Install LYSAGHT ROOFTRAK®

LYSAGHT ROOFTRAK® walkways may be used in cyclonic and non-cyclonic areas. For use in cyclonic areas you must install in accordance with this publication, and the roof cladding must be fixed in accordance with our cyclonic area design manual for steel roofing and walling.

Australian Standard 1657-1992 allows a maximum slope of 20 degrees along cleated or grated walkways. For LYSAGHT ROOFTRAK® installed at 90 degrees to the ribs, the side slope (pitch of roof) should not exceed 5 degrees.

The roof supporting LYSAGHT ROOFTRAK® must be verified to have sufficient capacity to withstand all the additional loads.

For LYSAGHT ROOFTRAK® 450 applications, approval from regulatory authority must be obtained as it is narrower than the minimum provided for in AS 1657-1992.

Before you start

In planning where your walkway will go, consider:

• Where the start and finish of the walkway will be;
  
• Whether the ROOFTRAK® is laid parallel to, or at 90 degrees to the roofing ribs, or both; and
  
• ROOFTRAK® laid at 90 degrees to roofing ribs should be directly over purlins or battens supporting the roofing.
  
• Certain profiles (Such as LYSAGHT KLIP-LOK 700 HI STRENGH®) may require an additional stiffening plate. A Universal Support Plate is available for this situation. 
  
• In some projects a larger gap may be required between the cladding and the ROOFTRAK®. In these situations a packer or spacer can be installed that is installed between the Support Bracket and the cladding ribs.

Components

Kit Ordering Example

 

 

Kits Required for This Example

Item	Description	Kit	No. of kits
a	Planks (675 x 6 metres)	RTK67516073	3
b	End Plates	RTK675SFEP	2
c	T-connection	RTK675TC	1
d	Planks (675 x 3 metres)	RTK67513018	3
e	X-connection	RTK675XC	1
f	L-connection	RTK675LC	1

All LYSAGHT ROOFTRAK® systems are made up of straight lengths, connections, end plates and brackets selected from the kits and parts listed below. The example above is a 675 system. It could be made as a 450 system if required. Universal support plates may be required for some roof cladding profiles.

For a full list of the components in each kit, please see LYSAGHT ROOFTRAK® specifications section.

Position support brackets

1. Position the first support bracket.

• If ROOFTRAK® is to be parallel to roofing ribs, position the support bracket centrally across the ribs, ensuring that it is square to the roofing ribs (Figure 1).
  
  If using LYSAGHT KLIP-LOK 700 HI-STRENGTH®, ensure the stiffening plate is placed below the bracket. This plate should extend to the next rib (Figure 3).
  
  
• If ROOFTRAK® is to be 90 degrees to roofing ribs, position the support bracket directly over purlins or battens, and parallel with roofing ribs (Figure 2). Place stiffening plate below bracket where applicable.

When a larger gap is required then thin packers or profiled spacers can be installed. Thin packers can be sandwiched between the Support Brackets and the cladding ribs as described for stiffening plates. Deeper profiled spacers will need to be first fixed to the cladding ribs, (as described for the Support Brackets) The support brackets are then in turn fixed to the top of the profiled spacer.

For stability the profiled spacer should be rigid and a continuous length extending over the cladding ribs for the full length of the Support Bracket. The material used for the packer or spacer must be  durable and also compatible.

Position the second and subsequent support brackets on a rib nominally 1500 mm from the previous support bracket (Figure 1 and 2). Use a string line and/or square to ensure a straight run.

Fix the support brackets with three Bulb-title® rivets into the cladding ribs.

	Figure 1: Laid Parallel to Roofing Ribs
	Figure 2: Laid 90 Degrees to Roofing Ribs
	Figure 3: Support brackets and plate

 

Lay the planks

Lay ROOFTRAK® planks between the brackets and stand on the planks to engage them (there is one male/male plank that is positioned at the edge of the walkway (Figure 4). Fix the planks to the support brackets with four 10-16 x 16 wafer-head, self drilling screws per bracket (Figures 4 and 5).

	Figure 4: End Section and Laying
	Figure 5: Fixing Planks to Support Brackets

Ends of planks

• If ROOFTRAK® is parallel with the roofing ribs, a single support bracket may be used to support the ends of two abutting ROOFTRAK® planks.
• If ROOFTRAK® is 90 degrees to the roofing ribs, a support bracket must be used on a roofing rib as close to the end of each plank to support the ends of two abutting ROOFTRAK® planks.
• An end plate is used at the open end of a ROOFTRAK® plank that abuts nothing (Figure 6).

Figure 6: Tee or L Intersection

 

Tee or L intersections

• Fit end plates to the open ends of the planks that don't abut anything. If required, fix with 10-16 x 16 wafer-head screws.
  
• Fix support brackets to deck ribs at centres not greater than about 1500 mm.
  
• Fix planks in place and secure the intersection with an L-bracket(s) (Figure 6)

Cross intersections

• Continue one unbroken run of ROOFTRAK® planks through the intersection (Figure 7).
  
• Fix support brackets on either side of the intersection to support the ends of the two broken runs of ROOFTRAK®.

• Fix planks in place and fasten an L-bracket to each corner of the intersection, with two 10-16 x 16 wafer-head screws per bracket (Figure 7).

Figure 7: Cross Intersection

Important clean up swarf

Sweep all metallic swarf and other debris from roof areas and gutters at the end of each day and at the completion of the installation. Failure to do so can lead to surface staining when the metal particles rust.