ROOFIX Catalog

SAINATHAYNAMAH

L E A D E R I N Q U A L I T Y R O O F I N G S O L U T I O N S

CATALOGUE - ROOFING & CLADDING FASTENERS

to build your BEST

you need THE BEST

REALM INTERMEDIATES (P) LTD. REALM INT RMEDIATES (P) LTD.

REALM INTERMEDIATES (PVT) LTD. is committed to being a partner with the roofing industry, having designed, developed and marketed contemporary standard fasteners and quality products in the Indian market since 1998. Over two decade long journey, REALM has earned a reputation in the industry for being a trusted representative for both national and international manufacturers. That’s because at REALM we realised long back that what often determines the success or failure of a

project, is the fastener. This spurred us on to channel our collective energy towards providing a quality range of fasteners and value added services that would not only speed up the construction, improve structural reliability, but also ensure performance under the most demanding weather conditions. Staying true to our policy of being a partner to the roofing industry, we have strived continuously to excel and innovate and have provided roofing solutions to pre-engineered building industry, construction companies, solar industry, quality roofing contractors and various other industries.

OUR VISION is to be India’s leading marketeer for quality products nationally and BE AHEAD of expectations of all its stakeholders.

Our mission is to protect the 3Ms MEN, MACHINERY, MATERIALS

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At REALM we are committed to the following

• To supply our clients with not just products but support them with innovative solutions.

• To increase our clients’ productivity and profitability, without compromising on quality.

• Sustaining our position as a market leader in quality construction fasteners.

• Meeting the expectations of a competitive market.

• Creating stake holder value with outstanding products, categorical assistance and assured safety standards.

• To create a culture in pursuit of excellence through continuous innovation and learning.

• To contribute positively to society.

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WE safeguard YOUR investment

REALM does not compromise on quality and all our products are installed with True Blue EPDM washers. Our products undergo the most stringent quality tests to ensure long lasting durability. In fact, we give 20 years warranty on all our products, to enable your structure to withstand the most extreme weather conditions. We leverage our strong relationship with manufactures to create and innovative India- specific products. To ensure quality, we only import from ISO certified companies. Recognising that profitability is a key objective, we focus on value-for-money pricing, without compromising on quality.

WE add value to YOUR project

Which client doesn’t look for added value? We create that added value by offering a superior high quality of products and customer services. Our range of fast, convenient and cost effective products gives you that competitive edge. Since most of the products mentioned here are stock items, they are readily available for shipment within 24 hours. The fact that we have authorised distributors across India makes for a hassle-free and quick delivery. And happy clients mean more goodwill and business to the architects, engineers and designers.

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WE make YOUR task easy With so many options available in the market, how do you choose the correct fastener for your specific project? The ROOFIX fasteners are easy and faster to install. Thus saving time and effort for workers. Our application specialists will analyse your product design and provide detailed and reliable guidelines for choosing the most suitable fasteners for your needs. They also offer design and material options. In short, they tell you the right product for the right application. Our commitment to you continues during and after construction. We optimise our services to you with logistical support. If a problem should arise, our technical teams are available to investigate the cause and suggest a viable solution. We also offer special services like Head Painting. We can match any colour by using the best quality paint available to maximise adhesions and minimise chipping.

product range For more range of products please contact us.

Q uality R oofing F asteners

STITCHING & ROOFING FASTENERS

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STITCHING FASTENERS

STITCHING FASTENER

NEEDLE POINT

APPLICATION For overlapping of two metals roofing sheets to each other. MATERIAL Case hardened carbon steel Rustshield coating AISI 1002. SEALING WASHER EPDM washer. PLATING Rustshield coating is a unique co-polymer coating that provides greater resistance than Zinc or Cadmium plating. Tested in accordance to ASTMB117 & AS3566. HEAD Hex washer head. ACCESSORIES Power fastener-gun with speed under 3000 RPM.

STITCHING FASTENER

DRILL TIP POINT

EZI

Description (GXTPIXL)

Point Type

Drill

Box

Carton

Find

Thickness

Packing

Qty.

(mm)

STITCHING FASTENER 10G - 16TPIX20MM 12G - 16TPIX20MM 10G - 16TPIX16MM 10G - 16TPIX20MM

HEX WASHER HEAD

Illustrated stitching fasteners application.

101 102 103 104

ring EPDM washer Needle point ring EPDM washer Needle point ring EPDM washer Drill point

Sharp point Sharp point

1.2mm 1.2mm

1000

8000 4000 8000 6000

500

#2 #2

2mm 2mm

1000

metal bonded

Drill point

500

EPDM washer Common fastener sizes are mentioned above. For other sizes please contact us.

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ROOFIX Carbon Steel Fasteners are designed for fastening metal sheet to light to heavy section steel framing with or without intermediate insulation layers

Illustrated fastener application.

ROOFING FASTERNERS

DRILL TIP POINT

APPLICATION For fixing of horizontal / top metal roofing sheets to structural steel / secondary substrate is said to be roofing / crest fixing. The fixing is done on the crest / top of the metal sheet. Secondary substrate could be a cold rolled steel (z/c purlins square pipes with thickness not more than 4mm).

COATING A unique co-polymer coating that provides resistance than Zinc and Cadmium plating. Tested in accordance to ASTM B117 & AS 3566. MATERIAL Case hardened carbon steel Rustshield coating AISI 1022. HEAD

CLADDING FASTENERS

Hex washer head. SEALING WASHERS

DRILL TIP POINT

EPDM washer. ACCESSORIES Power fastener-gun speed under 2500 RPM.

FASTENERS FOR STEEL THICKNESS LESS THAN 4.5MM

APPLICATION For fixing of vertical metal roofing sheets to structural steel/secondary substrate is said to be wall cladding/valley fixing. The fixing is done on the valley between two tops on the roofing sheet. Structural steels could be cold rolled steel (i.e. purlins, square pipes with thickness not more than 4mm).

EZI

Description (GXTPIXL)

Point Type

Drill

Box

Carton

Find

Thickness

Packing

Qty.

(mm)

STITCHING FASTENER 10G - 16TPIX25MM 12G - 14TPIX25MM 12G - 14TPIX45MM 12G - 14TPIX55MM 12G - 14TPIX68MM

HEX WASHER HEAD

201 202 203 204 205

with washer with washer

drill tip drill tip drill tip drill tip drill tip

#3 #3 #3 #3 #3

3.0 mm 4.5 mm 4.5mm 4.5mm 4.5mm

500 250 250 250 200

4000 3000 3000 3000 1600

double threaded with edge guard double threaded with edge guard double threaded with edge guard

Common fastener sizes are mentioned above, For other sizes please contact us.

Illustrated fastener application.

C R S E R I E S F A S T E N E R S

H R S E R I E S F A S T E N E R S

FASTENERS DRILLING < THAN 8MM

APPLICATION For fixing of horizontal / top metal roofing sheets to structural steel / secondary substrate is said to be roofing / crest fixing. The fixing is done on the crest / top of the metal sheet. Secondary substrate could be a cold rolled steel (Z/C purlins Square pipes, angles with thickness not more than 8mm). COATING A unique co-polymer coating that provides resistance than Zinc and Cadmium plating. Tested in accordance to ASTM B117 & AS 3566. MATERIAL Case hardened carbon steel Rustshield coating AISI 1022. HEAD Hex washer head 8mm. SEALING WASHERS

Illustrated fastener application.

EZI

Description (GXTPIXL)

Point Type

Drill

Box

Carton

Find

Thickness

Packing

Qty.

(mm)

EPDM Washer. ACCESSORIES Power fastener-gun speed under 2500 RPM.

STITCHING FASTENER 12G - 14TPIX30MM 12G - 14TPIX40MM 12G - 14TPIX45MM 12G - 14TPIX60MM

HEX WASHER HEAD

301 302 303 304

Fully Threaded Fully Threaded Fully Threaded Fully Threaded

drill tip drill tip drill tip drill tip

#4 #4 #4 #4

8 mm 8 mm 8 mm 8 mm

250 250 250 200

3000 3000 2000 1600

Common fastener sizes are mentioned above. For other sizes please contact us.

HR SER I ES FASTENERS

FASTENERS DRILLING < THAN 12MM

APPLICATION For fixing of horizontal / top metal roofing sheets to structural steel / secondary substrate is said to be roofing / crest Fixing. The fixing is done on the crest / top of the metal sheet. Secondary substrate could be a hot rolled steel (i.e. I beams/angels/channels with thickness varies from 4.5mm to 12mm). Carbon steel fasteners are designed for fastening metal sheet to heavy section steel framing up to thickness of 12mm steel with or without intermediate insulation layers. COATING A unique co-polymer coating that provides resistance than Zinc and Cadmium plating. Tested in accordance to ASTM B117 & AS 3566. MATERIAL Case hardened carbon steel Rustshield coating AISI 1022. HEAD Hex washer head 8mm. SEALING WASHERS

Illustrated fastener application.

EPDM washer. ACCESSORIES Power fastener-gun speed under 2500 RPM.

EZI

Description (GXTPIXL)

Point Type

Drill

Box

Carton

Find

Thickness

Packing

Qty.

(mm)

STITCHING FASTENER 12G-24TPI x 32mm 12G-24TPI x 38mm 12G-24TPi x 50mm 12G-24TPi x 65mm 12G-24TPi x 70mm

HEX WASHER HEAD

401 402 403 404 405

Fully Threaded Fully Threaded Fully Threaded Fully Threaded Fully Threaded

Drill TIP Drill TIP Drill TIP Drill TIP Drill TIP

12.0mm 12.0mm 12.0mm 12.0mm 12.0mm

250 250 250 200 200

3000 3000 2000 1600 1600

Common fastener sizes are mentioned above. For other sizes please contact us.

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WAF ER HEAD FASTENERS

FASTENERS DRILLING < THAN 12MM

FASTENERS DRILLING < THAN 4.5MM

DRILL TIP POINT

DRILL TIP POINT

APPLICATION For fixing of clips to the secondary substrate. The clips hold the roof. MATERIAL Case hardened carbon steel Rustshield coating AISI 1022 PLATING Rustshield coating is a unique co-polymer coating that provides

greater resistance than Zinc or Cadmium plating. Tested in accordance to ASTMB117 & AS3566. HEAD Wafer head. ACCESSORIES Power fastener-gun with speed under 3000 RPM.

EZI

Description (GXTPIXL)

Point Type

Drill

Box

Carton

Find

Thickness

Packing

Qty.

(mm)

WAFER HEAD FASTENERS

HEX WASHER HEAD

601 602 610

10G - 24TPIX25MM 10G - 24TPIX25MM 12G - 24TPIX32MM

Wafer Head Zinc Coated

drill tip drill tip drill tip

2.5 mm 2.5 mm 12 mm

1000

8000 6000 4000

Wafer Head Rust shield Coated Wafer Head Rust shield Coated

500 500

CSK WAFER HEAD FASTENERS HEX WASHER HEAD

631 632

8G - 18TPIX25MM 8G - 18TPIX40MM

CSK Wafer Head 6 Ribbed CSK Wafer Head 6 Ribbed

Wing Teks Wing Teks

2 mm 2 mm

1000

8000 6000

500

Common fastener sizes are mentioned above. For other sizes please contact us.

W A F E R H E A D F A S T E N E R S

CSKWAFER HEAD FASTENER

FASTENING FOR FIXING FIBRE CEMENT, CALCIUM SILICATE, GYPSUM & BISON BOARDS

APPLICATION For direct fastening of different boards to steel. MATERIAL Case hardened carbon steel Rustshield coating AISI 1022. PLATING Rustshield coating is a unique co-polymer coating that provides greater resistance than Zinc or Cadmium plating. Tested in accordance to ASTMB117 & AS3566. ACCESSORIES Power fastener-gun with speed under 2500 RPM.

FIBRE CEMENT FASTENERS

FIBRE CEMENT FASTENER FASTENING FIBRE CEMENT SHEET TO STEEL STRUCTURE APPLICATION For direct fastening of fibre cement sheet to steel. MATERIAL Case hardened carbon steel Rustshield coating AISI 1022. SEALING WASHER EPDM dome washer. PLATING Rustshield coating is a unique co-polymer coating that provides greater resistance than Zinc or Cadmium plating. Tested in accordance to ASTMB117 & AS3566. HEAD Hex washer head with special wings. ACCESSORIES Power fastener-gun with speed under 3000 rpm.

EZI

Description (GXTPIXL)

Point Type

Drill

Box

Carton

Find

Thickness

Packing

Qty.

(mm)

STITCHING FASTENER 14G - 14TPIX90MM 14G - 14TPIX100MM 14G - 14TPIX110MM

HEX WASHER HEAD

501 502 503

DOME with washer Drill Tip DOME with washer Drill Tip DOME with washer Drill Tip

#5 #5 #5

12mm 12mm 12mm

50 50 50

400 400 400

Common fastener sizes are mentioned above. For other sizes please contact us.

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POLYCARBONATE & FRP FASTENERS

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DRILL TIP POINT FRP FASTENERS

APPLICATION Self drilling fasteners PolyFix are used for polycarbonate sheet fixing • Pre drills and self centers during installation. • Unique wing design cuts its own thermal expansion hole. • Modified drill point allows application into both timber and steel. • Save 50% on installation time. SEALING WASHER DEKS engineered EPDM dome washer 26mm/32mm diameter PLATING Rustshield coating is a unique co-polymer coating that provides greater resistance than Zinc or Cadmium plating. Tested in accordance with ASTM B117 and AS 3566. Chrome free coating as per the European standards. HEAD Hex flange washer head. ACCESSORIES Power fastener-gun with speed under 3000 RPM. FASTENER FOR POLYCARBONATE (POLYFIX) DRILL TIP POINT

FASTENERS FOR FIBRE-REINFORCED PLASTIC SHEETS

APPLICATION Self drilling fasteners FRPFix are used for FRP sheet fixing • Pre drills and self centres during installation. • Unique wing design cuts its own thermal expansion hole. • Modified drill point allows application into both timber and steel. •  Save 50% on installation time. SEALING WASHER DEKS engineered weather-lok washer. PLATING Rustshield coating is a unique co-polymer coating that provides greater resistance than Zinc or Cadmium plating. Tested in accordance with ASTM B117 and AS 3566.Chrome free coating as per the European standards. HEAD Hex flange washer head. ACCESSORIES Power fastener-gun with speed under 3000 RPM.

EZI

Description (GXTPIXL)

Point Type

Drill

Box

Carton

Find

Thickness

Packing

Qty.

(mm)

POLYCARBONATE & FRP FASTENERS WASHER HEAD

510 511 512 513

M 6.50 X 50MM M 6.50 X 65MM M 6.50 X 50MM M 6.50 X 65MM

Polycarbonate 26mm EPDM Washers Polycarbonate 26mm EPDM Washers

drill tip drill tip drill tip drill tip

5 mm 5 mm 5 mm 5 mm

250 200 250 200

2000 1600 2000 1600

Weatherlok Washer Weatherlok Washer

Common Fastener sizes are mentioned above, For other sizes please contact us.

BIG TIP - CONCRETE - CSK HEAD FASTENERS

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BIG TIP SERIES FASTENER DRILL TIP POINT APPLICATION For fixing metal sheets with steel substrate over 12mm but <18mm. MATERIAL Case hardened carbon steel Rustshield coating AISI 1002. SEALING WASHER EPDM washer. PLATING

ROOFIX carbon Steel Fasteners are designed for fastening metal sheet to heavy section steel framing up to thickness of 12mm steel with or without intermediate insulation layers.

Rustshield coating is a unique co-polymer coating that provides greater resistance than Zinc or Cadmium plating. Tested in accordance to ASTMB117 & AS3566. HEAD Hex washer head. ACCESSORIES Power fastener-gun with speed under 3000 RPM.

EZI

Description (GXTPIXL)

Point Type

Drill

NET Weight Box

Carton Packing

Qty.

Find

Thickness

(KG/1000)

(mm)

approx

STITCHING FASTENER 12G - 24TPIX65MM

HEX WASHER HEAD

250

with washer

_____

#6

18mm

6.40

250

3000

Common Fastener sizes are mentioned above, For other sizes please contact us.

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CONCRETE & WOOD FASTENERS

CONCRETE FASTENER

WOOD FASTENERS DRILL TIP POINT

DRILL TIP POINT

APPLICATION Self drilling fastening to fix directly into pre drilled holes in concrete and brick, as well as pre-cast panels, lightweight cement blocks, without inserts or chemicals. MATERIAL Case hardened carbon steel Rustshield coating AISI 1002. SEALING WASHER EPDM washer. PLATING Rustshield coating is a unique co-polymer coating that provides greater resistance than Zinc or Cadmium plating. Tested in accordance to ASTMB117 & AS3566. HEAD Hex washer head. ACCESSORIES Power fastener-gun with speed under 3000 RPM.

APPLICATION Self drilling fasteners for fastening metal sheets to woods. MATERIAL Case hardened carbon steel Rustshield coating AISI 1002. SEALING WASHER EPDM washer. PLATING

Rustshield coating is a unique co-polymer coating that provides greater resistance than Zinc or Cadmium plating. Tested in accordance to ASTMB117 & AS3566. HEAD Hex washer head. ACCESSORIES Power fastener-gun with speed under 3000 RPM.

EZI

Description (GXTPIXL)

Point Type

Drill

Box

Carton

Find

Thickness

Packing

Qty.

(mm)

TAPCON/WOOD FASTENER HEX WASHER HEAD

551 552 553 554 555

M6.3 x 32mm M6.3 x 58mm

HEX Washer Head Slotted HEX Washer Head Slotted

Drill Tip Drill Tip

12mm 12mm Type 17 Type 17 Type 17

150 150 150 150 150

1200 1200 1200 1200

12G - 14TPIX65MM 12G - 14TPIX75MM 12G - 14TPIX90MM

Hex Washer head Hex Washer head Hex Washer head

Needle Tip Needle Tip Needle Tip

1200 Common fastener sizes are mentioned above. For other sizes please contact us.

STAINLESS STEEL & COMPOSITE PANEL FASTENERS

EZI

Description (GXTPIXL)

Point Type

Drill

Box

Find

Thickness

Packing

(mm)

TAPCON/WOOD FASTENER HEX WASHER HEAD

551 552 553 554 555 556

12G - 14TPIX80MM 12G - 14TPIX105MM 12G - 14TPIX135MM 12G - 24TPIX90MM 12G - 24TPIX110MM 12G - 24TPIX130MM

HEX Flange Head HEX Flange Head HEX Flange Head HEX Flange Head HEX Flange Head HEX Flange Head

Drill Tip Drill Tip Drill Tip Drill Tip Drill Tip Drill Tip

4.5mm 4.5mm 4.5mm 12mm 12mm 12mm

150 150 100 150 100 100

Common fastener sizes are mentioned above. For other sizes please contact us.

STAINLESS STEEL FASTENERS

COMPOSITE PANEL FASTENERS

DRILL TIP POINT

DRILL TIP POINT

APPLICATION Self drilling fasteners are available in stainless steel. These are custom made and are made available on order. The material is available in various grades (304 / 316 / 410). There is a SS Cap only offered on carbon fasteners. Fasteners made of stainless steel are available. Bi-metallic fasteners are a combination of carbon steel tip and stainless body. SEALING WASHER DEKS True Blue EPDM washers. HEAD Hex flange washer head. ACCESSORIES Power fastener-gun with speed under 3000 RPM.

APPLICATION Self drilling fasteners for fastening metal sheets of composite panels. SEALING WASHER DEKS True Blue EPDM washers. PLATING Rustshield coating is a unique co-polymer coating that provides greater resistance than Zinc or Cadmium plating. Tested in accordance with ASTM B117 and AS 3566. Chrome free coating as per the European standards. HEAD Hex washer head 8mm. ACCESSORIES Power Fastener-gun with speed under 3000 RPM.

W ashers

With 4.5 fasteners per square meter of roofing sheet, washers play a significant role in any roofing project.

EPDM is the short form of Ethylene Propylene Diene Monomer. The American Society for Testing and Material (ASTM) classifies this material as a M class Polymer. Ethylene and Propylene oil and natural gas are organic building blocks of EPDM. When combined with Diene, they form a large molecule that is very stable when exposed to sunlight, heat, ozone(UV) and moisture. EPDM It is well suited for sealing due to its resistance to water, chlorinated water, dilute acids, alkaline, ozone and oxidising chemicals. It has a negligible absorption rate, is not susceptible to swelling and can withstand temperatures up to 100C.

These qualities of the EPDM makes it the first choice for the leading fastener manufacturers. At REALM we recommend that the consumers ensure that the washer they purchase complies with industry standards and supports the life and integrity of the roofing system. The right balance of hardened, tear strength and compression performance determine how well a cut washer assembles, compresses and resists the tearing affects of swarf, and keeps the fastener sealed throughout its life on the roof.

Why WASHERSmatter?

Because washers are small and relatively inexpensive, their importance in a roofing project is sometimes overlooked. But poor quality washers can result in enormous cost if it is badly designed and made of inferior material. Here’s why:

• The washer is vital in maintaining the integrity of the roofing system. • There are four vital components to a good washer - design, material, conductivity and traceability. • Design - Early breakdown of the washers will result in, at best, the replacement of all fasteners and seals across the entire roof, and at worst, considerable water damage to the building. • Material - The secret of the DEKS washer is its premium EPDM (Ethylene Propylene Diene Monomer) blended with UV and Ozone stabilizers, curatives and processing oils. The blend is critical to sealing, UV resistance, life span and conductivity. • Conductivity – according to the Senior Principal Research Engineer, BHP RESEARCH -“We have found that DEKS black EPDM washers exhibit exceptional levels of performance and provide complete compatibility with BHP Colour board and Zincalume coated steels. A controlled level of carbon in this product provides superior mechanical properties and superior overall durability.” • Traceability - DEKS premium range of washers are always marked with the DEKS name or a registered feature such as the blue line.

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MULTI PURPOSE CUTWASHERS

POLYCARBONATEWASHERS

Engineered for precision Consistent fit, consistent performance. Seals tight-watertight Efficient sealing between fastener and surface every time.

Registered Deks Blue line marking Full traceability thanks to the Deks blue line. Superior quality EPDM Made to last. Perfect for automatic assembly Minimise downtime. UV and Ozone resistant Maximum life span in harsh environment. Non-conductive Low carbon prevents corrosion problems.

Four sealing points for extra protection

1

METAL BONDEDWASHERS

4

A metal face for extra strength EPDM encapsulates a metal support for greater strength. Double seal design Unique double seal acts under head and against the sheet surface. 12mm to 32mm size range A size to suit every fastener and roof system. Engineered load distribution Designed to minimise distortion. Aggressive environment Manufactured in Aluminium and stainless steel for ultimate corrosion resistance.

Each DEKFAST washer is designed to seal in 4 locations. This seals both the roof and the fastener to provide ultimate security.

2

3

For sizes please contact us.

A c c e s s o r i e s

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SOCKETS AND DRIVE BITS

Range of drive bits and sockets for quality ROOFIX Tm Fasteners

EZI

Description (GXTPIXL)

Box

Find

Packing

HEXAGON SOCKETS

For socket sizes up to 150mm long are stocked. For details please contact us.

701 702

5/16”x 45mm 5/16” x 65mm

10 10

PHILIPS DRIVE BITS

703 704

#2 x 50mm Single Head #2 x 65mm Double sided

10 10

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Measurement of fasteners

As a rule the correct length fastener should have at least 3 threads protruding behind the metal you are fastening to

THREE HEADS

TOTAL THICKNESS

D

A

B

C

E

12G - 14TPI x 60mm is better explained as 12 Gauge • 14 Threads per Inch • 60 mm in Length

The distinctive head mark consists of an engraved RX logo

A

B

C

D

E

THICKNESS OF FASTENER Gauge: the gauge of a fastener is determined by the basic size of the thread outside diameter. Standard Gauges:

THREAD SELECTION The TPI is the number of thread crest that can be counted along a lineal measurements of 1 inch (25.4mm). Always choose a fastener with sufficient threads to fully engage in the base metal. The thickness of material being fastened and diameter of fastener determine the types of thread pitch to be used. In general, the thinner the fastened materials, the fewer the number of threads. The thicker the material, the greater the number of threads. Thinner base material requires a coarser thread pitch to assure proper clamping. The thicker the material, the finer the threads must be.

HEAD STYLE AND SIZES There are three types of head. 1. Hexagon head with washer face. 2. Wafer head. 3. Countersunk rib head. The right head with correct size should be used for optimum results.

LENGTH SELECTION Length of the fastener (L).

DRILL POINT SELECTION Drill point selection is based on following criteria. 1. Top material to be drilled.

Depending on the fastener head, there are two different ways to measure the overall length of a fastener. For Hex washer head fastener the overall length is measured from the bottom of the collar under the head to the point of the fastener. For Wafer head fasteners, the overall length is measured from the top of the head to the point of the fastener.

2. Bottom material to be drilled. 3. Total thickness to be drilled. 4. Void or insulation.

10 gauge = 4.8 mm 12 gauge = 5.5 mm 14 gauge = 6.3 mm

Like death and taxes, corrosion is something we hope to avoid; but ultimately it is something we must learn to deal with.

THE CORROSION CHALLENGE

That India is geographically surrounded by a 7000 km. Coastline is a fact. That India is investing in industries and construction, involving metal usage in a big way, is also a fact. Put the two facts together and the conclusion is inevitable – that corrosion and its various fallouts will continue to be a major source of worry for the construction industry in India. So let’s acknowledge the truth – that corrosion is a fact of life that cannot be wished away. So what exactly is this corrosion that strikes so much fear in the construction industry? Corrosion is an electro-chemical action, where one metal is changed into a chemical or is simply eaten away. Thus in the presence of air, water or salt, non-precious metals like Steel, Zinc, Aluminium and Copper undergo a process called oxidation (rusting), which slowly disfigures the metals, rendering them unsafe and useless. Humidity and air pollution are the other factors that contribute to hastening the corrosion process.

THE DIFFERENT TYPES OF CORROSION

GENERALISED CORROSION (OXYGEN TYPE) This is the most common and prevalent type of corrosion, where humidity and moisture results in electrolytic reactions developing on the steel surface, leading to progressive corrosion. The rate of corrosion increases rapidly in the presence of other pollutants and raised humidity levels. GALVANIC CORROSION (HYDROGEN TYPE) In this case, the combination of two dissimilar metals with an electrolyte (moisture) is all that is needed to form a reaction, where the less noble metal migrates and dissolves into the solution. Galvanic corrosion is also used for corrosion

THE COST OF CORROSION Corrosion significantly affects the structural integrity of a construction. Premature deterioration or failure, results in greater maintenance, repair and replacement of damaged equipment. Besides this, costs also escalate, due to lost production hours and increased downtime of equipment; all arising from corrosion problems. Talking of cost, in India, the cost of corrosion has been estimated to be 3% of its GDP and that the roofing industry in particular, incurs a loss of no less than Rs. 360 crore annually.

prevention when a less noble metal like zinc is used to protect the carbon steel. BIOCHEMICAL CORROSION When metals dissolve in acid and caustic solutions of different strengths, chemical corrosion occurs because metals tend to combine with oxygen to form oxides. The less noble the metal, the stronger the tendency. The attacking acids often come from the atmosphere. For example, the sulphuric acid that comes from the sulphur dioxide emissions from burning fossil fuels, is found in urban and industrial areas; nitric oxides, chlorine, hydrogen chloride, formic

acid, acetic acid, etc. are found in the vicinity of industrial plants, while chloride and sodium chloride especially, are common atmospheric pollutants in coastal regions. AERATION CELL CORROSION An oxygen deficiency can develop in a damp thermal insulation or in any other situation when moisture is trapped and gathers pollutants. Corrosion will occur in the area of restricted oxygen supply, even in a non-polluted area of high PH value. Where other pollutants are present as in a lower PH value are, the corrosion will increase.

The choice of electrocoat over other coating techniques is usually driven by the lower total applied cost of electrocoat.

ELECTROCOATING FIGHTS CORROSION Electrocoating is an epoxy based organic polymer coating, which uses electrical current to deposit the paint. The process works on the principle of ‘opposite charges attract’, wherein an electrocoat system applies a DC charge to a metal part immersed in a bath of oppositely charged paint particles. The paint particles are drawn to the metal part and the paint is deposited on the part, forming an even, continuous film of coating over ADVANTAGES OF ELECTROCOATING APPLICATION & PERFORMANCE • Outstanding film uniformity – consistent film on all part-to-part surfaces. uses DC voltage to deposit paint only where it is needed. • Pre-assembly before coating – less post paint rejects. • Wide range of products – to meet corrosion, durability and other performance specifications. • Flexibility – multiple part configurations can be coated in one tank without having to change the application equipment. • Recycled water – closed-loop system reduces water loss. ECONOMIC VIABILITY • Totally automated process - no direct labour. • Very high productivity – dense and non-uniform line loading. • Very high transfer efficiency – closed- loop rinse system approaches 100% • Lower energy requirements – No dry-off oven, minimal exhaust equipment. • Minimal maintenance – minimal hook cleaning, no ‘booth’ maintenance. • Lower insurance coverage – no specific fire or health hazards. ENVIRONMENT FRIENDLY • Minimal solid wastes – closed-loop system reduces paint loss. • Reduced fire hazard – waterborne systems. • Total coverage of complex parts configuration – coating on all recessed area and sharp edges. • Precise film build control –

every surface, every crevice and corner, until the coating reaches the required thickness. The film insulates the part, electrical attraction stops and the electroplating is complete. Cathodic epoxy electrocoating has been widely used in the automotive industry for many years. REALM has adapted this process to fasteners and is now a benchmark for corrosion resistance in the construction industry.

• EPA compliance – low or zero VOC and HAPS coatings. • OSHA compliance – no special personal protection. • Cleaner application – totally enclosed system.

39

Fasteners cost less than 1-2% of the total cost of the building. Yet this is the weakest link that connects the Metal Roof to the secondary substrates.

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DECISIONANALYSIS

Fasteners are critical components of a building. Choosing the right fastening system can prove decisive in terms of the longevity and safety of the roof. Through this brochure, REALMgives youa clear guide to themost suitable fasteners for different roofing application. Specifying the right fasteners, for the right application is critical, because inadequate fasteners can cause major defects in a project, including replacement of roofs, water leakage, damage to machinery and other construction related issues. Since standard types and grades of fasteners are adequate in many construction application; fastener selection is usually based on industry standards, building code requirements and design loads. In some cases, it is deemed feasible to leave the fastener selection to the discretion of contractors or building product fabricators, allowing them to select fasteners based on cost, convenience and trade practices.

engineers need to be able to depend on the durability, quality andperformance of the fasteners that secure the roof; fastener selection has evolved into one of the most crucial aspects of the building design. That is why expert judgement is required to choose fasteners that: • Performas intended • Are dependable and economical •Lastequaltoormorethanthelifespanofthebuilding. Factors effecting fastener performance include: • Structural capacity and safety factor. • State and dynamic load resistance. • Pull-out and pull-over resistance. • Shear resistance of fastener and attachedmaterials. •Corrosion resistance in conditions of use. • Long termseal guarantee. • Seal against liquid or gas leakage (if required). •Constructibility, practicality and inspect ability. •Compatibility with design intent and aesthetics •Removability or other special requirements. • Service life exceeds that of attachedmaterials.

However, with the emphasis now on long term performance of a roof and because builders and

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Benefits of using ROOFIX self drilling fasteners “RX”

PRODUCT COATING Only single and best coating is offered. AVAILABILITY Ready stock. STANDARD Made as per Australian Standard AS 3566.

COATING Rustshield coating gives better corrosion protection. 1000 hrs of salt spray test as per ASTM B117-03.

Minimum of 15 Cycles of Kesternich SO2 Testing ASTM G-87

EPDM WASHERS Low carbon TRUE Blue EPDM washers last longer. SOLUTIONS Right fasteners are offered based on the application and thickness of steel.

STRUCTURAL INTEGRITY Fasteners hold roof sheets to the purlin and protect roof sheets from corrosion and water leakage.

DUCTILITY Fastener core hardness is ductile. PACKAGING Superior packaging in small boxes.

Small boxes are carton packed at factory in Taiwan. Product is labelled with batch numbers. Traceability of the product. WARRANTY Covered by ROOFIX warranty for more than 20 years.

ROHS COMPLIANT Environmentally friendly

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PRODUCT WARRANTY ROOFIX fasteners offer quality and performance with our range of self drilling fasteners. The Rustshield 3 coating that is standard on all our ‘RX’ marked self drilling fasteners, is a protective coating and is meant to sustain well in a variety of climatic conditions. It’s this confidence in our commitment that we do not foresee any defective fastener related problems. In the unlikely event that this may occur, ROOFIX fasteners undertakes to replace any such defective fasteners at no cost, subject to adherence to terms and conditions.

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APPROX LIFE

ENVIRONMENT CHARACTERISTICS

TERMS AND CONDITIONS 1. This certificate does not apply to product failure due to improper design or fastener selection, improper installation practice, in accordance with published installation practices, or when the environment or chosen location would hasten the degradation of the fastener. 2. Any alleged defects must be reported in writing after inspection only by ROOFIX or its authorised inspectors. 3. Warranty shall not be applicable in the following circumstances: • Damage due to acts of negligence, accidents or misuse, including but not limited to vandalism, civil disobedience or acts of war. 4. The fastener must be used with compatible roofing and substrate material. 5. The warranty hereby states that the liability of ROOFIX shall only be limited to the replacement of defective fasteners. All such replacement and installation are to be carried out by ROOFIX approved agent or installer. 6. It’s hereby made clear that no representatives of ROOFIX has the authority to make any representations or promises except as stated here. 7. The warranty is non-transferable from the original owner. • The system being damaged by natural disasters.

IN YEARS

Not recommended

Very Severe Marine (ISO Category 5) Includes off-shore area and up to 100m from high waterline area with breaking surf.

Not recommended

Severe Marine (ISO Category 4) Generally includes areas from beach front to 300m Inland, but may extend further with prevailing winds, strong salt smell, haze, salt smearing and salt build up in unwashed areas of structures are some of its characteristics. Moderate Marine (ISO Category 3) Generally between 300 and 1000 meter from marine surf, although strong prevailing winds may extend this distance. Airborne salt can be present but not visible as haze. Very Severe Industrial (ISO Category 5) Characterised by heavy fall-out and emissions from stacks, and strong sulphur and acid smells. Generally very high rate of corrosion in most building structure is evident. Severe Industrial (ISO Category 4) Area around major Industrial complexes characterised by heavy fall-out, strong sulphur and acid smells. Also includes buildings with high humidity and corrosions from operations within. Industrial (ISO Category 3) Characterised from fall-out from adjoining severe industrial environment i.e. where small industries are congregated in large clusters. Light Industrial /Urban (ISO Catagory2- 3) Area with light Industrial pollution and includes most Inland and cities. Away from environments, especially mentioned above, and between 500m from heavy industrial fallout.

6

Not recommended

Not recommended

15

25

30

Mild Urban/Rural (ISO Category 1-2) Approx distance from marine Influences: 2-0 km.

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Foamclosures

To enhance the appearance and the weather tightness of the polycarbonate coverings, foam closure strips are recommended for sealing the opening created where the corrugated sheet meets flat surfaces at flashing, curbs, girts, etc. At REALM we offer custom made foam closure strips.

Technical Specifications

Double Side FoamTape

Double Side Foam Tape is designed for sealing metal overlap joints in the pre-engineered building industry. It is easy to apply and compress during installation. It exhibits excellent application and performance characteristics over a wide range of temperature. It will not become brittle, crack or flow during service. It is available in cut to use size and supplied in ready to use rolls. APPLICATION Double Side Foam Tape is designed to seal and prevent the entry of dust, air and moisture and assures a weather tight seal in sheet metal/polycarbonate buildings. • Metal rib and end joint • Sealing roof curbs, roof jacks and skylights • Sealing polyethylene sheeting • Metal to metal joints for center fold roof

Average Pullout Loads (Kilo Newtons kN) The load required to pull the fasterner out of the material it is fastened into. ROOFIX publishes a wide range of technical performance data on its fasteners. Generally the values give the ultimate value the engineer would then apply a safety factor appropriate to the regulations standards. To determine the actual frequency of fasteners it is necessary that all loading criteria are made available to include wind load. With this information available, we work it in close cooperation with the designers, the system supplier and the contractor to assist in determining fastener frequencies.

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Technical Specifications

MECHANICAL PROPERTIES OF STEEL

Gauge

Thread per Inch

Min Axial force for withdrawal Min torque for torsional strength Kilp Newton Nm in-Lbs

10G

16TPI 24 TPI 14 TPI 24 TPI 10 TPI 20 TPI

2.5

6.9 7.3

61 65 93

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12G

2.8

10.9 11.3 14.1 17.6

100 125 156

14G

3.1

Note: Data based on only fastener. Base material limitation not considered.

Axial Tensile Strength (kN) The tensile load required to break the fastener

ULTIMATE AVERAGE FASTENERS PULLOUT VALUES -POUNDS -LBS (KN)

Description

point

Standard Sheet Metal Thickness (mm)

26Ga

24Ga

22Ga

20Ga

18Ga

16Ga

14Ga

12Ga

mm

(0.457)

(0.610)

(0.762)

(0.914)

(1.219)

(1.524)

(1.905)

(2.692)

08G-18TPI

2

120

197

268

301

494

702

961

1615 (7.17) 1632 (7.25) 1906 (8.47) 1553 (6.90) 1844 (8.20)

(.53)

(.87)

(1.19)

(1.34)

(2.2)

(3.12)

(4.17)

Single Shear Strength (kN) The shear load required to break the fastener

10G-16TPI

2

134 (.6) 161

218

281

340

539

741

991

(.97)

(1.25)

(1.51)

(2.4)

(3.29) 1096 (4.87) (3.4) 1060 (4.71) 767

(4.24) 1544 (6.86) 1078 (4.79) 1288 (5.72)

10G-24TPI

2

238

293

324

517

(.72)

(1.05)

(1.3)

(1.44)

(2.3)

12G-14TPI

3

142

214

296

349

580

(.63)

(.95)

(1.32)

(1.55)

(2.57)

12G-24TPI

5

311

452

Torsional Strength (kN) The torque to break the fastener

(1.38)

(2.00)

Applicable for available head type - PAN Head, Hex Head, Wafer Head, and Flat Head. For Design purpose lower value of pull out and tension strength of fastener to be consider.

ULTIMATE AVERAGE FASTENERS PULLOUT VALUES -POUNDS -LBS (KN)

Contact head Diameter

Description

Standard Sheet Metal Thickness (mm)

26Ga

24Ga

22Ga

20Ga

18Ga

16Ga

14Ga

12Ga

mm

(0.457)

(0.610)

(0.762)

(0.914)

(1.219) 1383 (6.14) 1444 (6.42) 1370 (6.09) 1554 (6.90) 1300 (5.78)

(1.524) 1383 (6.14) 1444 (6.42) 1395 (6.20) 2016 (8.97) 2216 (9.84)

(1.905) 1383 (6.14) 1444 (6.42) 1395 (6.20) 2300 (10.22)

(2.692)

ULTIMATE STRENGTH VALUES- CARBON STEEL CASE HARDENED PRODUCT

08G-18TPI

8.5mm

348

551

723

933

1383 (6.14) 1444 (6.42) 1395 (6.20) 3882

(1.54)

(2.44)

(3.21)

(4.15) 1105 (4.91) 1004 (4.46) 1009 (4.88) 1057 (4.69)

TPI

Tensile Lbs. Min

Shear Avg

Torque Min.

10G-16TPI

10.10mm

368

675

890

Lbs. Ult.

In-Lbs

(1.63)

(3.00)

(3.77)

4.2mm/8G 4.8mm/10G 4.8mm/10G 5.5mm/12G 5.5mm/21G

18 16 24 14 24

1615 2200 2362 2950 2400

1100 1470 1535 1960 2275

42 61 65 92

10G-24TPI

10.10mm

459

735

860

(2.04)

(3.26)

(3.82)

12G-14TPI

10.54mm

396

375

908

(1.76)

(3.0)

(4.03)

(17.01)

12G-24TPI

10.54mm

3064

3970

100

(13.61)

(17.91)

Applicable for available head type - Hex Washer Head Metal to Metal Application. For Design purpose lower value of pull out and tension strength of fastener to be consider. (To convert lbs force to Newton multiply values by 4.4482)

ROOF IX we connect ROOF IX we connect

ROOF IX ROOF IX

RX

RX

ROOF IX we connect

ROOF IX

C & P REALM INTERMEDIATES (PVT) LTD

concept-design-production

KRUTI DESIGN

photography

BAJI PAWAR

text

JAYASHREE MENON

printing press

PRAGATI ART PRINTERS

ROOF IX ROOF IX

ROOF IX we connect ROOF IX we connect

we represent brands RX

RX

RX

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ROOF IX

ROOF IX

L E A D E R I N Q U A L I T Y R O O F I N G S O L U T I O N S

SUITE NO. 19, PLOT NO. 3A, UDYOG NAGAR, GOREGAON (W), MUMBAI - 400062, MAHARASHTRA, INDIA Tel +91 22 2876 2876 Fax +91 22 2876 3244 Email hp@realmrx.com, sales@realmrx.com w w w . r e a l m i n d i a . c o m w w w . r o o f i x . i n

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