MODUROOF SYSTEM MANUAL

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• Contents • System Overview • Questions & Answers • Typical Details • NHBC Chapter 7.2 • Client pre-installation checklist • Roof Design • Tile fixing details • Manufacturing Checklist • Site Manager Checklist • Moduroof installer on-site Checklist • Health & Safety Information • Contact Details

 

   

 

 

Moduroof System overview

MODUROOF® by Charcon provides a fast, safe means of roof construction perfect for time sensitive developments such as residential schemes and social affordable housing.

The innovative roofing solution is manufactured offsite under controlled factory conditions, ensuring a level of accuracy and build quality unmatched by traditional in situ methods. This type of construction offers many benefits including timely delivery of a ready to install roof, minimal onsite waste and improved health and safety by reducing the need to work at height.

• MODUROOF® by Charcon offers a fast, COMPLETE roofing solution with design flexibility using Mitek Truss Software

• A standard truss construction with tiling and fascia fitted during manufacture as standard - can accommodate roof windows, dormers and PV units

• It is a bespoke factory engineered product manufactured indoors, eliminating delays caused by bad weather

• Delivered when you need; on time, every time. Installation in as little as a day • Available for both Cold and Warm Roof requirements • Approved for use on NHBC Registered Sites

Key Benefits of Moduroof

• IMPROVED HEALTH AND SAFETY: Modular installation drastically reduces working at height, particularly during the tiling process.

• DELIVERY CERTAINTY: Roofs are delivered when required as they are constructed whilst the house is being built up to wall-plate

• SUSTAINABILITY: Offsite construction aids Part L Code 4 achievability

• EFFICIENCY: Offsite manufacture significantly reduces waste and onsite movements and is not weather dependant

• SPEED OF BUILD: Installation for a typical pair of semi-detached homes or a detached home is installed in only one day fully tiled and weather-proof

• COST CERTAINTY: Know exactly what the completed roof will cost you. One roof = One Invoice. Also benefit from the ability to save on Prelim Costs.

Quality Assurance

MODUROOF® is factory engineered and all components undergo rigorous quality control checks.

You can be assured of the high precision and consistency that comes as standard with offsite construction.

 

 

The process for a typical cold roof installation

• Client house/apartment design drawings, specifications and fit out requirements received from client.

• Roof designed by our roof designer using MITEK software as per a standard roof with the addition of identifying the appropriate junctions for the modules. MODUROOF approved connection details incorporated into design. All roofs are designed in accordance with NHBC chapter 7.2, appropriate BS/EN standards and Building Regulations.

• Client consulted if minor amendments are required to improve system efficiency. • Tile/slate fixing schedules provided by the tile/slate manufacturer. • Roof construction undertaken in the factory. • All roofs are fully assembled in the factory including all bracing, strapping etc. The roof is

then separated ready for transportation to site to ensure on-site installation is as straight forward as possible.

• Completed modules are then transported to site.

• Wall plates are fitted and strapped down by client. • The roof modules are then installed on site to the awaiting structure.

• The roof modules are moved into place, junctions bolted and restraint straps fixed to the structure below as

 

 

required.

• The roof junctions are then sealed using the MODUROOF zip junction detail and install the tile/slates externally.

 

 

Typical room in roof installation

A roof in roof installation is much the same as a cold roof that except if necessary the roof is separated to incorporate top hat trusses for transportation purposes.

                       

 

 

Questions and Answers

• Is the system acceptable to NHBC?

NHBC have reviewed the system and they have agreed that the system is accepted on NHBC sites subject to their requirements being incorporated.

• Is a BBA or system approval required?

Moduroof is essentially a method of delivery rather than a construction type. The system therefore does not have BBA approval however it is not required by LABC or NHBC.

• Who is responsible for the roof design?

Each roof is either designed or supported by Mitek software or in the case of specialist designs these would be designed by our structural engineer and supporting design and calculations provide to clients.

• NHBC requires batten joints to be staggered how does the system met these requirements?

• NHBC treat each 3m section as a separate roof therefore as long as the individual sections comply with NHBC 7.2 their standards are met. Battens within the module are staggered where necessary in accordance with the standards.

• As the roof is in sections should bracing be used to link the modules together?

No as long as bracing is installed correctly within the modules no additional timbers are required. Each module is viewed as an individual roof for bracing and tile lath purposes.

• NHBC require tiles to be fixed in accordance with manufacturers fixing schedules can this be achieved.

All slates/tiles will be fixed in accordance with manufacturers fixing schedules and a copy of the fixing schedule will be included within the technical manual.

• Can the system incorporate warm and cold roof constructions.

Yes both cold and warm roofs can be incorporated and if necessary insulation can be pre-installed.

 

 

• Can spandrel panels be incorporated into the system.

Yes gable and party wall spandrel panels can be incorporated. However if party walls are to be incorporated, the block work needs to be built up above ceiling level in accordance with Robust Details requirements.

• What are the maximum spans possible with the system

Truss sizes are restricted by transportation sizes however roofs can be broken down into modules. This allows most spans to be achievable.

• Is the system compatible with different build methods?

Yes Moduroof can be used in conjunction with most systems of build including timber frame, concrete panel, steel frame.    

 

• What Health and Safety accreditation do Moduroof have?

Moduroof are SMAS accredited and all documentation is provided in accordance with regulatory requirements

 

 

Typical Details

 

Abutment soaker For Parapet Wall situation

 

Please  note  the  Lead  or  GRP  bedded  in  the  masonary  and  dressed  over  the  soaker  is  excluded  from  Moduroof  scope  of  works  and  deemed  to  be  by  Bricklayer/or  others.    

 

 

Green Solutions

The modules can be supplied with preinstalled PV Panels and heat recovery units if required

 

Truss Design

Truss design illustrating the module split locations

Detail of the pediments to be installed onsite

 

 

NHBC Chapter 7.2

 

 

 

 

 

 

 

 

 

Client Office Pre-installation Checklist

Action Yes N

o

N/A

Comments

Overall wallplate layout and dimensions including standard requirement of no blockwork above wallplate level (except party wall upstands and gable walls where applicable) provided by client.

Overall span between wallplates to be provided within tolerance of +/-50mm.

Overall span between gables to be provided within tolerance of +/-50mm (if moduroof are supplying external finish this is reduced to 10mm).

Party wall spandrel detail and fixing detail agreed.

Gable wall spandrel detail and fixing detail agreed.

Gable and spandrel strapping details are acceptable to clients building designer/engineer (normally every 200mm).

Wallplate size to be agreed (either 100x50mm or 100x75mm).

Wallplate and strapping to be fitted by client in accordance with NHBC standards prior to module installation (including mortar curing time)

SVP & Vent tile layout provided prior to tiling/at initial order stage.

Details of roof vapour control layer and ventilation strategy to be provided by client.

Materials and design of roof finishing material in compliance with NHBC standards supplied by client

 

 

 

 

NAME SIGNATURE DATE

 

 

 

 

   

Flashing requirements and interface responsibilities agreed with client.

Scaffolding designed to provide level platform typically 900/950mm below wallplate level with fall protection on both sides. Platform to have no vertical or horizontal scaffolding protruding which would restrict installation.

TRAD Deck or equivalent agreed system to be provided for roof module installation including providing sufficient working space to fix straps below bottom chord of truss.

Moduroof design package provided to client.

Supplied Crane Lifting plan approved by client.

Supplied Method statement & risk assessment approved by client.

 

 

Tile/Slate Manufacturer Fixing Specification

1) When slates arrive on site every pallet should have an accompanying document attached. This is known as an “ACD” This should have CE marking, the origin of the slate, producers address and BS EN 12326 test results. Ensure the information and details comply with the slate specified.

If required you can remove the ACD’s and keep for reference

If there are no ACD’s present the slates should be rejected

2) Slates are usually supplied pre holed,

3) The installer should correctly sort and grade the slates into a minimum of three or four grades, i.e.”Thicks” (to be laid to the lower part of the roof/eaves) “Mediums” (to be laid in the middle of the roof) “Thins” (to be laid towards the top of the roof/ridge). If the slates are graded to a 4th thickness these may not be used in the main body of the roof but cut to form eave or top slates or cut for use around features in other areas of the roof

It is important during this process to “tap” each slate, usually with a Slater’s axe, to confirm soundness. This simple process will detect any possible flaws prior to fixing. Any slate that does not ring true or is considered to be flawed should not be fixed but placed to one side. Again these slates may be suitable for cutting to be used as eave or top states.

Only when all these processes have been carried out should fixing commence. Slates should be fixed in accordance with the current BS5534, Code of practice for Slating and Tiling, BS 8000 Part 6 Workmanship on Building Sites, Natural Slates and Best practice.

The correct selection, sorting and grading of the slates is extremely important to achieve a neat and attractive finish

When battening out the roof the rafters/roof trusses require being in line, if they are not then the battens should be fixed using packers to ensure they are level with true rooflines ready for slating

Roofing battens or boarded roofs should be marked with perpendicular lines commonly known as plumb lines usually 3 or 4 widths of slate to ensure vertical bonding ready for slating

Slates should be laid in horizontal uninterrupted evenly graded lines with 5mm gaps between the slates.

Slating to a hip or valley should be constructed using slates cut from slate and a half. The minimum width of cut slate at the top edge should be not less than 150mm. Small triangular pieces of slate are not permitted

When slating to a verge or abutment the minimum width of slate should be 150mm. When a slate would be less than 150mm then Slate and a half should be used on alternate courses.

 

 

 

 

Manufacture Checklist Bracing

ACTION YES

NO

N/A

NOTES

All bracing minimum 25mm x100mm fixed

Bracing fixed with minimum 2x3.35x65mm nails

Longitudinal bracing fixed to gable spandrel panel

Bracing installed in accordance with table below

   

 

 

Trusses

ACTION YES

NO

N/A

NOTES

Trusses spaced at max 600mm

Truss spacing as per roof design

End trusses bolted through gable spandrel panel with fixings visible on inside

Truss bolting installed to detail

Tiling battens

ACTION YES

NO

N/A

NOTES

Tiling battens marked with supplier, origin & graded to BD5534

Tile battens to finish 25mm-50mm from projecting undercloak

Nails for fixing battens 3.35mm (10gauge)x65mm long

Minimum batten sizes in accordance with manufacturers recommendations but not less than table below:

 

 

Strapping

ACTION YES

NO

N/A

NOTES

Restraint straps fixed at not more than 2m centres and ceiling chord and rafter level.

Restraint straps fixed to solid noggins with minimum of 4 fixings which one is fixed to 3rd rafter (4no. steel screws or 4no. 75mmx4mm (8SWG) round nails

Holding down straps as per roof design fixed at 2m max centres with hardened nails 4mm dia x 75mm long or no12 wood screws x 50mm long into plugs

Restraint straps example Holding Down straps example

 

 

 

 

Firebreaks

ACTION YES

NO

N/A

NOTES

Fire stop insulation installed below roof membrane above separating wall

Fire stop insulation laid above roof membrane above separating wall between battens

Where fascias are installed wire reinforced insulation fixed in eaves box on separating wall line as below.

Isover 100mm cavity socks To Gable wall cavity (fixed to the timber gable panel in factory)

 

 

Roof Membrane

ACTION YES

NO

N/A

NOTES

Roof membrane installed as per manufacturers recommendations eg. Tyvek laid with 10mm drape.

Roof membrane sealed as per manufacturers recommendations.

UV resistant/5U felt or proprietary eaves guard supported on tilting fillet at eaves level.

Slates / Tiles

ACTION YES

NO

N/A

NOTES

Slates/tiles installed in accordance with provided manufacturers fixing details.

Cut tiles not fitted at eaves

Proprietary dry fixed system installed to manufacturers recommendations

No cut tiles used at verge

No sections less than a tile and half of cut single lapped interlocking tiles have been used.

Natural slate verges formed with a full slate or half a slate at least 150mm wide.

Tiles & slates mechanically fixed at verge in accordance with NHBC Appendix 7.2A

Ridge and hip tiles which are bedded on mortar mechanically fixed with non-ferrous fixings into timber batten.

Proprietary ridge & hip systems installed as per manufacturers recommendations.

 

 

Ventilation/SVP/Flue

ACTION YES

NO

N/A

NOTES

Roof ventilation installed to clients requirements.

Over corbel/fascia ventilation strip

Proprietary tile vents for extractors/svp etc installed.

Flue penetration installed

Roof Mortar

ACTION YES

NO

N/A

NOTES

Roof mortar 1:3 cement:sand with plasticiser on sharp sand or approved proprietary mortar

Mortar bedding & jointing completed in one operation

Verges

ACTION YES

NO

N/A

NOTES

Verge tiles bedded on an undercloak

Slates/plain tiles projecting 38-50mm beyond wall/bargeboard

Interlocking tiles to project 30-60mm from face of undercloak

NAME SIGNATURE DATE

 

 

Site Manager Checklist

Action Yes N

o

N/A

Comments

TRAD Deck or equivalent agreed system ready for roof module installation including providing sufficient working space to fix straps below bottom chord of truss

Scaffolding installed to required level typically 900/950mm below wallplate with fall protection on both sides. No vertical or horizontal scaffolding protruding which would restrict installation.

Wallplates bedded to line and level by client.

Wallplate straps installed by client in accordance with NHBC standards prior to moduroof installation (including mortar curing time).

Wallplate dimensions in accordance with roof design 100x50mm or 100x75mm as agreed with client.

Overall span between wallplates within tolerance of +/-50mm of approved design.

Overall span between gables within tolerance of +/-50mm of approved design (if moduroof are supplying external finish this is reduced to 10mm).

Blockwork supporting spandrel party wall panels built up minimum 300mm above underside of truss ceiling chord.

Party wall blockwork cavity closed in accordance with robust details with cavity closed and acoustic sealant provided by client prior to Moduroof installation.

Moduroof design package on site

Approved crane lifting plan on site.

Approved method statement & risk assessments on site.

   

NAME SIGNATURE DATE

 

 

MODUROOF Installer On Site Installation Checklist

Stage   Checked By

Signature

Wallplate assessment

Check levels of all wall plates conform to design if required adjust wall plate accordingly

   

Check spans of wall plates conform to design and if required adjust wall plate accordingly

   

Setting out and module lift

Check lifting points are correctly positioned and chains spreader/lifting beams are clear from the module structure.

   

Lift the modules into place following the designed sequence and setting out correctly to the designated datum pints.

   

Fixing of modules

Check all M20 bolts are inserted correctly through both trusses and packing plates at each module joint min. of four fixings per joint. A spread washer is to be used on either side of the trusses.

   

Check all truss ends are correctly fixed to the wall plate

   

Restraint straps installed as per roof design and NHBC requirements at ceiling and rafter level (max 2m centres)

   

Restraint straps fixed to solid noggins with minimum of 4 fixings which one is fixed to 3rd rafter (4no. steel screws or 4no. 75mmx4mm (8SWG) round nails

   

Holding down straps as per roof design fixed at 2m max centres with hardened nails 4mm dia x 75mm long or no12 wood screws x 50mm long into plugs

   

Diagonal bracing to extended over wallplate cut on a splay and fixed to the top of the wallplate with a 30x5mm bent galvanized strap , twice nailed into each member.

   

 

 

In cold roof version fix the correctly specified cross truss bracing as per manufactures directions

   

Sealing of joints

Check that a continuous seal is formed by the expanding flexible sealant from ridge to eves along all of the module joints.

   

Check that the tabard is correctly aligned and fix to prevent “pooling” and afford min. 150mm lap to either side of the joint.

   

Tiling of Zip Joint

Check that all required tiles are correctly inserted and seated on tile batten with the approved clips as per manufactures installation instructions

   

Soffits Fascias and Rain Water Goods (If applicable)

Check alignment of soffits and fascia    

Make sure all gutters and down pipes are correctly fixed and all seals in place

   

Handover Moduroof technical manual provided to site manager

   

 

Stage Deviation Description Approved by                                      

NAME SIGNATURE DATE

 

 

 

 

 

Health and Safety Information

EXAMPLE SITE INSTALLATION METHOD STATEMENT.

1. Wall plate assessment.

Prior to lifting the first module an assessment of the wall plate is to be made. Taking

account of the following:

• Check levels of all wall plates conform to design if required adjust wall plate accordingly

• Check spans of wall plates conform to design and if required adjust wall plate Accordingly

2. Setting out and module lift

Installation teams are to comply with lift method statement and slinging of the modules must be done by the Appointed Person and in accordance with the designed lifting points in the module.

• Check lifting points are correctly positioned and chains spreader/lifting beams are clear from the module structure.

• Lift the modules into place following the designed sequence and setting out correctly to the designated datum pints.

3. Fixing of modules

Once the modules are lifted into place they are to be fixed correctly to the wall plate and to each other with the locating bolts and fix each truss to the wall plate using BAT Truss Clip, Framing Anchors or similar suited to the truss size in accordance with the manufactures instructions. 30 x 5mm galvanised steel lateral restraint straps are to be fixed across three min. Truss and attached to the perpendicular structural walls of the building at min 2m ctrs.

• Check all M20 bolts are inserted correctly through both trusses and packing plates at each module joint min. of four fixings per joint. A spread washer is to be used on either side of the trusses.

• Check all truss ends are correctly fixed to the wall plate. • Check all lateral straps are in place • In cold roof version fix the correctly specified cross truss bracing as per

manufacturers directions

 

 

4. Sealing of joints

The external seams of the joints are filled with expanding flexible sealant to provide a

continuous waterproof barrier to the joint form ridge to eve. The addition of a min.

300mm continuous breathable membrane tabard is to be run over the ridge and down to the eaves fixed to the tile batten to prevent pooling and affording min. 150mm lap to either side of the joint.

• Check that a continuous seal is formed by the expanding flexible sealant from ridge to eaves along all of the module joints.

• Check that the tabard is correctly aligned and fix to prevent “pooling” and afford min. 150mm lap to either side of the joint.

5. Tiling of Zip Joint

Replace the Zip Joint missing tiles in accordance with the manufactures installation

instructions working from eves to ridge and fix dry ridge tile to complete the joint.

• Check that all required tiles are correctly inserted and seated on tile batten with the approved clips as per manufactures installation instructions

6. Soffits Fascias and Rain Water Goods

If specified with the roof the soffits and fascias will be fixed at the factory they should be adjusted to correctly align with the external skin of the building once the Modules are fixed in place.

• Check alignment of soffits and fascias • Make sure all gutters and down pipes are correctly fixed and all seals in

place.

 

 

 

 

 

 

Site specific Lifting Plan

 

 

Site Specific Risk Assessment and Method Statement

 

 

Contact Details

 

Contact:  Alan  Gulliver  

Position:  Moduroof  Managing  Director  

Contact  number:  07736  160880  

Email:  alan.gulliver@moduroof.co.uk  

 

Contact:  Mark  Westmoreland  

Position:  Commercial  Manager  

Contact  number:  01765  647161  

Email:  mark.westmoreland@charconcs.com  

 

Contact:  Keith  Stockburn  

Position:  Contract  Supervisor  

Contact  number:  07889  402522    

Email:  keith.stockburn@charconcs.com