Roof Coverings

An in-depth presentation about the building material, Roof Coverings:- Manufacturing Process, Types, Materials, Installation, etc.

1. Roof Coverings BUILDING MATERIALS 1818

2. What is a Roof Covering? A roof is the top covering of a building, including all materials and constructions necessary to support it on the walls of the building or on uprights; it provides protection against rain, snow, sunlight, extremes of temperature, and wind.

3. What Types of Roofing Material Are There? Roofs have been around ever since humans started living in shelters so you can imagine there are several different types of roof covering available all around the world. The most popular roof covering in the entire world is roofing tiles. Other popular materials include slate tiles, metal roofing, wood shakes and even green roofs in certain parts of the world.

4. How Do I Know Which Roof Covering to Choose? With so many different roof coverings available it’s hard to know where to get started. There are several different factors in choosing a roof covering including aesthetic appeal, what type of home you own, what type of weather you face in your area, your annual mean temperatures, even what your HOA will allow in your neighborhood.

5. Choosing based on weather conditions 1. Fiberglass Asphalt Shingles In extreme weather conditions than organic shingles. 2. Cement “S” Tiles Fantastic choice for areas with extreme wind, hail, heat, and snowy weather. Something to consider is that the cement tiles will be very heavy 3. Metal Extreme cold,extreme hot and windy conditions 4. Clay “S” Tiles Fantastic for hot climates. 5. Slate Recommended material for sloped roofs created with the main goal of waterproofing.

6. Types of Roof Coverings

7. Asphalt Coverings Appearance: Available in traditional tiles in sets of 3 or laminated thicker tiles, called “architectural”. Ecological: oil is a product that is not environmentally friendly. It can be recycled, although they are often taken to landfills. Durability: not very durable. Algae-resistant tiles are available in damp climates to prevent stains. Weight: moderate. Can cause overload on more delicate structures Angulation: can be used on sloping roofs up to steeper. Fire & Wind: good fire resistance, acceptable wind resistance. Cost : cheap to moderate.

8. Slate Tiles Slate is one of the oldest building materials. Although fragile and expensive, it is very durable and resists both wind and fire. Materials: made from natural slate. Appearance: normally dark gray, with irregular appearance. Ecological: made from natural materials. Durability: Long lasting, durable (depending on where it was mined). Weight: Heavy, require reinforced roof structure to support itself. Angulation: only sloping steep roofs. Fire & Wind: good resistance to fire and wind. Cost : very expensive. Requires specially trained workers for installation

9. Wood shingle roofing Wood shingles are made from wood that is resistant to rot and have low fire resistance if left untreated . Materials: Normally cedar, but also can be made from other hardwoods. Appearance: gives natural appearance and ages to a silvery gray. Available in sawn or thicker division tiles. Ecological: made from natural materials. Durability: short service life, requires periodic maintenance. Weight: moderate. Angulation: Can be used in moderate slope to steep sloping roofs. Fire & Wind: good wind resistance, lack of fire resistance (can be treated with a fire retardant). Cost: moderate.

10. Metal tiles Although more expensive than asphalt, metal roofs last longer and are more resistant to wind. Materials: can be composed of steel, aluminum, copper, or zinc alloy. Steel roofs come with a zinc coating or painted finish. Copper roofs are installed unfinished and acquire a protective green patina with age. Appearance: Available in sheets or tiles that resemble other materials. Can be installed with concealed (exposed) or exposed fasteners. Ecological: can be made from recycled materials, and can be recycled when replaced. Absorbs one-third less heat than asphalt. Durability: Relatively durable to very durable, depending on material. Weight: light. Angle: available for low or steep sloping roofs. Fire & Wind: good resistance to both fire and wind. Cost: moderate (from steel) to expensive (copper).

11. Metal roofing

12. Less expensive than clay tiles, concrete tiles are also heavy but can last a long time and are very fire resistant. Materials : made from a mixture of cement and sand. Appearance: Can be made to look like traditional clay, wood or slate tiles. The color can be made across the tile or just applied over the surface. Ecological: made from natural materials. Durability: Long and low maintenance but can break. Weight: Heavy, require reinforced roof structure to support itself. Angulation: Can be used in moderate slope to steeper inclined roofs. Fire & Wind: excellent fire resistance, moderate to low wind resistance. Cost: moderate. Concrete roofing

13. PVC Flat Roofing PVC or vinyl flat roofing is one of the most common forms of flat roof coverings. It is a lightweight choice, very long-lasting and very resistant to leaks due to its heat-welded seams. It is also a great choice for cool roofs, as it primarily comes in white. Rubber Roofing Rubber roofing is an eco and budget friendly choice for your home. It is long lasting roof covering , and is relatively easy to install and maintain . Rubber roofing is available in a number of different color and style options, and can be designed to look like slate, asphalt or cedar. You can also choose a rubber roll, which is virtually leak-proof. Shingle Roofing Shingle roofing generally refers to asphalt shingles, but encompasses any roof covering system comprised of tiles or shingles that interlock or overlap in a way that channels water off of a pitched roof. Most shingle types are comprised of materials that are locally available.

14. Pvc flat roofing Shingle roofing Rubber roofing

15. Spray Foam Roofing Spray foam roofing , also known as Spray Polyurethane Foam (SPF ) roofing is a lightweight flat roofing option. It is essentially a liquid plastic sprayed overtop of the roofing substrate, which foams and expands to cover your flat roof seamlessly. Tar and Gravel Roofing Tar and gravel roofing , also known as built-up roofing, has been the go-to flat roof technology for decades. A tar and . gravel roof covering consists of a waterproof base layer, multiple layers of roofing felt laminated together with bitumen, and a surface layer of mineral aggregate. There are a wide variety of materials available for each layer.

16. Spray foam roofing Tar and gravel roofing

17. Stone Belt Roofing If you are building in a stone belt, such as the Cotswolds or many parts of the north of England, you may well be required by planners to use local materials. In such instances, you are unlikely to have much choice as to what you use. If planners don’t insist, there are numerous reconstituted stone tiles you can opt for which give something of a vernacular feel, without being exorbitantly expensive.

18. Functions Insulation Because the purpose of a roof is to protect people and their possessions from climatic elements, the insulating properties of a roof are consideration in its structure and the choice of roofing material. Some roofing materials, particularly those of natural fibrous material, such as thatch, have excellent insulating properties. Concrete tiles can be used as insulation. When installed leaving a space between the tiles and the roof surface, it can reduce heating caused by the sun. Forms of insulation are felt or plastic sheeting, sometimes with a reflective surface, installed directly below the tiles or other material; synthetic foam batting laid above the ceiling and recycled paper products and other such materials that can be inserted or sprayed into roof cavities. Cool roofs are defined as roofs with both high reflectivity and high thermal emittance. Poorly insulated and ventilated roofing can suffer from problems such as the formation of ice dams around the overhanging eaves in cold weather, causing water from melted snow on upper parts of the roof to penetrate the roofing material.

19. Drainage The primary job of most roofs is to keep out water. The large area of a roof repels a lot of water, which must be directed in some suitable way, so that it does not cause damage or inconvenience. Flat roof of adobe dwellings generally have a very slight slope. In a Middle Eastern country, where the roof may be used for recreation, it is often walled, and drainage holes must be provided to stop water from pooling and seeping through the porous roofing material. Similar problems, although on a very much larger scale, confront the builders of modern commercial properties which often have flat roofs. Because of the very large nature of such roofs, it is essential that the outer skin be of a highly impermeable material. Most industrial and commercial structures have conventional roofs of low pitch. In general, the pitch of the roof is proportional to the amount of precipitation. Houses in areas of low rainfall frequently have roofs of low pitch while those in areas of high rainfall and snow, have steep roofs. The water repelled by the roof during a rainstorm is potentially damaging to the building that the roof protects. Most buildings have a system in place to protect the walls of a building from most of the roof water. Most modern roofs and many old ones have systems of valleys, gutters, waterspouts and drainpipes to remove the water. Areas prone to heavy snow benefit from a metal roof because their smooth surfaces shed the weight of snow more easily and resist the force of wind better than a wood shingle or a concrete tile roof.

20. Solar roofs Newer systems include solar shingles which generate electricity as well as cover the roof. There are also solar systems available that generate hot water or hot air and which can also act as a roof covering. More complex systems may carry out all of these functions: generate electricity, recover thermal energy, and also act as a roof covering. Solar systems can be integrated with roofs by: integration in the covering of pitched roofs, e.g. solar shingles. mounting on an existing roof, e.g. solar panel on a tile roof. integration in a flat roof membrane using heat welding, e.g. PVC. mounting on a flat roof with a construction and additional weight to prevent uplift from wind.

21. Solar roof coverings

22. Manufacturing Process Of Roof Coverings

23. Clay Tiles Step 1: Preparation Following extraction, the clay is prepared by grinding and milling to achieve consistency and homogeneity in particle size. Water, sand and other additives such as recycled or secondary- source materials are mixed with the clay at this stage. Step 2: Shaping An extruded brick is produced when clay is pressed into shape through extrusion dies and subsequently cut into individual bricks. Whereas soft mud bricks, with their higher moisture content, are pressed into singular moulds then turned out onto a tray.

24. Step 3: Drying The shaped products are then stacked on reusable metal pallets or kiln cars and transported to the dyer. The drying process prepares the bricks for firing by extracting moisture from the soft "green" bricks. Depending on the type of product, the drying period lasts between four and 45 hours. During this time, the moisture content drops to below 2%. Step 4: Firing After drying, the products are transferred to a kiln where they fired in the range 1000-1100 degrees C. This high temperature is necessary to establish the inherent durability, strength and fire-resistance associated with clay construction products. Step 5: Packaging Packaging and delivery After the fired products have cooled, they undergo a quality inspection and are packed ready for dispatch.

25. Asphalt Shingles Step 1: Dry looping A jumbo roll [6 ft (1.83 m) in diameter] of either organic felt or fiberglass mat is mounted and fed into the roofing machine. The base material first passes through a dry looper. Matting is accumulated accordion-style in this reservoir, so that the machine can continue to operate when the supply roll is exhausted and a new one is mounted. Step 2: Saturation The base material passes through a presaturation chamber, where it is sprayed on one side with hot asphalt to drive out any moisture that may be present. It then goes into a saturator tank filled with hot asphalt. Soaking in the asphalt coats the fibers within the mat and fills the voids between them. Step 3: Wet looping The matting is again formed into accordion-like folds. While the asphalt coating on the mat cools, it is drawn into the felt, creating an even greater degree of saturation.

26. Step 4: Coating Coating asphalt, which has been stabilized with powdered minerals, is applied to both surfaces of the mat. The mat passes between a pair of coating rolls, which are separated by an appropriate distance to ensure that the desired amount of coating asphalt is applied to the mat. This step may be sufficient to coat fiberglass filaments and fill voids between them; in this case, the saturation and wet looping steps can be bypassed. Step 5: Mineral surfacing Granules of ceramic-coated minerals of the desired color are applied to the top surface of the asphalt-coated mat. A coating of fine particles of a mineral, such as talc or mica, is applied to the back surface of the mat. The sheet of treated mat then passes through a series of rollers that embed the coating particles in the asphalt and cool the material. Step 6: Finishing The strip of roofing material is accumulated, accordion-style, on a cooling looper to finish cooling.

27. Step 7: Cutting The sheet of finished shingle material then passes into a cutting machine, where it is cut from the back side into the desired size and shape. The machine separates the shingles and stacks them in bundles. Bundles generally contain enough shingles to roof 25-35 sq ft (7.62-10.67 sq m). Step 8: Packaging The bundles of shingles are transferred to equipment that wraps them and affixes labels.

28. Concrete Tiles River sand is mixed with a clean finer pit sand to provide the correct sand grading before 42.5MPa Portland cement is added and mixed with water. Colour is obtained by adding various coloured synthetic iron oxide pigments at the mixing stage at around 3% of cement mass. The wet mix is then fed into the "tile extrusion machine", which extrudes the concrete into the required shape onto an aluminium pallet, which has already been sprayed with a pallet release agent. Water ratios in the mix are normally around 8.5% depending on the aggregate quality. The wet tile is then cured overnight, in heated curing chambers for at least 8 hours at very high humidity of +90% RH and +42°C temperatures. After curing the dry tile is then separated from the aluminium pallet so that the pallet can be re-used for every shift in the tile extrusion process. The dry tile can either be directly stacked in the yard or first coated with and acrylic coating if required. If this occurs a further drying process is necessary before stacking the tiles.

29. Roof Installation & Manufacturing Videos

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