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EJOT flat roofing solution helps housing developer avoid weather-related delays

The McCarthy & Stone scheme in Swindon comprises of two blocks accommodating around apartments for the over 60s-B

An EJOT fixing combination, which is designed for rapid installation of flat roof systems with tapered insulation, has been instrumental in market-leading retirement property developer McCarthy & Stone meeting the strict completion deadline at one of its latest developments in Wiltshire.

Pull-out substrate testing prior to specification-B

The scheme at Wichelstowe in Swindon is formed of two blocks which accommodate a range of one and two bedroom apartments designed to offer stylish independent living for the over 60s, with around 120 new properties in total. McCarthy & Stone has co-developed the site with Anchor Hanover Group (Anchor), England’s largest not-for-profit provider of specialist housing and care for people in later life, to deliver a retirement community close to the picturesque Wilts and Berks Canal.

The developer’s firm commitment to delivering the scheme to new residents on time, as promised, meant that the construction team had to pull out all the stops to find creative solutions to keep the build schedule on track. One particular challenge resulted from the relatively small window available to install the extensive flat roofs of the apartment blocks which fell at a time when temperatures had plummeted unexpectedly.

The original proposal was for a tapered insulation system, incorporating a Bauder PVC membrane plus mineral wool insulation, to be bonded to the concrete deck. However, given the cold weather conditions, it was not possible to apply the adhesive during the planned installation window.

As waiting for the temperature to rise to the required level would have resulted in unpalatable delays to the construction programme, nationwide roofing contractor Protec Roofing was tasked with finding a solution that would ensure the proposed flat roof system could still be used.

Protec Roofing’s managing director Ian Green approached EJOT UK’s flat roofing specialist Kevin Rackley for assistance. He had recently been introduced to EJOT’s mechanical fixing solution for flat roof systems involving a combination of the JBS-R fastener and EcoTek tube-washer at an industry event, and after recommending it to the project team, it was subsequently approved for use by Bauder.

The EJOT JBS-R/EcoTek combination brings together a high-performing organically coated concrete screw (JBS-R 7.5) with a high-quality telescopic tube-washer (EcoTek) to provide a fixing solution that is adjustable to fit the required depth of insulation. It is suitable for all types of commonly used tapered insulation, principally mineral fibre, EPS, XPS and PIR.

3 The system requires fewer combinations and saves valuable time

The combination is suitable for any insulation depth of between 70mm and 590mm, and it has the benefit of requiring fewer fastener / washer combinations than any other current mechanical fixing approach. As a result, fastener use can be significantly rationalised, subject to the application, a site survey and pull-out tests, which EJOT UK is able to assist with.

At the Wichelstowe development, the tapered insulation depth on one of the roofs ranged from 90mm to 330mm, using four lengths of JBS-R fastener of between 80mm and 210mm. The roof on the second building involved insulation depths between 140mm and 380mm, which required three fastener lengths of between 120mm and 210mm.

In addition to keeping the construction schedule on track during the cold weather, the installation process also proved popular with the team on site. Installation of the EcoTek/JBS-R combination is easy because only one embedment depth is needed whatever the insulation thickness. Easy adjustability is also provided through the innovative way that the EcoTek tube-washer is driven into place using a custom tool with the fastener already in place.

Where the roof features a particularly deep layer of tapered insulation to maximise thermal performance, as was the case at Wichelstowe, EJOT’s flanged A-cone and driver bit extension is used to avoid the awkwardness associated with drilling deep using standard SDS drills. This means installers can avoid a highly delicate procedure requiring long-length SDS drills, which are often difficult to source.

The simplified installation process offered by the EcoTek/JBS-R tube-washer and fastener combination also means that fewer on-site calculations were required compared to using other mechanical fixing approaches.

Luke Pickering, Protec Roofing’s site supervisor on this project, said:

“Switching from the proposed bonded application method to using the EcoTek/JBS-R combination proved to offer far more benefits than simply allowing us to continue installation during the cold weather – as critical as this was. We were working with insulation depths of up to 380mm, so we knew the fastening approach would make a huge difference to how efficiently we could work on site, and we were really pleased with how the process worked out.

“The single embedment depth, regardless of the length of fasteners, and how EJOT’s tooling allowed us to make simple adjustments saved a considerable amount of time compared to other mechanical fixings we’ve used in previous tapered insulation projects. The A-cone and extension tooling helped here too, making it easier for our team to drill at the deepest point and achieve a consistent efficiency and quality across the roof area.”

Long term performance is assured when using the JBS-R/EcoTek fastening system given the quality materials used to manufacture both fastener elements. The JBS-R fastener is manufactured from case hardened steel and the EcoTek tube-washer is formed from high quality plastic to provide a lasting solution.

Kevin Rackley is EJOT UK’s Business development Manager for Flat Roofing products:

“The Wichelstowe project is a perfect example of how the EcoTek/JBS-R combination can contribute to more efficient construction and help developers avoid site delays due to the UK’s highly unpredictable weather.

“We offered two options to mechanically fix the Bauder membrane and the mineral wool insulation – one using the JBS-R system and the other using one of our other concrete screws, the FBS-R. Both would have provided an effective fixing solution, but with fewer different lengths of the JBS-R required, we could help the Protec Roofing team rationalise fastener use as much as possible for a more streamlined installation process.”

The EcoTek/JBS-R combination is part of EJOT’s extensive range of fastening solutions for flat roofing, encompassing fully mechanical and part-bonded systems, and fully compliant with the guidelines published by the Single Ply Roofing Association (SPRA). Flat roof designers, contractors and installers benefit from highly specialised support from the EJOT UK team at all stages of the flat roofing project to ensure all the performance objectives can be met without compromise.

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SFS facilitates faster fixing of tapered insulation over steel decks with BSA system launch

 

Ongoing investment in research and development by SFS Group Fastening Technology Ltd has brought the launch of the construction industry’s first ever adjustable fastening system for use with tapered – AKA cut-to-falls – insulation, installed over steel decking.

The SFS BSA adjustable fastening system follows on from the success the manufacturer has enjoyed with its TIA product, introduced a decade ago for use on concrete roof decks. Importantly, it offers roofing contractors a faster, simpler, and more cost-effective solution for securing insulation or single-ply membranes across multiple insulation layers up to 500mm thick.

There are three primary components to the patented system – the choice of a 110mm or 160mm fastener; thermally-broken polyamide sleeves available in lengths from 70-330mm; and five different stress plates which clip onto the sleeves for membrane or insulation securement.

The BSA fastener features two different thread zones separated by a thread-free zone.  To install, the efficient drill point cuts through the steel deck while the lower thread is designed to threadform and also restrict penetration through the crowns of the deck to a maximum 20mm.

The specialist drive bar tool then engages with the locking nut, held captive in the sleeve, to effectively tighten the assembly down into position. Then if the roof is trafficked the nut is free to move within the sleeve, before returning to its original position when the load is removed; this telescopic arrangement making BSA a very safe option for use with PIR and stone wool insulation.

For membrane installation when using BSA with tapered insulation, there is a choice of either the traditional isotak seam (or lap fixing) system or field fixing using the isoweld induction welding system.  Using isoweld, single ply membrane is welded to dedicated stress plates.  No fixings penetrate the waterproofing as a result.  Rather than seam fixing, induction welding uses a field fixing arrangement where the stress plates are installed in a grid pattern.  The Isoweld fasteners provide for both insulation and membrane retention and are evenly distributed, independent of the membrane seams and the result is increased efficiency, security and cost saving opportunities.

The BSA adjustable fastening system is CE-marked, fully tested and carries ETA Approval, while it has been successfully trialled on projects in the UK and Germany, receiving excellent feedback from contractors.

 

Martyn Holloway, Business Development Manager, Flat Roofing for SFS, comments:

“The use of adjustable fasteners for installing tapered insulation and single ply membranes on flat roofs removes complexity and simplifies the install. The BSA system offers up to 85mm adjustability using the same fastener and sleeve combination so this means that with a1:60 fall the same combinations can be used for four separate boards, whilst achieving a consistent 20mm fastener penetration through the deck.

 

“By contrast, using standard fasteners significantly more components and rationalisation of fastener lengths will result in varying penetration depths ranging from 20 to 70mm.  A consistent 20mm penetration across the complete roof significantly cuts the risk of damaging M&E services below the deck.

 

“Compared with adhesive fastening of tapered insulation schemes, the BSA adjustable fastening system will provide for a significantly faster and more cost-effective solution. One fastener will fix through multilayers of insulation and without the need for priming the deck nor expensive bitumen-based Air and Vapour Control Layers. Additionally, mechanically fastening is less weather dependant, especially in terms of temperature”.

 

SFS is pleased to offer project specific technical guidance and specification support, including wind load calculations and site pull-out testing to assist determine the correct number of fixings for either field or seam fixing methods of single ply membrane installation – or alternatively for insulation attachment, for example, where liquid applied membrane systems are specified.

 

 

 

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further information or call 0330 0555888

 

 

 

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SFS reports strong sales growth as it unveils first complete envelope package

(Photo caption: the recently completed new Alchemist bar and restaurant at Salford Quays, which features a striking golden building envelope installed by Longworth, created using fastening systems by SFS. Courtesy of Artez / James Andrews.)

Global group sales growth of 13.7% in 2017 for fastening systems manufacturer SFS, reflects the growing customer demand here in the UK for high performance fixing solutions for the building envelope, which the company is set to support further with its unveiling of the industry’s first complete package for rainscreen systems.

In addition to an expanded range of SFS-branded products and services being readied for launch in 2018, the company now offers Nvelope rainscreen support systems after the manufacturer joined the SFS family in 2016. This enables SFS to provide high performance Nvelope bracket and rail systems for rainscreen cladding and SFS-branded fasteners as one package, offering important warranty benefits and a simplified supply chain.

An extension to this package is also available to customers seeking to incorporate a working at height safety system as part of their envelope project. This is provided by SFS with its industry-leading Soter Safety Systems solutions, giving specifiers and contractors the assurance that key elements of the building envelope’s construction and installation are provided by a market-leader renowned for its technical excellence.

Across the globe, SFS provides fastening solutions in a diverse range of industries, including medical equipment, automotive, electronics and industrial. In the UK, SFS is synonymous with high performance fasteners for roofing and cladding, as well as other structural applications, and its range of precision-engineered door hinges. Over the last 12 months, its organic sales have grown strongly by 7.4%, to achieve overall sales of around £1.24bn (CHF 1.633bn Swiss Francs).

David Wigglesworth, UK Managing Director of SFS, said: “The SFS brand stands for quality and engineering excellence, so our customers can be confident that every solution we provide meets the highest expectations. Nvelope and Soter Safety System are, therefore, perfect additions to the SFS family as architects seek greater certainty on building envelope quality and performance, and installers look to solutions that help them work quicker, more profitably and safer.

“With our new family of systems, SFS is unique in the market in providing a complete solution that is underpinned by quality and reliability. Customers of SFS fasteners have long benefited from the extended life of our superior A4 stainless steel fasteners, often with powder coated colour finishes for outstanding visual appeal, and our innovative flat roofing systems, but they can now access so much more for projects incorporating rainscreen and where a reliable safety system is required.”

Superior quality products backed by expert technical support has been at the core of SFS’s success in serving the building envelope market for more than 30 years with a wide range of solutions for pitched roof, façade and flat roof construction. The company is part of the SFS Group which has annual sales in excess of £1.1bn and a history dating back to the 1950s serving customers in the construction, automotive, electronics, industrial and medical products markets.

Find out more about SFS at www.sfsintec.co.uk.
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