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corrugated-steel roof for new house

  • 03-02-2008 5:58pm
    #1
    blackiebest
    Registered Users, Registered Users 2 Posts: 650 ✭✭✭


    Hello all,

    I will start build of 320 sq mtr in March. The house will be a low energy house with very high spec roof and outsulation. I have permission for standing seam zinc roof but am pretty sure I will not afford it. The roof system will be very insulated and soundproof and I am now seriously giving consideration to using corrugated, for economic, practial and even aesthitic reasons. Would love to hear opinions on this, based on reason other than "dont like it"! i think the look for our design would work, I am more worried about problems associated with corrugated that I may not be aware of. Info appreciated


Comments

  • #2
    AckwelFoley
    Registered Users, Registered Users 2 Posts: 12,555 ✭✭✭✭AckwelFoley


    You would want to get a heavy gauge sheet (thickness) as they vary.

    I presume you will get them coloured, ie.. dipped in colour similar to metal cladding? If you wernt, the galvanised sheeting fades fast and looks poor.


  • #3
    Builderfromhell
    Registered Users, Registered Users 2 Posts: 1,570 ✭✭✭Builderfromhell


    I recently built a large house with a very low pitch roof. I, as the builder, had a PC sum for the roof and did much research into different types. I looked at standing seam but found the companies un helpful and not too interested. It is also very expensive.
    I then looked at a 'single ply membrane' over tapered insulation on OSb board on jouists with VCL. Many practical problems with this method which I won't go into here.
    eventually put OSB bords on joists. This acted as supports for roof and working platform. Built sloping structure from Gyproc channell. Put 400mm Rockwool insulation over OSB (dry day) and fixed profile metal sheeting as I went along. Got Profile sheeting from Duggan's steel but others do it (see web site).
    I cannot emphasise enought the need to ventilate the roof space, uses a Vapour control membrane.
    we alos fitted mesh over all ventilation opes to stop bats, bees, birds and rodents from availing of rent free accomodation.
    I believe metal profile roofs are far superior to traditional tile or slate in that they have minimal joints and have a very long life. Good Detailing is crucial.


  • #4
    galwaytt
    Registered Users, Registered Users 2 Posts: 12,822 ✭✭✭✭galwaytt


    blackiebest wrote: »
    Hello all,

    I will start build of 320 sq mtr in March. The house will be a low energy house with very high spec roof and outsulation. I have permission for standing seam zinc roof but am pretty sure I will not afford it. The roof system will be very insulated and soundproof and I am now seriously giving consideration to using corrugated, for economic, practial and even aesthitic reasons. Would love to hear opinions on this, based on reason other than "dont like it"! i think the look for our design would work, I am more worried about problems associated with corrugated that I may not be aware of. Info appreciated

    A couple of things come to mind:

    1. Does your planning permission allow you to use the roof you want? Are you sure it doesn't stipulate slates/tiles?

    2. A house done near me in metal coloured sheeting (tile-effect, can't remember the name.......), about 6 years ago looked fine. But now, 6yrs on, there is very definately a colourfastness problem.....

    3. Noise. Metal roofs are, by their nature, noisy.........

    4. Standing seam Zinc - we're currently fitting roof panels to a commercial development in Galway, and a contractor is following on with standing seam zinc. It seems to be a very protracted operation, but does look well, but an awful of attention to detail required. However, in pre-contract discussions, the zinc people were very very specific in their requirements for the roof, and what they would/would not, attach to. One co, Rheinzinc, would only fit to their own panels..............

    5. Std corrugated roofing is quite heavy gauge, so you'll need to be a good tinsmith to work it, and there are no suitable complentary pieces to go with it, so how you'll make up complementary flashings, gutters etc, I don't know.........remember, wherever you cut it, it's no longer galvanized/zinc'd, so it just a plain ferrous edge, just waiting to rust.............

    Ode To The Motorist

    “And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road” 



  • #5
    Mellor
    Registered Users, Registered Users 2 Posts: 39,902 ✭✭✭✭Mellor


    blackiebest wrote: »
    Hello all,

    I will start build of 320 sq mtr in March. The house will be a low energy house with very high spec roof and outsulation. I have permission for standing seam zinc roof but am pretty sure I will not afford it. The roof system will be very insulated and soundproof and I am now seriously giving consideration to using corrugated, for economic, practial and even aesthitic reasons. Would love to hear opinions on this, based on reason other than "dont like it"! i think the look for our design would work, I am more worried about problems associated with corrugated that I may not be aware of. Info appreciated

    Thats quite a large house, so I can see material cost will have a large impact. Being so big it won't really be very low energy, but it will probably get a good rating due to the floor area. (But thats another thread, but feel free to start it)

    As for "economic, practial and even aesthitic reasons". I wouldn't agree really. Most likely economic, but not really aesthetic superiour than a zinc roof. as for practical, depends, it will be "quick" to fit, but won't be easier than traditional methods. Detailing will be important, and you don't want some builder saying "sure I can do that". 99% of people working with these sheets are used to sticking them on sheds where detailing doesn't matter.
    galwaytt wrote: »
    5. Std corrugated roofing is quite heavy gauge, so you'll need to be a good tinsmith to work it, and there are no suitable complentary pieces to go with it, so how you'll make up complementary flashings, gutters etc, I don't know.........remember, wherever you cut it, it's no longer galvanized/zinc'd, so it just a plain ferrous edge, just waiting to rust.............
    Good points in general made by galwaytt, so i'm not going to repost them, but I do have to reinforce the last one!!.
    Not only with the cut edge be exposed for rusting, it will actually rust quicker than if it was plain steel. This is due to a reaction between the two metals, esp in wet conditions.

    and eaves and valley will be tricky as galway said. The pieces would be simple to make, just cutting plain sheets are correct angle and welding. But it will be an extra cost.


    To the OP;
    If this is what you prefere then it is possible. But as an alternitive I think it is sub-par. I don't think it would look as good or even close. It could easily end up looking like a barn, worksmanship will need to be a far higher standard. Very little margin for error.


  • #6
    blackiebest
    Registered Users, Registered Users 2 Posts: 650 ✭✭✭blackiebest


    Thank you for the interesting replies. I understand the reservations expressed and am especially gratful for the 'rust' warning. Indeed it would be a disaster to be unhappy with the finished look and posts have opened my eyes to the detailing that would be required for a satisfactory finish. Frankly I do not really like slate or tile, the house is contempory in design with only one valley joint to worry about, all others mono pitch. Anyhow I am still researching and would love to hear from anyone who has used corrugated on a domestic house over the last few years. Regarding noise I feel confident that it will not be an issue internally and feel that the majority of noise externally will be eliminated be the insulation/structure beneath.

    MAny thanks


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  • #7
    galwaytt
    Registered Users, Registered Users 2 Posts: 12,822 ✭✭✭✭galwaytt


    just to add about Mellors observation: welding: first, galvanising has to be removed to weld.........so that joint will no longer have any protection, as well as looking pretty awful.

    Regarding cutting, etc, remember that if water cascades off that edge, it will also wash a rust-coloured stain from that point downwards.........

    How about a plastisol covered profiled sheet panel, e.g. from someone like Newell Roofing ?? Light, workable, cuts with tinsnips (not grinder.......), and they could make up all sorts of flashings, etc for you. We use some of their products for cabins that we make, and I have a large garage done with it at home. They have different profiles available.

    Ode To The Motorist

    “And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road” 



  • #8
    250882
    Closed Accounts Posts: 206 ✭✭250882


    Any time we have specced zinc on a large roof the developer has used Trocal or sarnafil roofing membrane. The first time I saw it I was horrified with the thought of using something so obviously plasticy and I still dont like the stuff. but the welded joints are actually really clean as opposed to zinc or copper , theres no need to worry about expansion and contraction and theres no problems with noise from heavy rain(you can even get a plastic stick on standing seam that looks alright from a distance). Dont know if its even worth consodering but I thought i'd mention it as an option.


  • #9
    blackiebest
    Registered Users, Registered Users 2 Posts: 650 ✭✭✭blackiebest


    250882,
    Thank you for this interesting idea. I had a look at the web sites and mostly seems to be for commercial projects but I do like the look. Our design is contempory with almost all the roofs being monopitch. I am looking for somthing that will look better than slate and I am not afraid to use 'unusual' application but would love to be able to get good value for money and a product which will do what it should, keep the rain out through time. The more I imagine it the more I am attracted to corrugated steel:eek: Will keep looking.

    Thanks for info guys


  • #10
    rathmore
    Closed Accounts Posts: 7 ✭rathmore


    Hi there,

    these links may be of interest, all produce metal roofing in one form or another.

    http://www.kalzip.com/co_uk/Default.htm

    http://www.tegral.ie/metalforming/

    http://www.steel.ie/DP/DPHomePage.html

    http://www.euroclad.ie/


  • #11
    250882
    Closed Accounts Posts: 206 ✭✭250882


    Careful with large sheets on a monopitch roof, make sure they are properly fixed down, generally with sheds its a 175 x 50 timber or steel purlin they will be screwed into. If you are using standard 35 x 47 slating battens then there is a real chance that the roof could be ripped off by the wind. I've seen it happen with Nordeman sheeting where it literally took the battens with it when it went.


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  • #12
    250882
    Closed Accounts Posts: 206 ✭✭250882


    PS I dint mean to sound too negative with my above post.
    I think its fantastic that somebody is being adventurous with their house design by incorporating monopitch roofs and non-homebase building materials.

    Its great that somebody in this country is actually designing a house and not just a 2200sqft shoebox.


  • #13
    galwaytt
    Registered Users, Registered Users 2 Posts: 12,822 ✭✭✭✭galwaytt


    250882 wrote: »
    PS I dint mean to sound too negative with my above post.
    I think its fantastic that somebody is being adventurous with their house design by incorporating monopitch roofs and non-homebase building materials.

    Its great that somebody in this country is actually designing a house and not just a 2200sqft shoebox.

    non-shoebox is easy, all you have to add is €€€€€. Look at OP, he wants what seems to be a 'simple' flat panel roof. It's not (that) simple, and it isn't cheap (zinc, that is.......).

    Ode To The Motorist

    “And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road” 



  • #14
    ednwireland
    Registered Users, Registered Users 2 Posts: 14,575 ✭✭✭✭ednwireland


    just a thought you looked at these guys (priced them for a job i never did)
    see one up the road looked pretty good - wasnt zinc coloured though

    <snip>

    My weather

    https://www.ecowitt.net/home/share?authorize=96CT1F



  • #15
    galwaytt
    Registered Users, Registered Users 2 Posts: 12,822 ✭✭✭✭galwaytt


    yesterday, on way to a site, I passed the company I mentioned above, Newell Roofing, wondering if they would be worth a try.

    Just for clarity - no connection other than that we use their products, and have found them to be good to deal with. In fact, I used their composite built-up panel on my own 12m x 8 garage.

    Well, lo and behold, out front yesterday were a number of new displays for an open day they're having tomorrow, including one with an alternative to zinc, for standing seam roof, called Prelaq.

    They also have a membrane product for decks/roofs/ponds etc, called Extrupol.

    Anyway, I got some info for myself, and took some pics with the phone, attached.

    This first pic is of a genuine zinc roof, on our SIP panels

    Zinc Roof


    This then, is the alternative, Prelaq

    Prelaq

    I think it looks well, I have no idea on pricing - so you'll have contact Newell's directly.

    As for the membrane product, Extrupol, here's some pics both used as-is, and with various roof coverings (grass, stone etc) Lots of scope there for design, I'd have thought.

    Like I said, they're having an open day tomorrow, and I'm sure they'll be glad to chat. 091 790475 or http://www.newellroofing.com


    Membrane roof sample

    Falt membrane roof

    Green roof

    Gravel roof

    Ode To The Motorist

    “And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road” 



  • #16
    blackiebest
    Registered Users, Registered Users 2 Posts: 650 ✭✭✭blackiebest


    Big Thanks Galway,

    As it go's I was in touch with them last week and spoke to a helpful guy there however promises of pics to be emailed never arrived and I look forward now to getting back on to him. I will let you know how I get on. Pricing of this product is interesting to compare to alternatives. Truth be told however I am falling more and more for the idea of using traditional corrugated. Mainly because of the look but obviously the price helps. Sincerely I think it coudl look great on a domestic new house especially a contempory design, I just can not seem to find anyone who has done it before... Will I be the first, Haha spend 320k on construction and 5 for the 'tin' roof!!!!!!!


  • #17
    galwaytt
    Registered Users, Registered Users 2 Posts: 12,822 ✭✭✭✭galwaytt


    no prob - update - the open day is NEXT week, not tomorrow......oops !

    So, that's 20th February then.

    Ode To The Motorist

    “And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road” 



  • #18
    blakewood
    Closed Accounts Posts: 3 ✭blakewood


    Hi,

    We are about to build in East Cork, well as long as we get planning.
    Looking to build a curved barn style roof, with red oxide corrugated steel, similar to barns in every other farm in rural Ireland. We are looking to use a oak wood frame and straw bale walls. Only new to this Boards.ie business, but very interested to make contact with or hear from others using similar materials for building or experience with these materials.

    Thanks.


  • #19
    Juantorena
    Registered Users, Registered Users 2 Posts: 147 ✭✭Juantorena


    blakewood wrote: »
    Hi,

    We are about to build in East Cork, well as long as we get planning.
    Looking to build a curved barn style roof, with red oxide corrugated steel, similar to barns in every other farm in rural Ireland. We are looking to use a oak wood frame and straw bale walls. Only new to this Boards.ie business, but very interested to make contact with or hear from others using similar materials for building or experience with these materials.

    Thanks.

    PM sent re corrugated sheeting.


  • #20
    Foot Soldier
    Closed Accounts Posts: 1 ✭Foot Soldier


    blackiebest wrote: »
    Hello all,

    I will start build of 320 sq mtr in March. The house will be a low energy house with very high spec roof and outsulation. I have permission for standing seam zinc roof but am pretty sure I will not afford it. The roof system will be very insulated and soundproof and I am now seriously giving consideration to using corrugated, for economic, practial and even aesthitic reasons. Would love to hear opinions on this, based on reason other than "dont like it"! i think the look for our design would work, I am more worried about problems associated with corrugated that I may not be aware of. Info appreciated
    blakewood wrote: »
    Hi,

    We are about to build in East Cork, well as long as we get planning.
    Looking to build a curved barn style roof, with red oxide corrugated steel, similar to barns in every other farm in rural Ireland. We are looking to use a oak wood frame and straw bale walls. Only new to this Boards.ie business, but very interested to make contact with or hear from others using similar materials for building or experience with these materials.

    Thanks.

    Have a similar notion for an extension to converted old stone farmbuilding.

    Would welcome any feedback on anyone who did construct with corrugated galvanised sheeting, particularly with regard to noise; flashings; insulation; and any rust issues after time.

    Thanks


  • #21
    Vel Satis
    Registered Users, Registered Users 2 Posts: 5 ✭Vel Satis


    Hi, Just about to start new build. Barrel shaped Zinc roof on plans but we cannot afford it. How did you get on with your roof ??? Any alternatives recommended????
    Thanks so much...


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