INSTALLATION MANUAL
Contents
1. Dimensions 400mm X 150mm Cover Length 370mm Weight textured 0 4A62kg Weight satin 0 324kg 101 V Ridge Dimensions Cover Length 400mm X 150mm 470mm 0 47 2kg 0 316kg Weight textured Weight satin 106 End Cap V Ridge 150mm x 150mm Dimensions 150mm x 150mm 0 082kg Weight textured 0 07 4kg 0 058kg Weight satin 0 052kg Dimensions Weight textured Weight satin 107 Angle Ridge Overall Length 2000mm Cover Length 1900mm Weight satin 1 63kg 102 Standard Ridge Overall Length 2000mm Cover Length 1900mm Weight textured 1 72kg Weight satin 1 20kg Installation Manual for Tilcor Roofing Systems October 2011 104 Standard Side Flashing 2000mm 1900mm 1 50kg 1 01kg Overall Length Cover Length Weight textured Weight satin 100mm imm i S4rmrn Overall Length 2000mm Cover Length Weight satin 1900mm 3 50kg 103 Standard Bare Overall Length 2000mm 1900mm 1 98kg 1 45kg Cover Length Weight textured Weight satin Page 13 roofmakers to the world 9 TILCOR Flashing Specifications Continued 108 Notched Barge LH Overall Length 2000mm Overall Length 2000mm Overall Length 2000mm Cover Length 1900mm Cover Length 1900mm Cover Length 1900mm Weight textured 2 50kg Weight textured 2 35kg Weight textured 2 54kg Weight satin 1 75kg Weight satin 1 64kg Weight satin 1 81kg 120mm 109 Not2. Ridge Installation It is recommended to fit the V Ridge or Barrel Trim up all hips and gables before moving to the ridge The starting and finishing trim on the ridge must be lapped over the hip or gable trim with silicon applied under the lap to create a waterproof seal To ensure a watertight joint and prevent the ingress of water a tight fit is required between the tile and the ridge cap Note Tiles must be turned up a minimum of 40mm against the batten hip board or where they butt against a vertical or an inclined surface The ridge trim can be fixed through the side of the trim using fasteners It is also recommended that the silicon spots be covered for aesthetic reasons using the Touch Up Kit Gable Starter V Ridge Installation Manual for Tilcor Roofing Systems October 2011 Page 34 Cp TILCOR roofmakers to the world Ridge Installation Continued Barrel Trim shown or V Ridge Barrel Trim Fixing through upstand Min cover of ridge tile 35mm at any point Tile battens standard Ridge Ridge Hip board Truss 50mm plus batten height 100mm x 25mm Ridge Hip board can be used for 900mm Truss Spacing where 50mm x 40mm tile battens are used Note Builder to supply and install nage boards Care must be taken when installing the Ridge Hip boards to ensure that they are straight true and securely fixed Installation Manual for Tilcor Roofing Systems October 2011 Page 35 Cp roofmakers to t
3. Roof penetrations shall be flashed as follows a Pipe penetrations up to 60mm shall be flashed using an EPDM boot flashing as shown in below figure Roofing Underlay Installation Manual for Tilcor Roofing Systems October 2011 Page 41 TILCOR roofmakers to the wor E E MHH iil TH Tilcor Roofing Systems Ltd 1c Inlet Road Papakura Auckland New Zealand PO Box 72062 Papakura 2244 P 64 9 299 9498 F 64 9 298 4114 E info tilcor com W www tilcor com
4. j TILCOR roofmakers to the world INSTALLATION MANUAL BOND CLASSIC TUDOR SHAKE ROMAN ROYAL These installation details are provided to demonstrate the recommended installation methods for Tilcor products and accessories The details and information in this document reflect current roofing practices used in New Zealand Consult with Tilcor Roofing systems Ltd for additional information Tilcor Roofing Systems Ltd 1c Inlet Road Papakura Auckland New Zealand PO Box 72062 Papakura 2244 P 64 9 299 9498 F 64 9 298 4114 E info tilcor com W www tilcor com Gp con Table Of Contents ee cig sico Migieldialeiiiola TITEL T tere ert ey en ete ee ee ere 3 2 Recommended Tools NI nme EE nennen 9 SPOS 1218 616 6 cm E E o ee re US 11 S dleciastebver elleeienme e t E NE A E E AN 12 5 Detail Reference Guide 200 0 sss mmm 15 CRPIO S TOO O MET OU 16 7 Tile laying Instructions are Tudor Specific oo 19 8 Tile Laying is Shake Royal Specific sssssssseem e 24 9 Valley Installation General sss mH 2 ism GODIS SOGNO gem m mE ce E N E E 30 TLREGJe IAS TOIGHNON siriano r E E EEO S aN 34 12 Sidewall Installation Mm teen eet en ee tertata E EEE eee EREEREER EEEE 37 a l ce ehel Blac silicic eee tere nr te tnt EO ODE Trt erty nett torte 39 14 Penetration Installation EE EEE 4 Installation Manual for Tilcor Roofing Systems October
5. 2011 Page 2 IL 1 General Information 1 0 1 1 _ l w N O D Description Tilcor products are manufactured in accordance with Part 2 of NZS 4217 1980 New Zealand Standard for Pressed Metal Tiles and provided our roof products are installed in accordance with our specifications they will meet the requirements of the New Zealand Building Code Manufactured to ISO9001 NZS3604 and NZS 4217 Tilcor currently have three roofing profiles available Tudor Shake Royal covered by this manual The roofing tiles are printed on the underside with the brand name The following flashings form an integral part of the roofing system 2m flashings effective cover 1 9 m e Standard Barge Flashing e Standard Ridge for Hip and Ridge capping e Standard Side Flashing A E Barge and A E Apron Flashings are also supplied with alloy edging e 400mm flashings effective cover 370mm e Barrel Trim e V Ridge 50 x 3 05mm ring shank nails are used for fixing the roofing tiles Where tiles have to be fixed on top of a rib e g at the fascia eaves barges or on top of flashings 50 x 3 05mm ring shank nails fitted with neoprene washers are used or can be alternatively sealed with a MS type sealant 2 0 Materials 2 1 Zincalume consists of steel hot dip coated with an aluminium zinc alloy complying with NZS 344J The steel is G300 Structural Drawing grade 0 4mm thick To the topside of the Zincalume coated ste
6. 4 In all applications the choice of flashing fixing material shall take into account NZBC B2 Durability specific conditions of use and consideration of the surrounding material Durability requirements for flashings a 50 years where flashings are completely hidden behind claddings or not accessible b 15 years where flashings are exposed or accessible 11 0 Special Flashings 11 1 Special flashings are made as required by the manufacturer from uncoated steel and subsequently factory coated using the same coating process as used for tiles or alternatively manufactured on site by the roofer using factory finished tiles and accessories and cutting and bending to the desired shape 12 0 Durability 12 1 12 2 12 3 Tilcor warrants that each Zincalume roofing tile comprised in the roof fitted to the purchaser s property will carry an appropriate weatherproof warranty This warranty does not cover damage due to improper handling installation or damage occurinig after installation Please refer to Country Warranty for further information Installation must be in accordance with instructions of Tilcor Roofing Systems Ltd Where the roof space is not completely closed off to the elements the underside of the roof must be completely shielded with roofing underlay or sheathing such as fibre cement hardboard or plywood Installation Manual for Tilcor Roofing Systems October 2011 Page 6 9 TILCOR roofmakers to the world Limit
7. from prevailing winds or from discharging rain water pipes or valleys Where possible the tiles should also be laid with the laps facing away from the normal line of sight Fig 1 1 Tiles are laid by lifting both tiles in the course above and sliding the next course under the nose of the tiles already in place Fig 1 2 Figure 1 1 Figure 1 2 Tile Installation Procedure Hip Roof General instructions for tile laying as detailed above On the second to top course the higher most full tile course lay the top corner of the first tile 150mm from the hip board Continue to lay tiles towards the other hip until the last full tile will fit secure these tiles by tacking through the back flange Fig 1 3 Lay subsequent courses two at a time both starting about the same distance from the hip board Fig 1 4 amp 1 5 Figure 1 4 Installation Manual for Tilcor Roofing Systems October 2011 Page 19 roofmakers to the world p TILCOR Tile Lay Continued Care should be taken to line up the corrugations lo reduce waste use part tiles to complete rows within approximately 150mm of hip board Fig 1 6 This allows each end of a full tile to be cut and bent to fill the gaps 1 Part tile to allow each I end of a full tile to be cut and bent to fill the gaps I L Ts N Figure 1 6 Measurements and Marking Measurements are made on the roof but tiles are normally marked cut bent a
8. of flashing a min of 200mm Underlay Note Cladding not to project lower than the 5mm step in the apron flashing Installation Manual for Tilcor Roofing Systems October 2011 Page 38 p TILCOR roofmakers to the world Headwall Installation The wall cladding flashings must be positioned before the tiles and must be designed so that the turned up tile can be inserted behind the flashing Note All preparatory work of under flashing fixing of eaves gutters and valley gutters must be completed and all tiling battens must be in place before laying tiles Batten Standard Side Flashing Standard Side Flashing seated and fixed in place by nails rivets Installation Manual for Tilcor Roofing Systems October 2011 Page 39 Cp roofmakers to the world Headwall Installation Continued Cladding and building wrap Where cladding manufacturer requires more than 75mm of apron upstand under cladding cladding supplier to supply and install over flashing to suit their requirements For details refer to cladding manufacturer 40mm 75mm Support nog Tilcor tile ie Batten d Apron Flashing Side Flashing Underlay carried up face of framing behind upstand of flashing a min of 200mm Note Cladding not to project lower than the 5mm step in the apron flashing Installation Manual for Tilcor Roofing Systems October 2011 Page 40 Cp TILCOR roofmakers to the world Penetration Installation
9. roofmakers to the world 9 0 Tiling Battens 9 1 9 2 9 3 9 4 9 5 Battens must be treated sized and fixed according to NZS 3604 On new roofing underlay e g as given in Acceptable Solution E2AS1 Paragraph 1 3 must be fixed in place first in accordance with the instructions of the underlay manufacturer A row of battens is fixed directly behind the fascia board The next row of battens is generally fixed 320mm from the front of the fascia board and subsequent rows are fixed at 368mm centres and 370 centres satin Battens shall span at least three rafters or trusses at the edge of all roof planes The installer is to select tiling battens from pack and reject any unsuitable battens that may not support his her weight when spanning 900mm centres Tiling battens are required to support files In reroofing situations when counter battens are used they must be sized installed and fixed in accordance with the requirements of NZS 421 7 This must be done in low medium and high NZS 3604 building wind zones In very high wind zones counter battens must be spaced at 600mm maximum centres when the existing purlin spacing is 750mm and 450mm maximum centres when the existing purlin spacing is 920mm Where the counter batten sits directly on the purlin behind the fascia two 75mm x 3 15mm skew driven nails may be used as per NZS 4217 section 202 4 4 Preparation of roof 10 0 Flashings and Fixings 10 1 To comply With E2 AS1 8 2
10. 0mm against the hip battens hip board or where they butt against a vertical or inclined surface Ed Fr Cut and Bent 2 Install the cut tiles by starting at the bottom course and nailing the cut tiles to the hip batten Proceed up the hip length one tile at a time Installation Manual for Tilcor Roofing Systems October 2011 Page 24 p TILCOR roofmakers to the world Tile Lay Continued 3 secure files down on batten ensuring that they butt against hip batten as shown in step 2 4 In some instances it is desirable to Cut and lay a half tile to ensure a cut tile is a desirable size Proceed to lay and secure all tiles out across length of roof On the second to top course continue to lay tiles towards the other hip until the last full tile will fit Then continue to lay tiles down to the fascia and then across the roof to complete the roof plane with full tiles Installation Manual for Tilcor Roofing Systems October 2011 p TILCOR roofmakers to the world Tile Lay Continued 5 Measure the bottom length of each cut from the centre of the lap to the hip batten for each cut for the full length of the hip Mark with bevel cut and bend similar to the other side of the hip Fit cut tiles once again starting from the bottom course Care should be taken to ensure the cut tile fits underneath the full tile above 6 Place in position and secure each tile at the lap into the hip bo
11. 1 Cp roofmakers to the world Gable Installation Continued Barrel Trim shown or V Ridge or Standard Barge to Metal Fascia Tilcor tiles _ Barrel or V Ridge ra Barge batten 2 Fixing _ Flying rafter a as Underlay Outrigger T lt Barge board 39 Barge board must project at ay least to top of tile batten Eaves lining Barge board must project to at least the top of tile batten Minimum barge board cover is 50mm unless in very high wind zones where 70mm cover is required Turn Up Metal Fascia Tilcor tiles Batten Fd Outrigger REINDERGCQTUM e E aea pera N Lr Cot TT Pu NOM cm Underlay eee eee XL Metal fascia system Faves lining Installation Manual for Tilcor Roofing Systems October 2011 Page 32 p TILCOR roofmakers to the world Mansard Roof Including a Change of Roof Pitch 368mm Textured Bond Classic Roman Tudor Shake and Royal 370mm Satin Bond Tudor Shake Classic Tile batten Setout varies according to the tile type Underlay Batten set out follows pitch change As illustrated where the roof line changes pitch a batten is placed at this point In situations where you have a pitch change and a specific number of full tiles cannot d be laid down it is suitable to bend a full tile lengthwise to compensate Rafter Installation Manual for Tilcor Roofing Systems October 2011 Page 33 p TILCOR roofmakers to the world
12. 604 6 11 Uplift resistance achieved by using fasteners below Gun Nail 90x3 15 Ringshank Nail gun hand 90x3 2 Gun Nail 90x3 15 Twist Shank Nail 90x33 Purlin Screw c s head 10gx100 Type 17 screw 14gx100 Data obtained using 45mm thick battens ee ee 3 d 7 0 General Installation Information Tilcor Roofing Systems must be installed in accordance with the manufacturer s instructions as contained in this document 7 2 Care must be taken when handling cutting bending and installing the roofing in order to avoid damage fo the surface In particular the roofing surface must be kept clean of dirt and other substances such as metal swarf 7 3 Flat rubber soled shoes must be used when working on the roof and protective padding used on tools Loads must be applied only over battens and the installed roofing protected from other construction and finishing work being carried out on or above the roofing such as cladding materials plaster and paint 8 0 Roof Framing 8 1 Roof framing should provide support and fixing for the tile battens that will satisfy the design load wind requirements 8 2 Installers should check that the framing has been erected to an accurate and even line before roof fixing is started 8 3 An inspection and any rectification to the framing alignment must be carried out before roof fixing is commenced Installation Manual for Tilcor Roofing Systems October 2011 Page 5 p TILCOR
13. Coloured aerosol paints should never be sprayed on tiles or accessories made by Tilcor Installation Manual for Tilcor Roofing Systems October 2011 Page 8 9 TILCOR roofmakers to the world 2 Recommended Tools Tilcor Roofing Systems are installed with standard construction tools The tiles may be cut with tin snips or the Guillotine cutter supplied as part of the Tilcor installation kit that consists of 1 Guillo tine cutter 1 Bender 1 Top Course Bender Guillotine also known as a Cutter 356mm x 1016mm x 76mm 17 7kg This Guillotine is used for Bond Classic Roman Shake amp Shingle Top Course Bender 1549mm X 457mm X 101mm 28 1kg Bender 864mm X 508mm X 406mm 20 9kg Installation Manual for Tilcor Roofing Systems October 2011 Page 9 p TILCOR roofmakers to the world Recommended Tools Continued Impact or Screw Gun Hand Bender Hand Scribe Measuring Tape Nail Gun Tin Snips Set out Rod Bevel Installation Manual for Tilcor Roofing Systems October 2011 Page 10 j TILCOR roofmakers to the world Profile Specifications Overall Length Length of Cover Width of Cover Roof Cover Tile Tiles m2 Minimum Roof Pitch Nailing Points Per Tile Weight Tile Weight m2 Overall Length Length of Cover Width of Cover Roof Cover Tile Tiles m2 Minimum Roof Pitch Nailing Points Per Tile Weight Tile Weight m2 Overall Length L
14. R roofmakers to the world Ga ble Insta lation Bond Classic Roman Tudor Shake and Royal Tile ends are turned up a minimum of 40mm and installed against the barge batten that is covered by a Standard Barge Barrel Trim or V Ridge as shown Alternatives include under a metal fascia system where there is no barge batten or a hidden gutter Where a hidden gutter is used tile edges should be turned down into the gutter by a minimum of 20mm Installation Manual for Tilcor Roofing Systems October 2011 Page 30 roofmakers to the world p TILCOR Gable Installation Continued standard barge Timber Fascia Tilcor tiles Standard Barge Batten E _ Barge Batten a Hr nu j Min Barge Cover Underlay Flying rafter Outrigger RNC a dae oe EMCU M a TN e Barge board Barge board must project at SK least to top of tile batten Eaves lining Minimum barge board cover is 50mm unless in very high wind zones where 70mm cover is required Barrel Trim shown or V Ridge Timber Fascia Valley tile turned down Tilcor tiles into valley tray 50mm min Underlay Tile batten 25mm min thick valley boards cut and supported between rafters truss Top of valley boards flush with top of rafters truss Valley boards 25x150mm 250mm min gutter width Valley tray Underlay separating valley board and valley tray Installation Manual for Tilcor Roofing Systems October 2011 Page 3
15. ard and along the nose of the tile as required depending on the cut tile length 7 Once complete The hip battens are then ready to be covered with V Ridge Caps Installation Manual for Tilcor Roofing Systems October 2011 Page 26 roofmakers to the world j TILCOR Va ley Insta lation Bond Classic Roman Tudor Shake and Royal n 50mm x 40mm i Batten D The valley boards are installed between the D vem valley jack rafters and flush with the roof eee Underlay plane to support the Metal Tile Valley Valley z n boards are required to be set with their outer edge a minimum of 150mm fig 1 11 pg 28 from the centre line of the valley Valley boards are required to support a point load of 1 1 kN which is taken to be the weight of a tradesperson with a bag of tools Valleys are installed so that water discharges over the back of and into the eaves gutter Valley Tray The valley tray is cut to match the angle of the fascia boards A If is then further cut to create a downturn of 20mm B The valley end is then corrected to discharge in to eaves gutter C The valley tray should protrude into the gutter in line with the bottom row of tiles 50mm Fastening First run out a strip of roofing underlay over the valley board to prevent the valley tray from coming into direct contact with the valley board Valleys shall be secured by 90mm x 3 15mm H D Galvanised nails fixed into the valley board a
16. ations on use 12 5 12 6 12 7 12 8 Tilcor Roofing Systems must not be used in high alkaline environments such as on ntensive animal shelters or other buildings with high ammonia or urea concentrations and or contact with fresh concrete or plaster must be avoided The roofing must not be used in contact with permanently damp materials on industrial buildings in which corrosive processes occur or over swimming pools Copper in any form must not be allowed to contact the roofing and care must be taken to ensure that runoff from copper overflow or down pipes does not come into contact with the tiles Lead or lead edged flashings must not be used with Tilcor Roofing Systems unless a suitable barrier paint system is applied to both surfaces to ensure there is no metal to metal contact or contact through water runoff The manufacturer supplies flashings that are suitable for use with the roofing products Weathering 12 9 12 10 With granule coated products some loss of granules and overglaze can be expected over time Acrylic coated tiles may fade and chalk as time passes This may be more noticeable with some colours than others and is an expected part of the weathering process Maintenance 12 11 12 12 12 13 12 14 Tilcor pressed metal roofing tiles require minor maintenance to ensure the continued performance of the roof over its life Where possible a visual ground inspection of your roof should be perfo
17. ched Barge RH 111 Notched Sidewall RH 112 A E Apron Overall Length 2000mm Overall Length 2000mm Overall Length 2000mm Cover Length 1900mm Cover Length 1900mm Cover Length 1900mm Weight textured 2 50kg Weight textured 2 35kg Weight textured 2 56kg Weight satin 1 75kg Weight satin 1 64kg 113 A E Barge Overall Length Cover Length 300 Roman Birdstop i Overall Length 2000mm Overall Length Cover Length 1900mm Cover Length Weight textured 1 90kg Weight textured 1 88kg Weight satin 1 32kg Weight satin 31kg Weight textured Weight satin Installation Manual for Tilcor Roofing Systems October 2011 Page 14 Cp roofmakers to the world Flashing Specifications Continued 501 Classic Headwall Overall Length 2000mm Cover Length 1900mm Weight textured 1 97kg Weight satin 1 30kg Installation Manual for Tilcor Roofing Systems October 2011 Page 15 j TILCOR roofmakers to the world 6 Detail Reference Guide Gable Installation pages 30 33 Valley Installation pages 2 29 Hidge Installation pages 34 36 Penetration Installation page 41 Headwall Installation pages 39 40 sidewall Installation pages 37 38 Batten amp Tile Lay pages 16 26 Installation Manual for Tilcor Roofing Systems October 2011 Page 16 p TILCOR roofmakers to the world Preparatory Installation 1 Batten Spacing Disclaimer For purpose
18. e sure joining battens are centred on the rafters and cut ends off that are not straight Then cut all other joins on the centre line of each rafter where each batten extends to Then mitre cut each batten onto the hip and valley boards Installation Manual for Tilcor Roofing Systems October 2011 Page 16 E TILCOR roofmakers to the world Preparatory Installation 3 Underlay Installation x lt ___ Batttens stacked at top S as each run of underlay Once the battens are cut in completely Lf SS PRESS olaced the battens can be moved up to allow the underlay to be rolled out self supporting breather type building paper must be used Starting at the bottom roll out the underlay horizontally across the roof ensuring that the lower edge of the underlay overhangs the outside edge of the fascia by a minimum of 40mm Once each run of underlay is run out move the battens down to rest on pinout nails This will enable the installer to continue up the roof plane by walking along these battens Paper the whole roof horizontal to the fascia line ensuring that each lap is no less than 150mm unless it occurs directly underneath a batten in which case it can be reduced to 5mm Underlay is to be lapped over each hip and ridge line at least 150mm Cu R Battens placed back ESI over set out nails and Where the roof meets a wall the underlay must f nailed in position be folded and run up the wall no less
19. el formed profile one of the following coating systems is applied Textured Coating an acrylic base coat which binds a layer of stone granules covered with an acrylic overglaze or e Satin Coating an acrylic topcoat 3 0 Colours 3 1 32 3 3 3 4 Tudor is supplied in the following colours e Textured Autumn Brown Bark Cedar Charcoal Coffee Brown Greenstone Olive Silver Grey Slate Terracotta Satin Beige Ebony Grey Friars Ironsand Karaka Mist Green New Denim Blue Permanent Green River Gum Scoria Terracotta Wizard Shake is supplied in the following colours e lextured Ashwood Beechwood Brown Bark Ember Cedar Charcoal Coffee Brown Forest Greenstone Mesquite Walnut Weathered Timber Copper Brown Satin Ebony Grey Friars lronsand Karaka New Denim Blue River Gum Royal is supplied in the following colours lextured Charcoal Forest Mesquite Weathered Timber Copper Brown Bond is supplied in the following colours Textured Autumn Brown Bark Cedar Charcoal Coffee Brown Greenstone Olive Silver Grey Slate Terracotta Satin Beige Ebony Grey Friars Ironsand Karaka Mist Green New Denim Blue Permanent Green River Gum Scoria Terracotta Wizard Installation Manual for Tilcor Roofing Systems October 2011 Page 3 3 5 3 6 9 TILCOR roofmakers to the world Classic is supplied in the following colours Textured Autumn Brown Bark Cedar Charc
20. ength of Cover Width of Cover Roof Cover Tile Tiles m2 Weight Tile Weight m2 Minimum Roof Pitch Nailing Points Per Tile Installation Manual for Tilcor Roofing Systems October 2011 1335mm 1265mm 368mm 0 46m 2 19 12 5 4 Textured Satin 3 0kg 2 0kg 6 4kg 4 4kg 1325mm 1265mm 368mm 0 46m 2 19 135 4 Textured Satin 3 0kg 2 1kg 6 4kg 4 5kg Textured 1330mm 1260mm 368mm 0 46m 2 15 3 0kg 6 4kg 15 4 p TILCOR roofmakers to the world Profile Specifications Overall Length Length of Cover Width of Cover Roof Cover Tile Tiles m2 Minimum Roof Pitch Nailing Points Per Tile Weight Tile Weight m2 Classic Overall Length Length of Cover Width of Cover Roof Cover Tile Tiles m2 Minimum Roof Pitch Nailing Points Per Tile Weight Tile Weight m2 Roman Overall Length Length of Cover Width of Cover Roof Cover Tile Tiles m2 Weight Tile Weight m2 Minimum Roof Pitch Nailing Points Per Tile Installation Manual for Tilcor Roofing Systems October 2011 1325mm 1265mm 368mm 0 46m 215 12 4 Textured Satin 2 9kg 2 0kg 6 3kg 4 4kg 1325mm 1265mm 368mm 0 46m 2 15 12 5 4 Textured Satin 2 9kg 2 0kg 6 3kg 4 4kg Textured 1290mm 1220mm 368mm 0 45m 2 22 2 9kg 6 3kg 125 A TILCOR roofmakers to the world 4 Flashing Specifications 100 Barrel Trim
21. he CUTTING line Each tile should supply two cut pieces leaving a minimum of wastage Preferably a hip and valley cut from each tile will minimize this waste Fig 1 9 However two hip cuts will also provide a lower wastage factor Installation Manual for Tilcor Roofing Systems October 2011 Lefi Hand Side Example Top Bottom Top Bottom Top e g Bottom e g 4 5mm 845mm xmm ymm 342mm 710mm Right Hand Side Example Top Bottom Top Bottom Top Bottom Figure 1 8 530mm 900mm 600mm 970mm 380mm 50mm Page 21 Cp TILCOR roofmakers to the world Tile Lay Continued Preferred and Low Waste Usage Height of hip board Cutting line projection or width Valley Cut of bevel E d Bending line Figure 1 9 Hip Cut OR Two Hip Cuts Per Tile Height of hip board projection or width of bevel Cutting line x Bending line Figure 1 10 Installation Manual for Tilcor Roofing Systems October 2011 Page 22 E TILCOR roofmakers to the world Tile Lay Continued Hip Cutting Use the guillotine to cut along the pre marked cutting lines Hip Bending Place the tile in the bender and line up the marks showing the bend line Operate the foot controlled vice mechanism to hold the tile firmly and bend the tile upwards Each cut tile will vary slightly in size and as cutting and bending are done on the ground it is very important not to mix up the individuall
22. he world Ridge Installation Continued Ridge tile cut and bent to form upstand Standard ridge cap Tile battens Minimum upstand at mie Minimum cover Tilcor ridge 40mm ridgecap 60mm at any point Installation Manual for Tilcor Roofing Systems October 2011 Page 36 TILCOR roofmakers to the world Sidewall Installation Flashings at the ends of roofs where the wall continues past the roof require a stopend flashing that ensures water is directed into the gutter Sufficient material should be left standing out from the wall so that cladding installers can ensure a weather secure finish O a Building Building Wrap p Wrap 277 Tile turn up Stop End R available Building Wrap Sealsure nails in high points of tiles only in bottom course 5 Building Wrap Installation Manual for Tilcor Roofing Systems October 2011 Page 37 p TILCOR roofmakers to the world Sidewall Installation Continued Cladding and building wrap Where dadding manufacturer requires more than 75mm of apron upstand under cladding cladding supplier to supply and install over flashing to suite their requirements For details refer to cladding manufacturer Support nog Standard Side Flashing Apron Flashing Minimum upstand of Tilcor tile verge tile 40mm Minimum cover of over flashing 35mm Ln HE HELL HE LEO LUE LE T TG E Batten x S Underlay carried up face of framing behind upstand
23. llation Manual for Tilcor Roofing Systems October 2011 Page 7 p TILCOR roofmakers to the world Cleaning 12 15 Tilcor roofs must be washed down regularly with fresh water in all areas not washed by rain such as those areas sheltered by the eaves overhang of a higher roof In areas near the sea where salt deposition is noticeable on windows and similar surfaces or near areas of industrial pollution washing down should be carried out every 2 3 months In other areas washing down every 6 months should suffice 12 16 Lichen and mould growth must be removed with chemical cleaners recommended by Tilcor Roofing systems Limited such as Mossboss Tilcor Roofing Limited recommends to chemically clean the roof once every 2 4 years to maintain a good appearance and prevent the growth of algae moss and lichen Failure to carry out this maintenance program will void the coating warranty see Tilcor coating Warranty 13 0 Dissimilar Metals 13 1 To avoid adverse corrosion effects caused by dissimilar metals COPPER and LEAD flashings should not be used with Tilcor roofing products and accessories Under no circumstance should these materials be in contact or allow water runoff from these materials to flow on to the roof Failure to comply with this will void the weatherproof warranty 14 0 Touch Up Kit 14 1 Minor scuffing of the tiles can be repaired with the Touch Up kit from Tilcor Use the Acrylic Touch Up kit from Tilcor not sealants
24. llion roofs and specific flashing details Existing roofs must be inspected for soundness and the capobility of resisting likely structural loads Minimum roof pitch for Tudor Bond Classic and Roman profiles is 12 5 degrees and 15 degrees for the Shake and Royal profiles Note must also be taken of the requirements of Acceptable Solution E2 AS1 Paragraph 1 A ii for antiponding boards when the roof pitch is less than 15 degrees The flashings supplied by Tilcor Roofing Systems Ltd are acceptable alternatives to those specified in Figure 1 of Acceptable Solution E2 AS1 The designer must also provide weathersealing details for situations not covered by the manufacturers information The designer is responsible for ensuring that all of his her details are incorporated into the roof design and that those details are followed by the installer Batten size and fixing must be in accordance with the requirements of NZS 3604 for the relevant rafter spacing maximum 1200mm Installation Manual for Tilcor Roofing Systems October 2011 Page 4 9 TILCOR roofmakers to the world 6 10 Upliff resistance requirements fixing kN k fixing KN k fixing KN k fixing KN k P ven men men rr mon oro men Rr mm mm 5o o 90 o2 os o2 oa os os 05 07 _soxs0_ 1200 o2 os os os os o7 o 09 C 7 09 C 0 C 0 9 C C C pl pe pz Periphery is 20 of width of building as shown in NZS 3
25. nd VE A aa stacked on the ground ty d To save time marking cutting and bending each tile it is best done by two installers one to measure and the other to write the measurements down on a board or piece of paper as shown Fig 1 7 To avoid confusion cut bend and stack tiles in strict order I 845 mm gt Figure 1 Installation Manual for Tilcor Roofing Systems October 2011 Page 20 9 TILCOR roofmakers to the world Tile Lay Continued Note the following steps i The basic measurement recorded on paper or board is taken from the last corrugation on the bottom corner of the last full tile fo the hip board along the front edge of the batten Fig 1 7 ii Measure and mark on the tiles with chalk or similar The required measurements taken from the roof ensuring the MATCHING corrugation of the overlapping tile to be cut is taken as the measure starting point Fig 1 7 This forms the BENDING line Fig 1 9 Add to the bending line measurement the height of the ridge board projection above the tile line 40mm Mark on the tiles with chalk or similar This forms the cutting line Fig 1 9 ALTERNATIVELY Set a bevel to the angle formed by the hip board and tile batten Place the bevel on the tile so that the measuring mark on the front of the tile lines up with the inside of the bevel Mark along the inside of the bevel to give the BENDING line Scribe the other side of the bevel to form t
26. oal Coffee Brown Greenstone Olive Silver Grey Slate Terracotta Satin Ebony Grey Friars lronsand Karaka New Denim Blue River Gum Scoria Terracotta Wizard Roman is supplied in the following colours lextured Ember Forest Charcoal Sorrento Firenze Tuscany Walnut 4 0 Packing 4 4 2 The tiles are packed on wooden pallets protected with temporary waterproof covering for delivery to the site Flashings V Ridge Barrel Trim and other accessories are packed separately 5 0 Handling and Storage The product must be transported and handled with care to avoid damaging the surfaces Long term storage of roofing must be under dry ventilated cover For short term storage on site pallets should be placed separately on level ground The products must be left covered with the waterproof covering on when stored short term on site in order to avoid water stains 6 0 General Design Information 6 6 2 6 3 6 4 6 9 6 6 6 6 8 6 9 Tilcor Roofing Systems are pressed metal roof cladding products suitable for use on new or existing roofs when fixed to timber battens New roofs must be designed and constructed in accordance with NZS 3604 or to a specific structural design Roof design must take into account any requirements for areas subject to regular snowfalls as per the requirements of Acceptable Solution E2 AS1 Paragraph 1 2 the need to minimise roof cavity condensation e g in ski
27. rmed every year or after any significant storm for the following items Maintenance or repairs to these items should help prevent any major problems occurring e Damaged or displaced tiles or lashings e Blocked valleys spouting or downpipes with debris such as leaves other plant matter or foreign objects such as toys e Wash down any roof areas not effected by rain washing see Cleaning below In certain environmental conditions moss mould or lichen may present itself on areas of the roof To maintain the integrity of the coating and for aesthetic reasons this can easily be removed with a generic roof wash treatment such as Mossboss applied by low pressure spraying When the roof is used for collection of potable water ensure that the downpipes are disconnected for the period stated in the spraying instructions Failure to maintain the roof in this manner will void the coating warranty When repairs or maintenance are needed we recommend that you consult a metal tile roofing specialist as additional damage to the roof tiles can be caused by inexperienced foot traffic If you must access the roof follow these instructions to avoid denting or damaging the roof tiles you should wear soft sole shoes amp place your foot on the lowest point of the tile and at the front edge of the tile Also house holders unfamiliar with working at height pose considerable risk of injury to themselves by falling from ladders or the roof Insta
28. s of uniformity we have demonstrated 50x40mm battens as this is The most common batten size This may be substituted for 50x25mm or 50x50mm for different rafter truss spacings see Tiling Batten Specifications A 50x40mm batten is placed directly behind E the fascia around the entire roof This will serve Fascia board as the eave batten set out Nail Spacing for a Set out Nail Spacing for a The next batten is placed 320mm from the satin Tile Roof Textured Tile Roof outside edge of the fascia material to the front edge of the batten Battens are then placed every 370mm Satin or 368mm Textured measured from the front edge of each batten continuing up the roof The set out can be done using a setout rod which is made from a 50x40mm batten or measuring rod of similar thickness Measure every 3 0mm Satin or 368mm Textured measured up the setout rod and saw notches in the material making sure the notches are accurate and that the bottom of the notch is square to the rod The rod is then placed on the rafter and nails are placed in every notch so that you have a series of nails at 368mm or 370mm centres running up each rafter 2 Batten Cutting When placing the battens on the set out nails care should be taken to stagger the joins across several rafters and not to have multiple joins on the same rafter going up the roof truss Place the battens on the setout nails mitring each batten onto the hip and valley boards Mak
29. t no more than 1 0m centers and bent over the top lip of the valley to hold the valley tray in place 2 Under no circumstances must the fasteners penetrate the valley surface 90mm x 3 15mm H D Galvanisec Where joins occur the minimum overlap is to be no less than 200mm A Metal Tile Valley Installation Manual for Tilcor Roofing Systems October 2011 Page 27 p TILCOR roofmakers to the world Valley Installation Continued 3 Valley trays should be cut at the apex of the valley as depicted in the right hand picture silicon is placed on both trays before they Ln are sealed in place Silicon The top end of the valley should be turned poe up against the hip or ridge battens to the height of the batten Where two valleys meet over a dormer they are cut shaped joined and sealed so that they form a continuous p P valley Z d Metal Til Valley Tile Measuring Cutting and Bending Tile measuring cutting and bending for val leys is carried out as for hips except that the bends are downwards Measure the distance from the last corrugation of the installed tile to the desired finished tile line in the valley approximately 40mm to each side of the valley centre line This measurement is done at the top and bottom of the installed tile This is the BEND line To this measurement add the depth of the valley from the FINISHED TILE line minus 10mm which is the amount the Tile will drop into the valle
30. than 200mm 4 Batten Fastening Battens shall be nailed through to the rafter with one 90 x 3 15mm nail at each intersection unless greater wind uplift resistance is necessary as stipulated in table 5 10 page 5 Refer to section 9 0 Tiling Battens on page 6 of the manual within General Information 50mm x 40mm batten Installation Manual for Tilcor Roofing Systems October 2011 Page 17 p TILCOR roofmakers to the world Preparatory Installation Continued Tiling battens must be e H1 2 treated e Douglas fir of moisture content 2076 50 x 25mm for 450mm rafter truss spacing 50 x 40mm for 900mm rafter truss spacing 50 x 50mm for 1200mm rafter truss spacing Tilcor Tile Roofing underlay installed under battens and pulled tight over bottom batten and fascia ET Sealsure Type nail e When applicable Tile batten Min overhang at closest point of the tile 50mm Selected fascia amp gutter fascia board height not to exceed batten height Fascia board Similar design detail for metal fascia systems Detail shows roof pitch 159 with anti ponding board omitted Installation Manual for Tilcor Roofing Systems October 2011 Page 18 j TILCOR roofmakers to the world Tile Laying Bond Roman Classic Tudor Specific Tile Laying Tiles can be interlocked either right over left or vice versa except Roman only L over R but should be laid with the laps facing away
31. y This is the CUTTING line and will result in a tapered downturn The tile edge should be bent down to a minimum of 5mm from the valley floor Cut with the guillotine and bend down the tile at the bend line Install in the normal manner endeavouring to place one nail as close to the valley as possible to the end of the batten adjacent to the valley tray DO NOT nail in the valley itself Sealsure Nails in high points fites only in bottom course Installation Manual for Tilcor Roofing Systems October 2011 Page 28 roofmakers to the world E TILCOR Valley Installation Continued 7 The gap between tiles on opposing sides of the valley must be a minimum of 50mm Valley boards must be treated H3 2 and must be separated with underlay between any tile or flashing and the treated timber Valley tile turned down Tilcor tiles into valley tray Underlay Tile batten 25mm min thick valley boards cut and supported between rafters truss Top of valley boards flush with top of rafters truss j lt Valley boards 25x150mm 250mm min gutter width Valley tray Underlay separating valley board and valley tray Note Minimum width of valley tray may reduce to 160mm providing roof catchment area is 16mr or less Note Minimum width of valley tray may reduce to 160mm providing roof catchment area is 16m or less Installation Manual for Tilcor Roofing Systems October 2011 Page 29 p TILCO
32. y cut tiles Stack them in the sequence that they will be used A simple practice is to cut off tiles in order and re stack in order and then move to bending repeating the process Fig 1 8 Installation of Cut Tiles start installing the cut tiles from the bottom course and work up the hip Sometimes it is necessary to nail into the head of the tile to hold it in place before the next cut above is installed Install all cut tiles by nailing through the turn up into the hip board and one or more nails through the front edge into the battens Fig 1 9 Figure 1 8 Figure 1 9 Installation Manual for Tilcor Roofing Systems October 2011 Page 23 roofmakers to the world p TILCOR Tile Laying Shake and Royal specific As the Shake and Royal profiles have a straight head and nose the tiles can be laid any where along the length of the tile l Use a bevel fo set the angle of the hip by placing the bevel in line with the batten and moving the bevel to meet the hip batten Mark on the tile the cut and bend line allowing 40mm upturn Proceed to cut and bend up enough cut tiles for the number of courses up the hip To minimise waste it is advisable to use approximate half the tile for each cut so you can use the other half for a valley cut or another hip cut at the other end of the roof plane These cut tiles should vary a little in size to try to avoid a pattern Note Tiles must be turned up a minimum of 4
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