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Roofing : Advantage Aluminium

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Newer roofing materials are constantly being introduced in the market place with distinct and unique advantages like corrosion resistance, aesthetics, better insulation and easy installation.Abhijeet P Kale, Deputy General Manager-Technical & Marketing, Lloyd Insulations India Limited highlights the advantages of latest aluminum and single ply membrane built-up roofing systems.

Which is the latest roofing material offered by you?

Recent developments in infrastructure projects as well as modern architectural practices have given us opportunities to introduce new roofing and wall cladding concepts in the Indian market. Earlier, metal roofing was only used in industrial buildings with conventional concepts like screwed down corrugated metal roofing. The airport revamping programme in India has changed our conventional thinking in view of large roofs and modern architectural features. This has given opportunities to introduce new concepts like aluminum built-up roofing systems as well as single ply membrane built-up roofing systems both of which need specialization. Today, we offer almost all type of roofing and wall cladding systems in India which are available in international markets. Because of this we are in a position to offer roofing solutions for buildings with minimum slope (up to 2%) and for buildings with steep slopes (in the range of 1:10 to 1:3) based on shape, size and contour of the roof. We are in a position to engineer all types of roofing systems keeping in mind necessary wind load resistance and weather tightness of the building envelope.

We offer specialized aluminum built-up roofing system which can address thermal as well as acoustic performance requirements in functional buildings like airports, commercial complexes, supermarkets etc. The recent example is Terminal 1C at MIAL GVK domestic airport at Mumbai. This concept offers designers a clean finish by providing single length roof sheets as per the building requirements in curved shapes, both concave and convex.

For buildings with very low slopes like MIAL GVK’s Terminal II international airport project, we have introduced single ply TPO built-up membrane roofing system with structural decking, fiber reinforced gypsum boards, PIR insulation boards, vapour barriers and weather tight covering of fully adhered Thermo Plastic Olefin (TPO) membrane. This roofing system is also designed for specific thermal, acoustic and fire performance requirements in line with FM and UL guidelines. To support green movement in the country, we have introduced special grade of Lloyd Sandwich Panels with metal facings with core of Rockwool or PIR (Poly Isocynurate foam) to offer a “Zero ODP” material. Both the materials are top in the list of green building resource index.

Conventionally, sandwich panels were used for wall cladding application in vertical orientation. Recently, we introduced very special product in sandwich panel system which can be laid horizontally with plain architectural grade metal facing of desired color. We have completed such application for Imsofer Manufacturers (India) Pvt. Ltd, Baramati (a division of Ferero Rocher, Italy) for its chocolate manufacturing unit. The horizontally laid panel system concept can also replace aluminum composite panels which are used in building applications for architectural finish. This system offers an added advantage of heat and acoustic insulation with excellent architectural finishing.

What are the innovations in the Roofing & Cladding sector?

India started using metals in buildings very late, basically because of hesitation to change our conventional mindset towards building construction. There are certain concepts like copper roofing which are quite innovative but from the point of functional requirements and economics, there would be restrictions for using the same for large projects. Retro- fitting of old buildings has definitely given us a chance for innovation in this sector. Depending upon the actual condition of the building, we design tailor made system for such applications with various options: three choices of standing seam roofing — both with steel and aluminum, “KLIP FIX” non punctured roofing and TPO membrane system with best solar reflective index and to minimize heat island effect.

We have also introduced concepts like EIFS Exterior Insulation Finishing system which can be used with conventional wall cladding application. EIFS is designed to result in thermal insulated, protected and decorative exterior lagging system. High density water repellant mineral wool, rigid polyurethane foam, either as slabs or in-situ sprayed form are featured as insulant, to be protected externally with mineral or synthetic plastic. The thickness of insulation can be designed in line with R-Value requirements as per ECBC or IGBC norms. Apart from the insulation layer to achieve the requisite standards of thermal performance, the system incorporated provides weather proof finish of a plaster or rendering. It can also comprise bricks, slabs, tiles or decorative board as well.

What kind of material do you use for extreme climatic conditions?

This aspect is very sensitive as far as India is concerned. The environmental conditions up in the North are totally different from that of in the southern, northern or western regions. If a designer does not keep in mind the environmental factor while designing roofing and wall cladding application, serious failures may occur in terms of damage of architectural finishes, weather tightness, etc. For inland applications, colour-coated galvanized steel products are highly popular and affordable, although they offer restricted architectural features. Owners also prefer colour-coated zinc aluminum products which have a proven track record of last 10-12 years in Indian market. For severe environmental conditions, aluminum is the best option. But, it is quite expensive compared to above referred options. At the same time, aluminum offers great flexibility and becomes the only choice to convert designs into reality. Use of non-metal components like TPO membranes is feasible for roofing system in low slope roofing applications.

What type of materials is in demand? How durable are these?

Currently, colour coated galvanized and colour & zinc aluminum coated products are very popular in Indian industry. Aluminum products are also getting recognition in the market because of the flexibility offered to designers. Sandwich panels with metal facing are receiving because the can provide “one-step” solutions to insulation and weather tightness.

What are the environment friendly aspects? At Lloyd Insulations we always practice environmental safety in all our projects and products manufactured as our first business principle. The company has worked on prestigious projects like the American Consulate and new office complexes at Bandra Kurla complex wherein the insulation products like Rockloyd rockwool building insulations which are based on natural occurring raw materials. Super Foam polyurethane products have got approval from the overseas building operation divisions of the US government. The company has been selected for another high profile project by Bayer for their “zero emission” building at Noida. Today, we offer roofs with high solar reflective index and also “Green Roofs” (roof garden) to drastically limit heat island effect and thereby earn high carbon credits and LEED rating.

What about your new projects?

We are currently working on and almost on the verge of finishing roofing and cladding works for Imsofer, Baramati, wherein Loyd PIR sandwich panels are featured. There are total five buildings in this project which are all temperature controlled and all have Lloyd TR PIR panels used for roofing. These panels are manufactured with Traperoidal colour coated metal sheets on weather exposed side with 100mm thick polyisocynine foam core and slightly ribbed colour coat metal facing on the bottom side.

For wall cladding in all buildings, architectural grade horizontally laid PIR sandwich flat panels are used in three color combinations. The panel thickness used is 100mm. The outer facing of panel is flat PVDF colour coated galvanized steel with 100mm PIR core and slightly ribbed color coated liner. The panel joints are designed in such a manner that no where the fasteners used to fix the panels are visible. Due to this reason, this system is also called as “Secret fastener” system or “Hidden fastener” system.

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