ISSUE 11

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With a career spanningthirty years, specialising incommercial buildings,Alan Palmer’s design flare,experience and empathywith the ever changingcommercial developmentis positively huge.His attention to detail andthe use of a variety ofmaterials, in combinationwith metal claddings,caters for individualidentity, functionality andvariety of the occupant’sbusiness. The accent, forAlan Palmer, in this marketsector is designing forsustainability.In the following article heshares his insight on thedynamics of commercialdesign with a variety ofexamples from hisextensive portfolio.

Whilstconsidering thecontent of thisartlcle I becameaware of thedifferences inthe dynamics ofthe design andconstructionphases of thebuilding process

between commercial and industrialprojects and some other types ofbuilding.

A residential or institutional typeproject tends to be fairly static inits design dynamics. The designsolution is a response to a specificbrief provided by the client, whousually has definite ideas of whatthey want or don't want, and to theparticular features and constraintsof the building site, aside fromcompliance issues, which arecommon to most building types.

C O N T E N T I S S U E 1 1

Below is a brief introduction to the2006 executive of The NZ MetalRoofing Manufacturers Inc. It is intended that Scope berepresentative of the industry andtherefore material of interest iswelcomed from all sectors of thebuilding industry be it design,research, manufacture or construction.

Darrell Back, PresidentNZ Metal Roofing Manufacturers Inc.Managing Director of the SteelformGroup of Companies.

Immediate past PresidentTony Barbarich: Director of BusinessDevelopment for Metalcraft Industries.

Executive Members:

Gary McNamara: Sales and MarketingManager for Gerard Roofing. NZ/Aus.

Philip Meyers: Marketing Manager ofRoofing Industries Limited.

Warren Oliver: Managing Director ofFranklin Long Roofing.

Gregg Somerville: Marketing Managerfor Dimond.

Mark Winnard: General Manager for Steel & Tube Roofing Products.

If you would like to submitmaterial please contact anymember of the executive orthe publisher.

Advertising and editorial opinionsexpressed in Scope do not necessarilyreflect the views of the NZ MetalRoofing Manufacturers Inc., it’sexecutive, committees or publisherunless expressly stated.

PAGE 3With a career spanning thirty years architectAlan Palmer shares his insight on the dynamicsof commercial design.

PAGE 10Chris winning the title “2005 RegisteredMaster Builder of the year - Commercial” forhis work on Wilderness Lodge designed byarchitect Gary Hopkinson.

PAGE 13Gerard Roofing outline the requirements forentries in the Gerard Roofing 2006 DesignAwards.

PAGE 15Tom Evison, of Technical Press, reports onSusie Lees Nelson home, designed by architectHelen Richards, and the increasing trendtoward sustainable design.

PAGE 19Builder Grant Richards and his wife Amanda’snew home on the Hibiscus Coast byarchitectural designer Michael Manning.

COVERWilderness Lodge, Arthur’s Pass.

ARTICLESPAGE 17 The hazards of attachments to metalroofs. PAGE 21 Hopkinson Team Architecturewinners in the NZIA Resene Local awards forarchitecture.PAGE 22 Gerard Roofs new website. Designedto make design easier.

Scope is the official publication of The NZ Metal Roofing Manufacturers Inc.Executive Officer:Peter AtkinsonPrivate Bag 92 066, Auckland.DDI Ph: 367 0934, Ph: 09 367 0913Managing Editors: Gary McNamara, Warren Oliver,Gregg Somerville.Published by ICG Limited. 57 Glendhu Road, Glenfield,Auckland. Ph: 09 444 2424. Fax: 09 444 2524e-mail: conceptart@xtra.co.nz

visit our website at:www.metalroofing.org.nz

In the commercial field numerousparties can be involved, eachoperating with a different agenda inrelation to the project. Any one of,or all of, these parties may, andoften will, have an influence in thedecision making process in thedesign and construction of acommercial building.

One of the aspects of designingbuildings of this nature, beingbuildings for business, reflects theevolution of that business so thebuilding requirements vary. This isalso true of other building types butI believe is more so in thecommercial field. As businessesgrow, take over other smallercompanies, retrench or refocustheir activities in different areas, sotheir building needs change. Moreor less space may be required,company identities morph over timeas takeovers and mergers occur.

As more companies lease ratherthan own the buildings they occupy,the building ownership may alsochange. Add to this the fact thatmany buildings are oftencommissioned by developers,whose objectives in the processare often at variance with those ofthe investor or the end user oroccupier, and a extremely dynamicprocess exists which can make lifeinteresting for the architect.

Having specialized in this type ofbuilding over a period of somethirty years and having witnessedand been involved in the evolutionof many buildings to the specificrequirements of new occupants orowners. It has been evident thataside from the obvious aspects ofarchitectural design, which areusually to achieve attractive,efficient and cost effectivebuildings, which are safe and userfriendly for the occupants, anotherimportant and usually unstateddesign criteria is flexibility. Flexibilityto accommodate evolving needs.

In commercial building terms:

Designing with site area capable ofaccommodating future growth,either in floor area, staff numbersor both.

Zincalume® products have beenput to a variety of creative usesfrom entry shelter and security toprivacy for courtyard areas.

Designing to enable aggregation ofinitially separate tenancy units intolarger units to enable floor area tobe increased or to subdivide largerareas into smaller tenancy unitsincorporating self contained officeand amenities facilities.

Designing to provide the ability tosubdivide initially single ownershipmulti-tenanted developments intounit titled separate ownership unitsenabling part of a largerdevelopment to be sold orrefinanced.

Designing with the potential toaccommodate changes of use.

In other words designing forsustainability.

TYPICAL PALLETTE OFMATERIALS:

Building materials used in most ofthe buildings featured have beenselected with the criteria of attractiveness, durability, quality andcost effectiveness. Large roofareas utilize roll-formed lightweightZincalume® steel roofing andexternal wall areas similar roll-formed Colorsteel® metal cladding.

Roofing generally is 0.55 mm deepprofile trapezoidal section overdouble sided foil insulation ongalvanised wire netting on coldrolled galvanised steel purlins.Translucent rooflight strips arematching in profile to the roofingmaterial.

Wall cladding is 0.40 mm mediumprofile trapezoidal sectionColorsteel® on cold rolledgalvanised steel girts. Gable andeaves cladding is 0.40 mmcorrugated profile Zincalume® steelon timber framing. The horizontalbreak between wall and gable areasis intended to reduce the mass ofthe gable end of the building whichis usually facing the street and tomitigate the “shed” look whichwould otherwise be apparent.

Office façades are cladpredominantly with prefinishedcomposite aluminium panels fixed

over fire retardant breather typebuilding wrap on timber framing.Panels joints are sealed with Siliconsealant.

Small areas of selected stone veneerare utilised at some entries to providea feature material in relatively smallquantities to achieve maximum costeffectiveness and yet achieve a highquality appearance with lowmaintenance. Other feature materialsused in detail areas include curvedcorrugated profile Zincalume® canopyroofs on roll-formed, zinc sprayfinished, steel pipe frames; corrugatedprofile perforated Zincalume® screenfence infill panels on galvanised steelpipe frames and shiplap profile clearfinished Rimu boarding to entry canopysoffits.

EMERALD FOODS LTD.

Emerald Foods is a typical example ofthe evolution of a project. Initiallydesigned as a front site, spec.development commissioned bySynergy Properties Ltd. A generalpurpose spec. building of 2,547 sq.mwas designed to achieveapproximately 57% of the ultimate sitedevelopment potential with emphasison quality in both design andconstruction.This created the potentialfor either securing a sale or lease ofthe initial unit to a company looking toprovide for future growth or enabling asecond unit to be built on theremaining undeveloped site.Thebuilding was bought on completion bya family trust and leased to ChateauIce Cream Ltd. who had secured thelicence to manufacture Movenpick icecream in New Zealand in addition totheir own Chateau product range.Theinitial shell building was then fitted outto accommodate the new productionfacility, a warehouse area for storageof packaging materials etc. and theaddition of a 977 sq.m freezer storewith an environmental load out facility.The planning,design and constructionof the fit out and freezer extensionwas completed within 6 months.Subsequently Chateau Ice Cream Ltd.was sold and the company is nowEmerald Foods Ltd. Recently thefreezer area has been almost doubledto 1,884 sq.m.to service increasedexport production.

Emerald Foods main entry to theiroffice complex combines aluminiumpanels, stone and Zincalume®which is effective and cost efficient. 4

TURNCO ENGINEERINGLTD.

The brief for the projectencompassed the design of a totalsite development concept,maximising the developmentpotential of the 6,836 sq.m site.Buildings were to incorporating anew factory, administrative officesand staff amenities for TurncoEngineering Ltd. totalling 1,750 sq.min area, as well as a futurewarehouse for steel storage and asecond separate tenancy unitinitially for lease and for companyexpansion in the longer term. Theinitial office and amenities facilitieshave been designed to allow for theaddition of a future first floor toaccommodate expansion of theoffices and amenities. To service theproposed future site development,75 carpark spaces will ultimately beprovided.

The nature of the work undertakenby Turnco Engineering Ltd.necessitated heavy duty, highcapacity material handling equipmentcovering the entire area of thefactory floor. The scope of workincluded design and installation oftwo gantry cranes running the fulllength of the factory area. The maingantry hall houses a 15 tonnecapacity crane and the lean-toroofed side hall is served by a 5tonne crane.

The main gantry hall component ofthe building, housing the 15 tonnegantry crane was purchased by theowners, dismantled and transportedfrom Huntly to the Takanini site. Theportal frame columns which wereoriginally 7.0 metres long, werelengthened by 3.0 metres toincrease the maximum hook heightof the crane to 8.0 metres. Eachcolumn sits on a 2.5 metre x 1.5metre x .5 metre reinforced

concrete foundation pad and isstiffened by concrete encasementto a height of 3.0 metres abovefloor level.

The greatest challenge in the projectwas to design sliding doors whichwould allow the main gantry craneto travel out beyond the front endwall of the building to allow forloading and unloading of equipmentin the front yard area. This wasachieved without a top guide trackby cantilevering the top support foreach door panel from the adjacentdoor and wall panels. The resultingdoorway provides an 8.00 metre x8.00 metre clear opening. The steelRHS section door frames werefabricated by Turnco EngineeringLtd. and are clad with powder coatfinished corrugated profileZincalume® steel.

STIHL NZ LTD.

The commission for the design andconstruction of new headquarters forStihl NZ Ltd. came by way of theexposure and recommendationsgenerated by other previous highprofile projects such as Yamaha andMovenpick and is one of the mostrecently completed projects.Designed in conjunction with theGerman based chief design engineerresponsible for overseeing allcompany projects worldwide, thebuilding is the most highly spec'dproject undertaken to date and hasreceived very favourable commentfrom management, staff and visitors.The building accommodatesshowroom, administrative offices,training room and acousticallyinsulated workshop, meeting rooms,staff amenities and high studwarehouse incorporating the latest

computer operated spare partscarousels for high efficiency pickingand distribution of parts orders. Thesite area will allow for futureexpansion of the warehouse area,which is fully insulated. The buildingis designed to cater for all potentialmeans of transportation of products,both inward and outward,incorporating a ramped truck dockwith scissor lift and dock levellerbays, as well as side loading andend loading level entry doors.

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4 INDIVIDUAL TENANCYUNITS.

Designed as an investmentproperty for a family trust, the plan,on a corner site of 4,012 sq.m. wasdesigned in consultation with theleasing agent to achieve a mix ofindividual floor areas as well asmaximising the road frontageexposure for each unit. Unit 1,fronting Cryers Road is 1,024 sq.m.in area , units 2,3 and 4 frontingEchelon Place are 480 sq.m : 219sq.m and 279 sq.m in arearespectively. This allowed the unitsto be marketed to suit varyingtenant requirements and createdthe potential for some of thetenants to take up a larger orsmaller or even an additional unit inthe future if circumstances allowed.This project incorporated the use ofa new reverse profile ribbedColorsteel® wall cladding, whichhas received favourable feedback.

VIDAK.

This project began as a generalpurpose investment buildingcomprised of 315 sq.m Offices,101 sq.m Staff Amenities and 1,980sq.m Factory- Warehouse. The briefcalled for the building to present anattractive, high quality facade to thestreet which would appeal to aprospective tenant company andwould reflect and express theircharacter and focus.

Vidak Davies Ltd. a company highlyfocused on innovation and qualityentered into a lease agreementduring the early stages ofconstruction. In addition to theadministrative facilities offered in thebuilding, Vidak required a dedicatedshowroom area and an additionalarea to accommodate future officeexpansion. This was accomplishedby creating a mezzanine floor withinthe factory - warehouse with thearea below forming the showroomadjacent to the reception. Thisprovides visitors direct access to theshowroom from the reception. Theoriginal open office area was

Architect: Alan PalmerAucklandTelephone: 522 4324Mobile: 0274 769 673E-mail: alan.d.palmer@xtra.co.nz

Feature materials :Painted rolled steel portal frames. ( Interior ).Corrugate Zincalume® steel gableand eaves cladding.Colorsteel® metal wall cladding.Zincalume® steel canopy roofing.Painted, zinc sprayed rolled steelcanopy frames.Powdercoat finished galvanisedsteel roller shutter doors.Composite aluminium panels toOffice facade.Galvanised steel courtyard screenfences.

subdivided to provide a meetingroom and several individualexecutive offices. The mezzanine floor wasconstructed using Speedfloor, afloor system which consists of areinforced concrete slab, poured in-situ, over temporary plywood form

work panels supported onremovable steel bars. A suspendedceiling system was installed to theperimeter of the showroom, thecentral area being left open,exposing the Speedfloor system asa feature. The staff cafe opensonto a courtyard which is screenedfrom the carpark with perforatedmetal panels fixed to tapered,galvanised mild steel angle posts.Externally colours arepredominantly neutral, in tones ofgrey, expressing the inherentnature of the materials used andwhile internally, strong featurecolours are used against a whitebackground to create a stimulatingworking and display environment.

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In the mountain beechforest surrounding Arthur’sPass, on a 3,000 hectarenature reserve and highcountry Merino sheepstation, is WildernessLodge. Here there is astrong emphasis onconservation to ensure thesurvival of rare andendangered flora andfauna. Guests have a rareopportunity to explore andexperience theunsurpassed beauty of thisnatural paradise. OwnersDr Gerry McSweeney andAnne Saunders were keento expand the wellestablished lodge (built in1996) by adding four luxuryunits. Their vision, theinspiration of architect GaryHopkinson and thecraftsmanship of builderChris Yeats resulted inChris winning the title“2005 Registered MasterBuilder of the year -Commercial.” A welldeserved result which wasachieved despiteenvironmental and weatherconstraints for allconcerned.

The project brief required four newguest units to be located on ahillside, overlooking a glade in thebeech forest, with magnificent viewsof the Southern Alps beyond. Eachunit was to have unimpeded viewsbut was also required to offerprivacy to guests. To minimise theimpact and protect the integrity ofthe existing forest landscape theunits were “stacked” with the lowerunit being excavated into the hillsidereducing the overall height.

A WINNER IN THE

WILDERNESS

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Whilst the exterior may reflect theraw character of the New ZealandWest Coast the interior introducesguests to a world of sumptuouscreature comforts. A cosy refuge inthis mountainous retreat.

Each unit has uninterrupted viewsof the mountain divide from the bed(elevated on a plinth), the loungeand bathroom facilities. From thedouble glazing, the gas firedheating and high spec fittings thisproject offers absolute comfort andluxury to guests.

Chris Yeatsbegan workwith excavationof the sitewhile panelswere beingpre-cast inGreymouth.The weatherwas unreliablewith several

heavy snowfalls slowing progressand making access fromGreymouth difficult. The buildingsite was in the hillside, with atanked retaining wall forming therear wall of the building. Theconcrete wall panels were sized bythe design engineer to theconstraints of a 30-tonne crane,and its positioning on site, thenbuilt in Greymouth and transportedto the site via Arthur's Pass wherethey were lifted into place. Thiswas particularly difficult, with nodrive-on access to the site,requiring all materials, including thepre-cast panels, to be craned infrom an access point above thesite.

The extensive Colorsteel® Enduraroof and cladding was supplied andfixed by Stratco. “We took greatpride in our involvement with thisproject,” says Mark Moore ofStratco. “The cladding and flashingsystem was innovative and involvedbut the result superb.”

Due to rain and snow the wallframing, while kiln dried, neededconsiderable heating to dry oncethe building was closed in. Despitethe weather the buildings werecompleted in the contract period offour months.

A tribute to all concerned.

Gary Hopkinson,architect, has a specialaffinity with NewZealand’s West Coast andthis is confirmed by thejudges comment, “Thisbuilding blends into thelandscape so effortlessly,it could almost havegrown from the ground itsits on.” In addition the

judges credit the skills of builderChris Yeats, “The builder hasexhibited extreme attention todetail, innovation and organisationin testing circumstances. Despitethe building process thesurrounding landscape isuntouched. This faultless propertyis a truly magnificent piece ofconstruction.”

A result, Gary Hopkinson attributesto, “A close working relationshipbetween client, contractor andarchitect.”

The exterior design was keptrelatively austere using simpleforms created with horizontal andvertical colorsteel®. The intentbeing to emulate the “feel” of theiconic New Zealand bush hut. Alimited pallet of muted green incontrast to natural oiled timberechoes the beech forest surrounds.

The units are divided by a stairwaywhich enhances the “outdoor”ambience and offers entry shelter,separation and privacy to guests.

Top left: Colorsteel® and matchingjoinery details provide anunobtrusive frame in this naturalenvironment.

Top right: The simple formreminiscent of the bush hut revealslittle of the interior luxury to bediscovered.

Above: Clever design providesguests with private, panoramicviews from every area of theseluxurious units. From the lounge tothe shower, bath and bed.

Clients: Dr Gerry McSweeney andAnne Saunders. Wilderness Lodge

Architect: Gary HopkinsonHopkinson Team Architecture,Greymouth.Telephone: 03 768 4141Fax: 03 768 5922E-mail:hopkinson@teamarchitecture.co.nz

Building: Contractor and winner ofthe 2005 Registered MasterBuilder of the year - Commercial.Chris YeatsChris Yeats Builders Ltd.Greymouth.Telephone: 762 6040Fax: 762 6090Email: chris@cybl.co.nz

Engineer: John Mackenzie ofELMAC Consulting.Telephone: 03 351 3223

Manufacturer cladding & roofing:Stratco (NZSI) Ltd.Roofing & Cladding Contractor:Stratco (NZSI) Ltd.55 Hands Road, Christchurch.Telephone: (03) 338 9063Mobile: 021495533E-mail: mark.moore@stratco.co.nzProfile: Corrugate. Color: Colorsteel® EnduraRivergum.

Phographer: Stewart Nimmo.

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THE GERARD DESIGN AWARDS

REWARD DESIGNERS,BUILDERS AND HOME OWNERS

In 2001 Gerard Roofs implemented their awardsprogram. Five years later the program continues to growwith entries coming from every sector from North andSouth Islands of New Zealand, Australia and PacificIslands.“The success of the program is, in part, due tothe equal recognition of the three primary participants,”says Grant Williams, Business Development Manager forGerard Roofs.“Whilst we never under estimate designskills we see the synergy between designer, owner andbuilder as an integral part of attaining excellence. A bigplus, there’s no cost to enter and everyone involved winsthe same travel pack as first prize.”

The program is divided into severalcategories giving opportunity toboth new home design (under$250,000 and over $250,000)renovation and commercial. Theonly prerequisite is that the buildingmust have used one of the Gerardroofing products. The product andcolour range is extensive and

allows considerable scope forcreative flare from traditional tileto shakes and shingles. Alloptions can be viewed on theGerard website atwww.Gerardroofs.co.nzwhich provides homeowners and designerswith specific productinformation. (details onpage 21)

From all the entries receivedfinalists are chosen and thesupreme winner is judged fromthese. Judging is impartial and doneby a range of industry experts.

Who wins?There are 3 categories which givesdifferent types of building projects afair chance of winning.Each rewards different participants.

■ New Homes enter for theSupreme Winner Award. TheDesigner, Builder and Owners eachreceive the travel prize.

■ Refurbishment and renovation.The home owner is awarded thetravel prize.

■ Commercial. The architect isawarded the travel prize.

What is the prize? The prize for the home voted TheSupreme Winner is three travelpacks each to the value of$2000.00. For refurbishment the ownerreceives the travel pack of$2000.00

In commercial the architect receivesthe travel pack of $2000.00. To make the prize option as flexibleas possible Gerard contribute thistowards any travel destination ofyour choice within a 12 monthperiod of winning the award.

Who can enter?Anyone involved in the design,planning, building or ownership ofthe home or building can enter. Aspart of the entry condition GerardRoofs retains the right to take andpublish photographs of thecompleted building which requiresthe written consent of the owner.

The value of being seen.The Gerard Design Award programwas established to achieve twoprimary objectives:

1. As a marketing tool to illustratethat a Gerard Roof choice wasappropriate to a very wide range ofdesign from an aesthetic andfunctional perspective.

2. To give recognition to thosearchitects, designers and homeowners who chose to use theseproducts.

Where ever possible Gerard Roofspromotes excellence in design andthose who contribute towards theend result. It is difficult to quantifythe value of being seen, thealternative is being invisible. Ourrecognition of excellence isdesigned to promote those who areproud of their product and is notlimited to those who are winners ofawards but to all of the outstandingprojects entered.

How to enter.To enter you need only supplyreasonable photographs, which bestillustrate the design and homefeatures, and a brief designsummary. Gerard have a specificentry form, which simplifies thedetails required, and that is availablefrom all distributors, from theirwebsite ( www.Gerardroofs.co.nz ),by emailing info@gerardroofs.co.nzor calling 0800 104 868.

Left: Exceptional and yetvery different homessubmitted for the 2006 Awards from theportfolio of Lee Roofing, Hamilton.

Entries can use any ofthe extensive rangeGerard Roofing profilesin a variety of coloursand textures

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Further evidence that stylishsustainability in affordableresidential housing has becomemainstream in New Zealand ispresented by the latest homedesigned by acclaimed Nelsonarchitect Helen Richards.Situated in Mapua, west of Nelson,the new two-storey passive solarhouse sits well with its ruralsurroundings. Incorporating manyfeatures to enhance the health ofoccupants and environmentalperformance, the building isdesigned for year-round comfortand warmth - almost entirely fromsolar energy.Richards oriented this 3-bedroomhome 30 degrees west of truenorth which, she says, is veryefficient. Following principles ofbest solar performance, floors areconcrete, extensive windows arenorth-facing and there is doubleglazing throughout. Cooling andventilation are also passive throughjudicious use of windows andblinds.The design incorporates rainwatercollection, solar hot water andmajor use of sustainably-sourcedmaterials including native timbers.Says Richards: “We've taken thelevel of comfort very seriously withthis house. It also hasenvironmentally very smartperformance and will save a lot ofmoney on energy costs forheating”.Despite frosts in winter, spaceheating will seldom be necessaryand annual savings could amount to$500. Provision is included for asolid fuel burner to be added ifdesired.Further features of sustainabledesign include management ofnoise, minimal use of materials

containing chemical toxins, andabsence of mould due tocontinuous warmth and goodventilation. Maximum use is madeof natural lighting to give the homea powerful “feel-good” factor.Coloured concrete flooring isinsulated and provides passive heatstorage. The low maintenancesurface is sealed with a low toxicityhard floor oil form BioPaints. Toiletsuse minimal water reducing waste inthe dry climate and grey water is re-cycled to feed trees in thelandscaped area surrounding thehouse.

British-qualified Helen Richardsattracted national attention for thefirst sustainable house shedesigned and built in New Zealand -a single storey combined home andoffice in Nelson. That building andthe new two-storey home both offera strong element of surprise whilebeing contemporary, durable andminimizing greenhouse gasemissions.Data loggers are installed to providestatistics as evidence of highperformance year-round. Richards'company, Powered Living Ltd,actively promotes the architecturaldesign concept of her sustainablehomes.

Client: Susie Lees

Architect: Helen RichardsPowered Living Ltd.Nelson, New Zealand.Telephone: 03 548 1680 Mobile: 021 436 314

Contractors:Kevin Mayes.Telephone: 021 139 1706Daniel Whitten.Telephone: 03 543 2676

Roofing and Cladding:Contour, Nelson.Telephone: 03 546 4260Profile: 5 Rib Colorcote®

and Zincalume® Corrugate.

SUSTAINABILITY WITH STYLE

Tom Evison, of Technical Press, reports on Susie LeesNelson home, designed by architect Helen Richards and

the increasing trend toward sustainable design.

Landscaped two-storey Mapuahome packed with sustainabilityfeatures.Passive light, heat andventilation bring convenienceand cost savings.

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THE HAZARDS OFATTACHMENTS TO

METAL ROOFSLike most things exposed to theharsh outdoor environment in NewZealand, metal roofs are affectedby how they are maintained.Regular cleaning and painting whenrequired will increase the roof life.Equally, lack of cleaning or carecan reduce its service life. Someattachments quite commonly usedon or with roofs can significantlyshorten the life of the roof if notinstalled correctly, if made ofincompatible materials or if theycreate a permanently wet area.

A metal roof will remain corrosionfree and resistant to perforation fora long time provided it is washedfreely by the rain and can dry, hasno areas in which corrosion-causing deposits can build up, isnot in continuous contact withincompatible metals and hasregular routine maintenance carriedout.

The sort of things that can reducethe life of the roof are continuingpresence of leaves and dust or dirt(particularly when wet), damage oradditions allowing ponding(permanently wet areas),installation of vents, chimneys,gutters, down pipes running on toa roof, gutter protection systemsor any other devices which leaveincompatible materials inpermanent contact with (or runningoff onto) the metal roof.

The Zincalume® coated steelcurrently used in the majority ofmetal based roofs has greatlysuperior durability compared withthe old galvanised steel. Howeverit does have the disadvantage thatthe adverse situations listed abovecan have an even greater andmore rapid negative effect on its

life than on the life of galvanisedsteel. Note that steel guttering,with either metal coating, can alsosuffer from these hazards,particularly from build-up of dampmaterials and from ponding.

The correct care andmaintenance of a metalroof or gutter quite simplyinvolves avoiding damagecaused by:-

■ Ponding - allow no dents orareas where water can restpermanentl. Provide correctsloping of flashings etc.,ensuringthe product has the required fallfor all water to drain.

■ Build up of atmospheric dustand dirt - washing by rainfall withthe ability to dry out (and beingprepared to wash unwashed areaswith a hose and soft brush).

■ Incompatible materials - either inwet contact with the roof or waterrunning off such materials onto theroofing.

■ Attachments installed to the roofwith incorrect fasteners.

■ Gutter debris - clearing outgutters and avoiding build-up ofleaves etc

Typical examples of thingswhich are likely to causedamage are:-

■ Water from copper spoutingrunning off onto Zincalume® basedroofing, or splashing up onto theunwashed underside of the bottomof the roof;

■ Walking or loads from e.g. air-conditioning units causing dentingand ponding;

■ Solar water heaters, gutterprotection systems, satellite dishesetc fastened onto the top surface ofthe roof with incompatible fasteners, causing incompatible run-off, creating permanently wet areas,creating dirt traps for corrosivebuild-up, or preventing rain-washing;

■ Penetrations (skylights etc),chimneys or flashings not angled soas to prevent ponding and dirt build-up.

■ Tie wires or braces for pipes,aerials or flues made ofincompatible materials and/orattached with incompatiblefasteners.

There are of course many examplesof all these things that have notcaused problems and also quite afew where damage has occurred,sometimes requiring roofreplacement at significant cost.Damage can sometimes take manyyears to show, so even in caseswhere no obvious damage has sofar occurred, if one of the abovepoor practices has occurred the lifeof the roof and or guttering systemis still likely to be impaired andfuture problems may yet arise.

The manufacturers of unpainted andprepainted steel or aluminium roofsoffer good warranties but this doesdepend on the roofing not beingdamaged by such hazards as thoselisted above. Failures of roofing or

Metal roofing has beenused extensively in New

Zealand for over a hundredyears. In certain locations

(even some exposedsituations i.e. close to the

coast) the life ofgalvanised steel roofs has

exceeded one hundredyears, through appropriate

maintenance and byminimising any damage to

the roof caused by varioussorts of interference.

guttering caused in this way will notbe covered by the manufacturer'swarranties, and so any suchfixtures, devices or systems mustbe specified, detailed andmaintained so that they do notimpact on the durability of the roofor invalidate the warranty.

Note that the illustrations includedhere are schematic, not necessarilyto scale, and show what NOT to do.Refer to the NZMRM's NZ MetalRoof and Wall Cladding Code ofPractice for detailed methods forCORRECT specification andinstallation of roof penetrations,flashings and attachments, includingwhich materials are compatible /incompatible with each other.

The COP is available from the:NZ Metal RoofingManufacturers Inc.Private Bag 92 066AUCKLAND.

Indicates possible damagedue to water runoff fromincompatible materials.Indicates areas of potentialdamage.

1817

Grant Richards was the maincontractor/builder of the Red BeachPlaycentre and during the processof building, he and architecturaldesigner Michael Manningestablished a good workingrelationship.

At the time Grant and his wifeAmanda where planning to build inWeiti Views on the Hibiscus Coastand they invited Michael to design ahome for their site. The result wassupurb making the most of thelimited space the site offered. Itachieves its objectives of providinga work base for Richard’s businesswithout intruding on the comfortand aesthetics of the family homeand activities

Weiti Views is a new subdivisionand the Richards site was one ofthe most elevated with a panoramicurban outlook and distant seaviews.

The shape of the house wasinfluenced by the desire to catchthe views, which are easterly, andprovide a sheltered northerlyoutdoor area for entertaining and toprovide a safe play area for theRichards young family.

The Richards wanted a home thatwas both practical, constructed oftraditional materials, but with anaesthetic difference.

A combination of cedarweatherboards and plastercladdings, with cedar shingles tothe gables, topped off with acorrugated colorsteel® roof was

chosen. The shape of the house, itsroof lines and choice of materialsgave it the point of difference thatthe Richards where looking for alongwith a commanding presence on thecrest of the subdivision.Being single level with good indooroutdoor flow the home is very userfriendly for its young family. Thefamily room opens directly to thechildren's outdoor play area allowinggood visual contact from the kitchen,dinning room and master bedroom.

Grant has an enviable “buildersgarage” made to order with a 3.0mstud and doors for clearance shouldthe work 4WD have anythingstrapped to the top of it. Amplespace for two more cars, materialsand tools... it also features the pooltable which is currently used for“tradesman bonding” on Friday afterwork.

Client: Grant and Amanda Richards.

Architectural Designer Michael Manning.Manning Architectural Design.Red Beach, Whangaparaoa.Telephone: 09 426 2255Mobile: 027 280 8689

Main Contractor: Grant Richards.GDR Builders.Telephone: 09 426 2617Mobile: 027 496 9730

Roofing Manufacturer:NZ Steel and Tube.Auckland.Telephone: 09 274 4056Roofing Profile: Custom Orb

Roofing Contractor: Scott Riach.Rodney Roofing.Telephone: 09 424 2393

A private, safe and sunny northfacing spot to enjoy the view opensfrom the dinning room and familyroom. Above: A visable safe areafor the kids complete with swings,trampoline and even a camp out.

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BUILDING A GOOD WORKING

RELATIONSHIP

Gerard Roofs website:Designed to make designeasier.As a result of the 2004 BuildingAct Local Authorities now demandeven more extensive informationmaking CAD drawings increasinglycomplex and time consuming.Gerard Roofs have taken theinitiative to meet these standardsby providing working drawings,which meet E2/AS1 requirements,that can be directly placed intoplans and specifications.

The drawings for all aspects ofroofing can be downloaded fromthe Gerard website without theneed to search for, and use dataon, a CD. The accent is on ease ofuse and convenience.

To satisfy industry standards thetechnical information is available infour different formats;■ DWG for AutoCAD■ MOD for ArchiCAD■ DXF for CAD■ PDF for those who want highquality reproduction of detailswithout the need for a CADprogram.

The interface provides 99% of allroofing situations which arerequired for specification of allGerard roofing products. Followingthe steps ensures you select a roof“fit for purpose.” Choose yourdegree of pitch, type of roofstructure, then select a profile fromthe range available based on thesettings and design situation. Theprogram instantly finds andpreviews the detail on screenwithout the need to scroll throughcountless lists of drawings.

These drawings compliment themaster spec specifications whichare also available for downloading.

Anyone can register on the sitefree of charge and access all of theinformation required. Log onto theGerard website at:http://www.gerardroofs.co.nz andfollow the “partner Login” link.

Hot on the heels of Gerard Roofs’on line CAD library, the companyhas launched a new website tool

copyright Gerard 2005

Phone: 0800 104 868 Fax: 0800 766 324

Email: info@gerardroofs.co.nz

100mm*

150mm X 25mm Valley boards cut between

trusses fixed flush with the top

Fascia

Gerard Tile

Tile Batten

150mm X 25mm Valley boards cut between

trusses fixed flush with the topRoof underlay

Tile Batten

Combination Valley

Truss

Consult Gerard technical staff regarding

areas with snowfall

Truss

Figure 05

Valleys

*Minimum clearance between tiles

Roof underlay

featuring a user friendly “RoofChooser” application which allowshome owners and designers topreview potential roofingcombinations. Users can select thehouse style which resembles theirhome, customise the cladding typeand colour and then preview theeffect of Gerard Roofs’ eight mostpopular tile, shake and shingleroofing options, altering both colourand texture. Users can preview theroof, print the finished result or e-mail it.

An additional re-roofing section isnow under construction (shownright) which will provide owners anddesigners with a guide to optionsavailable to suit their existing homedesign style. As with the new homestyle guide roofing profiles andcolour options are inter-changeable.

Once the roof style has beenestablished with the home ownerthe designer, builder or specifiercan go on line to Gerard Roofs’

For further information about thewebsite you can contact GrantWilliams, Business DevelopmentManager, Gerard Roofs on 027 578 9043 or e-mail him atgrant.williams@gerardroofs.co.nz.

From productselection to finalout put ofdetailed drawingsGerard Roofsnew websiteprovides an easysolution.

Two contrasting homeswith two things in common.

Both were designed by architectGary Hopkinson, of HopkinsonTeam Architecture Greymouth, andboth were winners in the NZIAResene Local awards forarchitecture.

The Brickell-Pollock retreat islocated at Bethells Beach and theWild home on a small farm lot atTakaka. These homes illustrateinnovative design, a sensitivity totheir environments and the resultsthat can be achieved with thecreative use of a variety of materialsincluding Colorsteel®. Both homeswill be featured in future editions ofScope.

Team Architecture also designedWilderness lodge which was thewinner of the 2005 RegisteredMaster Builder of the year -Commercial.( Featured on pages 9 -12 )

The Brickell-Pollock retreat.

Wild home at Takaka.

“Partner” section of the websiteand quickly and easily download allthe technical details. These can becopied and pasted onto planssimplifying the work required indetailing the roof structure.

22

Members of the NZ Metal RoofingManufacturers Inc.

National Distributors

Calder Stewart Industries LimitedPO Box 1400InvercargillTelephone: 03 214 5544Contact: Andrew Protheroe

DimondPO Box 22201OtahuhuAucklandTelephone: 09 270 4392Contact: Gregg Somerville

Gerard RoofsPO Box 18071Glen InnesAucklandTelephone: 09 978 9010Contact: Gary McNamara

Metalcraft Industries LimitedPO Box 51286PakurangaAucklandTelephone: 09 274 0408Contact: Tony Barbarich

Steel and Tube Roofing ProductsPO Box 259 019East TamakiAucklandTelephone: 09 273 7628Contact: Rod Newbold

Regional Distributors

Brockelsby Roofing Products Ltd49 Rutherford StreetLOWER HUTTTelephone: 04 566 1971Contact: Mike Maher

AZKO Roofing Limited41 Shakespeare RoadChristchurchTelephone: 03 365 9808Contact: Maurice O’Flaherty

B J Moss LtdPO Box 1007GisborneTelephone: 06 867 1219Contact: Roger Moss

B R Roofing & Walling Co LtdFord RoadOnekawaNapierTelephone: 06 843 6968Contact: Phillip Fendall

Besalon Industries LtdPO Box 58325GreenmountAucklandTelephone: 09 278 3610Contact: George Ling

Brownbuilt Metal Folding Ltd PO Box 58217Greenmount Auckland Telephone 09 274 6487 Contact: Pete Bringans

Continuous Spouting New Zealand Ltd PO Box 151 Takanini Auckland Telephone 09 268 1555 Contact: Richard Mabin

Contour Roofing Nelson LtdPO Box 9015AnnesbrookNelsonTelephone: 03 546 4260Contact: Dave Freeman

Dan Cosgrove LtdPO Box 211TimaruTelephone: 03 688 4169Contact: Brian Cosgrove

A Ellery & Sons LtdPO Box 178GreymouthTelephone: 03 768 5029Contact: Clark Ellery

E R Freeman LimitedFreeman RoofingPO Box 2317Stoke, NelsonTelephone: 03 5443108Contact: John Archer

Franklin Long Roofing LtdPO Box 151PukekoheAucklandTelephone: 09 238 9249Contact: Warren Oliver

Glenwood Industries (1992) LtdPO Box 5009TinwaldAshburtonTelephone: 03 307 0593Contact: Bruce McNally

HB Longrun LtdPO Box 3056NapierTelephone: 06 843 6159Contact: Chris Patheyjohns

Marshall Industries LtdPO Box 846InvercargillTelephone: 03 218 2579Contact: Peter Marshall

N S Irwin LtdPO Box 27029Mt RoskillAucklandTelephone: 09 620 8149Contact: Gary Irwin

Roof Manufacturers LimitedPO Box 319TaurangaTelephone: 07 578 2650Contact: Gordon Taylor

Roofing Industries Ltd233 Bush RoadAlbanyAucklandTelephone: 09 414 4585Contact: Philip Meyers

Roofline Marlborough31 Stuart StreetBlenheimTelephone: 03 578 8793Contact: Phil Hogg

Silbery Long Run Ltd69 Montgomery CrescentUpper HuttTelephone: 04 526 9343Contact: Angie Silbery-Dee

Skyline Buildings LtdP O Box 12261PenroseAucklandTelephone: 09 579 1226Contact: John Paul

Stratco (NZSI) LtdPO Box 8494ChristchurchTelephone: 03 338 9063Contact: Jarrod Stratton

Taranaki Steelformers LtdWanganui SteelformersKing Country LongrunPO Box 36StratfordTelephone: 06 765 5191Contact: Darrell Back

Tri Web Industries LtdPO Box 408FeildingTelephone: 06 323 6037Contact: Des Signal

For further information on Metal Roofing or Cladding or details of any of the articleswhich appear in this publication please contact any of the members listed below.

Scope is the official publication of the N.Z. Metal Roofing Manufacturers Inc..http://www.metalroofing.org.nz