Fatra Retrofit Roof Systems - Why Remediating a Metal Roof Shouldn't be a Rip Off!
There are a catalogue of buildings in Australia which are protected by a traditional built up metal roof system, many of which are at the end of their service life and need to be replaced or repaired in some way.
The default approach for asset owners, engineers, designers & builders is to remove and replace like for like, but surely there must be a more efficient & cost effective way without impacting the clients operations....
Fatra Retrofit System
Well, there absolutely is a far more efficient and cost effective solution to remediating a metal, the Fatra Retrofit roofing system! Retrofit systems have been implemented globally for decades due to the substantial benefits they offer compared to traditional metal roof systems. The concept is very simple, keep the metal roof where it is (depending on the condition) and use it as a foundation to substantially increase thermal and waterproofing performance without shutting down your operations!
The Fatra Retrofit system comprises of three basic components. Vapour control layer, insulation boards and our Fatrafol PVC sheet membrane system
The Benefits - Using the Existing Metal Roof
Leaving the metal roof where it is offers substantial benefits for all parties.
Zero Operational Downtime
The old adage "Time is Money" has never been more relevant, clients expectations and demands are high which is why most warehouses and distribution centres run 24/7.
According to a report published on Atlassian's website (link below for reference), downtime costs vary depending on a few factors but the lowest estimated cost of downtime to a business could be $137 per minute ($8,220 per hour, $197,280 per day, $1,380,960 a week..you get the picture)
In most instances where the metal roof is being removed and replaced, it means the client will need to partially or fully shut down operations to enable the works to be completed. The Fatra Retrofit system uses the existing roof to ensure our clients operations continue without any loss of revenue.
Inclement Weather
By exposing the internal structure poses a risk of inclement weather damaging the contents of the building. Whether it's a residential apartment, home or distribution centre the contents hold significant financial value. By leaving the roof in place the structure is still weatherproof, eliminating the risk of weather damage.
Thermal Performance
There is no secret that externally insulating structures offer superior thermal performance as it proactively insulates the structure and prevents the conditions externally from migrating internally, its basic building science.
Metal roof systems typically implemented "Blanket Insulation" rolled over the purlins prior to the metal roof being implemented. What this results in, is the insulation is compressed along every purlin rendering it almost obsolete thus reducing thermal performance, increasing thermal bridges and promoting condensation.
The Fatra Retrofit system implements a rigid insulation board (Flute Filler) between the metal roof profiles, then a secondary insulation board to create a flat thermal insulation layer without thermal bridges.
Elimination of Condensation
Warm roof systems where insulation is implemented the external structure in almost every scenario eliminates the risk of interstitial condensation due to effectively reducing the temperature differential.
This dynamic provides consistent regulation of temperatures and conditions to the entire roof structure, including the space below. When the roof deck and the space beneath it are kept at a consistent level the risk of condensation forming due to temperature differences is minimised.
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Another contributing factor is preventing thermal bridging, something which isn't possible with a metal roof system. With Fatra Retrofit roof systems implementing insulation on the exterior of the roof , we see a huge reduction in thermal bridging, which occurs when heat escapes through the roof structure and causes cold spots where condensation can form
Below are 2 Condensation Risk Analysis Reports in accordance with ISO 13788:2002 provided by Kingspan Insulation for a project in Melbourne. The reports are for one project, one with the existing metal roof as it current is and the other with 60mm Kingspan Therma TR26 and Fatrafol membrane Retrofit system installed above.
The modelling, kindly provided by Jeremy Robb and his team, indicates that the dew point is likely to occur on the underside of the roof sheeting when it hits a temperature of 7 degrees. Moisture begins to accumulate at this interface in May, and does not start drying out until October.
The Condensation Risk Analysis using a combination of a 50mm R1.3 roofing blanket in conjunction with 60mm Therma PIR insulation & Fatrafol PVC membrane above the roof deck. You can see in this assessment that, thanks to the thermal performance of the 60mm of PIR, the temperature of the roof sheeting is approximately 16 degrees. By increasing the temperature of this surface, the modelling indicates that dew point is unlikely to occur.
A Fully Warranted Waterproof System
Metal roofing systems are extremely reliant on back trays & flashings for penetrations, that silicone sealed, butyl taped and fixed using self sealing fixings. All of which are not warranted and very reliant on continual maintenance to prevent water ingress.
Fatra Retrofit PVC membrane systems are connected along all joints, laps, penetrations and detailing via hot air fusion welding. This creates a physical and permanent monolithic waterproof system that is warranted for 20 or 30 years. By implementing a Fatrafol membrane system it eliminates exposed fixings, reliance of silicone seals, cover flashings and back trays and will protect your assets for 40/50 years with little to no maintenance!
Sustainability
Fatrafol PVC membranes come with a whole heap of independent accreditation such as Environmental Product Declarations (EPD), BREEAM, BBA & Solar Reflectivity (SRI), all of which contribute to Green Star requirements.
Over the next 5 years, The Australian Government are introducing phased Mandatory Climate Related Financial Disclosures which orientates around companies environmental impact, responsibility and resilience to climate change.
By building, implementing or creating more sustainable, thermally efficient properties which not only provide a more comfortable living or working environment internally, they substantially reduce energy consumption, save money on air conditioning costs and contribute to the overall Net Zero goal going forward.
Fatra Service
If you have a project that has an existing metal roof that is at the end of its service life and shutting down your operation is out of the question. Contact Fatra Australia for a free design consultation, this will allow us to ascertain project specific detailing and performance requirements and enable us to provide a full project specific specification.
Remember, remediating your metal roof doesn't need to be a rip off! Let us save you time and money with the Fatra Retrofit metal roofing system!