The document provides an overview of product performance testing for metal roofing systems. It discusses 6 main sections: 1) thermal movement testing, 2) paint finish testing, 3) air, water, and impact testing, 4) wind uplift testing, 5) fire resistance testing, and 6) common metal roof problems. Various ASTM standards and tests are described, including for thermal expansion, water penetration, impact resistance, and fire resistance. Different wind uplift test methods like UL 580, ASTM E-1592, and FM testing are also summarized. Common metal roof issues such as corrosion, staining, rusting, oilcanning, and improper installation are briefly outlined.

1. ProductProduct
PerformancePerformance
TestingTesting
March 16, 2015
Roger A. Wallace, CSI, AIA
Alliance Steel, Inc.
Architectural Products Division

2. Learning ObjectivesLearning Objectives
Section 1: Thermal Movement
Section 2: Paint Finish Testing
Section 3: Air, Water And Impact Testing
Section 4: Wind Uplift Testing
Section 5: Fire Resistance Testing
Section 6: Common Metal Roof Problems

3. Section 1: Thermal Movement

4. Thermal MovementThermal Movement
Expansion and contraction is a factor of:
• Material type (steel, aluminum)
• Temperature differential
• Length of panels
Most specify a default of 150 deg temp. differential,
unless greater is specified (COE up to 220 degrees)
Easy rule of thumb is 1/8” for every 10 ft of panel length !
(Steel panels at a 150-degree temperature change)

5. Thermal MovementThermal Movement

6. Thermal MovementThermal Movement

7. Thermal Movement FormulaThermal Movement Formula
Ice
Dam

8. AISI Thermal Expansion ChartAISI Thermal Expansion Chart

9. Is Thermal Design Important?Is Thermal Design Important?
Low Eave Over Expansion Oilcanning
Penetration

10. Thermal Movement In Other RoofingThermal Movement In Other Roofing
Modified Bitumen Roofing Asphalt Shingles

11. Section 2: Paint Finish Testing

12. Florida 45-Degree Paint Finish Test BedFlorida 45-Degree Paint Finish Test Bed

13. Paint FinishPaint Finish HunterHunter Fade UnitsFade Units

14. Kynar Vs. SMP Fade Rates
Kynar SMP (WeatherXL)

15. So does having a good fade rate matter?
This was a BLACK roof 5 years ago

16. Paint Finish Delamination

17. Paint Finish Chalking

18. Section 3: Air, Water And Impact Testing

19. • ASTM E-1680: test for air leakage through panels
• ASTM E-1646: tests for water penetration into the
panels, simulates wind-driven rain at the panel ribs.
• UL 2281/FM 4473: impact resistance test where steel
balls are dropped to simulate hailstones. “Class 4” is the
best rating possible, all Alliance panels meet Class 4.
Air, Water and Impact TestingAir, Water and Impact Testing

20. Suction
Usually 6.24 or 12.0 psf

21. This procedure tests for water penetration into the
panels, simulates wind-driven rain at the panel ribs.
ASTM E-1646 Water Penetration TestASTM E-1646 Water Penetration Test
Suction

22. The Cool Impact Resistance Test
UL Standard 2218
This test, developed and standardized in
1996, was designed for use in evaluating
resistance to impact by replicating the
impact energy of large hailstones on roof
covering materials. The test involves
dropping a series of varying sized and
weighted steel balls from distances
varying from 12 to 20 feet on test decks,
built to replicate actual roof installations.
Micro-Cracking of the top
Galvalume layer---------->
22 gauge Steel

23. Section 4: Wind Uplift Testing

24. Does Wind Uplift Really Effect Roofing?

25. The Uplift Failure That Started It All
RICOWI was formed to investigate the wind uplift
failures from Hurricane Katrina.

26. RICOWI: Roofing Industry Commission On Weather Issues
Established in 1990 as a non-profit organization to identify and
address important technical issues related to the cause of wind
damage which include:
•Dynamic testing of roof systems;
•Importance of sample size for tests;
•Role of wind tunnels and air retarders;
•Need for acceptable procedures for ballasted systems;
•Field data and response team reports;
•General lack of communication within the roofing industry
Main sponsor organization is Oak Ridge National Laboratory.

27. What Came Out Of The RICOWI Investigations
It was determined that roofs experience different wind uplift loads
depending on their size, shape, height, location and wind exposure.
Engineers now have to design for three roof wind exposure zones:

28. What Came Out Of The RICOWI Investigations
It was also determined that different geographical locations
experience different nominal (average) wind speeds. A new wind
zone design map was created:

29. There are three industry recognized wind uplift test
methods:
1. UL 580 Class 90
2. ASTM E-1592
3. Factory Mutual
Wind Uplift Test Methods

30. UL 580 Class 90UL 580 Class 90
• A measure of quality assurance only – it does not
model real world exposure!
• Often incorrectly specified as a UL-90 test; it should be
described as UL 580, Class 90
• A 10’ x 10’ assembly of various substrates are subjected
to incremental positive and negative pressures, both
static and oscillating. Note: the test sample is fastened
around the perimeter!!!
• Passing assembly must show no joint disengagement,
clip distress, or buckling.

31. UL 580 (cont’d)UL 580 (cont’d)
Quote from AISI (American Iron and Steel Institute)
Design Guide:
“UL 580 doesn’t give realistic panel strength values for
comparing to design wind pressures that a roof may
experience on an actual building. It is considered a
main field of roof simulation but due to the specimen size
and lack of test restrictions to the perimeter of the test
specimen, the panels behave like a pre-tensioned
membrane that results in un-conservative strength
results”

32. UL 580 Class 90 Test ChamberUL 580 Class 90 Test Chamber
Pressure is applied to the top and bottom of the panels

33. Time for a Quiz !Time for a Quiz !
What does the “90” in UL-90 stand for?
• 90 miles per hour
• 90 pounds per square foot
• The number of jobs Roger will sell
this month

34. Quiz Answer
What does the “90” in UL-90 stand for?
Nothing … it’s just their test number.
It could just as easily have been A9JX3

35. ASTM E-1592 Uplift TestASTM E-1592 Uplift Test
• Premier test method for evaluating the uplift capacity of
standing seam roof panels. Best method of evaluating
real world performance.
• Specimen size varies- 10’ x 25’, various end conditions
allowed (fixed, floating and open).
• Test is run until failure – this establishes the ultimate
load capacity of the panel.
• Ultimate load is then reduced by safety factor. (1) test
SF = 2.0, multiple tests SF can be reduced depending on
test repeatability. Allowable panel load is now
determined.

36. ASTM E-1592 Test PictureASTM E-1592 Test Picture

37. Factory Mutual (FM)Factory Mutual (FM)
• FM Global is world’s largest commercial and industrial
property insurance organization.
• Applicable standard for metal roofing is FM 4471.
Achieving a Class 1 rating involves tests for
Combustibility, Wind Uplift, Foot Traffic, Hail, and
Water Leakage.
• An FM rating does not mean the roof complies with the
applicable building code or wind pressures!
• If FM is not insuring the building – why is this
necessary?

38. FM I-90 ?FM I-90 ?
Many specifiers mistakenly call for an “FM I-90” rating. (I-90 is
a highway that runs through Chicago) The rating is actually
designated “FM 1-90”. Clip spacings example:
UC-6 HD 16" x 24 ga (standard clip)
Rating Field spacing (in) Edge Spacing(in) Corner Spacing(in)
1-60 60 50 20
1-75 60 40 20
1-90 50 25 16
1-105 40 20 13
1-120 30 15 10

39. Factory Mutual ExplainerFactory Mutual Explainer
• The FM uplift test is similar to ASTM E-1592, in that it
is run until system failure.
• The ultimate failure load determines the classification
(1-90, 1-105, etc.) where the 1-xx number is the ultimate
pressure load (psf).
• Ultimate failure for metal roofing panels is typically
around 1-120. For typical 1-90 spec, clip spacings would
be 4 ft. in the field of the roof.
• There is a difference between FM listing, FM approved,
and FM loading.

40. Factory Mutual Test To FailureFactory Mutual Test To Failure
ALok
Type
Panel

41. Section 5: Fire Resistance Testing

42. UL-790 Fire Resistance Testing
UL-790 includes three test procedures: Spread of Flame,
Intermittent Flame and the Burning Brand. During all
three tests, there can be no flaming or glowing wood
particles falling off the underside of the test deck, the
roof deck cannot become exposed, and portions of the
deck must not fall or break away in the form of glowing
particles.
Roof assemblies with combustible decks (plywood, plank
or tongue and groove) require two additional fire tests:
(1) an intermittent flame and (2) the burning brand
which measures the ability to resist flaming embers.

43. UL-790 Test Classifications

44. UL-790 Flaming Brand Test Material

45. UL-790 Flaming Brand Test

46. UL-790 Fire Resistance Proof
(flying embers do make a difference)

47. Section 6: Common Metal Roof Problems

48. Galvanic Corrosion/Dissimilar Metals
The most protective
metal will sacrifice
itself first – note the
copper is still new.

49. Wet Stack Staining

50. Swarf – Rusting Metal Filings
Swarf are rusting metal
filings that have landed
on and melted into the
paint system.

51. Rusting
Rust is scientifically called oxidation, which occurs when oxygen comes in long-term
contact with iron. Over time, the oxygen combines with the metal at an atomic level,
forming a new compound called an oxide and weakening the bonds of the metal itself -
it is a CORROSION problem. If the base metal is iron or steel, the resulting rust is
properly called iron oxide – it is not a “sacrificial action” of the finish.

52. Uneven Substrate - Oilcanning

53. Improper Storage

54. Don’t Step On The Flashings

55. Fire Station # 4
North Richland Hills, TX
Improper Design: More Pookie Didn’t Help

56. Mechanical SeamerMechanical Seamer
Ice And Snow Is Heavy

57. Proper “Avalanche” Valley Design

58. Why Snow Design Is Important
Before After

59. Why We Stock Masterflash Pipe Boots

60. How Does The Water Get Around?

61. Solution To A Dilemma

62. Use Touch-Up Paint Sparingly
Most Air-Dry Touch-Up Paints Fade Within Six Months.
That’s Why They Come With Little Tiny Brushes!

63. Thank you for your attention
Any Questions?