LYSAGHT KLIP-LOK® 406 Design and Installation Guide
Contents
1. HT Yi Ph LYSAGHT KLIP LOK 406 LYSAGHT KLIP LOK 406 is a strong durable versatile long spanning concealed fix roof and wall cladding with exceptional waterproofing characteristics Smart fluted pans and a lock action rib design enables use on low pitched roofs KLIP LOK 406 is available in long lengths therefore on most jobs you can have one sheet from ridge to gutter without end laps Long straight lengths of KLIP LOK 406 can be laid in place and easily aligned because fixing with our clips is simple and fast The smaller number of clips for a given area provides extra economy Overlapping rib 41mm 406mm coverage Material specifications e Next generation ZINCALUME aluminium zinc magnesium alloy coated steel complies with AS1397 2011 G550 AM125 550 MPa minimum yield stress 125 g m minimum coating mass e COLORBOND is prepainted steel for exterior roofing and walling It is the most widely used The painting complies with AS NZS 2728 2013 and the steel base is an aluminium zinc alloy coated steel complying with AS 1397 2011 Minimum yield strengths are G550 550MPa Minimum coating mass is AM100 100g m e COLORBOND METALLIC is prepainted steel for superior aesthetic qualities displaying a metallic sheen e COLORBOND ULTRA is prepainted steel for severe coastal or industrial environments generally within about 100 200 metres of the source The painting complies with AS NZS 2728 202. Not available in Vic or S A Qld amp W A by enquiry only Adverse conditions If this product is to be used in marine severe industrial or unusually corrosive environments ask for advice from our information line Lengths Sheets are supplied custom cut Tolerances Length Omm 15mm Width 4mm 4mm Minimum roof pitch You can use KLIP LOK 406 on roof pitches from as low as 1 degree 1 in 50 It can also be used on walls Maximum roof lengths for drainage measured from ridge to gutter m Penetrations will alter the flow of water on a roof Refer to the Lysaght Roofing amp Walling User Manual for more information Maximum roof lengths for drainage Peak rainfall Roof slope intensity mm hr 1 2 3 P 75 10 100 375 467 548 682 813 934 150 250 31l 365 454 542 623 200 188 234 274 341 406 467 250 I50 187 219 273 325 374 300 125 156 183 227 271 311 400 94 117 137 170 203 234 500 75 93 110 136 163 187 KLIP LOK 406 Limit state wind pressure capacities kPa Span Limit Span mm type state 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 Serviceability 2 69 2 38 2 07 1 78 149 1 20 0 92 0 64 SINGLE Strength 441 430 410 3 75 3 25 2 70 2 10 1 53 Serviceability 2 41 2 17 19 1 77 161 1 46 132 1 18 1 02 0 84 END Strength 3 60 3 45 3 30 3 05 2 70 2 35 200 1 70 145 1 30 Serviceability 2 82 2 76 266 2 53 2 35 2 05 1 80 1 65 150 1 27 INTERNAL Strength 410 3 55 3 05 2 65 2 35 2 05 1 80 1 6
3. do if there were no insulation Walking on roofs Always walk in pans and over the supports if possible Generally keep your weight evenly distributed over the soles of both feet to avoid concentrating your weight on either heels or toes Always wear smooth soft soled shoes avoid ribbed soles that pick up and hold small stones swarf and other objects Storage and handling Keep the product dry and clear of the ground If stacked or bundled product becomes wet separate it and wipe it with a Clean cloth to dry thoroughly Handle materials carefully to avoid damage don t drag materials over rough surfaces or each other don t drag tools over material protect from swarf s if end lap End Bansion joint in nee Spacing definitions ES End span IS Internal span O Overhang Spacing definitions ES End span Y IS Internal span O Overhang SS Single span o Metal 8 timber compatibility Lead copper free carbon bare steel and green or some chemically treated timber are not compatible with this product Don t allow any contact ofthe product with those materials nor discharge of rainwater from them onto the product Supporting members should be coated to avoid problems with underside condensation If there are doubts about the compatibility of other products being used ask for advice from our information line Maximum support spacings mm 0 48 BMT mm Type of span Roofs Single span 15
4. 00 End span 1800 Internal span 2100 Unstiffened eaves overhang 200 Stiffened eaves overhang 600 e Table data are based on supports of mm BMT e The data is governed by the ease installation of side lapping of the sheets at long spans Maximum support spacings The maximum recommended support spacings are based on testing in accordance with AS1562 1 1992 AS4040 0 1992 and AS4040 1 1992 Roof spans consider both resistance to wind pressure and light roof traffic traffic arising from incidental maintenance and assessment of ease of installation Wall spans consider resistance to wind pressure only and assessment of ease of installation The pressure considered is based on buildings up to 10m high in Region B Terrain Category 3 M 0 85 M 1 0 M 1 0 with the following assumptions made Roofs C 0 20 C 0 90 K 2 0 for single and end spans K 1 5 for internal spans Walls C 0 20 C 0 65 K 2 0 for single and end spans K 1 5 for internal spans These spacings may vary by serviceability and strength limit states for particular projects E F E P O A N 3 Latest Testing Technology State of the art testing methods have been used to determine the performance of KLIP LOK 406 The direct pressure testing rig at our NATA registered testing laboratory has been used to develop the limit state performance tables of KLIP LOK 406 This results in a much better modelling of wind loads compared t
5. 10 16x22 Metal Teks WH 10 16x16 Metal Teks WH 10 16x22 Metal Teks WH 10 12x25 Type 17 WH 10 12x35 Type 17 WH Side laps If required 10 16x16 Metal Teks HH or Roof Zips M6 11x25 or M5 16x25 Designer Head or Sealed blind rivet 4 8mm aluminium Notes 1 For other steel thicknesses not specified please seek advice from screw manufacturer 2 Values given are gauge threads per inch lengths mm HH Hex Head WH Wafer Head 3 Care is required during installation to prevent stripping of thin material Single ply 4 Screw specification as above or equivalent fastener 5 All side lapping screws with EPDM sealing washer E F G 6 a Step 4a Place the second sheet over the second run of clips again positioning the centre rib first A string line stretched across the bottom alignment of the sheets can be used to check that the ends of the sheets are in line Fully engage the interlocking ribs and the centre rib over each clip This can be achieved by walking along the full length of the sheet being installed with one foot in the tray next to the overlapping rib and the other foot applying pressure to the top of the interlocking ribs at regular intervals Also apply foot pressure to the top of the centre rib over each clip For complete interlocking which is essential the spurs of KLIP LOK 406 along the underlapping rib must be fully engaged in the shoulder of the overlapping rib Step 4b
6. 13 and the steel base is an aluminium zinc alloy coated steel complying with AS 1397 2011 Minimum coating mass is AM150 150g m COLORBOND Stainless is a pre painted steel and is used for severe and coastal environments The painting complies with AS NZS 2728 2013 and the steel base is a stainless steel complying with AISI ASTM Type 430 UNS No SA3000 The base metal thickness is 0 48mm Colours KLIP LOK 406 is available in an attractive range of colours in COLORBOND factory pre painted steel and in unpainted ZINCALUME steel COLORBONDO steel with THERMATECH technology The next generation COLORBOND steel incorporates THERMATECH technology which provides a new level of thermal protection by absorbing less heat Average reduction in solar absorption across all standard colours is 5 Now 14 of the 20 standard COLORBOND steel colours are medium to light under the BASIX colour classification which means reflective foil at the roof may not be required It also means a drop of roof insulation R rating may be applicable 203mm 203mm KL65 clip For KLIP LOK 406 Simple low cost concealed fixing Fixing clips effectively secure KLIP LOK 406 to steel or timber supports without puncturing the sheet With no exposed fasteners the straight lines of your roof remain clean and smooth Masses BMT mm kg m kg m m t 0 48 ZINCALUME 2 28 5 62 178 0 48 COLORBOND 2 32 5 7 1 175 Availability
7. 5 1 50 1 35 A capacity reduction factor off 0 9 has been applied to strength capacities Table values are based on supports of G550 steel Imm BMT Limit states wind pressures KLIP LOK 406 offers the full benefits of the latest methods for modelling wind pressures The wind pressure capacity table is determined by full scale tests conducted at Lysaght s NATA registered testing laboratory using the direct pressure testing rig Testing was conducted in accordance with AS 1562 1 1992 Design and Installation of Sheet Roof and Wall Cladding Metal and AS 4040 2 1992 Resistance to Wind Pressure for Non cyclonic Regions The pressure capacities for serviceability are based on a deflection limit of span 120 maximum fastener pitch 30 The pressure capacities for strength have been determined by testing the cladding to failure ultimate capacity These pressures are applicable when the cladding is fixed to a minimum of 1 0mm G550 steel For material less than 1 0mm thick seek advice from our information line Fasteners Where insulation is to be installed you may need to increase the length of the screws given below depending on the density and thickness of the insulation When the screw is properly tightened e into metal there should be at least three threads protruding past the support you are fixing to e into timber the screw must penetrate the timber by the same amount that the recommended screw would
8. See illustration of Step 4b above A distinct click will be heard as the interlocking ribs fully engage When engaging KLIP LOK 406 interlocking ribs stand only on the sheet being installed that is the overlapping sheet and not on the preceding sheet Install subsequent sheets by following Steps 3 and 4 and make periodic checks that the installed sheets are aligned with the roof perimeter On walling applications a rubber mallet must be used to fully engage the inter locking ribs and engage the centre ribs over the clips y f 77 an i Step 5a Part sheet cut longitudinally leaving full centre rib I Step5 If the space left between the last full sheet and the fascia or parapet is more than a half sheet width a sheet can be cut longitudinally leaving the centre rib complete This partial sheet can be fully clipped onto a row of clips as for a full sheet before installing the capping or flashing If the space left between the last full sheet and the fascia or parapet is less than a half sheet width it can be covered by the capping or flashing In this case the last sheet should be secured by cutting sheet in halves and fastening the underlapping rib at each purlin with a half sheet Similarly a half clip may also be used if required In this case where a partial sheet of less than two ribs is used it is necessary to turn up the lip along the edge of the cut sheet This can then be covered by the ca
9. ce of mind The consistent quality of LYSAGHT products made from leading brands such as COLORBOND and ZINCALUME steel means our products are the reliable industry favourite and enhance your reputation as a supplier or specifier of quality products We believe in a simple promise always choosing to do what is right At Lysaght our health safety environment and community responsibilities are integral to the way we do business Lysaght is proudly a division of BlueScope Australia s largest steelmaker and when you deal with Lysaght you can be assured you re partnering with a reputable and trustworthy supplier For generations Australians have relied on Lysaght and our diverse range of products including iconic brands such as CUSTOM ORB KLIP LOK and BONDEK When you choose LYSAGHT products we guarantee to deliver even more value than just a great steel product We re Lysaght and we re the Australian steel people WWW LYSAGHT COM Technical enquiries steeldirectobluescopesteel com or call 1800 641417 LYSAGHT KLIP LOK THERMATECH COLORBOND and ZINCALUME are registered trademarks of BlueScope Steel Limited ABN 16 000 011 058 Tek is a trademark of ITW Buildex The LYSAGHT range of products is made by or for BlueScope Steel Limited trading as Lysaght PM 1000 23 7 14 9 320075 075422 BLUESCOPE
10. o traditional air bag testing methods Our LYSAGHT brand has held the lead in Australian building products for over 150 years This position has been maintained through meticulous research and development The data in this publication are obtained from our direct pressure test rig which accurately reproduces the wind conditions experienced in the field Older air bag methods used by others distribute pressure unevenly so that air bags can produce misleading results and inflated strengths see diagram SS Ld FL Haye ttt tt er O The rigid shape of an inflated airbag does not apply pressure to the ribs of secret fixed cladding or adjacent to supports nt Xx A E A rt A Lysaght s direct pressure rig uses no air bags and applies pressure uniformly over the entire profile including the ribs Uniform pressure distribution of our direct pressure rig which accurately reproduces the wind conditions experienced in the field Maintenance Optimum product life will be achieved if all external walls and roofs are washed regularly Areas not cleaned by natural rainfall such as the tops of walls or roof areas sheltered by eaves should be washed down every six months Notching tool A tool is available for on site notching of transverse flashings and cappings Turn up down tools On all roofs of pitches less than 15 degrees the high end of all sheets must be turned up to stop water from being driven under the flashing and in
11. pping or flashing Y Step 5b Last rib fastened with half sheet and covered by capping or flashing We re Lysaght We re the people who brought CUSTOM ORB to Australia over 150 years ago We re the original maker of the shape that shaped a nation We re the trusted experience in steel Our quality Aussie made steel products are only part of our unique offer It s our commitment to delivering genuine and helpful customer service and technical support that have helped us become the trusted experts and industry leaders We know our customers value knowledge experience and personal service which is why Lysaght people are trained to work in partnership with you Whatever the solution you re looking for our people are located throughout Australia and are always ready to assist you Our dedication to excellent customer service is a commitment to you that we don t take lightly We pride ourselves in having a knowledge and technical expertise that s hard to match Our in house NATA registered research and technology laboratory reflects 150 years of technical innovation as well an eye to the future Our team of experts are available to provide advice and you can always rely on our published information to help you to design and install our products with absolute confidence Our quality products are made from 100 Australian steel are extensively performance tested come with a BlueScope warranty and offer you confidence and pea
12. ry by packing or easing between these members and their supporting structure Under no circumstances should packing be used directly under the fastening clips to adjust fall or alignment of roof Accurate alignment ensures efficient locking of sheets and clips Conversely misalignment can interfere with the locking action particularly on close support centres 2 To maintain maximum holding power the first and last supports and clips should be at least 75mm from each end of the sheet 3 Make spot checks for the alignment of sheets during laying to control fanning or creep 5 sheets 2030mm coverage To rectify alignment sheets may be adjusted 2mm by pulling the clip away or pushing towards the sheet while fastening the clip 4 For very steep roof or vertical wall applications a positive fastener screw or bolt is required in each sheet length to prevent movement down the fastening clips This is best positioned under or through the flashing or capping at the top end 5 KLIP LOK 406 can be fastened over insulation wool blankets up to 50mm thick when the blanket is draped over supports before installation of clips 6 Sheets should project a minimum 50mm into the gutter line Installation Procedure Step 1 When lifting sheet lengths onto the roof frame ready for installation make sure all sheets have the overlapping ribs facing towards the side where fastening is to commence The first run of clips must be located and fas
13. tened one to each support so that they will correctly engage in the overlapping and centre ribs of the first sheet when it is located and locked over them To do this fasten clips to the purlins at each end of the sheet having positioned them so that the first sheet will be in correct relation to other building elements Align and fasten the remainder of the first run of clips using a string line or the first sheet as a straight edge Fasteners without Insulation A z FLL Step 2 Position the first sheet longitudinally in relation to gutter overhang and locate it over the fastened run of clips positioning the centre rib first and engage the centre and overlapping ribs onto all clips by foot pressure Lp p WA Step 3 Position and fasten the next run of clips one to each support with the short return leg of the clip over the underlapping rib of the installed sheet If the clip fouls one of the spurs spaced along the outer free edge of the underlapping rib the spur can be flattened with a blow from a rubber mallet to allow the clip to seat down over the rib gt 1 y I Fix to Steel Fix to Steel Fix to Steel Fix to Timber Fix to Timber Single amp lapped steel thickness Single thickness steel Total lapped thickness of Hardwood Softwood 20 55 up to 1 0mm BMT 21 0mm BMT up to 3 0mm BMT 21 0mm BMT up to 3 8mm BMT J133 J4 Clip 10 16x16 Metal Teks WH Fixed 10 16x22 Metal Teks WH 10 16x16 Metal Teks WH
14. to the building Similarly the pans at the gutter end must be turned down to stop water running back along the underside of the sheets Tools are available for both applications Cutting For cutting thin metal on site we recommend a circular saw with a metal cutting blade because it produces fewer damaging hot metal particles and leaves less resultant burr than does a carborundum disc Cut materials over the ground and not over other materials Sweep all metallic swarf and other debris from roof areas and gutters at the end of each day and at the completion of the installation Failure to do so can lead to surface staining when the metal particles rust Sealed joints For sealed joints use screws or rivets and neutral cure silicone sealant branded as suitable for use with galvanised ZINCALUME or COLORBONDO steel Non cyclonic areas The information in this brochure is suitable for use only in areas where a tropical cyclone is unlikely to occur as defined in AS NZS 1170 2 2002 For information on the use of LYSAGHT products in cyclonic conditions refer to the Cyclonic Area Design Manual which is available by download on our website www lysaght com Installation Sheet 3 Sheet 2 Fei Prevailing weather 4 Direction of laying Figure 1 Lay sheets towards prevailing weather General Installation Notes 1 Check that the top faces of all purlins or battens are lying in one plane adjusting as necessa
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