Barrel Vault/ St Josephs High School Port Macquarie New South Wales

E610 Free span 7.163mtr

This project was finished recently, and this will help you understand the benefits of our system.

You will be able to see how quick the installation process is with our 74mm polycarbonate system, and how construction time is dramatically reduced. Installation time on this project was 2 days and four men were available on site. The steelwork was already erected and in place.

Everbright E610 Opal was installed above a central court yard. Everbright E610 was extruded and supplied in 7.384mtr curved panels and in 600mm configurations. Our panels simply clip together, making the installation process rapid, as our product only requires to be joined every 600mm on site. E610 free spanned 7.163mtr, incorporating Locking System 2.1 (see design loads). The total area was 310.05sqm, the curved panel length was 7.384mtr x 42mtr.

The front fix method was used on this project, as this is the preferred fixing method for larger span curved projects, this is different from the top fix method. The front fix method provides more strength and stability. On this particular project the steelwork was set at a 20degree angle to accommodate our panels.

E610 polycarbonate panels incorporate an excellent safety factor. All loading criteria are based on 0.75kN/sqm and a 50% safety factor as part of a standard specification detailing.

The brief was given for a modern curved roof to cover the schools central courtyard at the front of this development. The client was looking for a polycarbonate roof that would create a real statement and harmonize with the rest of this development. They required a system that could minimize the structure requirements and due to E610 being supported by steel columns this only added to the overall visual effect that our system can create. The specification was to make use of all the natural light available and they required a system that had superior thermal performance.

Therefore Opal was the colour selected due to a 65% light transmission for visible light and a thermal performance of 1.85W/mK (see test results).

Another key factor was a product which had a long life span. Makrolon 1243, is the material used in our polycarbonate roofing system which is part of the worldwide Bayer Group. Everbright E610 comes with a manufactures worldwide 10 year warranty and our panels have a life expectancy in excess of 30 years.

Since less structure is required with our system less shadows are created, and as such the natural light translucency is at it's full potential, making our system an excellent choice for this project.

Our polycarbonate system give a seamless and continuous line, with no steel frame work spoiling the visual effect. E610 Integral locking bars hide the aspect of where a panel starts and where it finishes, so it becomes a continuous system giving a uniformed and conformed design feature. Creating an architectural flare, that isn't possible with any other polycarbonate system available on the market. Other systems would necessitate the need for a framed grid work support system across the entire roof. On this project our system only needed to be secured to both sides of the eaves structure, all the joints are self sealing once the integral locking bar is fitted.

Our EL16 eaves angle is drilled on site at 200mm centres and is designed to fit our E610 sheeting.

We can confirm the E610 fixing accessories that were included for this project were;

  1. Eaves angle EL16 supplied in 6 mtr lengths and measures 40mm x 40mm x 4mm thick.
  2. Steel bolts EL26.
  3. E610 seals EL136.
  4. Aluminium sleeves EL24 pre-assembled within the panels during the manufacturing process at 300mm centres.

Once the eaves angle is secured, our panels drop in behind the eaves angle where the fixing bolts we supply are used to secure the roof to the angle. Our panels are very flexible as they are pack on top of each other during the delivery. This give an advantage in that the steel can be made with a tolerance of + / - 5 degree since our panels can easily accommodate this.

E610 drip nose is made on the sheets in the factory at either end of the barrel vault and measure 75mm. The drip nose section then simply hangs over the eaves angle.

The drip nose is incorporated into the top layer of our polycarbonate panels and simple just help water get past the end cap, this just helps keep it weather tight.

E610 is a very light weight product, that can be easily manoeuvred on site during the installation process. Our 74mm polycarbonate panels are also fully trafficable, which makes a huge difference to construction time, and helps with general service and maintenance of the roof.

The construction process with E610 is very simple and is less time consuming to install on site. We can advise that there was a significant cost saving on the structure requirements with our system on this project.

This project consisted of one area of 310.05sqm, the curved panel length was 7.384mtr x 42mtr. The geometry details on this project were:
Span 7.163mtr / Radius 10.65mtr
Springing angle 20 degrees
Mid point height 625mtr
Drip nose length at eaves 0.075mtr

More details on the front fix method for larger span projects

This fixing method comprises of an aluminium tube and sleeve which is installed in an assembled 600mm wide panel in our factory. The aluminium tube is a 20mm in diameter and located approx 20mm from he front edge of the panel. While this is being fitted, two aluminium sleeves are attached to the tube within the panel. These aluminium sleeves are positioned at 300mm maximum centres, and incorporates a threaded hole. The end caps are then fitted so that the panels are ready for installation on site.

Before the panels can be installed a 40x40x4mm aluminium eaves angle provided in 6m lengths must be pre drilled with a holes at 200mm centres and then secured to both left and right eaves structures. Our black 600mm length profile fillers are laid next to the eaves angle so that the panel compresses it to give added weather protection. Now the panels can be fitted.

To install the panels, a curved polycarbonate locking bar that is clipped onto the side of the panels, must be removed. The white backing tape on the joint of the panel must be peeled away to reveal the grey butyl seal. The end caps have an oblong knock out tab section. The tab in two of the end caps that line up with aluminium sleeves in the panel should be knocked out with the tap of a screw driver.

This first panel must be offered into position, so that it fits in behind both left and right eaves angles. The standard 75mm drip nose length then cascades over the eaves angle to create a drip for rainwater.

The next panel is prepared in the same way but is actually clipped over the first. The grey butyl seal becomes compressed to give an integrally sealed joint. Before the two panels are secured to the eaves, the previously unclipped polycarbonate locking bar must be fitted.

When 4 panels are in position, sealed and locked together, the first 2 panels must be secured. The temporary timber blocks are removed and all 4 panels are pushed against one of the eaves angles so that they can drop in place behind the other eaves angle. The installers must ensure that the holes in the eaves angle line up with the knocked out tabs in the two end caps per panel.

Our M8 X 25mm bolts are then fitted through the eaves angle hole, through the end cap and into the threaded hole of the aluminium sleeve. This pierces the aluminium tube to lock the panels into place. The same procedure should be complete to the other side of the 2 panels.

Now that 2 panels are complete, a further 2 panels are prepared and sealed/locked to the other 2 panels that haven't been secured to the eaves structure yet. Then the fitters must go back and secure 2 panels again in the same manner as before. Basically this is done so that there is always 2 unsecured panels at any one time so that there is plenty of flexibility to lift 2 panels to fit the locking bar.

This whole procedure is followed until the entire roof is installed.

E610 7.384mtr curved roof with a 625mm mid point height

Everbright E610 major advantages at a glance:

  • Rapid installation
  • Superior free span (see design loads)
  • Can be extruded to a maximum 20.5mtr
  • Minimal additional structure required with our system
  • Strongest translucent material in the world (74mm profile)
  • 100% fully trafficable
  • Passed the AS1562.3-2006 sand bag test
  • Impact resistance
  • Intruder resistance
  • Cyclone rated
  • Superior thermal/ acoustic performance
  • Long life span
  • Coextruded UV protection layer
  • Australian manufactured
  • Unique jointing arrangement
  • Self cleaning dome shape
  • Light weight product

This project is located at St Joseph's Regional High School, 946 Oxley Highway, Port Macquarie, NSW, New South Wales
The project can be viewed should site visits be required and adequate notice is given.

The Installation Visually

  • 7.2mtr free span

    7.2mtr free span

  • Modern uniformed look

    Modern uniformed look

  • Simple construction

    Simple construction

  • 65% light transmissions

    65% light…

  • Steelwork prior to installation below

    Steelwork prior to…

  • Steelwork prior to installation below

    Steelwork prior to…

  • E610 stacked prior to installation

    E610 stacked prior to…

  • Steelwork prior to installation below

    Steelwork prior to…

  • 1st panel laid in place above

    1st panel laid in…

  • 1st panel laid in place above

    1st panel laid in…

  • 1st panel laid in place above

    1st panel laid in…

  • 2nd panel been moved in position

    2nd panel been moved…

  • Easy handling

    Easy handling

  • Flexible polycarbonate locking bar

    Flexible polycarbonate…

  • Five panels locked and in place

    Five panels locked and…

  • Fully trafficable

    Fully trafficable

  • Pre drilling EL16 eaves angle 300mm centres

    Pre drilling EL16…

  • Pre drilling EL16 eaves angle 300mm centres

    Pre drilling EL16…

  • EL16 eaves angle fixed with EL26 8x30 bolts

    EL16 eaves angle fixed…

  • EL16 eaves angle fixed with EL26 8x30 bolts

    EL16 eaves angle fixed…

  • Maneuvering 6th panel into position

    Maneuvering 6th panel…

  • 90mins into E610 installation

    90mins into E610…

  • 15th panel locked in place underneath

    15th panel locked in…

  • 15th panel locked in place underneath

    15th panel locked in…

  • 15th panel locked in place underneath

    15th panel locked in…

  • 15th panel locked in place underneath

    15th panel locked in…

  • 15th panel locked in place underneath

    15th panel locked in…

  • View from Oxley Highway

    View from Oxley…

  • View from Oxley Highway

    View from Oxley…

  • View underneath finished roof

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  • View underneath finished roof

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  • View underneath finished roof

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  • View underneath finished roof

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  • View underneath finished roof right

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  • View underneath finished roof right

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  • View underneath finished roof

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  • View underneath finished roof

    View underneath…

  • View underneath finished roof

    View underneath…

  • View underneath finished roof

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  • View above finished roof left

    View above finished…

  • View above finished roof

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  • View underneath finished roof

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  • Steelwork set at 20degree springing angle

    Steelwork set at…