to the existing steel purlins by means of 25mm self-drilling fasteners that were drilled through the pans of the existing roof sheets. The new long span concealed fix roof sheets were roll-formed on site by Global Roofing Solutions and installed to the engineered Ashgrid bars by means of concealed fix clips and self-drilling fasteners.

OUTCOME Additionally, the original design of the roof itself posed further challenges. The original low-pitched design had incorporated a number of steps in the roof planes to accommodate the maximum transportable lengths of roof sheets that were available in the market at the time of construction. The majority of the roof leaks that were being experienced originated at those steps in the roof.

THE ASHGRID SOLUTION The Ashgrid spacer system with its variety of bracket heights provided the ideal solution to eliminate those steps whilst accommodating site-rolled, long span concealed fix roof sheets ideally suited to low-pitched roof designs. The Ashgrid over-roofing system was selected over alternative untested systems due to its proven 15-year track record, comprehensive testing, engineered design, and wide range of bracket heights.

Despite the project having been undertaken during Cape Town’s ruthless winter, the entire refurbishment process was completed without any disruption to Pick n Pay’s busy trade, whilst exponentially improving health and safety aspects for both the contractor and the shoppers below. Chris Ball, director of Chartwell Roofing Cape, commented, “The Ashgrid spacer system provided the perfect solution to what would have been a high-risk and challenging re-roofing project. The system was incredibly quick and easy to install, which allowed Chartwell Roofing to achieve a very tight, critical path programme in challenging weather conditions. Ash & Lacy South Africa’s onsite technical support and know-how proved invaluable on this prestigious and highly successful project.” For more information, visit the Ash & Lacy South Africa website at www.ashandlacy.co.za.

JAN/FEB 2016

GRS Klip-Tite

There is no approved or equivalent No other product has this performance! KLIP-TITE - ONLY FROM GRS Developed through continuous in-house testing of Klip-Lok 700, it was evident that failures occurred due to deflection of the pan during high wind loads causing the sheets to disengage. The following improvements were thus developed: • Transverse stiffeners were introduced in the pan, to achieve a balanced system design. • Transverse stiffeners reduce the deflection of the pan, increasing the wind uplift resistance. • The ultimate wind-uplift resistance of Klip-Tite exceeds expectations. • Klip-Tite has retained the superb properties normally associated with Klip-Lok 700. • Transverse stiffeners are a first in the South African sheeting market.

Talk to us, The Smart Roof People on 011 898 2900 or visit www.globalroofs.co.za or email info@globalroofs.co.za

Delivering the Exceptional

GRS Klip-Tite

GRS

GLOBAL ROOFING SOLUTIONS

S TA I N LE S S S TE E L ROO F I N G

Stainless Steel Roofing – Part 2 In this instalment of a three-part series of articles by the Southern Africa Stainless Steel Development Association (sassda), we learn more about the exceptional qualities of stainless steel that make this versatile metal such an obvious choice for roofing today and tomorrow.

The Isabel Bader Centre for the Performing Arts at Queen’s University in Kingston, on the shores of Lake Ontario.The architectural team describes the custom stainless steel panelling as a metaphor for that moment when water turns to shimmering ice. Architects of record: N45 ARCHITECTURE Inc. (www.n45.ca); Designer partners: Snohetta

hen considering metal roofing, whether traditional corrugated or IBR, it must be noted that the biggest disadvantage of mild steel is its lack of corrosion resistance. For it to last a reasonable amount of time, it must be coated in some manner. Initially, mild steel was simply painted; then followed the process of galvanizing. Galvanizing of roofing materials generally refers to the application of zinc (99.7%) and silicon (1.5%) plus a little aluminium and lead, to provide corrosion resistance to the mild steel. That said, over time and after extensive research into improving the traditional performance of galvanized steel, researchers discovered a way to greatly enhance corrosion resistance by blending aluminium with zinc in an alloy coating. The following alloy coating composite, when used to coat steel, will extend the life of the steel core up to four times longer than that of an equivalent galvanized coated steel used in similar conditions: Aluminium (55%), zinc (43.5%), lead (0.01%) and silicon (1.5%). It can be argued that stainless steel is a superior roofing material to coated carbon steel, especially insofar its corrosion resistance is concerned.

But its widespread use has been hampered by the belief that it’s more expensive and, more importantly, that it tends to be regarded as a special-order product. Whereas most carbon steel profiles are available ex stock, the same (sadly) cannot readily be said for stainless steel. In addition, although stainless steel may be easily formed into traditional roofing sheet profiles such as corrugated or IBR, there are converters who won’t (for reasons other than profiling equipment related) produce concealed-fix stainless steel roof sheets. And, South Africa lags in the use of standing seam profiles, no doubt because of the higher technical requirements for finishing (i.e. mechanical folding or continuous welding of the standing seam). Despite these challenges, stainless steel remains a viable, competitive building material and increased use within industry is well supported by sassda’s mandate to promote and market stainless steel.

JAN/FEB 2016

In architectural applications, stainless steel is often used because of its attractive appearance. Façades, interior cladding, lifts and escalators, handrails and parapets are some of the most typical areas of stainless steel use. But stainless steels, of which there are more than 200 grades, have more to offer than just good looks. Its technical properties make stainless steel an ideal choice for many other building applications in which additional durability requirements are essential. Few other elements of a building dominate its appearance as much as the shape of the roof. Stainless steel is suitable for any flat, pitched or curved roof geometry. Stainless steel products are available in many different finishes. The range of surfaces varies from subdued greys, to bright mirror-type finishes. And they will all change their appearance as they reflect even subtle changes in the lighting conditions around them. The architect and the roofing contractor can make a number of design decisions related to the required visual effect, the roofing technique and the environment. When the roof just has to be functional, the choice is easy: the most common finish is 2B, which has a rather reflective, smooth, flat surface. Stainless steel may be coated with a very thin layer of 100% tin. The advantage of this tin layer is not only the matt grey appearance, but it simplifies the soldering of finishing pieces such as gutters, roof penetrations and flashings. A dull, matt finish can be obtained by a cold rolling process. Several producers offer a wide range of different finishes. Another method of matt finishing is by blasting the material with a non-ferritic, benign granulate. This is often called bead blasting or shot peening. This process can be modified to produce a variety of plain reflective or dull textures, which are both attractive and durable. However, the process can result in distortion of shape, especially if only one side is blasted. The use of coloured stainless steel is very popular in some countries. Some producers offer a PVDF coating with a typical thickness of 35 µm. There are also acrylic coatings on the market in a colourful range that can be matched with those available in painted carbon steel. Other manufacturers produce colour by an electrolytic chemical process, which thickens the oxide layer to reflect a metallic look in gold, blue, bronze, green, black and red. The general corrosion resistance of the stainless steel is usually not altered by finishing processes, but it should be remembered that the smoother the surface, the better the corrosion resistance for that grade. Particularly, in severely polluted areas, rougher surfaces can harbour deposits of dirt and moisture that can stain or damage the stainless finish. It is important to design in such a way that rainwater will easily wash and drain from the surface. Although stainless steel is available in a vast range of grades, generally, convertors will use only a couple of grades for roof sheeting, namely 304 and 316, which also constitute about 80% of stainless steel use.

JAN/FEB 2016

ENVIRONMENTAL ROOF EXPOSURE

S TA I N LE S S S TE E L ROO F I N G

ARCHITECTURAL PROPERTIES & ROOF DESIGN

One needs to determine the environment to which the roof will be exposed. The following table provides a useful guide:

CLASS

DESCRIPTION OF ENVIRONMENT

TYPICAL GRADE

Low

Rural areas with frequent rainfall and/or high temperatures. Urban areas with low industrial activity and without significant pollution.

304, 3CR12, 2001, 2101

Medium

Urban areas with higher pollution. Industrial and coastal areas with higher rainfall.

316, 316L, 444, 2304

High

Industrial or coastal areas with high temperatures. Areas of higher risk where chlorides, sulphur dioxide and fluorides occur. Particular care should be taken to avoid crevices where corrosive material, chlorides, etc. may accumulate.

317, 2205, 904L

COMPATIBILITY WITH OTHER MATERIALS Whilst some other building metals or materials may suffer severe corrosion from run-off water, stainless steel is highly resistant. However, care must be taken in the case of combinations of metallic materials. These may be susceptible to galvanic corrosion, a process that reflects the principle of a battery: two metals (one relatively ‘noble’ and the other much less ‘noble’) get into electrically conductive contact with each other and are chemically connected through an electrolyte. In these circumstances, when a current flows from the less noble to the more noble material, the former is consumed. Stainless steel has a potential similar to that of silver and is generally the more noble partner. Rainwater and even the humidity in the air may suffice to form an electrolyte. If unprotected, the contact material may corrode, while the stainless steel will remain intact. A widespread error is the use of non-stainless steel fasteners (e.g. galvanized screws and aluminium rivets) on stainless steel components. Because the surface of the stainless steel on a roof is large and that of the fastener small, galvanic corrosion may quickly deteriorate less noble fasteners. The use of stainless steel fasteners is therefore strongly advised. Quite often, contact of stainless steel with other metallic materials is inevitable or even desired by the architect to create special visual effects. In these cases, the galvanic effect can be minimized if the stainless steel component is much smaller than the other metallic part (e.g. painted or galvanized carbon steel). For this reason, stainless steel fasteners in steel, aluminium, zinc or copper roofing do not create problems. The latest South African Building Regulations as presented in SANS10400 Part L (Roofing) has much to say on the matter of compatibility. The following tables will appear in the updated version of SANS10400 Part L. The data shown in red was an amendment.

S TA I N LE S S S TE E L ROO F I N G

Photograph courtesy of N45 ARCHITECTURE Inc. (www.n45.ca).

S TA I N LE S S S TE E L ROO F I N G

COMPATIBILITY OF METALS AND METAL COATINGS TABLE C1: COMPATIBILITY OF MATERIALS IN DIRECT CONTACT UPPER SURFACE

LOWER SURFACE

GALVANIZED

GALVANIZED + PAINT

AL/ZN

AL/ZN + PAINT

ALUMINIUM

STAINLESS STEEL

COPPER

Galvanized

Yes

Galvanized + Paint

Yes

Al/Zn

Yes

Al/Zn +Paint

Yes

Aluminium

Yes

Stainless Steel

Yes

LEAD

UNSEASONED OR WET TIMBER

Al/Zn=Aluminium/Zinc

TABLE C2: ACCEPTABILITY OF DRAINAGE FROM AN UPPER TO LOWER SURFACE LOWER SURFACE

UPPER SURFACE FIBRE CEMENT & CEMENT TILES

SLATE & GLAZED TILES

GLASS & PLASTIC

Yes

GALVANIZED

GALVANIZED + PAINT

AL/ZN

AL/ZN + PAINT

ALUMINIUM

STAINLESS STEEL

COPPER

Galvanized

Yes

Galvanized + Paint

Yes

Al/Zn

Yes

Al/Zn +Paint

Yes

Aluminium

Yes

Stainless Steel

Yes

THE MAIN ADVANTAGES OF STAINLESS STEEL ROOFS MAXIMUM LIFE EXPECTATION The presence of air pollution highlights the need for corrosionresistant materials on buildings. Stainless steel roofs constructed as long ago as the 1930s (e.g. Chrysler Building, New York) provide proof that stainless steel is the ideal answer to this requirement. Stainless steel has the remarkable capability to ‘self-repair.’ Containing at least 10.5% chromium provides the alloy with an inherent ability to protect itself from corrosion. Chromium in the metal reacts with oxygen in the air and/or water to which the surface is exposed, and forms an invisible protective film of a chromium-rich oxide. If this layer is damaged, it is spontaneously rebuilt if oxygen is present.

MINIMUM MAINTENANCE As maintenance costs continue to increase, this should be borne in mind from the planning stage of a building. Because of their long-term corrosion resistance and smooth surface finish, most stainless steel roofs require very little maintenance.

LEAD

LOW WEIGHT The high mechanical performance of stainless steel generally results in material thickness less than other metallic roofing materials. This can result in a lower overall erected weight and therefore a lighter, more cost-effective supporting structure. And stainless steel has even more to offer. The final article in this series will deal with the economics of roofing and aims to help demystify the concept and application of Life Cycle Costing. For more information, visit www.sassda.co.za.

ACKNOWLEDGEMENTS: Columbus Stainless, Roofing Article, 2014 Euro Inox ‘Technical Guide to Stainless Steel Roofing’ – Building Series, Volume 5; ISBN2-87997-016-4; 2004 Outokumpu ‘Handbook of Stainless Steel’; 2013 Safintra South Africa Southern Africa Stainless Steel Development Association (sassda): Architectural presentation; 2015 SS Profiling (Pty) Ltd Various brochures of merchants and converters

JAN/FEB 2016

LOW- CO S T C E I L I N G S

Proposed installation of a low-cost ceiling system in low-cost housing In the previous two issues of SA Roofing, we covered a City of Cape Town redress initiative aimed at tackling the problem of RDP houses that had been built without ceilings. The following research paper, which was authored by George E. Mathews and Edward H. Mathews and presented at the Domestic Use of Energy Conference (DUE) 2015, again reminds us of the importance of thermally efficient ceiling installations and offers a beneficial, low-cost option. PREFACE With the exclusion of houses benefiting from select government programmes more recently put in place to start addressing the matter, existing formal low-cost houses in South Africa have largely been shown to be very thermally and energy inefficient. This is problematic for the country, considering that roughly 2.8-million such houses were built. Energy inefficiency in these houses can be effectively addressed by installing ceilings, but the cost thereof is unfortunately too high to be affordable to the applicable sector of the population. New options need to be considered to reduce costs. Research has shown that practically any material can be used as a ceiling if it provides a barrier to heat flow and eliminates infiltration. The material should ideally possess good thermal properties and comply with standard building regulations, but most importantly, it must be very cheap and easy to install. The low-cost ceiling proposed here has all of these attributes, and installation thereof could result in substantial energy savings, improved indoor comfort, and a better quality of life.

THE PROBLEM OF ENERGY INEFFICIENCY With the advent of democracy in 1994, South Africa was faced with a significant housing problem. Studies at the time found that approximately 12.5-million South Africans were without proper housing [1]. In order to combat the problem, the government implemented several programmes [2,3,4] to renovate and construct new housing for those people. In the first 20 years since, the programmes had completed over 2.8-million new housing units and created over 3.8-million new housing opportunities [5]. However, many of the units built under those programmes followed a common design philosophy that has been proven to be energy inefficient [6-11]. This is largely due to the fact that many formal low-cost houses had been built with the option of having a ceiling installed at a

later stage, but then, and unfortunately in the vast majority of cases, never got fitted with ceilings [7-11]. Simulations performed in the past have revealed that winter heating requirements can be reduced by up to 74% with the installation of a ceiling [6]. This is a huge reduction in energy expenditure, and by far one of the most effective ways of improving energy efficiency in formal low-cost houses [9-11].

LOW-COST DWELLING: DEFINITION A typical formal low-cost type house generally consists of a brick walled structure enclosing one or two rooms. The roof typically consists of wooden trusses or beams covered with galvanized steel roof sheeting. The footprint of the houses typically covers between 35m2 and 50m2 , usually in a near-square layout, with full span trusses or beams spanning the usual 6m to 7m span between the two opposite walls. A low, double pitch roof with beams or trusses and minor gabled end walls is commonly employed. More often than not, there is no installed ceiling. This results in direct convective, conductive and radiation heat losses or gains (depending on the season and time of day) via the unenclosed roof space and thin (typical 0.5mm) steel roof sheeting [7,20]. Figure 1 shows the interior of a typical low-cost type dwelling. Partly visible at the top of the picture, the exposed roof trusses can be seen.

Figure 1.Typical low-cost type dwelling interior showing exposed roof trusses [20].

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The fact that ceilings are so effective at increasing year-round energy efficiency [12-14] can be attributed to the way in which they affect the various heat transfer mechanisms at work in a house. Firstly, ceilings provide an insulating effect. Secondly, they reduce the infiltration of air to and from a room. Thirdly, they reduce the effects of stratification within a room. Finally, they reduce the effect of radiative losses to a cold roof surface. [8] Further, the degree to which these attributes of a ceiling installation affect the various heat transfer mechanisms has previously been determined [15]. Energy simulations were also previously performed for a â&#x20AC;&#x2DC;typicalâ&#x20AC;&#x2122; South African formal lowcost house [16].

EFFECT ON WINTER ENERGY CONSUMPTION Simulations were previously performed by Mathews and Weggelaar [8] for all major provincial centres nationwide, to determine the effect of installing ceilings in low-cost houses on winter energy consumption. The results from these simulations are presented in the following table in terms of energy consumption figures and percentage reductions in energy consumption [8].

WITHOUT CEILING (KWH)

WITH CEILING (KWH)

REDUCTION (%)

Bloemfontein

8 138

4 194

Cape Town

4 115

1 153

Durban

3 024

548

East London

1 569

George

3 220

657

Johannesburg

5 525

2 191

Kimberley

5 317

2 154

Phalaborwa

1 511

264

Port Elizabeth

1 067

Pretoria

5 427

1 357

Upington

4 322

1 646

LOCATION

Table 1. Potential reduction in annual winter heating requirements in 2006 [8].

These results leave no doubt that enormous energy savings could be realized by installing ceilings in formal low-cost houses.

REQUIREMENTS The basic requirement for the ceiling of a formal low-cost type house is to separate the living space from the roof space above the lower beams of the roof trusses. This will eliminate one large heat flow path in the house since direct convective circulation between the living space and the hot or cold roof space is blocked.

JAN/FEB 2016

In addition, any conductive insulation above the ceiling material will further limit the heat flow between the two air volumes. Some form of radiation reflective surface on the ceiling material will also limit the radiation losses between the hot or cold steel roof sheeting and the roof space.

LOW- CO S T C E I L I N G S

CEILING INSULATING EFFECT

Notice also has to be taken of the regulatory requirements for ceilings and the thermal insulation of dwellings under the new South African National Building Regulations. The applicable parts of SANS10400 to this project are with regards to fire protection (Part T) and thermal performance (Part XA) [5]. This outline takes the basics of these requirements into consideration.

CEILING CONCEPT A previous ceiling concept for low-cost houses was envisioned by Mathews and Weggelaar [8]. However, this concept required the ceiling to be fastened to the wall, and this caused installation failures in buildings that were poorly constructed. The roof material also suffered some amount of sagging due to age. A new ceiling concept was thus envisioned. This new concept for an affordable ceiling for low-cost type houses consists of using a flexible membrane, with some inherent insulation properties, to separate the roof volume from the living volume. Several roof insulating membranes are commercially available. These are usually used as an insulating membrane to reduce air exchange and radiant heat through concrete tiled roofs. They are not, however, often installed in low-cost housing. They are usually applied when the roof is constructed in a position over the beams/trusses but below the purlins. A small but important air space is thus created between the membrane and the roof covering.

Purlins

Figure 2. Conventional roof structure [21].

While not having high conductive insulation properties, these membranes insulate as part of a system where the entrapped air space and the reflective aluminium foil surfaces work together to reduce either inward or outward heat flow, depending on the season. A further advantage of these materials is that they have been extensively qualified in terms of fire regulation requirements, and should be suitable for use as a ceiling material below the roof trusses or beams in dwellings that are already constructed. Roof trusses or beams are typically spaced at 1,200mm or less. Most of the commercial ceiling membrane materials are available in rolls with a width of 1,250mm and lengths of 40m. It would thus make sense to combine the trusses and membrane width in lengthwise sections as shown in Figure 3.

LOW- CO S T C E I L I N G S

INSTALLATION AND COST Installation of the ceilings in dwellings can be done by small, locally trained installation teams. Typically, such a team would consist of a general building/carpenter artisan assisted by a general building labour assistant. They would also need access to a light delivery vehicle to transport themselves and the necessary materials to site.

Figure 3. Single ceiling membrane sheet in place.

For appearance and sealing purposes it is important to have a tight and tidy joint overlap between two adjacent ceiling sheets. Thin wooden batons can thus be nailed or stapled to the bottom of the roof truss to create a neat and tight overlap joint. The membrane material and the slat can also be tidied after installation by cutting off loose ends and painting or varnishing the slat. At the support wall ends of the roof trusses, the ceiling sheet needs to be secured. For the purpose of this project, the use of wooden lengths, similar in size to the purlins, as end fastening batons is expected. The membrane can then be stapled to the top of an end baton, which in turn is nailed or screwed to the bottom of the truss beams right against the wall. It is, however, not advisable to fasten this beam to the wall structure as the condition of the walls in low-cost type housing is often uncertain. If necessary, a small foam strip can be used between the end batons and the wall to create a seal in the case of uneven wall surfaces. A special mitred joint between adjacent end batons is also required to ensure overlap continuity of the membrane at the wall ends. This can easily be prepared as part of the installation preparation. The end product should thus be a ceiling consisting of a relatively tightly stretched insulation membrane section, supported at the wall sides by end batons and sealed on the joint overlaps with overlap batons nailed to the roof truss lower beams. Figure 4 shows the components necessary for such a ceiling installation.

End batons Roof trusses

Further, in order to effectively and efficiently install a neat ceiling, some special tooling should be developed to neatly tighten and fasten the membrane between the end batons. A cutting tool for the mitred joint between end batons will also ensure consistently effective and neat joints without membrane wrinkling. A team would typically gather an installation ‘package’ consisting of the necessary materials (small items already prepared in pre-packed parcels), before proceeding to the installation site. The final cost for such a ceiling would be approximately R27/m2 .

RESULT By extrapolating, for houses built since 2006, from Mathews and Weggelaar [8], it can be estimated that the national peak electricity demand could be lowered by 250MW - 400MW through the installation of ceilings in low-cost houses that were built without. In addition, homeowners would be able to save in the region of R135 per year on winter heating requirements, and indoor temperatures could be reduced by up to 4°C in summer.

CONCLUSION Studies have shown that the installation of a ceiling in low-cost houses without ceilings can have a substantial impact on increasing the dwellings’ heating energy efficiency. This is especially important since about 2.8-million such houses have been built since 1994, with many of those being without ceilings. Subsequently, a ceiling design was proposed that used an entrapped air space and reflective aluminium foil surfaces to prevent heat loss and gain via the roof. The ceiling was also designed to be as cost-effective and easy to install as possible. The installation cost of such a ceiling, found to be approximately R27/m2 , would result in a yearly heating cost saving to the homeowner of approximately R135. Further, a nationwide initiative consisting of such installations could result in a national decrease of the peak demand by 250MW - 400 MW.

Ceiling membrane

Overlap baton

ACKNOWLEDGEMENTS End baton Figure 4. Basic components of ceiling system.

Principal author: George E. Mathews. Co-author: Professor Edward H. Mathews. (Both authors with the North West University’s Centre for Research and Continued Education (CRCED - Pretoria) and consultants to HVAC International (Pty.) Ltd. and TEMM International (Pty.) Ltd.)

JAN/FEB 2016

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LOW- CO S T C E I L I N G S

The redesign of the low-cost housing ceiling as described was conducted by Mr MN Nieuwoudt. The content of the above-referenced research paper is copyrighted. It is published here in SA Roofing courtesy of the Domestic Use of Energy Conference (DUE) 2015. More information is available on www.energyuse.org.za/due. For more information, send an email to the principle author George E. Mathews at 20270046@nwu.ac.za.

REFERENCES [1] T. Lodge, “The RDP: Delivery and Performance” in “Politics in South Africa: From Mandela to Mbeki,” Cape Town, David Philip, 2003. [2] African National Congress, “The Reconstruction and Development Plan,” Umanyano Publications, Johannesburg, South Africa, 1994. [3] African National Congress, “The National Development Program,” Johannesburg, South Africa, 2012. [4] Department of Human Settlements, “National Housing Code,” Pretoria, South Africa, 2009 [5] Department of Human Settlements, “2013-2014 DHS Annual Report,” Pretoria, South Africa, 2014 [6] P.G. Rousseau and E.H. Mathews, “A new integrated design tool for naturally ventilated buildings, Part 1: Ventilation Model,” Building & Environment, Vol. 29, pp. 461-471, 1994. [7] O.O. Kelvin and L.E. Meyer, “Energy Conservation Measure in RDP House in South Africa,” Fort Hare Institute of Technology (FHIT), University of Fort Hare Alice, Alice, South Africa, 2012. [8] E.H. Mathews and S. Weggelaar, “Enhancing the efficiency of formal low-cost houses by the development of a new lowcost ceiling system,” Journal of Energy in Southern Africa, Vol. 17, No. 1, pp. 18-27, 2006. [9] H. Winkler, R. Spalding-Fecher, L. Tyani, and K. Matibe, “Cost-benefit analysis of energy efficiency in urban low-cost Housing,” Development Southern Africa, Vol. 19, No. 5, pp. 593614, 2002.

[10] H. Winkler, R. Spalding-Fecher, and L. Tyani, “Energy efficiency in low-cost housing: Costs and benefits of global and local externalities,” Developing energy solutions for climate change: South African research at EDRC, Cape Town, South Africa, 2002, pp. 44-57. [11] R. Spalding-Fecher, A. Clark, M. Davis, G. Simmonds, “The economics of energy efficiency for the poor—a South African case study,” Energy, Vol. 27, No. 12, pp. 1099-1117, 2002. [12] R. Plank, A. Amato, and S. Neal, “Thermally efficient ceiling designs,” New Steel Construction, Vol. 5, No. 4, pp. 21-23, 1997. [13] W.K. Robertson, and S.P. Kimsey, “Design/Build: Obtaining energy efficiency,” Heating/Piping/Air-conditioning, Vol. 63, No. 1, pp. 79-82, 1991. [14] R.P. Rorich, “Low-cost ceiling as a feasible Clean Development Mechanism (CDM) project,” Eskom, Johannesburg, South Africa, pg. 3 & 17, 2000. [15] E.H. Mathews, and S. Weggelaar, “The development, testing and demonstration of a new energy efficient, low- cost ceiling system for the formal low-cost housing sector – Interim report,” Eskom, Johannesburg, South Africa, 1997. [16] D. Holm, K. Trieloff, D.F. Van Aswegen, and S.L.Van Wyk, “Towards a policy for passive thermal design in low- cost housing,” DME, Pretoria, South Africa, 1994. [17] R.M. Surtees, “What our customers use and when they use it,” Eskom, Johannesburg, South Africa 1992. [18] J.D. Wentzel, “Acceptable indoor thermal environmental conditions,” CSIR Environmental Engineering, Pretoria, South Africa, NBR1 CSIR, 1982. [19] R. Moola, N. Kotze and L. Block, “Housing satisfaction and quality of life in RDP houses in Braamfischerville, Soweto: A South African case study,” Urbani izziv; Vol. 22, No. 1, 2011. [20] Moladi Construction Website, http://www.moladi.net/ construction_gallery.htm, Accessed 24 October 2014. [21] C.M. Harris, ed, “Dictionary of architecture & construction,” McGraw-Hill, New York, NY, 2006.

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G U T TE R S

Roofing Matters:

Why you should specify seamless aluminium gutters In this edition of our article series that asks experts for advice and information on important roofing matters, Gus Behn, CEO of Longspan Gutters (Pty) Ltd., gives us the low-down on seamless aluminium gutters.

us Behn knows his business, and his business is guttering. Since joining Longspan Gutters (familyowned) in 1994, this full-service gutter business – which opened its doors in 1980 already – has continually reinforced its position in the residential, commercial and industrial markets and today stands as a provider of choice, offering customers a comprehensive solution to a vast range of configurations. Services include the provision and installation of standard roll-formed seamless gutters on site, purposemade gutters, fascia and barge board replacements, purposemade cladding and flashing, as well as rainwater harvesting solutions.

SA ROOFING: As part of the overall roofing structure, do you think sufficient attention is given to gutters?

BEHN: Unfortunately, no. Rain gutters are so often

neglected, ignored and/or not specified on residential, commercial and industrial buildings, that serious problems caused by the omission of these vital products are common. These problems, including rising damp and other similar or related issues, can be very costly to rectify. The primary purpose of a gutter system is to catch rainwater off the roof and channel it via the downpipes into an allocated

catchment (e.g. gullies) away from property so as to prevent rising damp. Rain gutters are therefore an essential component in the construction of any building and its roofing structure, and must not be overlooked.

SA ROOFING: What considerations are in play when selecting rain gutters and downpipes?

BEHN: Factors that should be taken into account when

specifying the correct rain gutters and downpipes include: • Roof pitch • Roof area • Run-off • Roof overhang The size of the roof area is a critical factor. The larger the roof area, the more water is going to require run-off and catchment – and this will determine the appropriate gutter and downpipe sizes needed for adequate protection. In some instances, the sheer size of the roof area may necessitate custom-made guttering. By specifying the correct rain gutters and accompanying downpipes, you can ensure that the building’s rainwater run-off is adequately managed, thereby preventing damage to the bricks and mortar.

JAN/FEB 2016

G U T TE R S

Photo credit:Timbercraft, courtesy of ITC-SA Downpipes may vary in size and specification, but primarily comprise the following variations: • 75mm x 50mm aluminium • 100mm x 75mm aluminium • 80mm diameter PVC • 110mm diameter PVC • 160mm diameter PVC

SA ROOFING: What is the best material for gutters? BEHN: Without hesitation, I recommend aluminium. There

Redirecting the downspout to a water barrel. Photograph by Roger Mommoarts.

SA ROOFING: What is the difference between sectional systems and seamless gutters?

BEHN: Sectional gutters are put together in sections, marked by closely-spaced joins and sealants, whereas seamless gutters are only joined at the corners where the gutter has to be cut and a mitred corner piece placed over it.

By far, the vast majority of gutter systems preferred and in place nowadays are seamless gutters, although sectional gutters do still get used – probably because they are more affordable. Sectional gutters do present a higher risk for leaks and problems with expansion and contraction than seamless gutters, which carry no external brackets, are uncluttered and present timeless lines, and, frankly, provide a more aesthetically pleasing look and feel to any roofing project.

SA ROOFING: Are there standards? BEHN: Seamless aluminium gutters that are roll-formed on site to exact lengths are manufactured in the following standard profiles:

are other materials (plastics and metals) available as an option, probably lower in cost and used mostly in climatic regions like Gauteng and Mpumalanga that pose a lower chance of rust, but in my experience those materials do eventually rust, and they also corrode. Aluminium gutters just last longer. The fact that they are recyclable is an added benefit.

In South Africa, aluminium-manufactured gutters come with a 15-year factory or manufacturing warranty against corrosion, flaking, peeling and chalking. In addition, aluminium gutters are easy to paint and come readily available in six pre-painted standard colours. For custom paints, you should check with your gutter company. Longspan Gutters, for example, can custom-order paint for a unique gutter project, provided it is in viable quantities.

SA ROOFING: How often should you inspect your gutters? What should you look out for?

BEHN: Gutters certainly need to be checked and maintained,

and I recommend doing so at least every six months. Leaves from trees, combined with sand, dust, dirt and other types of grime can easily fall into a gutter and remain unnoticed, causing problems if not taken care of. I recommend that basic gutter and downpipe maintenance (such as running a hosepipe in the gutter to spray out debris) be kept up regularly to keep the gutter system effective and looking good. Other aspects to look out for include dents, severed joins or other damage, and of course leaks.

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G U T TE R S

In many instances, gutter servicing forms part of normal commercial or industrial property maintenance agreements, and the property management company may or may not source the gutter work to a gutter specialist company as opposed to a general handyman. In cases of expansive gutter systems, where the maintenance needs are extreme, or any other scenario where safety during maintenance may be a concern, it is a good idea to consult a specialist gutter company that has a professionally trained workforce to take care of it.

SA ROOFING: Are the gutters available from home

improvement stores reliable? Are they easy and safe to install?

BEHN: For the most part, the gutters available on shelves

are fairly reliable, although they might eventually show a tendency to warp. It is a good idea to look for the SABS mark when choosing your gutters. As for the installation itself, I have to recommend using the services of a reputable, professional gutter company. It may not seem like an extremely complicated process to install a gutter, but a lot can go wrong and it is in fact a potentially risky if not dangerous DIY activity. Without a doubt, some skill is required to properly and correctly install a gutter.

SA ROOFING: What qualities should you look for when selecting a gutter company?

BEHN: A few things, all of them important: The company

should be registered with your regional Master Builders Association as a vetted professional. The company should have a minimum of five years’ experience in guttering. The company should offer you a workmanship guarantee. (Longspan Gutters offers a 12-month guarantee.) To ensure that you are not doing business with an unscrupulous operator who exploits people, who employs unsuitable people but then does not compensate them, check to see that the company is registered with the local industry bargaining council. Lastly, do not hesitate to ask for references or to follow through and actually check on those references.

SA ROOFING: Has the guttering industry experienced major technological advances of late?

SA ROOFING: What sort of lifespan should you expect from your gutter system?

BEHN: In the case of aluminium seamless gutters, I would say

30 years or more. As far as the paintwork goes, I can speak for Longspan Gutters and say that we have not had a single service recall complaint for paint ‘failure’ on an aluminium gutter within the 15-year guarantee.

BEHN: Apart from a handful of new profiles developed in more recent years, things have remained pretty constant. This is in line with the nature of our industry. No mobile app can take the place of a trained eye and skilled professional physically taking measurements and assessing a gutter system.

SA ROOFING: A final word on the benefits of seamless aluminium gutters?

SA ROOFING: What causes a gutter to fail? When should you replace it?

BEHN: Any number of causes could necessitate a

replacement, including severe corrosion but also scenarios like accidental and unintentional damage or dislodging of the gutter done while doing a roof inspection or unrelated roof repairs. Other examples include sectionals, asbestos or fibre cement gutters that develop leaks at the joins – the leaks become a persistent and ongoing problem that will eventually require a gutter replacement. Non-maintained gutters could become so severely clogged up that they eventually fall off and get seriously damaged. Although plastics will not withstand strong hailstorms, aluminium gutters usually only suffer some dents. In many instances such hail damage is covered under property insurance contracts.

BEHN: Rainwater harvesting is a totally free natural resource,

and you can capitalize on this by making your seamless aluminium gutters work for your building. Regarded as one of the most efficient rainwater gutter systems worldwide, seamless aluminium gutters have proven themselves for over four decades to work for almost any building. Simply channel the downpipes into rainwater tanks for use around the property. You will not regret specifying seamless aluminium gutters for your next project. For more information, send an email to info@longspangutters.com or visit www.longspangutters.com.

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A LU M I N I U M

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he Aluminium Federation of Southern Africa (AFSA) remarks on the many qualities of aluminium: Thanks to its strength, durability, corrosion resistance (it doesnâ&#x20AC;&#x2122;t rust), thermal protection and insulation, reduced sound transmission, low maintenance, attractive imaging, ability to be colour coated, flexibility plus its recyclability, aluminium has become an essential product for the building industry. Over the past 60 years its use in building applications has shown continuous and consistent growth.

ALUMINIUM, THE ALL-ROUNDER Aluminium alloy products â&#x20AC;&#x201C; whether extruded, rolled or cast â&#x20AC;&#x201C; are commonly used in many applications. These include window frames and other glazed structures ranging from domestic housing, commercial and industrial buildings and shop fronts, to large roof superstructures for shopping centres and stadiums.

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A LU M I N I U M Photo credit - Optik 360° Other applications include roofing, siding, guttering and curtain walling, as well as lighting, catches for windows, staircases, balustrades, partitioning, roof walkways, ceilings, awnings, insulation, heating and air conditioning systems, etc. In fact, there are a myriad other uses as well, from showers to ladders...the list is almost endless. Most recently in the renewable energy area, aluminium is used to produce PV frames and stands, and in solar geysers. Aluminium is playing a significant role in the renovation of old and historic buildings. The characteristics and properties of aluminium as a material have led to revolutionary and innovative changes in building techniques and architectural and engineering projects. Aluminium is leading the way into the future of the building industry. With its numerous advantages in versatility, durability, recyclability and light weight, it is ‘the material of opportunity!’ Every year, millions of aluminium windows and doors are installed in new homes and used for replacement. Highly resistant and rigid, they have low rates of expansion and contraction, and also of condensation. They are extremely stable, durable and thermally efficient. The new requirements under heat transmission standards, with extrusions as the basic building block of, for example, window frames, show how easy it is to include double glazing solutions.

CHARACTERISTICS Aluminium in construction form will not burn, nor give off toxic fumes. It is corrosion- and weather resistant: Aluminium naturally generates a natural protective oxide coating and is highly corrosion resistant. Different types of surface treatment such as anodizing or powder coating can further improve this property. Aluminium is particularly useful for applications where protection and conservation are required. Surface coating also provides decorative advantages. All materials have their advantages and disadvantages, and in an attempt to address some of the less desirable qualities by processing or reinforcement, cost and other penalties are incurred which tend to even out costs for the same performance requirements. The secret of success, therefore, is in the choice of materials for the application that may give an advantage to the house owner. Furthermore, the owner must consider the life cycle advantage of any material. Aluminium provides considerable advantages in this context. Article compiled by the Aluminium Federation of Southern Africa (AFSA) © 2005, and updated 2015. For more information, visit www.afsa.org.za.

Correctly manufactured and fitted, aluminium windows, doors, roofs, gutters and other items give a lifelong service in virtually all environments and duties.

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A LU M I N I U M

School complex (CEGEP and university building). Installation of 15 parabolic solar collectors. Photo credit - Optik 360°

ALUMINIUM CASE STUDY:

ALOUETTE UNIVERSITY BUILDING, UQAC In 2011, within the framework of its factory expansion projects, Aluminerie Alouette struck an accord with the government of Quebec to finance the construction of a university building in Sept-Îles with the goal of improving access to graduate studies in the region. The result is the impressive Alouette-UQAC university building. With a floor area of 3,200m² spread over three floors, it has capacity for 400 students. The new building shares services with the Cégep de Sept-Îles on a common campus located in the heart of a residential area. The build features more than 50 rooms, including several classrooms, four laboratories, multipurpose meeting spaces, two video conference rooms, an educational software library, a computer lab, offices for graduate students, teachers and researchers, administration offices, a student living area, and a multifunctional atrium.

DESIGN CONCEPT One of the key objectives that guided the design process was to, through the design of the building itself, attest to the importance of the aluminium industry to the region. The design concept underlines the participation of the building sponsor by creating an analogy between the industrial aluminium production process and the learning process. In both cases, raw material is processed and results in a refined product: In the industrial process, this leads to refined aluminium while in the academic process, it leads to knowledge.

SUSTAINABLE DEVELOPMENT AND MATERIALS Advanced environmental technology played a significant role in the project. Sustainable development strategies were divided into three categories: bioclimatic architecture, hightech solutions, and low-tech solutions.

Bioclimatic Architecture • Passive solar heating: The atrium features a south-facing curtain wall with silkscreened glazing to prevent overheating, and buffed concrete floors for efficient thermal mass. High-Tech Solutions • Parabolic solar heating system from Rackam, consisting of 15 adjustable aluminium reflectors on the rooftop. This technology is combined with an ejecto-compression cooling system, enabling both heating and air conditioning by solar energy. • Horizontal geothermal system and thermal storage. These systems were networked with the parabolic solar heating system in order to augment the performance of the system as a whole. Low-Tech Solutions • Wood structure featuring glulam timbers and crosslaminated timber (CLT) panels. Wherever possible, the structure was left visible, reducing the quantity of finishing materials required. • Thermal resistance of building envelope 25% higher than required by the National Energy Code for Buildings (NCEB). • 45m² solar wall preheats fresh air before it enters the ventilation system. • Modular reusable partitions enable the creation of multipurpose spaces as well as the reuse and recycling of materials for future uses. • Four cisterns collect rainwater from the roof for use in sanitary fixtures and for exterior irrigation. The wide variety of ways in which aluminium was used in the building emphasizes the many construction methods and forms made possible by this highly technological material produced in the region. For example: curtain wall mullions, modular reusable partitions, recycled aluminium foam cladding, solar reflectors, the ‘knowledge filter’ structure in the northeast façade, the central stringer and railing of the monumental staircase in the atrium, etc. For more information, visit www.bgla.ca.

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Construction

high corrosion protection The new coating WIROX provides excellent anticorrosion protection WIROX environment-friendly WIROX abrasion resistant

SPAX Design guide Notes on the design of loadbearing SPAX connections

Screw finder for wood construction

Distributer for Southern Africa

TÜV NORD CERT GmbH

M aProd

20 van der Berg Crescent Gants Centre- Strand 7140 Tel.: 021 853 5101 · Fax: 021 855 3108 info@fixtec.co.za · www.fixtec.co.za

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Faitsch Products

. t o TN - S t a n d

A RC H E D TRU S S S YS TE M

Custom 85m arched truss system for international airport When client Elmi Orlindo Construction appointed Hatch Goba as the structural and civil engineer tasked to construct a new maintenance hangar for Ethiopian Airlines at Bole International Airport in Addis Ababa, the bar was set high, calling for the hangar to accommodate a single Boeing 767, a Boeing 777, or two Boeing 737s.

The first Boeing in the new maintenance hangar.

s Hatch Goba commenced with the design component of the project in January 2013 and set a goal for project completion less than two years on, it was clear that sound structural engineering expertise and ingenuity was going to be needed to meet the requirements of the brief. But Pierre Olivier, managing director: AEM, Hatch Goba explains that Hatch Goba provided a unique design solution that addressed the projectâ&#x20AC;&#x2122;s challenges. By means of a unique 85m arched truss system, the company met the main design objectives for low steel tonnage, fabrication simplicity and erection safety without incurring the cost of temporary works staging.

BOXED TRUSSES AND LATERAL BRACING The arched trusses comprised 11.8m-long segments fabricated from lightweight square hollow sections, forming boxed trusses. The arch effect, combined with the use of these hollow steel sections, resulted in significant material savings. The total structural steel tonnage, inclusive of purlins, amounted to 240 tonnes, or 39kg/m2 .

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A RC H E D TRU S S S YS TE M

11.8m-long segments of lightweight square hollow sections formed the boxed trusses. Another design and detailing challenge was posed by the wind load transfer from the door pockets to the arch, given the load magnitude, arch geometry and bracing stiffness required. An innovative lateral bracing system was introduced that involved the use of tensioned cables and struts. The pretensioned cables effectively formed a net of diagonal ties throughout the roof at top cord level.

OTHER SPECIFICS

Cladding detail at the new maintenance hangar. The span involved meant that the arched trusses required aerial connection at the crown. This was achieved by means of temporary support on a mobile support tower. The door pocket towers were designed in such a way that they could function as temporary support towers during truss erection. One truss was erected at a time, after which the support tower was then moved on wheels to the next truss. Once all the trusses had been erected, the mobile tower was incorporated into the permanent works. “The design of the boxed trusses was a complex process that required careful consideration of erection safety and stability,” Tim Dubber, principal technologist: structures at Hatch Goba in the Eastern Cape, comments. The springing of each truss consisted of a double pin support, thereby providing sufficient lateral stability to individual trusses – even without lateral bracing. The design and detailing of the bolted and welded connections using square hollow sections meant that special attention had to be paid to the higher design and fabrication complexities of the connection type.

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The purlin system comprised specialized MetSec 12.5m-span sleeved Z-purlins, provided by Safintra South Africa. The arch foundations consisted of reinforced concrete pad footings with deep shear keys to resist the arch thrust. The Black Cotton soil type found on the construction site was replaced with selectable material up to a depth of 2.5m in order to counter the potential heave. All structural steel for the hangar was sourced from Italy and imported via the Port of Djibouti, from where it was transported via road freight to Ethiopia. Efficient ordering of the structural steel was achieved by means of Strucad 3D structural steel detailing software, which outputs comprehensive material ordering schedules.

STELLAR OUTCOME In addition to providing full structural and civil design services, Hatch Goba was also responsible for the foundation, hangar floor and apron design. Its innovative and tailor-made arched truss design allowed Ethiopian-based Elmi Orlindo Construction to clinch this prestigious project. “The hangar was erected successfully, and represents a quality structure that the Ethiopian construction industry can take great pride in,” Olivier highlights. “Hatch Goba provided an appropriate, cost-effective and local solution that maintained the quality of the end product while acknowledging some constraints of constructing in an Ethiopian environment,” Dubber concludes.

C E I L I N G S & ACO U S TI C I N S U L ATI O N

Fit for purpose Excessive noise in school halls can be a significant problem, occurring mostly where no acoustic considerations were included during planning or construction. But sensible acoustic absorbing materials offer a cost-effective solution.

ThermocousTex Fibre installed over purlin on straining wires, sandwiched up against the steel roof sheeting.This direct contact prevents the roof sheet from ‘drumming’ and results in significant noise reduction caused by excessive rain, wind or traffic. (ThermocousTex is also an excellent thermal insulator.) Romatherm Insulation Blanket serves as cost-effective bulk insulation within the ceiling void, adding to the R-Value in order to meet SANS10400-XA requirements.

igh noise reverberation or echoes in school halls can seriously compromise speech intelligibility and negatively affect audience concentration and enjoyment levels. Many of the hard surfaces found in that environment, including glass, tiled floors and gypsum board ceilings, among others, are – although practical – excellent reflectors of sound rather than sound absorbers, and therefore contribute to increased noise levels. But, as Datlink Insulation & Acoustics explains, dramatic improvements can be achieved with practical and cost-effective solutions by introducing and exposing approved acoustic absorbing materials within these noisy environments. One example is by using ThermocousTex Fibre Blankets within a simple timber frame, covered with a suitable, acoustically permeable material of aesthetic choice, and then mounted (exposed) on the hard wall surfaces to act as a ‘sound trap.’ This is a very effective, fit-for-purpose solution that greatly reduces the unpleasant and often unmanageable noise reverberation within school halls and similar noise-sensitive buildings. The result is an audibly intelligent environment and one that is fit for purpose.

THERMAL AND ACOUSTIC PROPERTIES OF THERMOCOUSTEX FIBRE WITHIN CEILINGS OR OVER PURLIN APPLICATION

50mm ThermocousTex Laminated Foil Roll (over Purlin)

ThermocousTex Fibre in frame, covered with acoustically permeable fabric.

FINISH

DENSITY

NRC VALUE

Foil Faced (Optional)

24kg/m³

0.73

R-VALUE (ON INSULATION ONLY)

1.34

ODP

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C E I L I N G S & ACO U S TI C I N S U L ATI O N

THERMOCOUSTEX™ POLYESTER FIBRE ACOUSTIC INSULATION (FOIL OPTIONAL) A thermally bonded polyester blanket (with or without foil) manufactured using recycled polyester and ideal for both thermal and acoustic insulation. • Packing: Polythene tube • Rolls: 1,200mm wide x 10m long • Thermal Conductivity: 0.0377 W/m²ºC • R-Value: 50mm – 1.34m².K/W • Density: 24kg/m³ and 50kg/m³ • NRC Value: 0.73 • Suitable for any application where acoustic and thermal benefits are required, including industrial, commercial and domestic applications • Excellent acoustic absorber and thermal insulator • Installed on top of ceilings, over purlin or within walls • Non-corrosive, lightweight and made to length • Complies with SAN 428 Fire Standards; does not contribute to flame spread • FTC15-004(b) 2015/07/8 – B/B1/2/H (USP) • Bespoke densities and thicknesses available on request

For more information, visit www.datlink.co.za.

Contractors might see

R1-billion – and an Ombudsman According to a statement by the SA Government News Agency, this February could bring much-needed financial relief to those contractors owed money by provincial governments and municipalities.

ollowing a consultative conference meeting held with more than 500 contractors and developers on January 28th, the Minister of Human Settlements, Lindiwe Sisulu, ordered the settlement of all undisputed invoices for work done – and within seven days. As required by law and a recent cabinet decision, undisputed, payable invoices should be paid within 30 days. This meeting was called following a national analysis of all unpaid projects and invoices as reflected in the payment systems, and the discovery that more than R1-billion had not been paid to contractors by the provinces in respect of invoices submitted. “As government we cannot sit with millions worth of work done by mainly black small contractors in the housing sector and not paid for. I want those undisputed invoices to be settled within seven days by provinces and municipalities,” said Minister Sisulu. She further announced that she will be meeting the Minister of Finance, Pravin Gordhan, to request relevant measures in order to ensure that the national department is able to facilitate payment of backlogs, due and payable to those contractors, within the said timeframe.

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The Minister also indicated that her department will, after the State of the Nation Address on 11 February, establish an Ombudsman Office to deal with conflicts between the contractors, provinces and municipalities. “With the Ombudsman Office, we are setting up a structure that will mediate, work with all stakeholders to resolve disputes, and cut through red tape for the best interests of the human settlements sector as a whole,” the Minister explained. She added that contractors are an integral part of human settlements delivery and “we are committed to solving the payment challenges faced by the sector in order to sustain a healthy business environment.” Minister Sisulu and MECs listened to complaints and suggestions on how systems can be improved and how non-payments are leading to retrenchments and the collapse of small companies. They promised to give feedback on all issues raised within 90 days.

I N D U S TRY N E W S

Marley Building Systems acquires Lafarge Gypsum Marley Building Systems has confirmed the finalization of its acquisition of the South African Gypsum business of Lafarge on 2 November 2015.

anaging Director, Mark Irving, issued a written statement that said, “The acquisition is complementary to our business, and the combined team will create a unique and competitive offer that capitalizes on today’s Southern African building trends. This acquisition is in line with Etex’s vision of strengthening our position by investing in Southern Africa.”

“Besides amplifying its presence in Southern Africa, Marley Building Systems will also combine the expertise of various support functions like marketing, sales and customer service. Thus, the company will achieve higher operational excellence and service quality, and a more streamlined structure in the region,” Irving concluded.

Firmly established in both Europe and Latin America since 1905 and 1937 respectively, Etex aims to strengthen its position in Africa, with the Southern African region and Nigeria viewed as the organization’s main drivers of growth. The demand for housing in the region has been on the rise for years, and Etex considers the growing population in Southern Africa as one of the main reasons for this trend, along with an emerging middle class, asserting that South Africa alone already accounts for 15% of Africa’s GDP.

ABOUT ETEX

Irving further commented on the Southern African market becoming increasingly regulated with various quality standards being adopted, including SANS204 for Energy Efficiency in Buildings and SANS517 for Light Steel Frame Building. “Consequently, alternative building methods, such as dry construction, are gradually replacing traditional construction,” he observed.

Etex is a Belgian industrial group that specializes in manufacturing and marketing sustainable building materials. Its four core businesses are: cladding and building boards in fibre cement and plaster, roofing materials, passive fire protection and high performance insulation, and ceramic floor and wall tiles. The group employs more than 17,000 people who operate on 118 production sites in 43 countries, yielding annual sales of about 3 billion euro. For more information, visit www.etexgroup.com or send an email to Sean Singh, Marketing and Business Development Manager: sean.singh@marley.co.za.

CALL 0861 727 663 TO BOOK YOUR SPACE IN

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