Roof seamer

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This roof seamer uses 5 sets of rolling forming dies to manipulate the metal roof panel at the "seam" where two panels meet. Electric roof seamer.jpg
This roof seamer uses 5 sets of rolling forming dies to manipulate the metal roof panel at the "seam" where two panels meet.
The Roof Runner(r) machine, manufactured in Sweden, was introduced by Butler Manufacturing for the MR-24(r) roof system. Roof runner.jpg
The Roof Runner® machine, manufactured in Sweden, was introduced by Butler Manufacturing for the MR-24® roof system.
Progressive roller dies of the roof seamer are used to bend the metal roof panel seam into the desired shape to produce a finished seam profile. This shows a cross-section profile of the seam. Roof seamer roller progression.jpg
Progressive roller dies of the roof seamer are used to bend the metal roof panel seam into the desired shape to produce a finished seam profile. This shows a cross-section profile of the seam.

A roof seamer is a portable roll forming machine that is used to install mechanically seamed structural standing-seam metal roof panels, as part of an overall metal construction building envelope system. The machine is small and portable to be handled by an operator on top of a roof. The machine is applied to the overlapping area when two parallel roof panels meet. The action of the machine bends the two panels together to form a joint that has weather-tight qualities superior to other types of roof systems and cladding.

Contents

History

Commonly, a roof seamer is developed as an afterthought. Since roof seamers are dependent on the metal roof system being used, their development was secondary to the roof panel. A roof seamer is a development that replaced a manual process and hand tools of the past. A hammer and small anvil were tools that were used for hemming and seaming roof panels together at the edge where they meet with the next roof panel in sequence.

In 1976, a German immigrant and inventor, Ewald Stellrecht, [1] helped develop an early version of a metal roof panel portable roll forming machine in Exton, PA. From this a version of the roof seamer was also created. Since that time, great strides and innovations have been made in the development of roof seaming machines. Also, in the 1970s, Butler Manufacturing developed and released a proprietary roof system that featured the use of an electric roof seamer, dubbed the Roof Runner®, along with hand tools and an operating platform. [2] Many developments have been made since that time to make roof seamers lighter, faster, and more user-friendly. In 1989, Developmental Industries refocused the niche market by developing a line of roof seamers that were universal to many different panel manufacturers' products and were available to rent by the end-user. [3] Traditionally, purchasing a roof seamer meant that it would work with one specific roof panel, manufactured by a specific roof panel manufacturer. By opening up builders and installers to the option of renting, this allowed them to have the option of buying from different sources and greatly reducing their cost, making metal roofing a more accessible option for many that would not consider it before.

Design and function

Today roof seamers are used around the world. As the rise in popularity in sustainable building products has risen in recent years, the need of a roof seaming tool has also increased. Most roof seaming machines can have a life expectancy of 20 or more years, if proper maintenance and care are exercised.

Variables

Many variables exist when using a roof seamer that may affect the final product outcome. All of the following variables should be considered and decided on during the design process of the building:

Power and usage

Traditionally, roof seamers are powered by electricity-driven motors. Depending on the operator's location, either 120-volt or 240-volt power may be required. On most construction sites, either temporary electrical power is supplied or power is offered by an electric generator. This gives the operator the flexibility to take the power source onto a roof with them instead of using extensions cords, which can depreciate the power supply and possibly damage the motor of the roof seamer.

Training

An operator monitors an electric roof seamer as it travels along a metal roof seam. Worker and roof seamer machine.jpg
An operator monitors an electric roof seamer as it travels along a metal roof seam.

While simple in concept, the effective use of the roof seamer requires a trained person to operate. Training is both practical and effective in on-site troubleshooting. While classroom and practical training are options to learn how to operate a roof seamer, on-the-job training is recommended as being the most effective method. Manuals, videos, and field guides are also methods that will support training. In all cases, training should be completed before operating alone with a roof seamer to teach proper preventive maintenance steps, simple adjustments and troubleshooting in the event of a machine problem.

In 2015, the Metal Construction Association published a "best practices" guide for proper use and operation of roof seaming tools. [4]

Maintenance

As with any tool, proper maintenance will increase the usefulness and life expectancy. Proper maintenance extends beyond the roof seamer, to the working surface on the roof. Before operating the roof seamer, ensure that the roof panel and seam are clean and clear of debris that could mark or gouge the forming dies. During operation check lubrication points and other recommended maintenance steps. In addition, most manufacturers will recommend scheduled service on an annual basis to ensure internal components are not worn or damaged.

Other tools

A hand crimper is used to flat-form the material ahead of a roof seamer or in place of roll forming in some applications. Hand Crimper.jpg
A hand crimper is used to flat-form the material ahead of a roof seamer or in place of roll forming in some applications.

In conjunction with the roof seaming machine, there are an array of hand tools that are used. The most common tool that is usually required when operating a roof seamer is a "hand crimper". The hand crimper is used to "flat form" the panel seams into the appropriate configuration to prepare the seam for the roof seamer to be applied. Other common tools are snips, nibblers, and shears.

Support organizations

There are numerous professional and trade organizations that support metal roofing, metal construction and the core market where roof seamers are used. The Metal Roofing Alliance (MRA), Metal Construction Association (MCA), Metal Buildings Manufacturers Association (MBMA), the Metal Buildings Contractors and Erectors Association (MBCEA), and the National Roofing Contractors Association (NRCA) are just a few. In addition, many distributors and suppliers offer resources and support documentation for their particular product offerings.

Related Research Articles

Roof Top covering of a building

A roof is the top covering of a building, including all materials and constructions necessary to support it on the walls of the building or on uprights, providing protection against rain, snow, sunlight, extremes of temperature, and wind. A roof is part of the building envelope.

Life-cycle cost analysis (LCCA) is a tool to determine the most cost-effective option among different competing alternatives to purchase, own, operate, maintain and, finally, dispose of an object or process, when each is equally appropriate to be implemented on technical grounds. For example, for a highway pavement, in addition to the initial construction cost, LCCA takes into account all the user costs,, and agency costs related to future activities, including future periodic maintenance and rehabilitation. All the costs are usually discounted and total to a present-day value known as net present value (NPV). This example can be generalized on any type of material, product, or system.

Siding (construction) Exterior cladding on building walls

Siding or wall cladding is the protective material attached to the exterior side of a wall of a house or other building. Along with the roof, it forms the first line of defense against the elements, most importantly sun, rain/snow, heat and cold, thus creating a stable, more comfortable environment on the interior side. The siding material and style also can enhance or detract from the building's beauty. There is a wide and expanding variety of materials to side with, both natural and artificial, each with its own benefits and drawbacks. Masonry walls as such do not require siding, but any wall can be sided. Walls that are internally framed, whether with wood, or steel I-beams, however, must always be sided.

Curtain wall (architecture) Outer non-structural walls of a building

A curtain wall is an outer covering of a building in which the outer walls are non-structural, utilized only to keep the weather out and the occupants in. Since the curtain wall is non-structural, it can be made of lightweight materials, such as glass, thereby potentially reducing construction costs. An additional advantage of glass is that natural light can penetrate deeper within the building. The curtain wall façade does not carry any structural load from the building other than its own dead load weight. The wall transfers lateral wind loads that are incident upon it to the main building structure through connections at floors or columns of the building. A curtain wall is designed to resist air and water infiltration, absorb sway induced by wind and seismic forces acting on the building, withstand wind loads, and support its own weight.

Sheet metal Metal formed into thin, flat pieces

Sheet metal is metal formed into thin, flat pieces, usually by an industrial process. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a variety of shapes.

Flat roof Type of roof

A flat roof is a roof which is almost level in contrast to the many types of sloped roofs. The slope of a roof is properly known as its pitch and flat roofs have up to approximately 10°. Flat roofs are an ancient form mostly used in arid climates and allow the roof space to be used as a living space or a living roof. Flat roofs, or "low-slope" roofs, are also commonly found on commercial buildings throughout the world. The National Roofing Contractors Association defines a low-slope roof as having a slope of 3 in 12 (1:4) or less.

Waterproofing Process of making an object or structure waterproof or water-resistant

Waterproofing is the process of making an object or structure waterproof or water-resistant so that it remains relatively unaffected by water or resisting the ingress of water under specified conditions. Such items may be used in wet environments or underwater to specified depths.

Batten Construction material

A batten is most commonly a strip of solid material, historically wood but can also be of plastic, metal, or fiberglass. Battens are variously used in construction, sailing, and other fields.

Flashing (weatherproofing)

Flashing refers to thin pieces of impervious material installed to prevent the passage of water into a structure from a joint or as part of a weather resistant barrier system. In modern buildings, flashing is intended to decrease water penetration at objects such as chimneys, vent pipes, walls, windows and door openings to make buildings more durable and to reduce indoor mold problems. Metal flashing materials include lead, aluminium, copper, stainless steel, zinc alloy, and other materials.

A metal roof is a roofing system made from metal pieces or tiles characterized by its high resistance, impermeability and longevity. It is a component of the building envelope. Zinc, copper and steel alloys are commonly used.

Duct (flow) Conduit used in heating, ventilation, and air conditioning

Ducts are conduits or passages used in heating, ventilation, and air conditioning (HVAC) to deliver and remove air. The needed airflows include, for example, supply air, return air, and exhaust air. Ducts commonly also deliver ventilation air as part of the supply air. As such, air ducts are one method of ensuring acceptable indoor air quality as well as thermal comfort.

A roof coating is a monolithic, fully adhered, fluid applied roofing membrane. Many roof coatings are elastomeric, that is, they have elastic properties that allow them to stretch and return to their original shape without damage.

Membrane roofing is a type of roofing system for buildings, RV's, Ponds and in some cases tanks. It is used to create a watertight covering to protect the interior of a building. Membrane roofs are most commonly made from synthetic rubber, thermoplastic, or modified bitumen. Membrane roofs are most commonly used in commercial application, though they are becoming increasingly common in residential application.

Architectural metals

Metals used for architectural purposes include lead, for water pipes, roofing, and windows; tin, formed into tinplate; zinc, copper and aluminium, in a range of applications including roofing and decoration; and iron, which has structural and other uses in the form of cast iron or wrought iron, or made into steel. Metal alloys used in building include bronze ; brass ; monel metal and nickel silver, mainly consisting of nickel and copper; and stainless steel, with important components of nickel and chromium.

The Metal Building Manufacturers Association (MBMA) was founded in 1956 and promotes the design and construction of metal building systems in the low-rise, non-residential building marketplace. A non-profit trade organization, MBMA's headquarters is in Cleveland, Ohio. The organization consists of building system members, who are certified according to standards which have been set by the International Accreditation Service of the International Code Council, and associate members, who work in the metal building industry. MBMA has a General Manager, and it has a chairman and Board of Directors who are elected by members on an annual basis.

Copper in architecture

Copper has earned a respected place in the related fields of architecture, building construction, and interior design. From cathedrals to castles and from homes to offices, copper is used for a variety of architectural elements, including roofs, flashings, gutters, downspouts, domes, spires, vaults, wall cladding, and building expansion joints.

According to EN 13523-0, a prepainted metal is a ‘metal on which a coating material has been applied by coil coating’. When applied onto the metallic substrate, the coating material forms a film possessing protective, decorative and/or other specific properties.

Metal profile sheet systems are used to build cost efficient and reliable envelopes of mostly commercial buildings. They have evolved from the single skin metal cladding often associated with agricultural buildings to multi-layer systems for industrial and leisure application. As with most construction components, the ability of the cladding to satisfy its functional requirements is dependent on its correct specification and installation. Also important is its interaction with other elements of the building envelope and structure. Metal profile sheets are metal structural members that due to the fact they can have different profiles, with different heights and different thickness, engineers and architects can use them for a variety of buildings, from a simple industrial building to a high demand design building. Trapezoidal profiles are large metal structural members, which, thanks to the profiling and thickness, retain their high load bearing capability. They have been developed from the corrugated profile. The profile programme offered by specific manufacturers covers a total of approximately 60 profile shapes with different heights. Cassettes are components that are mainly used as the inner shell in dual-shell wall constructions. They are mainly used in walls today, even though they were originally designed for use in roofs.

References

  1. "ESE Machines :: About Us". www.esemachines.com. Retrieved 2017-12-11.
  2. "About Us | Butler Manufacturing". butlermfg.com. Retrieved 2017-12-13.
  3. "History – D.I.ROOF SEAMERS". diroofseamers.com. Retrieved 2017-12-13.
  4. "Educational Resources for Architects and Building Owners". www.metalconstruction.org. Retrieved 2017-12-13.