INSTALLATION MANUAL - Gerard Roofing Systems
Contents
1. INSTALLATION MANUAL E GERARD www gerardroots eu ROOFING SYSTEMS INTRODUCTION AGERARD ROOFING SYSTEMS WELCOME TO THE GERARD ROOFS EXPERIENCE This comprehensive installation manual has been designed to assist with all aspects of installing Gerard roofs Following this step by step installation guide will result in a professional and aesthetically pleasing roof installation that will complement any home for many years to come It should be emphasised however that this Installation Manual is for guidance only It is the responsibility of the installer to ensure that all National Standards and Local Building Regulations are strictly adhered to and they must take precedence over the installation techniques recommended in this manual We have covered most eventualities in this guide Should you need to contact us for further assistance or for help in determining the minimum local building standards please see our office details on the back cover of this manual GERARD ROOFS TRADEMARK OF AHI ROOFING LIMITED AHI Roofing leads the world in steel roof tile production and technology Recognition of market needs has driven the company s success Roofs produced by AHI Hoofing have protected many thousands of homes and commercial buildings around the world since 1957 Gerard Classic and Heritage Tiles Shakes Shingles and Milano Tiles form the basis of an ever growing range of profiles that are in regular demand across E2. Lay the battens in rows across the rafters against the marking nails which will be removed after fixing the battens INSTALLATION MANUAL 17 8 TILE INSTALLATION Thinner support battens are recommended for the top row at the ridge This ensures that the top course of tiles follows the same pitch as the other courses Ensure that the batten joints are staggered 2 Tile Batten 3 Ventilation Space Batten o Ridge Batten 7 Ridge Bracket 8 Underlay 9 Rafter 18 Thinner Support Batten d GERARD ROOFING SYSTEMS ES 4 7 Bl 9 INSTALLATION MANUAL 18 8 TILE INSTALLATION GERARD ROOFING SYSTEMS INTERLOGKING OF THE TILES Senator Shingles only interlock one way they are laid m l l right to left along the roof Classic Tile Heritage Tile Milano Tile and Corona Shingle can be interlocked either right over left or left over right but should be laid with the laps facing away from the 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 bottom shake INSTALLATION MANUAL 19 8 TILE INSTALLATION GERARD ROOFING SYSTEMS TILE LAYING Start installation from ridge towards the eaves Lay the second course of tiles from the top from gable end to gable end turning the edge of the end
3. ANTENNA OUTLET PLATFORM STEP SCREWS NAILS TOUCH UP KIT INSTALLATION MANUAL 9 o HOOF STRUCTURE GERARD ROOFING SYSTEMS The conventional design of pitched roofs requires two ventilation zones to control condensation Modern roof construction prescribes one ventilation zone and the installation of vapour permeable underlay which can be used in both cold and warm roofs JX A COLD ROOFS With large voids above horizontal insulation WARM ROOFS With small or no voids above sloping insulation The harmful effects of condensation and ice damming can be avoided by ensuring that all the components of the roof are correctly installed The tiles should be instaled on a traditional batten structure The roof should be designed as a ventilated system with an open ended ventilation space breathable underlay thermal insulation and vapour membrane It is recommended that a heat loss calculation is carried out according to local regulations UNDERLAY Breathable underlays allow water vapour to escape through the material by diffusion They have a sufficiently fine structure to prevent liquid water penetration under service conditions They fulfil all the other demands made on a roof underlay the outflow of eventual condensation moisture or rain and snow water caused by improper design of the roof or poor workmanship VENTILATION SPACE A ventilation space should be provided abov
4. mark the cutting line from the nose of the tile and cut the Box Barge End along the cutting line Step 1 3 Place the Box Barge End in its final Option 2 Step 1 position and mark the bending line against the Eaves Flashing Step 2 4 Add 15 mm to the bending line and draw the cutting line Step 2 5 Cut and bend the Box Barge End into its final shape Step 3 Step 4 Option 2 Step 2 6 Place the Box Barge End in its final position Step 5 Option 2 Step 3 Option 2 Step 4 Option 2 Step 5 INSTALLATION MANUAL 37 15 VALLEY AZ GERARD ROOFING SYSTEMS CUTTING AND BENDING amp TILES The basic measurement is taken from the last corrugation of the bottom corner of the last tile to the end of the tile battens along the front edge of the batten Allow for tolerance in fit when measuring Bending Line Cutting Line Measure and mark the tile with the measurements taken from the roof ensuring the matching corrugation of the overlapping tile to be cut is taken as the measure starting point This forms the Bending Line Add 40 mm to the Bending Line on the back edge of the tile and 50 mm to the Bending Line on the nose of the tile to obtain the Cutting Line Each tile should supply two cut pieces leaving minimal wastage Cut and bend the tiles according to the measurements determined above 1 Flattening both up stands of the tile where the tile is to be
5. against any wind driven rain Install Milano Hidge Wall Flashing Ihe flash ing is fixed from the top into the top course tile using screws and by nailing through the small bend on the turn up into the ridge bat ten When installing the ridge us ing spacers nail through the turn up and through the spacer refer to page 31 RIDGE Installation The barrels are fixed from the top using screws or nails 1 Tile 7 Ridge Bracket 2 Tile Batten 8 Underlay 3 Ventilation Space Batten 9 Rafter 4 Barrel 18 Thinner Support Batten o Hidge Batten 29 Milano Ridge Wall Flashing 6 Air Outlet Opening INSTALLATION MANUAL 43 19 CHIMNEY FLASHING GERARD ROOFING SYSTEMS The Chimney Flashing may be 9 installed as per traditional roofing practice using aluminium or zinc coated flashings It is made in 4 parts front back and left and right sides It is essential to adequately prepare the supports for all parts of the chimney The back should rest on a board of approx 2 cm thickness The ends of the tile battens on both sides of the chimney should be notched approx 2 cm so that the left and the right sides of the flashing form a good fit Tile Tile Batten Ventilation Space Batten Hafter 2 Chimney Flashing O CNO The front of the chimney flashing should rest on the first row of tiles under the c
6. cut will make cutting easier 2 Cut the tile along the marked cutting line using the guillotine hand shears or metal cutting saw refer to page 4 IMPORTANT Cutting with a Saw 3 Bend the tile using a short tile bender INSTALLATION MANUAL 38 15 VALLEY AZ GERARD ROOFING SYSTEMS INSTALLATION Cut and bend the tiles at the Valley as straight as possible to obtain a straight line The last tile should be nailed into the tile batten as close to the batten end as practicable Never nail into the Valley gutter 1 Tile 2 Tile Batten 9 Ventilation Space Batten 8 Underlay 9 Rafter 10 Valley 14 Ventilation Space 30 Clip INSTALLATION MANUAL 39 16 WALL FLASHING A GERARD A Great care is needed where the roof surface joins a vertical wall It is 3 essential to bend the ends of the tiles under the flashing For measuring cutting and bending the tiles follow the same procedure as the Box Barges refer to page 34 BOX BARGE Cutting and Bending Tiles 1 WALL FLASHING AT A JUNCTION Dt o WITH FINISHED FACADE Where the roof surface joins a finished facade use a custom made flashing that will allow the junction of the flashing and the render to be sealed with a sealant It is also possible to bend the top edge of the side flashing In this case there is no need to use additional custom made flashing Tile 21
7. ends of the barrels at the overlap Intersection drawing of Option 1 1 Tile Hidge Bracket 2 Tile Batten 8 Underlay 3 Ventilation Space Batten 9 Rafter 4 Barrel 18 Thinner Support Batten o Ridge Batten 6 Air Outlet Ridge batten with air outlet INSTALLATION MANUAL 31 13 HIP GERARD ROOFING SYSTEMS CUTTING AND BENDING TILES rien Last matching corrugation The basic measurement is taken from Bending Line the last corrugation of the bottom corner of the last tile to the spacers on the hip tile batten When installing the hip without the use of spacers the width of the air outlet has to be deducted from the measurement Cutting Line Measure and mark the required measurements taken from the roof on the tiles with chalk or similar ensuring that the matching corrugation of the overlapping tile to be cut is taken as the measurement starting point This forms the Bending Line L Height of Hip Batten projection Bending Line E Add the height of the hip batten projection above the tile line to the bending line measurement to obtain the Cutting Line Basic dimension Spacer Cutting Line Each tile should supply two cut pieces leaving minimal wastage Cut and bend the tiles according to the measurements determined above 1 Flatten both up stands of the tile where it is to be cut This will make cutting easier 2 Cut th
8. ensure that the nail is placed outside of the hidden water channel Edge of shake B P an Edge of shake A Lap 60 mm Bottom shake INSTALLATION MANUAL 28 11 EAVES FLASHING GERARD ROOFING SYSTEMS Construct the eave very carefully as it is an important part of the roof ventilation An air intake opening should be provided protected by a metal or plastic mesh refer to page 10 ROOF STRUCTURE Ventilation Space and page 13 BATTENS Eaves Nail the eaves flashing from the top into the first batten Lay the first row of tiles the last to be installed and nail them at the nose of the tile and through the eaves flashing into the side of the first tile batten Tile Tile Batten Ventilation Space Batten Underlay Eaves Flashing 12 Mesh 13 Eaves Guard Flashing OO CO N INSTALLATION MANUAL 29 12 RIDGE CUT TING AND BENDING TILES Measure the distance A from the last tile to the spacers on the ridge batten refer to page 12 BATTENS Ridge Batten When installing the ridge without the use of spacers the width of the air outlet must be deducted from the measurement Add 40 mm to the measurement for a standard up stand and mark the tile to be cut The height of the upstand can vary depending on the pitch of the roof A longer turn up on the last tile at low pitches facilitates fixing the tile into the ridge batten Cutting Line GERARD ROOFING SY
9. integrated self adhesive tape or adhesive which contributes to better windproofing for the roof structure INSTALLATION MANUAL 11 f BATTENS GERARD ROOFING SYSTEMS COUNTER BATTENS Counter battens Ventilation Space Battens provide a ventilation space between the underlay and the roof covering refer to page 10 ROOF STRUCTURE Ventilation Space Rafters should be lined up before the roofer begins work this is the builder s responsibility When re roofing counter battens should be lined up The recommended counter batten dimension is 50 x 80 mm The minimum counter batten height is 25 mm TILE BATTENS Hafters can be set at various centres depending on the type of construction and the local regulations In most situations the following batten sizes are recommended based on rafter spacing Recommended Rafter Batten Size or Truss Centres up to 600 mm 30 x 40 mm 900 mm 40 x 50 mm 1200 mm 50 x 50 mm 1500 mm 50 x 65 mm on edge 1800 mm 50 x 75 mm on edge NOTE If necessary larger battens may be used BAT TEN FIXING Wind pressure applies wind uplift load to the fasteners When fixing counter battens to rafters and tile battens to counter battens it is recommended to use screws or twist shank nails or annular grooved nails for additional holding power In regions subject to strong winds special attention should be paid to the method of f
10. is of particular importance in areas prone to harsh winters Secure the valley with a clip Never nail inside the valley 1 INSTALLATION OF THE VALLEY ON THE LEVEL OF THE COUNTER BATTEN SPACE Tile battens are installed over the valley The advantage of this method is a free choice of valley width As the greater part of the valley is concealed beneath the tiles it allows the use of wider valleys maintaining the aesthetic appearance of the roof This is of particular importance in the case of extreme winter conditions and low pitches where a wider valley helps overcome the consequences of ice damming GERARD ROOFING SYSTEMS 8 Tile Batten Ventilation opace Batten 8 Underlay 9 Rafter 10 Valley 30 Clip INSTALLATION MANUAL 14 f BATTENS AZ GERARD ROOFING SYSTEMS 2 INSTALLATION OF THE VALLEY ON THE LEVEL OF THE TILE BAT TEN E SPACE Ensure that the tile battens end at the vertical edge of the valleys The advantage of this method is the easier installation of the valley around E N dormers where the valley ends on top Q S of the tiles L Sal SG CON AW NY V NA 2 Tile Batten 3 Ventilation Space Batten 8 Underlay 9 Rafter 10 Valley 30 Clip INSTALLATION MANUAL 15 7 BATTENS as A BATTEN SPACING BATTEN SPACIN
11. tiles up against the barge battens refer to page 34 BOX BARGE Installation Nail these tiles in position through the flat of the back edge sitting on the batten INSTALLATION MANUAL 20 8 TILE INSTALLATION GERARD ROOFING SYSTEMS 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 Starting from the course already laid lay the tiles two courses at a time from end to end The person laying the tiles should be two courses ahead of the person nailing Stagger the tile laps down the roof using parts of tiles at the gable end INSTALLATION MANUAL 21 8 TILE INSTALLATION GERARD ROOFING SYSTEMS TILE LAYING AT THE HIP On the second course from the top lay the top corner of the first tile approximately 150 mm from the hip batten Continue to lay tiles towards the other hip until the last full tile will fit and secure them through the flat on the back of the tiles Lay subsequent courses two at a time both starting about the same distance from the hip batten To fill the gap between the last full tile and hip batten use parts of tiles The amount of tile wastage can be reduced if each end of a full tile is cut and bent to fill the gaps If a small part of the tile less than a module width is required to fill the gap it will be necessary to rem
12. G FOR SENATOR SHINGLES The most critical factor in laying the tiles is accurately 1 An intermediate batten is obligatory for roof slopes setting out the tile battens If this is not done accurately of 15 to 30 The distance between the main battens then the tiles will not fit together correctly is 368 mm The intermediate batten is positioned at a distance of 185 mm to 190 mm from the lower All measurements should be made from the front of edge of the lower main batten the battens This is the surface where tiles will be fixed to the battens The batten spacings for all profiles are 2 For slopes above 30 an intermediate batten listed below is recommended but is not obligatory Name of the profile Batten space D Milano Tile Senator Shingle Classic and Heritage Tile Corona Shake Battenning for Senator Shingles requires the use of intermediate battens refer Batten Spacing for Senator Shingles INSTALLATION MANUAL 16 7 BATTENS A GERARD INSTALLATION PROCEDURE Measure up from the eaves edge D 3 mm to establish the position of the second batten Use the measuring rod to measure the subsequent battens in direction from the eaves to the ridge Use coloured string to mark the position of the marking nails If the rafter length does not accurately suit a full course of tiles the top course will have to be cut and bent to fit requiring the space between the top batten to the ridge to be less than usual
13. IC NAILER SOFT SOLED SHOES INSTALLATION MANUAL 6 3 GERARD TILES AGERARD ROOFING SYSTEMS Length of cover 1265 mm Width of cover 369 mm Tiles m 2 14 GERARD Weight m 6 4 kg CLASSIC Minimum Pitch 12 21 Length of cover 1250 mm Width of cover 369 mm 4 GERARD Tlos nt 2 17 Weight m 6 4 kg HERITAGE Minimum Pitch 12 21 Length of cover 1250 mm Width of cover 3 0 mm GERARD Shakes m 2 16 Weight m 6 6kg RONA SHAKE CORO S Minimum Pitch 15 27 Length of cover 1260 mm Width of cover 368 mm Shingles m 2 16 Weight m 6 6 kg Minimum Pitch 15 27 E GERARD SENATOR SHINGLE Length of cover 1215 mm Width of cover 368 mm Tiles m 2 24 Weight m 6 6 kg Minimum Pitch 12 2196 E GERARD MIL ANO INSTALLATION MANUAL 7 4 ACCESSORIES as BARREL 190 BARREL END 190 BARREL MOULDED END 190 Length of cover 405 mm Length of cover 400 mm Y HIP 190 15 30 Y HIP 190 30 45 ANGLE TRIM Length of cover 370 mm ANGLE TRIM END VISION TILE BOX BARGE MILANO RIDGE WALL FLASHING Length of cover 1900 mm Length of cover 1215 mm SIDE FLASHING EAVES FLASHING Length of cover 1900 mm Length of cover 1900 mm 2000 gl ASS oe p E INSTALLATION MANUAL 8 4 ACCESSORIES as FLAT SHEET 400 FLAT SHEET 490 VALLEY ROOF ESCAPE WINDOW Length of cover 2300 mm ES GAS OUTLET SANITARY VENT VENT
14. LASHING 42 Tile Battens 12 18 MILANO RIDGE WALL FLASHING 43 Batten Fixing 12 Installation 43 Ridge Batten 12 19 CHIMNEY FLASHING 44 Gable 12 Hip Batten 13 20 INSTALLING ACCESSORIES 46 Faves 13 Vents Antenna Outlets 46 Valley 14 Felt Penatration Sleeve 47 Batten Spacing 16 Roof Escape Window 48 Installation Procedure in Platform Steps 49 8 TILE INSTALLATION 18 21 MANAGEMENT OF THE WORK SITE 50 Interlocking of the Tiles 19 Estimating Materials 90 Tile Laying 20 Tile Laying at the Hip 22 f INSTALLATION MANUAL 3 GERARD ROOFING SYSTEMS 1 IMPORTANT STORAGE AND HANDLING If stored outside a waterproof cover must be placed over the tiles to keep them dry and prevent damage to the substrate PITCH Classic Heritage and Milano tiles can be installed from 12 to 90 Shakes and Shingles can be installed from 15 to 90 NON STANDARD ELEMENTS When installing non standard elements or gutters above the level of the roof it is strongly recommended that materials that could cause corrosion e g Cu stainless steel are NOT used ROOF TRAFFIC ooft soled shoes must be worn when walking on the roof When moving around the roof avoid avoid buckling the tiles by placing weight on the balls of the feet di rectly over the batten in the pans of tiles Traffic on the roof should be kept to a minimum to avoi
15. Lap 63 m PR UN Centerline of pan Bottom tile INSTALLATION MANUAL 24 10 NAIL POSITIONING a HERITAGE TILES Nails should be approximately 60 mm to the side of the centre of the pan of the tile and close to the bottom of the downturned flange Edge of tile V andi Edge of tile A Lap 63 mm S 60m Bottom tile Centerline of pan INSTALLATION MANUAL 25 10 NAIL POSITIONING AT MILANO TILES Nails should be approximately 10 mm to the side of the section of tile that rises Milano Tiles need to be nailed at the front and back of each tile where the tiles lao Place weight on the nose of the tile being nailed so that the lap is held firmly down Then place nails at every second module along nose of the tile Edge of tile B Edge of tile A Lap 122 mm 10 mm Bottom tile INSTALLATION MANUAL 26 10 NAIL POSITIONING GERARD ROOFING SYSTEMS SENATOR SHINGLE Nails should be spaced approximately 300 mm apart Care is required at the lap of the shingle to ensure that the nail is placed outside of the hidden water channel Edge of shingle B yo Edge of shingle A Shingle B Shingle A Lap 60 80 mm Bottom shingle 60mm Upper shingle INSTALLATION MANUAL 27 10 NAIL POSITIONING a CORONA SHAKE Nails should be spaced approximately 300 mm apart Care is required at the lap of the shake to
16. NUAL 33 14 BOX BARGE CUT TING AND BENDING TILES Before the installation of the Box Barge it is essential that the edge of the end tile is turned up against the barge batten refer to page 12 BATTENS Gable For measuring cutting and bending the tiles follow the same procedure as at the hips refer to page 32 HIP Cutting and Bending Tiles Cut and bend the tiles according to the measurements 1 Flatten both up stands of the tile where it is to be cut This will make cutting easier 2 Cut the tile along the marked cutting line using the guillotine hand shears or metal cutting saw refer to page 4 IMPORTANT Cutting with a Saw 3 Bend the tile using a short tile bender Gable Batten GERARD ROOFING SYSTEMS Cutting Line Bending Line Last matching corrugation Basic dimension Height of Gable Batten projection INSTALLATION MANUAL 34 14 BOX BARGE as INSTALLATION 9 Tiles are cut bent and fastened in place nailing the turn up to the gable batten Begin by laying the Box Barges at the eave and temporarily tack the barge covers in place working up the barge board The overlap should be 100 mm 1 Tile 14 Ventilation Space 2 Tie Batten 15 Box Barge 3 Ventilation Space Batten 16 Gable Batten 8 Underlay 17 Barge Board 9 Rafter Adjust the Box Barges in a straight line and fix them using nails or screws Note thatthe fa
17. STEMS 1 Place the full tile in the long tile bending attachment which can be bolted to the bender Line up the marks showing the bend line and bend the tile upwards It is important to bend the tile first to avoid distortion when cutting 2 Cut the tile along the marked cutting line using the guillotine hand shears or metal cutting saw refer to page 4 IMPORTANT Cutting with a Saw 3 When making the gap for the air outlet without use of spacers refer to page 31 RIDGE Installation the upstand of the tile needs to be bent so that it makes a step Bending Line INSTALLATION MANUAL 30 12 RIDGE AGERARD ROOFING SYSTEMS INSTALLATION fe 8 9 Install a thinner support batten at the ridge when the top course is less than the full width This keeps the slope of the top tile course the same as the other tiles on the roof The thickness of the support batten depends on the width of the top row tile Fix all the cut tiles by nailing into the ridge batten in 4 places through the small bend on the turn up This will leave space for ventilation refer to page 10 ROOF STRUCTURE Ventilation space An air outlet can also be ensured by installing spacers refer to page 12 BATTENS Ridge batten When installing the ridge using spacers nail through the turn up and through the spacer The barrels are fixed from the top using screws or nails The position of the fasteners should be at the
18. Side Flashing 2 lile Batten 22 Render 3 Ventilation Space Batten 23 Warmth Insulation 8 Underlay 24 Purpose Made Side Flashing 9 Rafter 25 Sealant 14 Ventilation Space eei HR e qa ws i INSTALLATION MANUAL 40 16 WALL FLASHING 2 WALL FLASHING AT A JUNCTION WITH AN UNFINISHED FACADE If the facade is not finished leave a part of the roof near to the facade uncovered Install a purpose made flashing on the bottom end of the facade and make the facade before finalising the roof covering Use sealant on the junction of the render and the oide Wall Starter Flashing Do not nail the tile to the wall Fix the side flashing to the wall ensuring that it is firmly in place and straight 1 Tile 2 Tile Batten 3 Ventilation Space Batten 8 Underlay 9 Rafter 14 Ventilation Space GERARD ROOFING SYSTEMS NO 1 14 3 21 26 25 22 28 21 Side Flashing 22 Render 23 Warmth Insulation 25 Sealant 26 Side Wall Starter Flashing fili E NN V AMAR INSTALLATION MANUAL 41 17 TOP WALL FLASHING Where the roof wall junction runs horizontally the principles of ventilation are the same as at a ridge It is essential to bend the ends of tiles under the flashing refer to page 30 RIDGE Cutting and Bending Tiles Install a thinner support batten at the ridge when the top course is less than the f
19. be installed onto the hip batten To provide an air outlet refer to page 10 ROOF STRUCTURE Ventilation Space a gap must be ensured between the hip batten and the upstand of the tile Spacers pieces of wood can be installed on both sides of the hip batten to provide this opening refer to page 33 HIP Installation Option 1 Hip batten installation with bracket Option 2 Hip batten installation with batten understructure EAVES Install eaves protection flashing underneath the underlay It can go behind the gutter into the open Option 1 or over and into the back of the gutter Option 2 The use of self adhesive tape is recommended to bond the underlay and the eaves protection flashing where they overlap The air inlet should be protected by a metal or plastic mesh to prevent insects birds or small animals entering the ventilation space Option 1 Protection flashing going behind the gutter Option 2 Protection flashing going into the gutter INSTALLATION MANUAL 13 f BATTENS VALLEY Measure and construct the valley very carefully as it is an important part of the roof The following details suggest two ways that the valley lining may be fitted Local practice building regulations and site conditions will dictate the final method used If not regulated by local legislation it is recommended to use a valley made from approx 50 cm wide painted Zincalume or aluminium sheet This
20. d amount of humidity is transported through the roofing structure This is always laid on the warmer side of the thermal insulation It is important that a special adhesive tape is used to securely seal any overlaps in the vapour barrier the junctions with walls and around any pipes chimneys antennas window openings and such like that may penetrate the roof surface There should not be any leaking joins in the vapour barrier INSTALLATION MANUAL 10 6 LAYING THE UNDERLAY GERARD ROOFING SYSTEMS e The underlay is traditionally laid in runs parallel to the eaves with an overlap over the adjacent roll The width of the overlap depends on the requirements of the manufacturer and on local regulations The traditional practice is to overlao waterproofed sheets by 150 mm e It is important that all protrusions pipes wires chimneys through the underlay are waterproofed e When installing a roof window lay a window protective flashing gutter above the window opening to divert possible running water away from the opening e It is recommended that you stick the underlay on the custom made eaves protection flashing which is installed underneath the underlay at the eaves edge The function of the eaves protection flashing is to provide a support for the underlay at the end of eaves and to direct water away from the roof refer page 13 BATTENS Eaves e Waterproofed sheets of underlay can be bonded together with an
21. d possible damage to the tiles Panels should be installed by working progressively from the top of the roof to the bottom so that completed sections are not crossed more than necessary to complete the instal lation IMPROPER TOOLS Only tools recommended by AHI Roofing should be used Tools such as angle grinders must NOT be used as swarf metal filings will corrode and leave a red rust stain on the surface CUTTING WITH A SAW When cutting tiles with a metal cutting saw which has been approved by AHI Roofing special tipped metal cutting blades should be used Cutting should be per formed with the chip coated surface facing down wards to reduce the amount of swarf adhering to the chip coating Failure to do so will result in rust stains on the tile surface A stable bench should be used when cutting tiles with a saw Installers should always wear safety equipment recommended by the saw and blade manufacturers INSTALLATION UNDER EXTREMELY COLD CONDITIONS Gerard roofs can be installed in areas that are subject to lengthy periods of extreme cold Special care is needed during installation in winter conditions to pre vent damage to the surface coatings 1 Tiles and accessories should be warmed stored in a warm place or lightly warmed NOT OVER HEATED before either cutting or bending 2 The use of nailing guns is NOT recommended in very cold conditions 3 The use of a nail punch to drive in the final 5 m
22. e the underlay by means of eaves and ridge ventilation This is achieved by the installation of counter battens nailed to the rafters The height of the counter battens can be from 25 to 50mm Thicker counter battens enlarge the ventilation space thus enabling humidity to exit more efficiently To achieve good air circulation an air inlet in the eaves and an air outlet in the ridge should be ensured The eaves inlet opening should measure e Min 2 o equivalent to 0 2 of the corresponding area of roof OR e Min 200 cm per m of eaves length equivalent to a continuous unobstructed gap 2 cm wide An air outlet at ridge level or on top of the roof should measure e Min 0 5 o equivalent to 0 05 of the correspon ding area of roof OR e Min 50 cm equivalent to a continuous unobstructed gap 0 5 cm wide per m of ridge length Dependingontherafterlength a thediffusion equivalent air layer thickness sq of the layers installed underneath the ventilated space should not be less than e a lt lOm sq gt 2m e a lt lom sq gt 5m e a gt 15m sq gt 10m THERMAL INSULATION Adequately sized thermal insulation will reduce energy costs prevent the possibility of condensation and the formation of ice dams in regions that experience severe winters The minimum thickness of the insulation should be calculated in accordance with the local building legislation VAPOUR BARRIER The vapour barrier ensures that only a limite
23. e tile along the marked Cutting Line using the guillotine hand shears or metal cutting saw refer to page 4 IMPORTANT Cutting with a Saw 3 Bend the tile using a short tile bender 4 When making a gap for the air outlet without the use of spacers refer to page 33 HIP Installation the upstand of the tile must be bent so that it makes a step INSTALLATION MANUAL 32 13 HIP mr ROOFING SYSTEMS INSTALLATION 6 9 Fix all the cut tiles by nailing through q the small bend on the turn up into the a hip batten This will leave a space for US ventilation refer to page 10 ROOF SIRUCTURE Ventilation space V An air outlet can also be ensured 7 s Q by installing spacers refer to page DR D 13 BATTENS Hip batten When Mg n installing the hip using spacers nail A through the turn up and through P 4 the spacer Add one or more nails through the front edge into the tile i Q batten starting from the bottom 2 ku course N The barrels are fixed from the top using screws or nails into the hip 4 batten The position of the fasteners Should be at the end of the barrel at the overlap Intersection drawing of Option 1 1 Tile 6 Air Outlet 2 lile Batten 7 Hip Bracket 3 Ventilation Space Batten 8 Underlay 4 Barrel 9 Hafter 5 Hip Batten 14 Ventilation space Option 2 Hip batten with spacers Option 1 Hip batten with air outlet INSTALLATION MA
24. f the tiles Product traceability is en sured from manufacturing through to installation The labels can be kept and filed The chip used to coat our textured roofing tiles is crushed natural rock and there may be slight colour variations between different batches of chip Each Run of tiles is colour coded at the time of manufacture using a letter code referred to as the colour code this letter code is located on the Pallet Label on each end of the pallet and not on the reverse side of the tile This letter code changes whenever there is a colour change in the tiles whether within a Run rarely or at the next Run Colours are matched against the last colour standard for the par ticular colour and profile of the tile It is essential that tiles used on an individual roof have the same colour code and it is also recommended that tiles used are from the same Run number if pos sible Where this is not possible e g for large roof installations tiles with different colour codes can be used on different areas of the roof but they should be separated by the edges of the roof e g ridges hips and valleys Tiles with different colour codes should NEVER be mixed on one roof area INSTALLATION MANUAL 5 2 TOOLS AGERARD ROOFING SYSTEMS GUILLOTINE COMBINED BENDER METAL ROOF ATTACHMENT maN METAL CUTTING SAW METAL CUTTING BLADE HAMMER SHEARS PELIKAN COLOURED STHING MEASURING ROD TAPE MEASURER i PNEUMAT
25. gs Flat Sheets determine the overall length of flashing required Divide by the lineal coverage per flashing unit ie 1 9 m to calculate the number of flashing units required 3 Barrels 190 determine the length of the ridge and hips Divide the lineal coverage by 0 41 m to calculate the number of Barrels required Determining the quantity of nails required For every 22 m of roof area the following will be required 1 kg of nails 1 kg is app 300 nails This calculation covers both tile and accessory requirements Storing material Tiles and accessories should be stored in a dry well ventilated area away from damp INSTALLATION MANUAL 50 GERARD ROOFING SYSTEMS NOTES f A H f INSTALLATION MANUAL 51 EUROPEAN OFFICES European Head Office AHI Roofing Kft Feh rv ri t 28 14 8100 V rpalota Hungary Phone 36 88 552 800 Fax 36 88 552 888 Email office gerardroofs eu www gerardroofs eu Poland AHI Roofing Poland Space Distribution Center ul Modularna 3a 02 238 Warszawa Poland Phone 48 22 575 5225 Fax 48 22 575 5223 E mail infoGahiroofing pl www ahiroofing com pl Slovenia AHI Roofing Adriatic Dunajska cesta 129 Sl 1000 Ljubljana Slovenia Phone 386 1 56 00 730 Fax 4386 1 56 00 735 Mobile 386 51 444 888 Email info ahiroofing si Technical Marketing Office Europe AHI Roofing d o o Dunajska cesta 129 Sl 1000 L
26. himney Bend the tiles down along the upper stand of the side flashings INSTALLATION MANUAL 44 19 CHIMNEY FLASHING Ow N 2 28 Tile Tile Batten Ventilation Space Batten Rafter Chimney Flashing Board GERARD ROOFING SYSTEMS INSTALLATION MANUAL 45 20 INSTALLING ACCESSORIES GERARD ROOFING SYSTEMS VENIS ANTENNA OUTLETS Position Vents and Antenna outlets below tiles at the sides Nail them as shown on the drawing Avoid nailing into plastic E te cy Ua i yc UR PIE y Ta peL 47 b gt WE ING Ie giv Ne Ne ONS LA yy 9 INSTALLATION MANUAL 46 20 INSTALLING ACCESSORIES A CGERARD It is important to securely seal all the openings in FELT PENETRATION SLEEVE the underlay around any ventilation pipes that may penetrate the underlay Special adhesive tape can be used to securely seal these openings Installing a felt penetration sleeve will achieve better protection 1 Mark where the opening is to be made in the underlay 2 Cut the underlay 3 Fix the Penetration Sleeve into the bottom of the tile battens using nails or screws 4 Use sealant at the junction of the underlay and the Felt Penetration Sleeve Step 2 Step 4 INSTALLATION MANUAL 47 ROOFING SYSTEMS 20 INSTALLING ACCESSORIES AGERARD ROOF ESCAPE WINDOW Fix the escape window through its timber frame in
27. ixing the counter battens and tile battens RIDGE BAT TEN Install the top ridge batten onto the ridge bracket Option 1 or along the batten under structure Option 2 The height of the top ridge battens can vary depending on the slope of the roof This setup must be accurate as the barrel will be installed onto the ridge batten To provide an air outlet referto page 10 ROOF STRUCTURE Ventilation opace agapmustbeensured betweenthe ridge batten and the upstand of the top tile Spacers pieces of wood can be installed on both sides of the ridge batten Option 2 to provide this opening refer to page 31 HIDGE Installation Option 1 Ridge batten installation with bracket Option 2 Ridge batten installation with batten understructure GABLE Install a 40x50 mm batten across the tile batten Fix the barge board into the counter batten and gable batten The underlay should be turned up at the gable end of the roof Note that the edge of the tile is bent up under the barge cover when finishing the installation of tiles This will ensure complete weather security INSTALLATION MANUAL 12 f BATTENS GERARD ROOFING SYSTEMS HIP BAT TEN Install the top hip batten onto the ridge hip bracket Option 1 or along the batten under structure Option 2 The height of the hip batten can vary depending on the slope of the roof This setup must be accurate as the barrel will
28. jubljana Slovenia Phone 386 1 56 00 733 Fax 4386 1 56 00 735 Mobile 386 51 617 744 Email technical info ahiroofing si Hungary AHI Roofing Kft Budapest Trade Office 1125 Budapest Hungary Zirzen Janka utca 38 Phone 36 1 391 4414 Fax 36 1 376 6027 www gerard hu France AHI Roofing France Espace Mi plaine 20 Avenue des Freres Montgolfier 69680 CHASSIEU Phone 33 04 72 67 92 11 Fax 33 04 72 67 92 53 Email ahi roofing free fr www ahiroofing com fr Every effort has been made to accurately reproduce colours but for technical reasons connected with colour reproduction printed colours may differ from actual product colours Please refer to actual colour samples before purchasing E GERARD ROOFING SYSTEMS Authorised partner of GERARD AHI Roofing Kft Feh rv ri ut 28 14 8100 V rpalota Hungary Phone 36 88 552 800 Fax 36 88 552 888 Email office gerardroofs eu www gerardroofs eu G INSTALLATION EU 0711
29. m of the nail is recommended SAFETY Please ensure that local safety regulations are fol lowed and appropriate personal protective equipment is used at all times Care should be taken to ensure that all live electrical cables are well clear of any nail ing positions INSTALLATION MANUAL 4 IMPORTANT GERARD ROOFING SYSTEMS WET SURFACE To prevent surface damage it is important not to walk or work on the roof when it is wet RESPONSIBILITY It is the responsibility of the architects builders and roof installers to ensure that all the elements of the roof e g underlay ventilation space thermal insulation and vapour barrier are constructed correctly PACKAGING Tiles and accessories are stored on wooden pallets and protected by a plastic cover A pallet consists of between 250 and 350 tiles This represents a roof ing area of between 115 and 160 m The base di mensions of the tile pallets are 1400 x 1100 mm The maximum height of a pallet is 1000 mm Tiles should be stacked on each pallet up to a maximum weight of 1150 kg Reverse side of the tile Close up of the label HANDLING Care should be taken when handling the tiles to avoid damage to the surface If minor damage does occur the finishing kit should be used to repair it IDENTIFICATION Each Run is individually identified this identification can be found on the labels attached to the pallets and on the backs o
30. ove the adjacent full tile and insert a part tile This will allow a full width tile to be cut to fit INSTALLATION MANUAL 22 9 NAILING TECHNIQUE GERARD ROOFING SYSTEMS Tiles are secured to the battens by nailing through the nose of the upper tiles and through the back up stand of the lower tile into the side of the battens The positioning of the nails and the number of nails per tile are determined by the type and length of the tile refer to pages 23 28 NAIL POSITIONING The tiles should be fastened two courses above the tiles that are being laid Apply weight when nailing The person nailing should stand on tile being installed facing the eaves Gun nailers can also be used to securely fasten the tiles INSTALLATION MANUAL 23 GERARD ROOFING SYSTEMS 10 NAIL POSITIONING H H CLASSIC TILES The correct positions for nailing different profiles are shown below Correct nailing ensures good holding of Nails should be approximately 60 mm to the side the tile and ample penetration of the nail at the same time restricting nail penetration to a maximum of two Of the centre of the pan of the tile and close to the thicknesses bottom of the downturned flange NOTE In areas prone to extremely strong winds installation must meet the local standards and by laws and nailing should be at 7 points per tile 8 points per Classic tile Edge of tile B Edge of tile A
31. stenersneed to be near the bottom edge of the Box Barge to ensure that the bottom edge is firmly positioned against the barge board INSTALLATION MANUAL 35 14 BOX BARGE as BOX BARGE END 1 Mark the required measurements indicated by the blue lines on the Box Barge Step 1 These measurements are universal to all roof pitches Step 1 Left view 2 Cut the Box Barge along the Cutting line solid blue line using hand shears Using right and left handed shears can make cutting easier Step 2 3 Bend the Box Barge along the Step 1 Right view Bending line dotted blue line Step 3 to Step 5 Step 2 Left view Step 3 Left view Step 2 Right view Step 3 Right view INSTALLATION MANUAL 36 14 BOX BARGE A GERARD A BOX BARGE END Option 1 The nose of the tile at the junction with the barge batten is close to the eaves batten first batten Option 1 Step 1 Option 1 Step 2 1 Place the Box Barge End in its final position and mark the bending line against the Eaves Flashing Step 1 2 Add 15 mm to the bending line and draw the cutting line Step 1 3 Cut and bend the Box Barge End into its final shape Step 2 Step 3 em 4 Place the Box Barge End in its final Option 1 Step 3 B Option 1 Step 4 position Step 4 Option 2 The nose of the tile at the junction with the barge batten is not close to the eaves batten 1 Place the Box Barge End on top of the tile
32. to the batten construction using screws Avoid nailing into plastic d AI MA IN wh r k f INSTALLATION MANUAL 48 20 INSTALLING ACCESSORIES A GERARD PLATFORM STEPS Install the base plate first then drill the holes into the tile and install the tile Finally install the platform or steps Platform Steps Washer INSTALLATION MANUAL 49 21 MANAGEMENT OF THE WORK SITE ESTIMATING MATERIALS The following outlines some simple methods for estimating the quantity of tiles and accessories required for a roof AHI Roofing can also assist with estimating and provide further technical information or assistance Estimating the quantity of tiles required A simple method for determining the quantity of tiles required is 1 To calculate Tile Shake and Shingle profiles multiply the surface area of the roof by 2 2 For Milano Tiles multiply by 2 3 An example using Gerard Classic Tile roof size 578 m x 2 2 tiles m 1271 tiles 2 We recommend you build in a wastage factor using the following guidelines Add 3 5 96 to the quantity for gable roofs Add 8 10 96 to the quantity for more complex roofs with valleys or hips Estimating the number of accessories required 1 Box Barges determine the length of the barges Divide the lineal coverage per accessory i e 1 9 m to calculate the number of units required 2 Side Flashin
33. ull width refer to page 31 RIDGE Installation For measuring cutting and bending tiles follow the same procedure as the ridges refer to page 30 RIDGE Cutting and Bending Tiles If the facade is not finished leave a part of the roof near the facade uncovered Install a purpose made flashing on the bottom end of the facade and make the facade before finalising the roof coverage Use sealant on the junction of the render and the Top Wall Starter Flashing Where the roof surface joins a finished facade use a custom made flashing that will allow the junction between the flashing and the render to be sealed with a sealant refer to page 38 WALL FLASHING GERARD ROOFING SYSTEMS Tile Tile Batten Ventilation Space Batten Underlay Rafter Support Batten Top Wall Starter Flashing Top Wall Spacer Side Flashing Render Warmth Insulation Sealant INSTALLATION MANUAL 42 18 MILANO RIDGE WALL FLASHING GERARD ROOFING SYSTEMS dd 1 2 3114 15 6 17 29 118 8 9 Install a thinner support batten at the ridge when the top course is less than the full width refer page 31 RIDGE Installation Cut tile ap proximately 30 mm from the ridge batten The flat on the back of the tile then needs to be turned up ap proximately 25 mm This brings the tile shape back to its shaped pro file and provides a barrier
34. urope and throughout the rest of the World Our company s vision is to provide innovative high quality roofing systems that everyone aspires to have on their home Our company s core values include a willingness to meet all challenges to conduct our affairs with honesty and integrity and very importantly to provide our customers with genuine value for money AHI Roofing is a subsidiary of Fletcher Building Limited a company with a world wide reputation in the building materials sector Our staff at AHI Roofing is committed to working with you to achieve the home of your dreams INSTALLATION MANUAL 2 CONTENTS AZ GERARD ROOFING SYSTEMS 1 IMPORTANT 4 9 NAILING TECHNIQUE 23 nal kubi f 10 NAIL POSITIONING 24 Nonstandard Elements 4 Classic Tiles 24 Roof Traffic 4 Heritage Tiles 25 Improper Tools 4 Ia Lo SD Cutting with a Saw 4 Senator Shingle 21 Installation Under Extremly Cold Conditions 4 Corona Shake 26 f 4 tat JR 11 EAVES FLASHING 29 Responsibility 5 12 RIDGE 30 Packaging 5 Cutting and Bending Tiles 30 Handling 5 Installation SI Identification 13 HIP 32 2 TOOLS 6 Cutting and Bending Tiles 32 3 GERARD TILES 7 Installation 33 14 BOX BARGE 34 ae as Cutting and Bending Tiles 34 Underlay 10 Box Barge End 36 Ventilation space 10 15 VALLEY 39 Thermal Insulation 10 i Vapour Barrier 10 Cutting and Bending Tiles 38 Installation 39 6 LAYING THE UNDERLAY 11 16 WALL FLASHING 40 7 BATTENS 12 Sr 12 17 TOP WALL F
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