Coated Metal Roofing & Cladding

Contents

Executive Summary 1

Acknowledgements 5

Programme 7

Chapter 1 Review of current practice for coil-coated and roll-formed metals 9

1.1. Controls, approvals and defects feedback from manufacture to construction 9

1.1.1. Trade associations and other organisations 9

1.1.2. Investigations of supply chain from manufacture to construction 16

1.1.3. Defects feedback from other sources 23

1.1.4. Guarantees offered by suppliers 26

1.1.5. Standards for coil 27

1.1.6. Analysis – coil-coated metals roll formed into conventional profiles 30

1.1.7. Analysis – other materials and techniques 33

1.2. Gaps in approval systems 34

1.2.1. Weaknesses in procedures in the supply chain 34

1.3. The Latham Report – recommendations relevant to the roof sheeting and cladding industry 37

1.3.1. Workmanship on site 37

1.3.2. Latham recommendations 38

1.3.3. Training the Team – report of Construction Industry Board Working Group 6 38

1.3.4. The Construction Industry Training Board and the Direct Training Unit 40

1.3.5. Training by manufacturers of specialist systems 40

1.4. Conclusions 41

1.5. Recommendations 41

Chapter 2 Trends in materials and techniques 43

2.1. Trends in coatings 43

2.1.1. Review of changes since 1976 43

2.1.2. Developments in coil coatings 43

2.1.3. Other developments 50

2.1.4. Health, safety and environmental issues 52

2.1.5. Corrosion prevention, maintenance and repair 56

2.2. Trends in design 58

2.2.1. Review of changes since 1976 58

2.2.2. Developments in design in profiled sheeting since 1976 58

2.2.3. Other developments in design 62

2.3. Trends in metals 64

2.3.1. Aluminium 64

2.3.2. Galvanised steel 65

2.3.3. Other metal coatings on steel 69

2.3.4. Stainless steel 72

2.3.5. Other metals 73

2.4. Conclusions 73

2.4.1. Coatings 73

2.4.2. Design 74

2.4.3. Metals 74

2.5. Recommendations 75

Chapter 3 International comparison 77

3.1. Europe (excluding the United Kingdom) 77

3.1.1. Trade associations and other organisations 77

3.1.2. Holland 79

3.1.3. Germany 85

3.1.4. France 88

3.1.5. Scandinavia 91

3.1.6. Other European countries 93

3.2. United States 93

3.2.1. Industry structure 93

3.2.2. Survey results 95

3.2.3. Site visits 96

3.2.4. Standards 97

3.3. Australasia 101

3.4. Conclusions 102

Chapter 4 Current and proposed standards 105

4.1. Background to standardisation 105

4.2. Review of standards 106

4.2.1. General 106

4.2.2. Standards for substrates 112

4.2.3. Test methods for coatings 114

4.2.4. Standards for coil-coated steel 118

4.2.5. Standards for coil-coated aluminium 124

4.2.6. Standards for powder-coated products 125

4.2.7. Standards for roofing 126

4.2.8. Fire 128

4.2.9. Colour 129

4.2.10. Fixings/fasteners 130

4.2.11. Rooflights 131

4.2.12. Design and installation 131

4.2.13. Cooperation 132

4.2.14. Maintenance 133

4.2.15. Design life 134

4.3. Conclusions 135

4-4. Recommendations 139

References 141

Appendices 153

Appendix 1 Current Agreement Certificates for coated metals 153

Appendix 2 Summary of replies to postal surveys, from manufacture to construction 155

Appendix 3 Reproduction of Annex E from pr EN 505 and pr EN 508-1: 1996 (Roofing products from metal sheet – steel) 177