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Fully Soldered Metal Roofing: More Complicated Than You Think

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Fully Soldered Metal Roofing: More Complicated Than You Think Fully Soldered Metal Roofing: More Complicated Than You Think Nicholas Floyd, PE, and Amrish K. Patel, PE, LEED GA Simpson Gumpertz & Heger Inc. 2500 City West Blvd., Houston, TX 77042 Phone: 781-424-9547 • Fax: 781-907-9009 • E-mail: [email protected] and [email protected] S Y M P O S I U M O N B U I L D I N G E N V E L O P E T E C H N O L O G Y • O C T O B E R 2 0 1 6 F L O Y D A N D P A T E L • 1 2 3 Abstract Copper roofing has been used for centuries, particularly on ornate institutional or his­ torical buildings where access and roof maintenance are impractical. When fully soldered, copper roofing can provide a watertight, durable roof with a decades-long service life; how­ ever, these roofs are highly dependent on proper design and careful craftsmanship during installation. The presenters will discuss common issues with fully soldered metal roofing, including improper accommodation for thermal expansion, improper rivet or joint detailing, and drain details for contemporary copper roofs that incorporate membrane underlayment. Speaker Nicholas Floyd, PE — Simpson Gumpertz & Heger Inc. NiCK FlOYD is a senior project manager who specializes in the investigation and remediation design of building enclosures. His past and current copper roofing design and investigation projects include historical and large public structures, including the New York, massachusetts, Kansas, and iowa state capitol buildings. Floyd also has experience design­ ing and investigating various membrane roofing systems, slate roofing, masonry, plaza and below-grade waterproofing, fenestration systems, and architectural terra cotta. Nonpresenting Coauthor Amrish K. Patel, PE, LEED GA — Simpson Gumpertz & Heger Inc. AMRISH PATEL is a senior staff ii at SGH. He specializes in roofing and waterproofing projects and has experience investigating and remediating multiple copper roof and wall cladding systems on large historical and landmark buildings for universities. His work expe­ rience also includes various other roofing and façade systems for a wide range of projects, including residential and commercial buildings, parking structures, plazas, schools, hospi­ tals, and many other structures in both public and private sectors. 1 2 4 • F L O Y D A N D P A T E L S Y M P O S I U M O N B U I L D I N G E N V E L O P E T E C H N O L O G Y • O C T O B E R 2 0 1 6 Fully Soldered Metal Roofing: More Complicated Than You Think INTRODUCTION watertight to provide durable and reliable mit more heat to the work. The solder used Copper roofing has been used for centu­ performance. Fully soldered metal flashing for stainless steel also typically has a higher ries, and metal roofing is still regularly used is often similarly relied upon for watertight melting point, making it more difficult to today, particularly on ornate institutional or performance. The material selection, expan­ keep hot enough to flow through seams. historical buildings where access and regu­ sion detailing, and jointing discussion con­ While copper and stainless steel have lar roof maintenance are challenging. When tained in this paper also generally applies different material properties, they present fully soldered, metal roofing can provide to such flashing, though flashing is not the similar challenges in soldered roofing appli­ a watertight, durable roof with decades- focus of our discussion. cations. For simplicity, the following sec­ long service life; however, these roofs are tions use the terms “sheet metal” or “metal highly dependent on both proper design Sheet Metal Materials roofing” interchangeably to indicate both and careful craftsmanship during instal­ Most architectural sheet metals can copper and stainless steel systems, unless lation. Industry guides—such as Revere’s be soldered (with the correct materials noted otherwise. Copper and Common Sense (C&CS), the and techniques); however, copper (either Copper Development Association’s Copper as uncoated “red” copper, zinc-tin-coated G ENER AL JOINING PROC EDURE S in Architecture Handbook, the Sheet Metal copper, or lead-coated copper) and stainless AND JOINING IS SUE S and Air Conditioning Contractors’ National steel are the most commonly used metals in Sheet metal is durable and watertight; Association’s (SmACNA’s) Architectural soldered roofing applications for the follow­ the problem is, it typically cannot be trans­ Sheet Metal Manual, and the National ing reasons: Both are common construction ported and installed in sheets larger than 3 Roofing Contractors Association’s (NRCA’s) materials readily available in sheet stock, to 5 ft. wide and 10 ft. long. As such, metal roofing manuals—provide designers and they are relatively easy to bend and join roofing performance relies significantly on installers with direction for basic system in the field, and they are well-suited for the joinery between sheets. For watertight details and general joining procedures (e.g., exposed roofing conditions due to their sheet metal applications, these joints are locking, riveting, and soldering), but careful relatively long expected service life and low typically soldered. Sealant or welding can consideration is required to carry these con­ risk of corrosion from atmospheric condi­ also form watertight joints; however, the cepts through to project-specific conditions. tions or contact with other typical construc­ blind application of sealant into locked In this paper, we discuss common pit­ tion materials (e.g., fasteners, flashing, and seams does not provide reliable watertight­ falls associated with fully soldered metal drain hardware). ness, and the sealant’s expected service roof applications, with particular focus on Copper is particularly well-suited for life is typically less than that of solder. joining procedures, detailing for thermal soldered roofing as it is relatively soft and For these reasons, sealant is typically only expansion, and drainage of “bi-level” metal easier to form and work in the field than appropriate for steep-sloped or noncritical roof systems that incorporate a membrane some other sheet metals. Copper also has applications (for example, note C&CS rec­ underlayment. high conductivity, which helps draw solder ommends sealant-filled joints only for roof into joints; and it does not oxidize as quickly slopes greater than 3:12). Welding or braz­ FULLY SOLDERED METAL as some other metals, thus requiring less ing is often not practical for the thin sheets ROOFING APPLICATIONS rigorous cleaning and flux application dur­ used in sheet metal roofing applications. “metal roofing” covers many applica­ ing soldering. tions and configurations, such as field-fab­ Stainless steel requires more patience Soldering ricated standing or batten seam, corrugated and skill to solder than copper, but it can Unlike welding, which requires higher panels, composite metal panels, prefabri­ also be used for soldered metal applications temperatures to melt the base material, cated “snaplock” systems, etc. most metal —particularly where required for aesthetic soldering is done at a lower temperature roofing applications are used on steep-slope reasons or where copper may result in green and involves melting a soft alloy metal that roofs and are constructed with loose locked patina staining on porous materials below. bonds to the base metal. Soldering uses a seams or lapped joints; these systems are Stainless steel sheets are stiffer and more heat source (e.g., a soldering iron or solder­ not watertight and rely on the roof slope and difficult to form and work than copper of ing torch) to apply sufficient heat to the a weather-resistant underlayment material similar thickness. Soldering stainless steel base metal so that the solder flows freely to function. These types of water-shedding also typically requires higher heat due to and can be drawn (or “sweated”) into locked systems are not the focus of this paper. the material’s lower thermal conductivity. or lapped seams. This paper instead focuses on fully soldered Overheating the metal can result in warp­ To facilitate the soldering process, sol­ low-slope metal roofing and built-in gutter ing and buckling, so the soldering process dering alloys must have a relatively low applications. These applications collect or for stainless steel typically requires a cooler melting point and, typically, a lower ductili­ hold water (or ice/snow) and must remain iron in good contact with the metal to trans­ ty than the base metal; unfortunately, these S Y M P O S I U M O N B U I L D I N G E N V E L O P E T E C H N O L O G Y • O C T O B E R 2 0 1 6 F L O Y D A N D P A T E L • 1 2 5 Figure 1 – Pretinning the copper sheet edge prior to seaming. Figure 2 – Soldering a lapped and riveted seam with a soldering torch. traits make the solder weaker than the base metal and prone to failure when exposed to tensile or shear stresses. To prevent joint failure from thermally induced stresses or mechanical loads (e.g., live loads, sliding snow, etc.), soldered sheet metal seams must be mechanically locked or—for thick­ er sheets—strengthened with rivets. These mechanical attachment methods are dis­ cussed further in the next section. Copper roofing applications typically utilize tin-lead alloy solders. Tin is the pri­ mary soldering component, but the lead reduces melting temperature and adds duc­ tility to the alloy. Pure tin or tin-silver sol­ ders are used in lead-free applications and for stainless steel seams; these lead-free solders have a higher melting point and, thus, require more care and patience to sweat into seams, particularly on vertical or sloped applications.
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