Uniclass
L3525:G33:P4
CI/SfB
(25.9)
July 2016
Hh
RoofDek
Structural roof decking and trays
RoofDek Introduction
About Tata Steel
Contents
Tata Steel, formerly known as Corus, is one of Europe's largest steel
producers. We serve many different and demanding markets
worldwide, including aerospace, automotive, construction, energy
and power, and packaging. Our primary steelmaking operations in
the UK and the Netherlands are supported by a global sales and
distribution network.
3
Introduction
4
Shallow deck profile range
6
Deep deck profile range
8
Liner tray profiles
Innovation and continuous improvement are at the heart of our
performance culture. We aim to create value by offering a sustainable
and value-added steel product range supported by unrivalled customer
service. By working in partnership with you, we find the best solutions
to meet your needs and help your business to perform.
Our European operations are a subsidiary of Tata Steel Group, one of
the world’s top ten steel producers. With a combined presence in
nearly 50 countries, the Tata Steel Group including the Europe
operations,
Tata Steel Thailand and NatSteel Asia, has approximately 80,000
employees across five continents and a crude steel production capacity
of over 28 million tonnes.
We are able to offer a wide range of products, systems and services
specifically developed for the construction market. These include
Colorcoat® pre-finished steel products, roof and wall cladding systems
for the building envelope, hot rolled and tubular sections for the
primary structure, lintels and other ancillary construction components.
10 Acoustic profiles
13 Technical information
14 Structural design
15 Diaphragm design
16 Acoustic systems
18 Roof Safety
19 Service and support
20 Sustainability
21 Case Study
Peacehaven
22 Case Study
West Cheshire College
23 Case Study
West Burton Power Station
2
RoofDek Introduction
Introducing RoofDek
Structural roof decking and trays
Tata Steel offers the most comprehensive range of structural roof decking all under one UK
manufacturer’s roof
To offer the structural deck specifier more choice, we can supply additional profiles to
compliment our UK manufactured range from Tata Steel Europe.
Technically the best, with a structural design
service providing diaphragm design for decks
and full support calculations for all profiles.
With decks ranging from 32mm to 210mm
deep and a range of structural trays, we
support all types of insulated roof systems:
•
Single ply membrane
•
Standing seam systems
•
Green roofs
•
Slates and tiles
•
Three ply felt
•
Asphalt
Quality assurance
To provide the best quality and the most up to
date design information, Tata Steel is quality
assured to BS ISO 9001:2000 Quality systems.
Tata Steel is an active member of MCRMA
(Metal Cladding and Roofing Manufacturers
Association), SPRA (Single ply Roofing
Association), BCSA (British Constructional
Steelwork Association) and supports R&D
throughout the industry.
Professional support
Tata Steel maintains a friendly technical help
desk which is freely available to all Architects,
Consulting Engineers and Contractors to assist
all aspects of roof deck and liner tray design
The technical help desk is available on:
01244 892 199 or via roofdek@tatasteel.com
Shotton Works
Our Shotton operations take place in an
environmentally sensitive area. We are
surrounded by the Dee Estuary, which is
designated as a Special Area for Conservation,
Special Protection Area and Site of Special
Scientific Interest.
An area of man-made lagoons within our
boundary has similar environmental
designations, being a breeding ground for
Common Terns and an important reed bed
habitat, leading to our proud tradition of
co-existing with the natural world in this
special place without compromising
biodiversity.
Clearance and maintenance work is regularly
undertaken to ensure the lagoon areas are
preserved in optimum conditions and we
manage the open areas of our site to
maximise their potential as habitats to flora
and fauna, including a wide range of breeding
and migratory birds.
01244 892 199 | www.tatasteelconstruction.com/roofdek
3
RoofDek Profile ranges
Shallow deck profile range
Developed to optimise the designer’s needs for
efficiency, aesthetics and structural performance
Structural RoofDek profile range
Tata Steel provides the designers needs for efficiency, aethestics and
structural performance by offering a comprehensive portfolio of
shallow RoofDek profiles.
Load/span figures
The tables are based on a total ‘Dead & Super’ imposed load of
1.50kN/m2, a line load of 2.00kN/m and a deflection limit of L/200. The
factor of safety used is 1.5 for live load and 1.35 for dead load. Where
actual design loads exceed these, the spans must be reduced. Subject
to satisfactory fixings, the decks will resist wind uplift to at least the
value of 1.50kN/m2, and a deflection limit of L/90. Full load span tables
may be obtained from our website: www.tatasteelconstruction.com
or from our technical department.
D32s
Maximum cantilevers assume a 0.9kN point load on the end, with the
adjacent span being the single span as shown in the table. The end of
the cantilever must be stiffened with an angle flashing. Steel type is
taken as galvanised and coated at 280N/mm2.
Point and impact loads
Metal decking may mark if subjected to extreme point or impact load.
Where the sheet is required as an exposed soffit, a thicker gauge should
be considered if localised marking is not acceptable.
D35
Curving
Self curving can induce stress marking in the sheet. The radius limits
suggested in the tables reduce the visible effect of this; however some
perceptible distortion may occur.
D46
D60
For material specification see page 13.
4
RoofDek Profile ranges
Structural profile specifications
Profile
D32s
D35
D46
D60
Material
Gauge and
finish
Weight
(mm)
(kg/m2)
Load/span
maximum
single span
(mm)
Load/span
Minimum
maximum
self curve
double span
(mm)
(m)
Minimum
factory
curve
(mm)
Cantilever
(mm)
Steel
0.70 Interior Liner & Galvatite®
6.67
1650*
1800
40
–
325
Steel
0.90 Interior Liner & Galvatite®
8.58
1875*
2300
45
–
375
Steel
1.20 Interior Liner & Galvatite®
11.46
2100*
2800
50
–
450
Aluminium
0.90 Stucco
2.98
1075*
1500*
40
–
250
Aluminium
1.20 Mill
3.97
1250*
1900*
50
–
300
Steel
0.70 Interior Liner & Galvatite®
7.08
1803
2519
40
400
400
Steel
0.90 Interior Liner & Galvatite®
9.11
2114
2835
50
400
475
Steel
1.20 Interior Liner & Galvatite®
12.16
2404
3224
60
–
575
Aluminium
0.90 Stucco
3.16
1311
1960
40
400
300
Aluminium
1.20 Mill
4.21
1525
2267
50
–
350
Steel
0.70 Interior Liner & Galvatite®
7.20
2433
3120
55
400
575
Steel
0.90 Interior Liner & Galvatite®
9.26
2708
3631
65
400
650
Steel
1.20 Interior Liner & Galvatite®
12.37
2994
4015
75
–
725
Aluminium
0.90 Stucco
3.21
1762
2501
55
400
400
Aluminium
1.20 Mill
4.28
2051
2761
65
–
475
Steel
0.70 Interior Liner & Galvatite®
8.34
3022
3772
70
–
725
Steel
0.90 Interior Liner & Galvatite®
10.73
3348
4489
80
–
800
Steel
1.20 Interior Liner & Galvatite®
14.32
3672
4923
85
–
875
Aluminium
0.90 Stucco
3.72
2300
3060
70
–
575
Aluminium
1.20 Mill
4.96
2542
3408
80
–
625
Notes
1. RoofDek profiles are available with Colorcoat HPS 200 Ultra® pre-finished steel, however these load tables do not apply - please
contact us for load span data. Aluminium, other finishes and materials are available subject to minimum order quantity.
2. Calculations accord to Eurocode, however a fixings check is also required.
3. Load table is based on the deck bearing onto 100mm min. flange steel beam.
4. Load spans calculated to Eurocode 3 and 9.
01244 892 199 | www.tatasteelconstruction.com/roofdek
*Span limited by 2kN/m line load.
5
RoofDek Profile ranges
Deep deck profile range
Designed for exceptional strength and span capability
for all roofing types
Structural RoofDek profile range
Deep decks have exceptional strength and span capability, providing a
rugged structural platform for all roofing types. They are ideal for
architecturally interesting large space buildings as they eliminate the
need for purlins, but are used in any situation where a strong solid base
for the roof is required.
D100
Single ply roofs, metal standing seam, asphalt and bitumen roofs all use
deep RoofDek, and in recent years they have been the default choice
for green roofs, which impose a heavy dead load.
When specifying deep decks, designers frequently take advantage of
Tata Steel's free diaphragm design service to reduce or eliminate in
plane roof bracing.
Load/span figures
The tables are based on a total ‘Dead & Super’ imposed load of
1.50kN/m2, a line load of 2.00kN/m and a deflection limit of L/200. The
factor of safety used is 1.5 for live load and 1.35 for dead load. Where
actual design loads exceed these, the spans must be reduced. Subject
to satisfactory fixings, the decks will resist wind uplift to at least the
value of 1.50kN/m2, and a deflection limit of L/90. Full load span tables
may be obtained from our website: www.tatasteelconstruction.com
or from our technical department.
Sheet lengths – extended end laps
Sheet lengths in excess of 12 metres are not practical for installation on
site and may also be subject to delivery restrictions. Extended end laps
can be used to create a double span whilst keeping the deck length to
a minimum. If a deck length in excess of 12 metres is nevertheless
required, contact our Technical Department for assistance.
D135
D153
D159
D200
D210
For material specification see page 13.
6
RoofDek Profile ranges
Structural profile specifications
Profile
D100
D135
D153
Material
Gauge and
finish
Weight
(mm)
(kg/m2)
Load/span
maximum
single span
(mm)
Load/span
Minimum
maximum
self curve
double span
(mm)
(m)
Minimum
factory
curve
(mm)
Cantilever
(mm)
Steel
0.70 Interior Liner & Galvatite®
9.64
4409
4696
110
–
1000
Steel
0.90 Interior Liner & Galvatite®
12.41
4788
5869
120
–
1150
Steel
1.20 Interior Liner & Galvatite®
16.57
5245
7034
125
–
1250
Aluminium
0.90 Stucco
4.30
3298
3769
110
–
850
Aluminium
1.20 Mill
5.74
3642
4883
120
–
925
Steel
0.75 Interior Liner
9.49
4929
4506
150
–
1100
Steel
0.88 Interior Liner
11.14
5511
5376
160
–
1200
Steel
1.25 Interior Liner
15.84
6164
7435
180
–
1350
Steel
0.75 Interior Liner
10.50
5162
4898
165
–
1250
Steel
0.88 Interior Liner
12.33
5946
5865
175
–
1300
Steel
1.25 Interior Liner
17.54
6737
8150
195
–
1400
Steel
1.25 Interior Liner
19.19
7101
8595
220
–
1550
Aluminium
1.50 Mill
7.97
5243
6559
200
–
1200
Steel
0.88 Interior Liner
13.81
5698
6405
260
–
1550
Steel
1.25 Interior Liner
19.65
8403
9217
280
–
1800
Steel
1.50 Interior Liner
23.59
8947
10781
300
–
1900
Steel
1.25 Galvatite®
16.24
7600
See note 4
250
–
1750
D159
D200
D210
Notes
1. RoofDek profiles are available with Colorcoat HPS 200 Ultra® pre-finished steel, however these
load tables do not apply - please contact us for load span data. Aluminium, other finishes and
materials are available subject to minimum order quantity.
2. Calculations accord to Eurocode, however a fixings check is also required.
01244 892 199 | www.tatasteelconstruction.com/roofdek
3. Load table is based on the deck bearing onto 100mm min. flange steel beam.
4. For maximum Load/Span in double span conditions, contact the technical department.
5. The Interior Liner colour on D135, D153 and D200 is RAL9002.
7
RoofDek Liner trays
Liner tray profiles
Structural liner trays
Structural liner trays provide a neat planar inner surface, flat except for
the stiffening ribs. It is suitable for both roof and wall cladding
applications spanning across the main steels and omitting the need for
purlins or cladding rails.
HLT90/600
HLT130/600
HLT145/600
For material specification see page 13.
8
RoofDek Liner trays
Structural liner tray profile specifications
Profile
HLT90/600
HLT130/600
HLT145/600
Material
Gauge and
finish
Weight
(mm)
(kg/m2)
Load/span
maximum
single span
(mm)
Load/span
Minimum
maximum
self curve
double span
(mm)
(m)
Minimum
factory
curve
(mm)
Cantilever
(mm)
Steel
0.75 Interior Liner
8.62
3100
3000
–
–
700
Steel
1.00 Interior Liner
11.49
3800
3900
–
–
1150
Steel
1.25 Interior Liner
14.36
4100
4300
–
–
1300
Steel
0.75 Interior Liner
9.57
4100
4100
–
–
800
Steel
1.00 Interior Liner
12.75
5100
5300
–
–
1500
Steel
1.25 Interior Liner
15.95
5500
5900
–
–
1700
Steel
0.75 Interior Liner
9.81
4300
4000
–
–
650
Steel
1.00 Interior Liner
13.08
5300
5600
–
–
1450
Steel
1.25 Interior Liner
16.35
6000
6300
–
–
1700
The colour of the Interior Liner on all HLT profiles is RAL 9002.
01244 892 199 | www.tatasteelconstruction.com/roofdek
9
RoofDek Acoustic profile ranges
Acoustic profiles
Acoustic RoofDek range
Tata Steel offers a range of tried and tested acoustic profiles which
achieve various sound absorption ratings from A–D. Please contact
our technical department for more information.
Acoustics
The decks illustrated on this page are available with perforated webs
to provide acoustic absorption. Two different open area percentage
figures are in general use and both are shown. The percentage of
exposed area is the open area divided by the exposed area of steel
following around the profiles. The percentage of cover area is the open
area divided by the plan area of the soffit. The perforating patterns are
illustrated here.
D46, D60 and D100 use perforating
pattern 4546
4.5mm holes at 6.3mm triangular
centres. Pattern open area 46%.
D159 uses perforating pattern 3327
3.3mm holes at 6.0mm triangular centres.
Pattern open area 27%. Fully perforated
deck may be available, please enquire if
required.
D135, D153 and D200 use perforating
pattern P3L-S
3.0mm holes at 5.5mm square centres.
Pattern open area 23.5%.
D46
Perforated
10.7% of exposed area
13.0% of cover area
D60
Perforated
13.9% of exposed area
19.6% of cover area
4.5
60°
D100
6.3
Perforated
13.3% of exposed area
21.1% of cover area
3.3
60°
6.0
D135
Perforated
6.1% of exposed area
10.0% of cover area
3.0
5.5
D153
Perforated
6.2% of exposed area
11.0% of cover area
D159
Perforated
7.6% of exposed area
14.2% of cover area
D200
Perforated
5.0% of exposed area
10.0% of cover area
10
RoofDek Acoustic profile ranges
Acoustic profile specifications
Profile
D46
Perforated
D60
Perforated
Material
Gauge and
finish
Weight
(mm)
(kg/m2)
Load/span
maximum
single span
(mm)
Load/span
Minimum
maximum
self curve
double span
(mm)
(m)
Minimum
factory
curve
(mm)
Cantilever
(mm)
Steel
0.70 Interior Liner & Galvatite®
6.49
1614
2152
55
400
475
Steel
0.90 Interior Liner & Galvatite®
8.35
2667
3003
65
400
550
Steel
1.20 Interior Liner & Galvatite®
11.15
2959
3874
75
–
600
Aluminium
0.90 Stucco
2.89
1202*
1602
55
400
325
Aluminium
1.20 Mill
3.86
2037
2441
65
–
400
Steel
0.70 Interior Liner & Galvatite®
7.25
1647
2196
70
–
600
Steel
0.90 Interior Liner & Galvatite®
9.33
2725
3425
80
–
675
Steel
1.20 Interior Liner & Galvatite®
12.45
3621
4499
85
–
725
Aluminium
0.90 Stucco
3.23
1232
1642
70
–
475
Aluminium
1.20 Mill
4.31
2123
2778
80
–
525
Steel
0.90 Interior Liner & Galvatite®
10.92
3574
4453
120
–
975
D100
Steel
1.20 Interior Liner & Galvatite®
14.58
5212
6066
125
–
1050
Perforated
Aluminium
0.90 Stucco
3.79
1647
2196
110
–
700
Aluminium
1.20 Mill
5.05
3062
3733
120
–
775
Steel
0.75 Interior Liner
8.90
3150
3772
150
–
1000
Steel
0.88 Interior Liner
10.46
4526
4626
160
–
1100
Steel
1.25 Interior Liner
14.87
6142
6717
180
–
1200
Steel
0.75 Interior Liner
9.86
3421
4200
165
–
1100
Steel
0.88 Interior Liner
11.58
5012
5150
175
–
1150
Steel
1.25 Interior Liner
16.46
6730
7442
195
–
1250
D159
Steel
1.25 Interior Liner
17.80
7084
7853
220
–
1400
Perforated
Aluminium
1.50 Mill
7.40
5222
5942
200
–
1100
Steel
0.88 Interior Liner
13.13
3583
4778
260
–
1200
Steel
1.25 Interior Liner
18.67
7739
7890
280
–
1700
Steel
1.50 Interior Liner
22.41
8945
9494
300
–
1800
D135
Perforated
D153
Perforated
D200
Perforated
Notes
1. Aluminium profiles are subject to minimum order quantities.
2. Calculations accord to Eurocode, however a fixings check is also required.
3. Load table is based on the deck bearing onto 100mm min. flange steel beam.
4. The Interior Liner colour on D135, D153 & D200 is RAL 9002.
01244 892 199 | www.tatasteelconstruction.com/roofdek
*Span limited by 2kN/m line load.
11
RoofDek Acoustic profile ranges
Acoustic profiles
Acoustic structural liner tray
Tata Steel offers a range of acoustic liner trays which achieve a Class
A sound absorption rating. Structural Trays offer a wider flat soffit
enabling a greater perforated area, achieving the best acoustic
absorption result.
The percentage of exposed area is the open area divided by the
exposed area of steel following around the profiles. The percentage of
cover area is the open area divided by the plan area of the soffit.
The perforating pattern is P3 ZZ, illustrated below:
3.0
3.0mm holes at 5.5mm square centres.
Pattern open area 23.5%.
HLT90/600
Perforated
18.8% of exposed area
18.8% of cover area
HLT130/600
Perforated
18.8% of exposed area
18.8% of cover area
5.5
HLT145/600
Perforated
18.8% of exposed area
18.8% of cover area
Acoustic profile specifications
Profile
HLT90/600
Perforated
HLT130/600
Perforated
HLT145/600
Perforated
Material
Gauge and
finish
Weight
(mm)
(kg/m2)
Load/span
Minimum
maximum
self curve
double span
(mm)
(m)
Minimum
factory
curve
(mm)
Cantilever
(mm)
Steel
0.75 Interior Liner
7.52
3100
2900
–
–
700
Steel
1.00 Interior Liner
10.02
3400
3800
–
–
1100
Steel
1.25 Interior Liner
12.52
3700
4300
–
–
1300
Steel
0.75 Interior Liner
8.47
4000
3900
–
–
750
Steel
1.00 Interior Liner
11.28
4900
5000
–
–
1400
Steel
1.25 Interior Liner
14.12
5300
5600
–
–
1600
Steel
0.75 Interior Liner
8.72
4200
3700
–
–
650
Steel
1.00 Interior Liner
11.63
5200
5200
–
–
1350
Steel
1.25 Interior Liner
14.54
5700
5900
–
–
1600
The colour of the Interior Liner on all HLT profiles is RAL 9002.
12
Load/span
maximum
single span
(mm)
RoofDek Technical Information
Technical information
Fire rating
All non-perforated deck sheets provide a fire rating of Class 1 to BS476:
Part 7 and Class 0 in accordance with current Building Regulations.
Fixing
Profile
Main fixings at
ridge and eaves
Main fixings
(Intermediate)
Side lap
fixing
D32s
every pitch
every other pitch*
not essential**
D35 –> D200
every pitch
every pitch
450mm centres
D210
every pitch
every pitch
350mm centres
HLT 130/600
4 per tray
4 per tray
450mm centres
D210 requires alignment cleats to prevent profile spread.
* Every other pitch is based on always starting with a fixing in the first pitch of every sheet, and a profile pitch of 200mm or less.
** Side lap fixing is not essential where using a fully supported under lap, otherwise it’s recommended to fix at 450mm centres.
Extended end laps
Sheet lengths in excess of 12 metres are not
practical for installation on-site and may also
be subject to delivery restrictions. Extended
end laps can be used to create a double span
whilst keeping the deck length to a minimum.
Load span data for double spanning
continuous sheet can conservatively be
applied, provided these rules are followed.
The end lap must extend into 10% of each span
and must be tail fixed by means of 5.5mm
diameter self drilling steel stitching screws
connecting each web (not the flange) of the
overlying profile, to the web of the underlying
profile, one fixing in each web (2 per pitch or
the sheet) at each end of the end lap.
The web is the inclined upright part of the
profile (as opposed to the horizontal flanges).
The deck is fixed to the support in the normal
way.
The web fixings must not be made through
perforated sections of webs. Extended laps are
not recommended for perforated profiles.
Every web is
stitched at the
end of the lap
5.5mm diameter self drilling steel
stitching screws connecting each
web
Fixing to
Support
10% of
span
Total overlap
20% of span
10% of
span
Material specification
Galvanised steel:
Tata Steel Galvatite®, hot dip zinc coated steel
EN 10326-S280GD+Z275.
Guaranteed minimum yield stress 280N/mm2.
Minimum zinc coating mass 275g/m2 total
both sides. (Except D159 which uses
EN 10326-S320GD+Z275).
Interior liner steel (standard decks):
Tata Steel Galvatite®, hot dip zinc coated steel
EN 10326-S280+ZA80 substrate, with
Colorcoat® Interior Liner 15 micron
coating to interior, colour bright white.
Interior liner (D159):
Tata Steel Galvatite®, hot dip zinc coated steel
EN 10326-S320GD+ZA100 substrate, with
Colorcoat® Interior Liner 15 micron coating to
interior, colour: bright white.
Aluminium:
Stucco embossed or plain Aluminium.
Aluminium alloy to BS EN 485-1/2/3/4:1995.
Mill and stucco - grade 3005 H27.
ARS coated - grade 3004 H44.
Interior liner (Tata Steel NL Profiles):
Tata Steel Galvatite®, hot dip zinc coated steel
EN 10326-S320GD+ZMA100 substrate, with
Colorcoat® Interior Liner 15 micron coating to
interior, colour: Hamlet (RAL 9002) for Tata
Steel Europe decks.
RoofDek profiles are also available with
Colorcoat HPS200 Ultra® pre-finished steel.
For further information please contact us.
01244 892 199 | www.tatasteelconstruction.com/roofdek
13
RoofDek Structural design
Structural design
Structural
Loading
Eurocode design
BS EN 1993 Eurocode 3: Design of steel
structures.
Eurocode design
Calculate loading to BS EN 1991 Eurocode 1:
Basis of design and actions on structures.
Part 1-3: Cold-formed thin gauge members
and sheeting.
Part 1-1: BS EN 1991-1-1 General actions –
Densities, self-weight, imposed loads for
buildings.
BS EN 1999 Eurocode 9: Design of aluminium
structures.
Part 1-4: Cold-formed structural sheeting.
British Standards design
BS5950 Structural use of steelwork in building.
Part 1-3: BS EN 1991-1-3 General actions –
Snow loads.
Part 1-4: BS EN 1991-1-4 General actions –
Wind actions.
Part 6: Code of practice for design of light
gauge profiled steel sheeting.
British Standards design
Calculate loads to BS 6399.
Part 9: Code of practice for stressed skin
design.
Part 2: 1997 Code of Practice for wind loads.
Part 3: 1988 Code of Practice for imposed roof
loads (including snow and snow drifting).
Fragility
Non-fragility requirements are determined by
ACR(M)001:2000 Test For Fragility of Roofing
Assemblies (second edition).
14
UK National Annex to Eurocode 1
Actions on structures
Part 1-1: General actions – Densities,
self-weight, imposed loads for buildings
Table NA.7 – Imposed loads on roofs not
accessible except for normal maintenance
and repair
Roof slope,
α degrees
α < 30º
30 º < α < 60º
α >= 60º
αk
kN/m2
0,6
0,6[(60 – α)/30]
0
Qk
kN
0,9
Span types
Single span – one length of deck with a
support at each end.
Double span – one length of deck with a
support at each end plus a support in the
middle.
Multi span – The length of deck extends over
more than 3 supports.
Where the deck end laps, it must be lapped
over by at least 50mm. This does not provide
continuity – extended end laps are required
for continuity, please see previous page.
RoofDek Diaphragm design
Diaphragm design
Function of diaphragm action
• Transfers wind load from walls to brace
•
walls running perpendicular.
Replaces in plane roof bracing.
Benefits
• Removes visual clutter in the roof - popular
•
with architects
Saves money by removing some of the steel
elements.
Limitations
• Diaphragm area must be surrounded by at
•
least 3 braced walls.
Deck must be fixed to the structure on all 4
edges of diaphragm area.
To design we need:
• Drawings showing deck layout and braced
•
Seam Fasteners
Irregular roof plan
showing division into
diaphragms.
walls.
Line loads at diaphragm edges.
C
Vertical bracing
Roof Light
B
A
D
Purlin
Rafter
Purlin/Rafter
connector
Sheet/Shear
connector fastener
Shear Connector
Edge Member
(Purlin)
Sheet Purlin
Fastener
Diaphragm analysis
program
We offer a free diaphragm design service.
The analysis assumes that the diaphragm area
is rectangular and braced on at least 3 sides.
At the time of publication, our analysis uses
BS EN 1993-1-3.
01244 892 199 | www.tatasteelconstruction.com/roofdek
15
RoofDek Tested acoustic systems
Acoustic systems
Sound absorption and reduction
Tata Steel has carried out a number of acoustic tests at Salford University which examines the sound absorption of the most popular acoustic
decks and trays in the range.
Absorption (αp)
D46
D60
D100
D159
HLT130/600
Frequency
(Hz)
Open
trough
Filled
trough
Open
trough
Filled
trough
Open
trough
Filled
trough
Open
trough
Filled
trough
125
0.95
1.00
0.90
1.00
0.95
1.00
0.95
1.00
1.00
250
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
500
1.00
0.95
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1000
0.85
0.90
0.85
0.90
0.80
0.85
0.50
0.60
0.95
2000
0.50
0.60
0.50
0.60
0.50
0.60
0.30
0.55
0.85
4000
0.40
0.40
0.35
0.45
0.40
0.45
0.35
0.50
0.85
αw
0.55
0.60
0.50
0.60
0.55
0.60
0.40
0.60
0.95
CLASS
D
C
D
C
D
C
D
C
A
PIR – for sound reduction
• Kingspan insulation (SRL test report
•
•
•
•
•
C/00/5L/7950/1)
Weighted Sound Reduction Index Rw =
27dB
Mechanically fastened single ply membrane
system
Kingspan Thermaroof TR26 (85mm)
Polythene vapour control layer
Tata Steel D60 0.7mm steel deck
PIR + Rubbertech – for sound
reduction
• Kingspan insulation (SRL test report
•
•
•
•
•
•
16
C/03/5L/0830/2).
Weighted Sound Reduction Index Rw =
35dB.
Mechanically fastened single ply membrane
system.
Kingspan Thermaroof TR26 (85mm).
Rubbertech R10 Acoustic Membrane.
Polythene vapour control layer.
Tata Steel D60 0.7mm steel deck.
Rain noise
Approved Document E, 2004
Amendment requires construction of new
school buildings to follow guidance provided
by Building Bulletin 93. BB 93 advises
designers to consider the effect of impact
noise from rain at an early stage of the roof
design in order to minimise disturbance
within the building.
A tank positioned 3.5m above the test roof is
filled with water and consistently recharged.
The perforated base area, height and flow rate
are calibrated to ensure a rainfall intensity of
0.67 Lmin/m3 (40mm/h). Sound intensity
measurements are taken below the roof
construction in the frequency range of 50 Hz
to 5000 Hz.
What constitutes a problem level of rain noise
is subjective. Roof systems employing a
weatherproofing layer in full contact with
insulation, supported by a metal deck are not
usually problematic in practice. However for
more critical applications rain noise may be
reduced by the selective specification of the
insulation system, and to a lesser extent the
membrane, the fixing system, and the vapour
control layer.
Indicative sound level test results on D60
0.7mm deck are between 52 - 60dB.
Rain generated impact sound transmission is
measured by a test to Draft International
Standard ISO 140-18.
The sound intensity level measures the
amount of sound being transmitted through
the roof and therefore the lower this figure is,
the better.
Further details, test reports and details of
other combinations are available from
Rockwool Limited and Kingspan Insulation
Limited respectively.
RoofDek Tested acoustic systems
Sound reduction
RoofDek D60 typical acoustic build up
Fully bonded single ply membrane system
1.5mm thick PVC single ply membrane fully adhered
100mm thick Hardrock Dual Density SPA
2mm thick aluminium cored vapour control
50mm thick Hardrock Dual Density TFA layer
Tata Steel RoofDek D60 web perforated deck
•
•
•
Absorption co-efficient (αw) = 0.55
Absorption Class D
Weighted sound reduction (Rw) = 39dB
Sound reduction
The acoustic performance of the profiled metal cladding construction
detailed below has been predicted using a computer programme
developed by the Department of Applied Acoustics at the University of
Salford under a research contract funded by the Metal Cladding and
Roofing Manufacturers Association.
CAUTION: The Predicted SRI values should be used only to provide
guidance for preliminary design and/or appraisal of build construction
systems. Laboratory measurements should still be used to provide
definitive acoustic data. For a project specific calculation contact
Tata Steel Technical Department on 01244 892 199 or e-mail:
roofdek@tatasteel.com
Predicted sound reduction values (dB)
Construction details (typical)
Frequency
(Hz)
0.7 mm
0.9 mm
1.2 mm
100
17.4
19.4
21.7
125
19.2
21.2
23.7
160
21.8
24.0
26.5
200
26.1
28.3
30.8
250
30.4
29.9
29.5
315
30.1
35.7
35.4
400
29.3
40.2
40.6
500
22.4
39.2
45.1
630
37.0
37.8
50.0
800
45.3
31.2
48.6
1000
56.4
45.3
47.2
1250
60.8
56.4
39.3
1600
59.9
67.0
56.7
2000
70.6
66.9
67.2
2500
75.5
76.6
74.9
3150
77.8
81.9
83.1
4000
86.4
85.1
88.8
5000
91.9
93.0
92.8
Weighted Rw
37.0 dB
40.5 dB
43.2 dB
01244 892 199 | www.tatasteelconstruction.com/roofdek
Weather sheet:
Membrane thickness = 1.2mm
Insulation:
Cavity width = 200mm
Insulation thickness = 200mm
Density = 80kg/m3.
Fixing spacing = 233mm
Purlin spacing = 4000mm
Type = SOFT
Liner Sheet:
D100 Pitch = 233mm
Crown = 109mm
Valley = 63mm
Depth = 100mm
Thickness = 0.7/0.9/1.2mm
17
RoofDek Roof safety
Roof safety
Latchways have conducted numerous tests
using the Constant Force® Post in
conjunction with Tata Steel RoofDek.
The information below shows a typical
application of a Latchways Mansafe® system
with a Single Ply membrane roof.
Installation, Annual Inspection
and Certification
Only a Latchways Registered Installer is able to
design, supply, install and certify Latchways
ManSafe products.
Thereafter Latchways Plc. strongly
recommend that any annual inspection, recertification or servicing of ManSafe products
be undertaken by a Latchways Registered
Installer.
Only a Latchways Registered Installer will have
received the necessary Latchways training,
have access to technical documentation and
original parts should replacement be
necessary.
For further details please contact Latchways
directly on +44 (0) 1380 732700.
Profiles & widths
Base plate
fixing centres
Steel deck
specification
459
D32S
459
D35
210
D46
210
D60
210
D100
Base plate fixing centres†
The Single Ply Constant Force post is suitable for use with insulation thicknesses’ of 50 mm – 220 mm. The advice of the Single Ply
manufacturer should be sought when specifying all aspects of the vapour control layer, fasteners, waterproof covering and overall
roof construction.
All roofing components must be installed strictly in accordance with the manufacturers’ recommendations and specification.
The standard colour of the post is Dark Grey – RAL 7037. Other colours are available to order at additional cost subject to availability
and lead time. Contact Latchways technical department for further information. The post is not suitable for use within gutters or
areas where standing water occurs. Adequate falls for drainage must be provided within the finished roof construction.
The welding of the Single Ply membrane to the Constant Force post base plate must strictly follow the Single Ply manufacturer's
recommendations regarding application and working temperatures.
The base plate fixing centres must line up with the crowns of
the steel deck.
† Latchways reference to base plate fixing centres is defined as
the width of the fixing points for the Latchways base plate.
245mm
6,000 – 10,000mm
6,000 – 10,000mm
Weld
Single Ply membrane
Protective plastic cap
Plastic toggle guide
Toggle bolt
18
Weld
RoofDek Service and support
Service and support
Tata Steel maintains a friendly technical help
desk which is freely available to all
Architects, Engineers and Contractors to
assist with all aspects of RoofDek and liner
tray design.
Specification service
Analysis Software
The Tata Steel RoofDek team are able to
provide a comprehensive Specification
Service. Assistance in creating NBS
specifications for RoofDek and trays can be
provided to ensure the correct deck or tray is
specificed for the right application.
RoofDek Analysis Software has been created
in partnership with leading international
developer CSC, best known for the very
widely-adopted Tedds structural design
software. With all calculations compliant with
Eurocodes, the package enables structural
engineers and designers to carry out full deck
analysis to achieve optimum design and cost
efficiencies.
Design calculations & diaphagm
design
To assist the specifier, the team are able to
provide design calculations for live, dead,
wind and snow drift loads and where required
diaphragn design calculations.
01244 892 199 | www.tatasteelconstruction.com/roofdek
To download the RoofDek software, visit
www.tatasteelconstruction.com/roofdek
19
RoofDek Sustainability
Sustainability
At Tata Steel, we are committed to making the
products society needs and to making them in
the safest and most responsible way possible.
CO2 is a by-product of the steel making
process and we have a well-developed
strategy to minimise our CO2 footprint. In fact,
over the last 40 years we have reduced the
energy needed to produce steel by 50%. And
we have set a target of reducing our CO2
emissions by a further 20% in the next ten
years.
Some of our savings in CO2 come from major
investments, like the recovery of waste gases
at our Port Talbot site. This investment of
£60m is already saving 297,000 tonnes of CO2
emissions annually. Other reductions have
come from smaller site-based initiatives such
as the zero-carbon scheme at our Shotton site.
Since starting this in 2005, the site has
reduced its CO2 footprint by more than 25%.
We are also investing in the future to realise a
major step-change in steel making with lower
CO2 emissions. We are a leading partner in the
€59m ULCOS project which aims to cut the
CO2 emissions from steel production by 50%
by 2050.
The first phase of ULCOS involved research to
evaluate a new generation of steel making
technologies, while the second phase will
operate the most promising of these on a
demonstration plant. The pilot HIsarna
furnace is operated by Tata Steel, in
cooperation with representatives from steel
plants across Europe and will demonstrate
technology for producing steel with up to
50% less CO2 emissions. This is potentially the
first step to the dawn of a new era in steel
making.
All Tata Steel manufacturing sites are certified
to ISO 14001, the international standard for
environmental management systems. We also
recognise the responsibility we have both up
and down our supply chains and we work to
ensure that sustainable practices are adopted
throughout by close co-operation with both
suppliers and customers.
For more information on our sustainability
strategy, visit www.tatasteelconstruction.com/
sustainability
For Tata Steel, sustainability is not all about
CO2. There are initiatives ongoing across our
sites to reduce waste, minimise emissions and
contribute to our communities.
“We take our
responsibility as a
sustainable steel
producer very
seriously and have
taken a leading role
in reducing CO2
emissions across
the steel industry.”
Tata Steel’s Shotton site – now with 25% less CO2
emissions than in 2005.
20
RoofDek Case Studies
Peacehaven
RoofDek D100 Case Study
Wastewater Treatment Works
Peacehaven, E. Sussex
Featuring the UK’s largest curved green roof
and covering an area equal to 2.5 football
pitches, Southern Water’s £300m, state-ofthe-art water treatment plant will service the
entire Brighton and Hove area. The roof
features over 18,000m2 of Tata Steel
RoofDek D100 and the Tata Steel C19 profile
on the walls, all in Olive Green, double-sided
Colorcoat HPS200 Ultra®.
Peacehaven Wastewater Treatment Works is
an environmental improvement scheme at
Lower Hoddern Farm in Peacehaven, East
Sussex, UK. The project will treat 95 million
litres (ML) of wastewater a day.
Designed to blend in with the landscape the
plant will treat wastewater generated from
Brighton and Hove, Rottingdean, Saltdean,
Telscombe, Woodingdean and Peacehaven
and is scheduled to be fully operational by
spring 2013.
The biggest challenge on-site was logistics in
terms of transferring the thousands of tonnes
of substrate onto the roof and covering the
complete area using mobile tower cranes. To
overcome this issue, a series of conveyor belts
were used to transport the volume of material,
which was then raked to follow the curve of
the building.
The green roof has been installed over
18,000m2 of Tata Steel RoofDek D100 in Olive
Green double-sided 0.9mm Colorcoat HPS200
Ultra®.
Designed to accommodate the additional
loadings imposed by green roof construction,
RoofDek D100 features a 700mm cover width
and a 233.3mm pitch that provides a very
strong deck and offers excellent insulation
support. Its lightweight construction also
minimises the load on the building structure.
“The metal deck single ply structure with
shear batten support overcame initial design
concerns,” explained Project Manager Paul
Webb.
The project involved a total envelope solution,
including walls featuring the Tata Steel C19
profile in Olive Green 0.7mm double-sided
Colorcoat HPS200 Ultra® in single and double
skin configurations. Colorcoat HPS200 Ultra® is
the most durable pre-finished steel on the
market.
Based upon a revolutionary coating system,
Colorcoat HPS200 Ultra® provides outstanding
colour and gloss retention, and corrosion
resistance even at the cut edge.
Double-sided Colorcoat HPS200 Ultra® is ideal
for the demanding internal environment at
Peacehaven Wastewater Treatment Works,
where the same unique formulation topcoat
and corrosion-resistant primer applied to the
reverse side provides a robust barrier on both
sides of the steel substrate.
01244 892 199 | www.tatasteelconstruction.com/roofdek
21
RoofDek Case Studies
West Cheshire College
RoofDek D135 case study
Ellesmere Port Campus
and Chester Campus
West Cheshire College prides itself on its
standards of teaching and the courses it
provides. In order to enhance the learning
experience offered, it has committed to
building two new high-quality campuses.
Featuring ComFlor® composite floor decking
and RoofDek Structural Roof Decking, the
new facilities will improve vocational
opportunities for young people and extend
the range of opportunities for adults to
develop skills.
The Ellesmere Port Campus involves the
construction of a 19,500m2 new build art,
design and media, hospitality and catering
and hairdressing and beauty block. Running in
parallel, the Chester Campus construction
programme consists of a 6,000m2 state-of-theart science and technology teaching facility.
The main focus of both campuses is an
internal project court where vocational
students of different trades are able to work
alongside one another in building a house,
within the project court itself.
As part of the new build programme,
11,000m2 of ComFlor® 80 composite floor
decking was specified for both campuses.
Alongside this, 2,300m2 of RoofDek D135
structural metal roof decking was specified.
By offering a comprehensive range of steel
composite floor and roof decking systems, Tata
Steel were in the unique position of being able
to meet all of the roofing and flooring
requirements for the College project.
22
RoofDek Case Studies
West Burton Power Station
HLT130/600 liner tray case study
CCGT Power Station, West Burton,
Nottinghamshire
EDF Energy's 1300MW Combined Cycle Gas
Turbine (CCGT) power station at West
Burton, Nottinghamshire, will meet the
needs of 1.5 million people. The project
features 40,000m2 of a Tata Steel Acoustic
Structural Liner Tray Built Up System, for
high sound reduction and absorption levels
in three giant turbine halls.
It is adjacent to EDF’s existing 2,000MW coal
fired power station and has been built using
advanced, yet proven technology to provide
an efficient and flexible power station to meet
future energy supply requirements and to
help reduce the intensity of the company’s
CO2 emissions from its electricity production.
A major construction project by any standard,
West Burton CCGT saw over 1000 individual
contractors working on site at the height of
the very complex build programme.
The project’s three 32m tall, steel-framed
turbine halls, each measuring 82m long x 35m
wide, feature a total of 40,000m2 of a Tata
Steel Acoustic Structural Liner Tray Built Up
System, installed by Hertel Technical Services.
The very stringent acoustic requirements were
fully met at West Burton, thanks to the wealth
of experience Tata Steel could bring to the
project, drawing on an excellent track record
in full acoustic systems at other CCGT power
station projects at Rye House, Hertfordshire
and Killlingholme, Lincolnshire.
The roof and wall constructions feature the
Tata Steel HLT130/600 0.75mm gauge
acoustic structural liner tray.
Forming the base of a roof and wall
construction incorporating two dense mineral
fibre insulation layers, HLT130/600’s inherent
properties greatly assisted sound reduction
and absorption, simultaneously controlling
noise breakout and reducing internal high and
low frequency noise levels in the three halls.
A sound reduction figure of 36dB was
achieved in each of the halls, significantly
reducing their acoustic impact in the
surrounding area.
The built up roofing and cladding system
included a rigid mineral fibre slab in the pans
of the HLT130/600 structural liner tray.
A further semi-rigid mineral fibre slab was
inserted above the tray flanges. This was
separated from the rigid insulation layer by a
flat 0.7mm galvanised steel sheet, helping to
provide vital mass in the built-up system
The external roofs feature the Panels and
Profiles R32 profile. The external walls are clad
in the C32 profile.
Both products have a 0.7mm Colorcoat
Prisma® Silver Metallic finish, plus a Denim
finish on the lower levels of C32. Versatile,
lightweight and strong, Colorcoat Prisma® is
an ideal choice when it comes to exposed
external environments like West Burton.
Offering outstanding UV resistance, Colorcoat
Prisma® gives first-class colour and gloss
retention, following comprehensive natural
weathering testing in a variety of contrasting
climates.
The R32 roof profile accommodates 800
metres of lightweight aluminium walkways,
complete with tubular handrails, with stainless
steel fixings to the Panels and Profiles sheets.
This facilitates easy servicing of 100 rooflights
and ventilators on each of the three roofs,
which also feature parapet walls in C32 on all
sides.
01244 892 199 | www.tatasteelconstruction.com/roofdek
23
www.tatasteelconstruction.com/roofdek
Trademarks of Tata Steel
Colorcoat, Colorcoat HPS200 Ultra, Colorcoat Prisma
and Galvatite are trademarks are registered
trademarks of Tata Steel UK Limited.
Care has been taken to ensure that the contents of
this publication are accurate, but Tata Steel Europe
Limited and its subsidiaries, (including Tata Steel UK
Limited), do not accept responsibility or liability for
errors or information that is found to be misleading.
Suggestions for, or descriptions of, the end use or
application of products or methods of working are
for information only and Tata Steel Europe Limited
and its subsidiaries accept no liability in respect
thereof.
Before using products or services supplied or
manufactured by Tata Steel Europe Limited and its
subsidiaries, customers should satisfy themselves as
to their suitability.
Printed with biodegradable vegetable inks on
material sourced from responsibly managed forests,
certified in accordance with the FSC. Contains 10%
recovered fibre, diverting waste from landfill.
Sales Contact Details
Tata Steel
Shotton
Deeside
Flintshire
CH5 2NH
United Kingdom
T: +44 (0) 1244 892 199
F: +44 (0) 1244 892 121
E: roofdek@tatasteel.com
Copyright 2016 Tata Steel UK Limited, Registered Office: 30 Millbank London SW1P 4WY, Registered in England No. 2280000
Language English UK 0716