Refurbishment solutions External roof and wall panel system · of Tata Steel Group, one of the world’s top ten steel producers. With a combined presence in nearly 50 countries,

Refurbishment solutionsExternal roof and wall panel system

Uniclass

CI/SfBL5221:P41:N75

(4-) Nh2 (W7)November 2011

A global brandTata Steel, formerly known as Corus, is one of Europe’s largest steel producers. We serve many different and demanding markets worldwide, including aerospace, automotive, construction, energy and power, and packaging. Our primary steelmaking operations in the UK and the Netherlands are supported by a global sales and distribution network.

Innovation and continuous improvement are at the heart of our performance culture. We aim to create value by offering a sustainable and value-added steel product range supported by unrivalled customer service. By working in partnership with you, we find the best solutions to meet your needs and help your business to perform.

Our European operations are a subsidiary of Tata Steel Group, one of the world’s top ten steel producers. With a combined presence in nearly 50 countries, the Tata Steel Group including the Europe operations, Tata Steel Thailand and NatSteel Asia, has approximately 80,000 employees across five continents and an aggregate crude steel production capacity of over 28 million tonnes.

Building Envelope SectorTata Group SustainabilityTata Steel is part of the Tata Group, a diversified global company with operations in every major world market. The Tata Group of Companies has business operations in seven defined sectors – Materials, Engineering, Information Technology and Communications, Energy, Services, Consumer Products and Chemicals.

In the past ten years the Group has expanded internationally and now owns major brands such as Tetley, Jaguar and Land Rover. Tata Steel, with its acquisition of Corus in 2007, has secured a place among the top ten steel manufacturers in the world and it is the Tata Group’s flagship Company.

Steel is an essential material, intrinsic to our way of life and to the products society will demand in a sustainable future. Steel is a material that is used, not consumed. It is recycled and used again, without any loss of quality, time after time. At Tata Steel, we are committed to making the products society needs and to making them in the most responsible way possible.

This means, practically, that we commit to: • Producingsteelproductsforthefuture• Investinginsustainablesteel-making• Improvingourexistingprocesses• Facilitatingtherecyclingloop

Our steel enables our customers to make safer cars, more energy-efficient buildings and infrastructure, easily-recoverable and recyclable packaging and many other products which help to move society towards our vision of a sustainable future.

Tata Steel has extensive panel and profiling manufacturing capabilities. We are the only company able to offer a comprehensive range of insulated panels, built-up systems, facades, structural roof and floor decking profiles from one single UK source, with the support and backing of a truly global company and complete supply chain.

With such a diverse product portfolio and over 40 years experience, we are uniquely able to offer the specifier an unbiased solution to meet the design criteria for any project.

Offering unrivalled technical support, practical guidance, performance and quality you would expect from one of the industry’s most trusted brands enables our customers to exceed their clients’ requirements over the long term.

Refurbishment solutions

22 0845 30 88 330 | www.tatasteelconstruction.com/theworks


With over 40 years experience serving the refurbishment market and the most comprehensive range of building envelope products, Tata Steel is uniquely placed to offer the client the most appropriate solution to any refurbishment requirement.

Backed by a unique Tata Steel Platinum® System Guarantee our focus is on delivering quality Refurbishment solutions designed to perform to the highest standards of energy efficiency, air permeability and structural performance and guaranteed for longevity.

Refurbishment presents building owners with a means of significantly improving the appearance, value and performance of existing buildings without the economic and environmental costs associated with new build construction.

Tata Steel’s refurbishment solutions provide a cost-effective means of refurbishing the building envelope, thereby improving the energy performance as a whole, enhancing its appearance and extending its life.

Several refurbishment options exist and the choice of solution will depend on the reasons for refurbishing:• thetypeofbuilding• thestateoftheexistingbuildingfabric• technicalandoperationalconstraintssuch

as not interrupting activities within the building and the available budget.

This brochure explains the key reasons for choosing to refurbish a building, the performance required by the Building Regulations, available grant schemes and describes the various options available using Tata Steel Refurbishment solutions.

West Huskisson Grain Store, Huskisson Dock, Liverpool

Client: Peel Ports

Installing contractor: Lester Fabrication and Cladding

Cladding system: R32 profile (roof ) and C32 profile (walls)

Colorcoat® product: Colorcoat HPS200 Ultra® in Merlin Grey


30845 30 88 330 | www.tatasteelconstruction.com/theworks

CPP7479_TataRefurbINNERS_aw.indd 3 14/11/2011 17:57

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The benefits of refurbishmentThere are a number of benefits associated with the refurbishment of an existing building. The benefits outlined below range from improving the performance and functionality of the building to pure aesthetics. There are many situations when it can make more sense to refurbish and upgrade an existing building rather than demolish the building and start again. With the most diverse range of products Tata Steel is able to offer the most appropriate solutions to any refurbishment requirement.

The benefits associated with refurbishment are:• Increaseinthermalefficiencyandreduction

in energy costs• Changethefunctionalityofthebuilding• Increaseinthevalueoftheproperty• Improvetheappearanceofthebuilding• Extendingthelifeoftheproperty• Improvetheworkingenvironment• Increaserentalincome• Repairdamagetotheexistingbuilding

envelope

One of the most important reasons is to increase the energy performance of the building through improvements to the insulation and air-tightness of the building envelope.

Figure 1. Reasons for refurbishment

0% 10% 20% 30% 40% 50% 60%

Environmental / technical upgrades

Change of tenant / use / aesthetics

Damage / vandalism

Leakage

Replacement of asbestos

Other

Source: Research commissioned by Tata Steel in 2001 (associated with diagram above)

Research suggests that refurbishment tends to be undertaken for positive reasons, such as technical upgrades, more often than it is used to overcome problems with the building envelope.

Research commissioned by Tata Steel highlights that refurbishment tends to be undertaken for positive reasons, such as technical upgrades.This is highlighted in figure 1.




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In many cases refurbishment of a building offers a practical alternative to a complete new build. There are considerable benefits in three areas as follows:

SocialThe refurbishment of an existing building minimises disruption, when compared to the demolition and rebuild of the building. Significant improvements to the aesthetics of the building can be made.

EconomicWhen the building envelope is replaced the majority of the building structure can be retained, with consequent savings in time and money.

EnvironmentalRe-using functional parts of the building minimises the impact on the environment from material production and transport. In order to maximise the environmental benefits of refurbishment, the materials removed from the building should either be re-used or recycled.

Misconceptions about refurbishment When refurbishment of the building envelope takes place, Clients and building owners consider the disruption to production or the workplace during the refurbishment phase a major issue.

In many of the Refurbishment solutions described in this brochure, the business operation can continue within the building while the refurbishment work is undertaken.

A certain level of disruption will always occur during construction work. However, with a good understanding of the potential problems, detailed planning and the involvement of an appropriate contractor most of these difficulties can be avoided.

Clients and building owners also consider that cost, standards of workmanship and the time involved in organising and checking on the refurbishment work also of key importance. These issues can be overcome through the involvement of specialist contractors who recognise and understand the issues associated with refurbishment. The contractor will also be able to provide detailed advice about health and safety issues.

London Victoria Station

Client: Network Rail

Main contractor: May Gurney

Design engineer: WSP

Installing contractor: Everlast Waterproofing Ltd

Cladding system: R46, C19 and PM13 profiles

Colorcoat® product: Colorcoat HPS200 Ultra®



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Thermal inspection

Sustainable solutions

The carbon (CO2) footprint of any building can be divided into two component parts:

• EmbodiedCO2 – associated with the building material, structure, fixtures and fittings.

• OperationalCO2 – associated with the use of the building including heating, cooling and lighting.

When considering a modern single storey shed, of the total CO2 footprint, around 80% to 90% is operational CO2. Only 10% of the embodied CO2 is associated with the building envelope, equating to 1% to 2% of the building’s total CO2 footprint.

It is apparent that any increase in embodied CO2 brought about by the refurbishment of a building will easily be offset by the reduction in its operational CO2.

This is usually achieved by improving the energy performance of the building and, more specifically, that of the building envelope. Refurbishment will, therefore, not only reduce the CO2 footprint of a building, but will also reduce its running costs due to lower energy bills.

Copyright 2009 Thermal Inspections Ltd.




Operational CO2

A numerical modelling study was carried out on a 120m x 60m medium-sized industrial warehouse to investigate the potential benefits of refurbishing the building in terms of a building’s energyperformance.ThiswasmodelledusingtheIES3thermalanalysis software, Dynamic Simulation Model (DSM). Two categories of building were considered: Before refurbishment and after refurbishment.

The ‘before refurbishment’ category represented typical retail sheds where the building envelope had not been refurbished. Three examples were considered:

• Un-insulatedindustrialwarehousebuiltbefore 1985 with fibre cement roof

• Insulatedindustrialwarehousewithpre-finished steel external sheet over a polystyrene insulation board built before 1985

• Pre-finishedsteelbuilt–upcladdingsystemincorporating a thin layer of insulation material built during the 1990s

The ‘after refurbishment’ category included a wide range of potential refurbishment standards from a 2006 Part L Building Regulation compliant building to the best energy performance achievable in terms of air permeability and U-valuesusingcurrentcladdingtechnology.

The heating, cooling and lighting demand on the building remained constant across all cases, as did the efficiency of the building services. Any recorded improvements in energy performance were entirely due to the upgrade of the building envelope.

The results for total energy and heating energy, expressed in m3/hr/m2, are presented graphically below. The percentage figure shown against each pair of bars in the chart represents the proportion of total energy demand attributed to heating.

Figure 2. Thermal simulation results for a range of as-built and refurbished buildings

0 1,000 2,000 3,000 4,000 5,000 6,000

Key

Total energy MWhHeating energy MWh

Uninsulated industrial warehouse builtbefore 1985 with fibre cement roof

Insulated industrial warehousebuilt before 1985

Insulated industrial warehousebuilt during ’90s

Cladding system, Part L compliant U-valuesand poor air-tightness of 27m3/hr/m2

Cladding system, Part L compliant U-valuesand air-tightness of 10m3/hr/m2

Cladding system, Part L compliant U-valuesand good air-tightness of 3m3/hr/m2

Cladding system, best performance U-values and air-tightness of 3m3/hr/m2

Roof/Wall:0.4 /0.8

U-valuesW/m2K

Roof/Wall:0.8/0.8

Roof/Wall:0.45/0.45

Roof/Wall:0.25/0.35

Roof/Wall:0.25/0.35

Roof/Wall:0.25/0.35

Roof/Wall:0.18/0.18

Building description MWh per year

Source: SCI Retail Warehouse renovation study March 2009.



Summary of Building Regulation requirements

Newly constructed or replacement elementsReasonable provision is given as follows in AD-L2B:• Fornewlyconstructedthermalelementssuch

as those constructed as part of an extension – Table 1 column (a)

• Forthosethermalelementsconstructedasreplacements – Table 1 column (b)

• NoindividualelementshouldhaveaU-valueworse than those set out in – Table 1 column (c).

Renovation of thermal elementsAD-L2B states that reasonable provision would be to achieve the standard set out in Table 2 (b) where works cover more than 25% of the surface area.

However if the area is less than 25% reasonable provision could be to do nothing to improve the energy performance.

If such an upgrade is not technically or functionally feasible or would not achieve a payback of 15 years or less the element should be upgraded to the best standard that is technically or functionally feasible and which can be achieved within a simple payback no greater than 15 years.

Retained thermal elementsRetained thermal elements refers to the following circumstances:• Whereanexistingelementispartofa

building subject to a material change of use• Whereanexistingelementistobecome

part of the thermal envelope and is to be upgraded

• Whereanexistingelementisbeingupgradedas a consequential improvement

AD-L2B states that reasonable provision would be to upgrade those thermal elements whose U-valueisworsethanthethresholdvalueinTable2column(a)toachievetheU-valuegivenin column (b) providing this is technically and economically feasible.

A reasonable test of economic feasibility is to achieve a simple payback of 15 years or less. Where the standard given in column (b) is not technically or functionally feasible, then the element should be upgraded to the best standard that is technically or functionally feasible and which can be achieved within a simple payback no greater than 15 years.

The Government has published revised Approved Documents to Part L of the Building Regulations (conservation of fuel and power). The changes took effect from October 2010. This section of the brochure summarises the requirements of the building fabric of non domestic refurbishment projects as per the guidance provided in Approved Document L2B.

Table 1. U-values for new cladding systems in refurbishment

Element a) Standard for new thermal elements

b) Standard for replacement thermal elements

c) Limited U-value for existing elements – not worse than

Walls 0.28 0.30 0.70

Roof (with integral insulation) 0.18 0.18/0.20* 0.35

* A lesser provision may be appropriate if there are particular problems associated with the load-bearing capacity of the frame or the upstand height.

Table 2. Add U-values for renovation and upgrading retained thermal elements

Element a) Threshold U-value b) Improved U-value

Walls – external or internal insulation 0.7 0.30

Roofs (with integral insulation) 0.35 0.18/0.20*

* A lesser provision may be appropriate if there are particular problems associated with the load-bearing capacity of the frame or the upstand height.




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Government tax relief schemes

Land remediation reliefLand remediation relief was introduced in 2001 to address issues of market failure relating to the bringing back into use of land that had been blighted by previous use for industrial purposes. The relief extends to both capital and revenue expenditure.

In 2009, land remediation relief was extended to address issues of market failure relating to long term derelict land. Again an incentive is offered to bring back into productive use land whose development is blighted by various kinds of dereliction including asbestos removal.

Land remediation relief is a relief from corporation tax. It provides a deduction of 100%, plus an additional deduction of 50%, for qualifying expenditure incurred by companies in cleaning up land in a contaminated state.

Who can claim the relief? A company, carrying on a trade or property business, can elect that capital expenditure on qualifying land remediation is allowed as a deduction in computing their taxable profits.

The deduction is allowed in the tax computation for the accounting period in which the capital expenditure is incurred.

The relevant conditions for relief are that: • LandintheUKis,orwas,acquiredbythe

company for the purposes of its trade or property business, and

• atthetimethecompanyacquiredthelandall, or part, of the land was in a contaminated state, and

• thecompanyincurscapitalexpenditureonqualifying land remediation in respect of the land.

For more information visit: www.hmrc.gov.uk/briefs/company-tax/brief2909.pdf

Business Premises Renovation Allowance (BPRA)Business Premises Renovation Allowance is a tax scheme designed to encourage the reuse of vacant commercial property for economic and social regeneration. It applies only to assisted areas – parts of the UKwithhighlevelsofunemploymentwherefirms are given grants and other aid from the government – and commenced on 11 April 2007. It is possible to make retrospective claims back to that date.

It aims to stimulate investment by allowing a 100% first-year capital allowance on qualifying expenditure associated with the conversion, refurbishment or renovation of qualifying business properties that have been vacant for at least 12 months. Qualifying buildings need to have been last used for a commercial purpose and need to be retained for seven years after completion of capital expenditure in order to avoid a 100% claw back of any tax gains.

This list provides a quick check on the potential compatibility of a scheme:• Haveyouundertaken,orareyouplanningto

undertake, capital expenditure on a building in any of the towns or areas that hold assisted area status since 11 April 2007

• Hadthebuildingbeenpreviouslyusedforacommercial purpose

• Hasallofthebuilding,oranyportionofit,been empty for 12 months or more

• Doesthespenderofthemoney–landlordortenant–paytaxintheUK

• Willtheinterestinthebuilding–freeholdor leasehold, be retained for the next seven years.

If the building fulfils all of these criteria, then a claim for an allowance is likely and can be processed on behalf of those landlords or tenants.

For more information visit: www.hmrc.gov.uk/manuals/camanual/ca45000.htm

Empty building ratesThe Government has reformed empty property relief in order to provide a strong incentive to bring empty property back into use. This will help to increase the supply of premises to let, and so reduce business rents and improve the competitivenessoftheUK,aswellasbringingforward brownfield sites for redevelopment and so reduce the need for new development on environmentally valuable greenfield land. The reforms to empty property relief have consequential impacts for the rates liability of partly occupied properties that have been apportioned.

So what will this mean for my rates liability? As of 1 April 2008, most property that has been empty for more than three months – or, in the case of industrial property, for more than six months – will no longer receive relief from rates. After the initial three or six month rate-free period expires, empty property will be liable for 100% of the basic occupied business rate.

For more information visit: www.businesslink.gov.uk

Carbon Trust – Building Design AdviceThe Carbon Trust Building Design Advice service helps to identify carbon savings in new and renovation projects. Support ranges from self-help guidance, to free or subsidised design and construction consultancy to help you maximize opportunities for specifying energy efficient plant and fabric.

Business loans are available of 0% interest for sumsof£3,000-£100,000.Tohelporganisationsfinance and invest in energy saving projects, the value of the loan is dependant on the anticipated CO2 savings for the building improvement proposed.

For more information call on 0800 085 2005, or visit www.carbontrust.co.uk/cut-carbon-reduce-costs



The Platinum® System Guarantee offered by Tata Steel provides peace of mind to clients for up to 25 years. The guarantee is free of charge and covers material performance and workmanship.

The guarantee encompasses all of the components used in the construction of the building envelope solutions provided by Tata Steel. It is the most comprehensive system guarantee offered on the market.

Tata Steel are in a position to provide this reassurance due to the innovative supply chain partnerships with the component suppliers.

All components (fixings, roof lights, fall arrest, gutters, walkways etc) used in the system are covered under the guarantee through our innovative supply chain partnerships with third party component suppliers.

The approved Platinum® suppliers are selected on the basis of their ability to meet the stringent technical criteria and performance set for each component and provide a component guarantee of up to 25 years.

Specifiers and contractors benefit from the guarantee with the freedom to choose from the list of approved suppliers.

As part of the Platinum® System Guarantee, approved Platinum® contractors undertake the installation. The workmanship of the Platinum® approved contractors is continually checked to ensure the systems are installed accurately and expertly without compromising performance. The workmanship of the installation is guaranteed for up to 12 years.

Tata Steel act as a one point of contact from beginning of the project right through to the duration of the guarantee period. The Platinum® System Guarantee provides the client with a direct link to Tata Steel in the unlikely event of a building failure.

The Platinum® System Guarantee, incorporates the unique Confidex® Guarantee which is only availablewithColorcoatHPS200Ultra®andColorcoat Prisma® pre-finished steel. Confidex® is the most thorough and rigorous guarantee forpre-finishedsteelproductsinEuropeandprovidespeaceofmindforupto40years.Unlikeother guarantees, Confidex® covers cut edges for the entirety of the guarantee period and does not require mandatory annual inspections.

Step 1. Step 2.

Tender process• TheNBSPlatinum®Specificationisusedaspartofthe

tender documentation, sent to the approved Platinum® contractor network.

• ThemaincontractorselectsaPlatinum®approvedcontractor to complete the project.

• Priortoordersbeingplaced,theapprovedPlatinum®contractorcheckstoensuretheNBSPlatinum®Specification meets the requirements of the project.

• ThePlatinum®contractorselectsancillarycomponentsfrom the approved supplier list and confirms to Tata Steel.

• TataSteelcreateauniquefilerelatingtotheproject.

Pre-tender process• RequestraisedforanNBSPlatinum®Specificationwith

Tata Steel commercial team.

• Thetechnicaldepartmentofferadviceandguidanceonthe most appropriate solution that meets current Building Regulations and building requirements.

• AnNBSPlatinum®SpecificationisgeneratedandauniquePlatinum® reference number is registered for each building.

• TheNBSPlatinum®SpecificationisthensenttotheArchitect/Specifier for approval.

• FinallyTataSteelprovidealistofPlatinum®approvedcontractors that will be able to tender for the project.

Refurbishment solutions in four easy steps…

Technical experience… Comprehensive range of products…




Why do buildings fail?

Why take the risk?

50%

5%

45%

Materials

•Colorcoat®pre-finishedsteelproductsareusedas standard on all systems, offering long-term performance with the assurance of quality and service.

•TheConfidex®GuaranteeisonlyavailablewithColorcoatHPS200Ultra®andColorcoatPrisma®pre-finished steel, offering peace of mind for up to 40 years.

•Allcomponentpartsusedinthebuildingenvelopearesourced through our approved supplier network.

Design

•Ourtechnicaldepartmentprovidesadviceandguidance on the most appropriate solution that meets current Building Regulations and building requirements.

•AprojectspecificNBSPlatinum®Specificationisgenerated by the technical department.

•Workmanshipiscontinuallycheckedon-sitetoensurethat systems are installed in line with the specification.

Workmanship

•Platinum®SystemGuaranteeoffersthefreedom to choose from a list of approved Platinum® contractors who are based throughouttheUnitedKingdom.

•Qualityofworkmanship,healthandsafetystandards and installed materials are all of the highest order.

•Theworkmanshipofeachprojectisguaranteed for up to 12 years.

Issue of Platinum® Guarantee• Uponcompletionoftheproject,thecontractorcompletes

a Platinum® guarantee application. This provides details of all interested parties and copies of all material orders for components used within the project.

• Platinum®SystemGuaranteecoveringthebuildingenvelope is issued to the contractor who passes onto the client providing peace of mind for up to 25 years on materials and 12 years on workmanship.

• TataSteelthenactasthesinglepointofcontactintheunlikely event of a building failure.

Construction phase• ProjectundertakenbyPlatinum®approvedcontractors

using components from the approved Platinum® supply chainpartnersaspertheprojectNBSspecification.

• Duringconstructionaninspectionwilltakeplacetoensure Tata Steel material(s) and all associated third party components (fixtures and fittings) from Platinum® approved suppliers are used on the project.

Step 3. Step 4.

Quality workmanship… Peace of mind…



Roof replacementInsulated panel system/Built-up system/Roof decking system

This section of the brochure considers the option of a complete refurbishment to a pitched roof. This would require full removal of the existing roof envelope back to the existing structural support frame. A list of benefits and possible considerations are listed below when considering this refurbishment option.

Industrial building before the replacement of the roof Industrial building during the replacement of the roof

Benefits: Roof replacement

The internal appearance of the building can be improved.

There is potential to improve the working environment for occupants, with regards to aesthetics, acoustics and climate control.

It is easy to alter lighting configurations to optimum levels i.e. change pattern of roof lights.

Air-tightness and thermal performance levels similar to new buildings can be achieved, and hence provide a large reduction in operational energy use.

The existing structure is normally suitable for re-sheeting applications, due to the weight of the new system normally being less or equal to that of the existing.

There is an opportunity to alter the building configuration.

Any potentially hazardous existing materials can be completely removed.

Considerations: Roof replacement

Tolerance and condition of existing support frame needs to be assessed to ensure suitability for new roofing system.

The cost of disposal of any hazardous waste should be accounted for.

The need for internal protection should be accounted for during the installation phase, netting and edge protection will be required.

The disturbance to occupants and operational processes should be considered. Phasing the construction may help this situation.

Access and storage around the building needs to be assessed to ensure there is enough space for removed materials (skips etc), and receipt and handling of new roofing system.




Solution 1: Trisomet® 333 SystemInsulated panel systemTheTrisomet®333Systemisaninsulatedroof panel system comprising of a straightforward side lapping detail allowing faster installation and a wider spaced trapezoidal steel external Colorcoat® pre-finished steel sheet, providing optimum performance for water drainage, strength and walkability. Its auto-hesively bonded polyisocyanurate (PIR) insulation core uses the latest foam technology providing enhanced environmental benefits (GWP <5), together with fire performance approved by LPCB..

Solution 2: Trisobuild™ SystemBuilt-up systemTrisobuild™ systems comprise of a Colorcoat® pre-finished steel trapezoidal liner, a Platinum® approved spacer system, an insulation layer and a Colorcoat® pre-finished steel external weathering profile. A comprehensive range of internal and external profiles are available. All profiles and spacer systems have been comprehensively tested, and third party assessed for structural capability by the Steel Construction Institute (SCI). Walkable 0.7mm steel liner specifications are also available.

Solution 3: RoofDekStructural roof deckingRoofDek structural roof decks offer the complete structural package with single ply membrane, for long and short span designs. The roof decks rangefrom32mmto210mmdeepandastructural design service providing diaphragm design and full support calculations for all profiles is provided.



Roof upgradeUpgrade of existing Built-up system/Insulated panel system

This section of the brochure considers the option of retaining the existing roof covering and introducing a thermal improvement and new external covering. This could be an upgrade to a non-insulated roof or an existing panel or built-up system. A list of benefits and possible considerations are listed below when considering this refurbishment option.

Benefits: Roof replacement

It is usually less expensive to over clad the roof.

On site installation is fast.

There is minimal disturbance to building occupants.

Insulation can be easily upgraded.

Air-tightness levels can be improved if considered at design stage and existing roof is of sufficient standard.

Considerations: Roof upgrade

A survey to establish the material and product, material condition and fixing specification of existing system will be required.

Using the above survey the refurbishment system solution must be designed to provide a satisfactory finished non-fragile platform and also to avoid any risk of interstitial condensation. For further information and advice contact the Tata Steel technical department.

There could be a need to consider the ‘old’ roof as fragile during construction phase, if evidence of fixing methods cannot be provided. If this is the case, netting and edge protection will be required during the installation phase.

Structural calculations are required to prove that the existing frame is satisfactory to take the additional load of the over clad system.

If asbestos cladding is to remain, preparation to fixing areas will be required to prevent contamination when drilling.

Boyatt Wood, industrial building during the upgrade of the roof Boyatt Wood, Industrial building during the upgrade of the roof




Solution 1: Single profile over clad systemThe system uses an engineered support spacer fixed through the existing sheeting in the purlins to provide an insulation space with minimal cold bridging. A new insulation layer isaddedtoprovidethedesignedU-value.Finally,theColorcoat®pre-finishedsteelexternalweathering profile is installed. If the existing roof is not deemed to provide an adequate vapour control layer (VCL), an assessment on interstitial condensation risk is required, this together with the intended building use will evaluate whether a separate VCL is required.

BoththeU-valuecalculationsandtheinterstitialcondensation risk analysis can be undertaken by the technical department.

Solution 2: Trinsal® insulated over clad systemMetalfacedInsulatedpanelshaveoverthepast30years become increasingly used for the external metal cladding of a wide range of buildings across virtually every construction sector.

Many of these roofs (i.e. prior to 1995) will have U-valuesoflessthan0.45W/m2Kandwillbeapproaching their end of life or repaint decision. Therefore the insulated panel over clad system provides a fast, light weight and shallow solution to both increase the insulation performance of these roofs to current requirements and also provides an outer covering, which can be installed using standard insulated panel fasteners.



Roof upgrade – flat to pitchUpgrade from existing flat roof to pitch roof

This section of the brochure considers the option of a permanent refurbishment solution for failed flat roofs, by using a lightweight steel sub-frame over the existing roof (which is then over-clad), creating an effective pitch to facilitate water run-off. A list of benefits and possible considerations are listed below when considering this refurbishment option.

School in Lancashire before upgrade of the roof

Benefits: Roof upgrade – flat to pitch

Provides a permanent solution to flat roof failure and moves water drainage to the outside of the building.

Framing systems are individually designed and tailored to suit structural requirements by approved Platinum® System Guarantee suppliers.

There is minimum disruption to building occupants.

Dramatically upgrades building aesthetics.

Provides opportunity to easily upgrade thermal performance.

Life of building considerably extended and future maintenance costs reduced.

Considerations: Roof upgrade – flat to pitch

Any existing roof lights may need to be substituted with sun pipes.

Patching may be considered as a lower cost option for repair to the existing flat roof. This can prove more expensive in the longer-term as it only masks the problem.

Issues associated with patching are moisture ingress and the continued degradation of the roof structure. If these are not addressed any water trapped within the structure usually finds another route into the building, which can compound the problem further.




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School in Lancashire after upgrade of the roof

Framing system during the roof upgrade

Framing systemsPropped rafter system This system takes advantage of the inherent strength and loading capabilities of the existing structure. This system utilises bespoke rafter sections installed at centres between 1,200mm and3,000mm,dependantonexistingroofconstruction. Vertical post sections fixed to the existing flat roof structure support these rafters. The lightweight structural framework can be assembled on site.

Trussed rafter system This system is designed for use on existing roofs that do not have the capability to support any further load. Instead, factory assembled clear spanning trusses constructed using a series of purpose made sections are supported by the existing load bearing walls or columns. Once in place, the trusses are fixed into the connection plates, braced, and the roof purlins secured. Depending on the size of roof the spanning trusses will be delivered as a full unit or in two halves.

Platinum® System approved suppliers for flat to roof framework systems are listed below:

Ash & Lacy Building SystemsBromfield LaneWest BromwichWest MidlandsB70 7JJTel: +44 (0)121 5251444www.ashandlacy.com

FTP Systems LtdWilson-Barker HouseSevern RoadStourport-on-SevernTel: +44 (0)1299 878558www.ftpsystems.com



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Wall replacementInsulated panel system / Built-up system / Rainscreen and insulated panel

This section of the brochure considers the option of a total refurbishment to an existing wall elevation. This would require full removal of the existing wall envelope back to the existing structural support frame. A list of benefits and possible considerations are listed below when considering this refurbishment option.

Benefits: Wall replacement

The external appearance of the building can be vastly improved.

There is potential to improve the working environment for occupants, with regards to aesthetics, acoustics and climate control.

It is easy to alter lighting configurations to optimum levels i.e. change pattern of windows.

Air-tightness and thermal performance levels similar to new buildings can be achieved, and hence provide a large reduction in operational energy use.

The existing structure is normally suitable for re-sheeting applications, due to the weight of the new system normally being less or equal to that of the existing.

There is an opportunity to alter the building configuration.

Any potentially hazardous existing materials can be completely removed.

Considerations: Wall replacement

Tolerance and condition of existing support frame needs to be assessed to ensure suitability for new cladding system.

The cost of disposal of any hazardous waste should be accounted for.

The disturbance to occupants and operational processes should be considered. Phasing the construction may help this situation.

Access and storage around the building needs to be assessed to ensure enough space for removed materials (skips etc), and taking receipt and handling of the new wall cladding system.

Pimbo Point, Skelmersdale before refurbishment Pimbo Point, Skelmersdale after refurbishment




Solution 1: Trisomet® 333 SystemInsulated trapezoidal panel systemTheTrisomet®333Systemisaninsulatedtrapezoidal wall panel system. Its auto-hesively bonded polyisocyanurate (PIR) insulation core uses the latest foam technology providing enhanced environmental benefits (GWP <5), together with fire performance approved by LPCBandfireresistanceapprovalofupto30minutes insulation and 240 minutes integrity. The panel can be used either vertically or horizontally.

Solution 2: Trisobuild™ SystemBuilt-up systemBuilt-up systems comprise of a Colorcoat® pre-finished steel trapezoidal liner, a Platinum® approved spacer system, an insulation layer and a Colorcoat® pre-finished steel external weathering profile. A comprehensive range of internal and external profiles are available. Systems can be offered both vertically and horizontally with specifications that can provide a wide range of sound reduction and absorption performances and also fire resistance approval of up to 60 minutes insulation and 240 minutes integrity.

Solution 3: Trimapanel® SystemInsulated micro rib panel systemThe Trimapanel® System is an insulated, secret-fix micro ribbed architectural wall-cladding system, which can be used either horizontally or vertically. Its auto-hesively bonded polyisocyanurate (PIR) insulation core uses the latest foam technology providing enhanced environmental benefits (GWP <5) together with fire performance approved by LPCB, and fire resistance approval of up to 15 minutes insulation and 60 minutes integrity.

1,000, 900 & 600 Modules

70 & 90 thickness

Trimapanel® System



Wall upgradeUpgrade from existing Built-up system / Insulated panel system / Brick wall

This section of the brochure considers the option of retaining the existing wall covering and introducing a thermal improvement and new external covering. This could be an upgrade to a non-insulated single skin wall or an existing brick or block construction. A list of benefits and possible considerations are listed below when considering this refurbishment option.

Mersey Docks and Harbour, Liverpool during refurbishment

Benefits: Wall replacement

The external appearance of the building can be vastly improved.

The material costs are usually less expensive to over clad than to strip and re-sheet.

On site installation is fast.

There is minimal disturbance to building occupants.

Insulation can be easily upgraded.

Air-tightness levels can be improved if considered at design stage and existing wall is of sufficient standard.

Upgrades to the fire resistance performance of the wall elevation may be possible.

Considerations: Wall replacement

Upgrading of internal appearance and window configurations is difficult.

Structural calculations are required to prove that the existing frame is satisfactory to take the additional load of the over clad system.

If asbestos cladding is to remain, preparation to fixing areas will be required to prevent contamination when drilling.

Due to the extension outward from the existing finished wall construction, consideration needs to be taken with regards to the existing roof rainwater system, i.e. positions of down pipes and ground level drainage points.




Mersey Docks and Harbour, Liverpool after refurbishment

Solution 1: Single profile over clad systemThe system uses a Platinum® approved spacer support system attached over the existing sheeting and fixed into the existing rail to provide an insulation space with minimal cold bridging. A new insulation layer is added to provide the designed U-value. Finally, the Colorcoat® pre-finished steel external weathering profile is fixed to the new spacer bar. Dependant on the existing support structure the orientation of the new external sheet could either be horizontal or vertical.

Both the U-value calculations and the fire risk analysis can be undertaken by the Tata Steel technical department.

Solution 2: Stratascreen® Facade SystemThe Stratacreen® Facade System can be used to refurbish or reface conventional brick, stone or concrete walls or existing rainscreen systems. Stratacreen® Facade System can be fixed to a new supporting structure attached to the existing wall, or alternatively, the Stratascreen® Facade System can be fabricated to a size that will suit the existing supporting steel work once the old rainscreen panels have been removed. The Stratascreen® Facade System offers exceptional flatness and design flexibility providing an aesthetically dynamic solution.



nwc5

Highlight

Repainting solution

Pre-finished steel provides an inherently flexible and adaptable surface that can be over-painted at any point during its lifetime. The process of over-painting is quick and can be carried out with minimal disruption to the activities within a building.

What to look forWhen to repaint will depend on the location and circumstance of the building and its owners, however the following factors have a significant effect on the long term performance of cladding. UVradiationexposuremakescoatingshardandbrittle over time, limiting their ability to expand and contract with the sheet. Surface moisture and salt spray can penetrate a coating causing discolouration, peeling and rusting whilst barrier and anti-corrosion additives eventually lose strength through natural erosion, part of the self-cleaning process of paint.

Therefore, you need to consider the building location – inland or coastal, whether the surface is a roof or a wall, its colour and the direction it faces since the orientation of a surface to the sundeterminesitsexposuretoUVradiation.Youalso need to know what pre-finished steel your building is clad with as they perform differently.

Leathergrain PlastisolPlastisol is a tough, durable 200 micron embossed finish coating whose long term performance is dependent on a number of key factors,especiallysunlightandUVradiationcausing phases of change over time.

Phase 1: The coating will gradually fade with chalking but will still be adherent.Action: Repainting may be chosen now.

Phase 2: Finecrackingorliftappearsoverprogressivelylarger areas.Action: Repaint to prevent costly phase 3.

Phase 3: If neglected, the steel will corrode and perforate requiring a new sheet.Action: Strip, abrade and repaint.

Pvf2 (PVDF)A smooth finish coating with excellent colour retention. Relatively thin, it has a greater tendency to permeability so is more inclined to break down from corrosion of the underlying steel substrate. The repaint decision time for Pvf2 is generally no longer than 15 years.Action: Power-wash, abrade and repaint.




Delcote® System – architectural coatingChoosing the wrong re-coating material can mean frequent and costly repaints. The Delcote® System is the ideal product for reinstating an effective coating on roof and wall cladding such as Leathergrain Plastisol, where a standard coat 200 micron application will provide protection equal to or, in the case of Pvf2, better than the original product.

• NaturallyresistanttoUVradiationandtemperature extremes, the Delcote® System retains permanent flexibility without cracking or peeling.

• TheDelcote®Systemalsorepelswaterandforms a tenacious, oxygen-free bond that controls corrosion by allowing vapour to vent.

• Noprimersarenecessary.TheDelcote®System does not self clean and contains no bonding or anti-corrosion additives.

Seamsil® System – metal edge protection

Over-painting may be carried out far earlier than may actually be necessary for reasons such as restoring the building condition as a requirement at the end of a lease in the case of self-repairing lease contracts. The system can be:• Carriedoutwithminimumdisruption• Maintainshighbuildingprotection• Quickandeasysolution• CoveredbythePlatinum®SystemGuarantee

for up to 12 years

Built in simplicity makes the Seamsil® System the most cost-effective and reliable cure for cut edge corrosion. Its excellent elasticity ensures optimum performance in the most aggressive environments.

The repaint and edge protection systems described above can be supplied via Giromax Technology Ltd, who are an approved Platinum® System Guarantee supplier.

They will arrange to undertake, free of charge, full existing condition surveys, issuing a comprehensive report that will include:• Detailedrecommendations• Fullprojectspecifications• Mostsuitablequalifiedapplicators• Pre-tenderbudgetcostings

Once let, Giromax will monitor the project installation and provide progress site visits and reporting, ensuring full technical compliance.

Giromax Technology Ltd.EagleHouse,BiltonWay,Lutterworth, Leicestershire.LE174JATel. +44 (0)1455 558969 Fax.+44(0)[email protected]

The need for such repainting solutions is gradually becoming less due to the introduction of new paint technologies such as Colorcoat HPS200Ultra®andColorcoatPrisma®.



Colorcoat® products and servicesUnrivalled performance – guaranteed

Product comparisonThe choice of pre-finished steel for cladding refurbishment is critical as it provides the long-term appearance and function of the building envelope. The Colorcoat® pre-finished steel product range has been extensively tested to provide products that are the best performing on the market, and are available in a wide range of colours and finishes. When choosing which Colorcoat® product to use it is not just the initial cost that needs to be considered, using a product with a longer durability in terms of corrosion, aesthetics and robustness will pay off in thelongertermascanbeseenbelow.ForexampleifColorcoatHPS200Ultra®,isusedinsteadofColorcoat®LG,overa40yearperiod,withnorequirement for costly repaint and annual inspections, the associated costsforusingColorcoatHPS200Ultra®willbe73%lower.

Product comparison table

Product Typical guarantee period/Performance statement

Corrosion performance

Aesthetic performance

Robustness Guarantee Relative 40 year life cycle cost

Maintenance and inspection free

Colorcoat HPS200 Ultra® 40 0 Y

Colorcoat Prisma® 30 +41% Y

Colorcoat LG® 25 +73% N

Colorcoat® PVDF 10-15 +96% N

Best available Well suited Suitable Adequate

Y No maintenance or inspection required for guarantee to be valid.

N Maintenance and inspection recommended and some cladding system manufacturers request documented evidence to support this on the submission of a claim.

Notes

1. Relative life cycle cost is based on a 40 year lifetime using the installed cost of a Colorcoat HPS200 Ultra® cladding system as the base case. Figures are based on 1,000m2 building and are indicative. (Will vary for building size and location).

2. The cost of the coating difference is accounted for in the price per m2 of the installed system but this is relatively small.

3. It has been assumed that a repaint will be necessary at the end of the pre-finished steel guarantee period and that the over paint systems have a 10 year durability. It has also been assumed that building inspection is carried out every 5 years unless the system is maintenance and inspection free. This is a realistic inspection frequency and should prevent any structural failure of the pre-finished steel substrate.

Plate Processing Centre, Cradley Heath before and after refurbishment




Colorcoat HPS200 Ultra®The latest generation product for roof and wallcladding,ColorcoatHPS200Ultra®istheonly pre-finished steel product to ensure your building envelope maintains its integrity and aesthetic appeal for up to 40 years, without ongoing maintenance or inspection costs. We guarantee it won’t let you down.

Key benefits include:• Confidex®guaranteedforupto40years

including cut edges• 40standardcoloursinsolidandmattshades• SurpassesrequirementsofRuv4andRC5

asperEN10169:2010provingoutstandingcolour retention and corrosion resistance for the whole colour range

• OptimisedGalvalloy®metalliccoatingforexceptional corrosion resistance and cut edge protection

• Scintilla®embossedasamarkofauthenticityfrom Tata Steel

• AvailableCarbonNeutral®through Confidex Sustain®

• Allstandardcoloursavailablein small quantities

Colorcoat Prisma®Designed to withstand the rigours of the external environment, versatile, lightweight and strong, Colorcoat Prisma® pre-finished steel is the ideal choice for your building envelope for long lasting colour. With a contemporary new colour range and an optically smooth finish, inspire your imagination.

Key benefits include:• Confidex®guaranteedforupto30years

including cut edges• 27standardcoloursinsolid,metallicand

matt shades• Allsolidandmetalliccolourssurpass

requirements of Ruv4 and RC5 as per EN10169:2010provingoutstandingcolourretention and corrosion resistance

• Reversesidebrandingmakingtraceabilityeasy, so you can rest assured that your building is protected with the highest quality from Tata Steel

• AvailableCarbonNeutral®through Confidex Sustain®

• Allstandardcoloursavailablein small quantities

Colorcoat® LGA leathergrain embossed plastisol product suitable for roof and wall cladding applications where good performance is required at a competitive price. Available with a 25 year performance guarantee.

Colorcoat® servicesConfidex® GuaranteeThe Confidex® Guarantee has evolved from nearly 50 years experience in pre-finished steel development and manufacture. Available with ColorcoatHPS200Ultra®andColorcoatPrisma®,the Confidex® Guarantee is clear and simple to register and can easily be transferred if building ownership changes. Tata Steel are so confident in these products that cut edges are guaranteed for the entirety of the guarantee period and there are no mandatory inspection or maintenance to uphold the validity. Formoreinformationvisit www.colorcoat-online.com/confidex

FormoreinformationaboutColorcoat®productsand services visit www.colorcoat-online.comor call the Colorcoat Connection® helpline on+44(0)1244892434.

Boiler House project during refurbishment Boiler House project after refurbishment



Case study Pimbo PointTata Steel provided a total building envelope refurbishment solution for the conversion of a derelict 9,500m2 1960s portal-framed building into a prime, lettable warehouse/distribution/manufacturing facility at Pimbo Point, Potter Place, Skelmersdale, Lancashire.

Pimbo Point is situated close to Junction 5 of the M58, providing excellent access to the M6.ItisownedbyNationwideCommercialand industrial property investor Spencer Holdings Plc. Spencer owns and manages over five million square feet of industrial and commercial properties with over 1,000 tenanted units.

“The original building was in a pretty dilapidated state,” said Mark Clemson, Commercial Director, EnvelopeProducts,TataSteel:“Ithadanumberof failed areas for both the existing brickwork and asbestos cement sheeting. The air leakage rate was high, at about 27m3/hr/m2 per hour, at a rate of 50 Pa, well below modern energy efficiency standards.”

The project was managed by Greenbrook Construction, Spencer’s own multidiscipline contractor. Company Director and Project Manager Jonathan Halfpenny commented: “I think it’s fair to say in these challenging times that the market is more demanding and where there is more accommodation available, tenants are looking for a quality building as well.” Providing that quality refurbished building, we hopefully are able to set ourselves above the competition and make our units more lettable than others.

“Tata Steel were involved right from the beginning of the project, in terms of discussing what we were trying to achieve with the refurbishment, specifying the products and also utilising their preferred contractors to tender for the project.”

Mitie Tilley Roofing Ltd, Manchester was the appointedinstaller.OperationsManagerEricPodstolec explained how the new roof was constructed: “Our first task was to carefully remove the asbestos sheeting, in accordance with current regulations. We also removed the original steel gutters, which were also replaced, having failed at joints.”

“We then installed a new built-up insulated claddingsystemtotheroofcomprisingofR32external weathering profile in Colorcoat Verso®, quilt insulation and 0.4mm LP1000 liner to achieveaU-valueof0.25W/m2K.Thewallswerealso constructed using the Tata Steel built-up insulatedcladdingsystemutilisingtheirC32external weathering profile, quilt insulation and LP1000linertoachieveaU-valueof0.35W/m2Kin accordance with ADL2.”

A key requirement of Spencer Holdings was to ensure the building complied with the requirements of ADL2 in terms of both thermal and air leakage performance. Tata Steel specified a built-up system that guaranteed the building envelope not only met the necessary building regulations, but that it would also benefit from reduced energy consumption throughout the lifetime of the building.

Given the previous air leakage rate of 27m3/hr/m2 it was imperative that the cladding/interfaces were designed to minimise the air leakage rate.

Tata Steel worked with both Spencer Holdings and Mitie Tilley Group to ensure that the design details used on the project delivered the required improvement to the air leakage rate.

By achieving good levels of air-tightness and thermal performance through the building envelope, it was possible to construct a facility that operates efficiently in terms of both energy usage and CO2 emissions. With environmental considerations, government legislation and faced with escalating energy bills, considering a building’s long term sustainability credential simply makes good business sense.

Tata Steel’s Mark Clemson described one key final touch at Pimbo Point: “Tata Steel offer a service called the Repertoire® Colour Consultancy which is a bespoke colour matching service that we use on a regular basis for certain clients. Spencer Group have a clear identity in terms of their buildings, and I am pleased that we were able to offer a specific colour solution for this project.”

Spencer Holdings Chairman, Jim Spencer, reflected on the final result: “When we do a refurbishment job, we do it to a high standard. In fact, it’s part of our policy to get the finished job looking at least as good as new. Surprisingly, we get people saying ‘your branding is very good’, simply because when they go onto an estate and see the green strip they don’t need to ask whose estate it is, they already know who the owners are.”

Pimbo Point, Potter Place, Skelmersdale

Client: Spencer Holdings Plc

Main contractor: Greenbrook Construction

Installing contractor: Mitie Tilley Roofing Limited

Cladding system: R32 profile (roof ) and C32 profile (walls) and LP1000 liner

Colorcoat® product: Colorcoat Verso® in Albatross and Sargasso




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Trademarks of Tata Steel UK Limited Colorcoat, Colorcoat Prisma, Colorcoat Verso, Colorcoat HPS200 Ultra, Confidex, Confidex Sustain, Galvalloy, Platinum, Repertoire, Scintilla, Stratascreen, Trimapanel, Trisobuild, Trisomet are registered trademarks of Tata Steel UK Limited.

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Care has been taken to ensure that the contents of this publication are accurate, but Tata Steel Europe Limited and its subsidiaries, (including Tata Steel UK Limited), do not accept responsibility or liability for errors or information that is found to be misleading. Suggestions for, or descriptions of, the end use or application of products or methods of working are for information only and Tata Steel Europe Limited and its subsidiaries accept no liability in respect thereof.

Before using products or services supplied ormanufactured by Tata Steel Europe Limited and itssubsidiaries, customers should satisfy themselves as to their suitability.

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