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INTRODUCTION
INSTALLATION MANUAL | 2
CONTENTS
INSTALLATION MANUAL | 3
1 IMPORTANT
ROOF TRAFFIC
Soft-soled shoes must be worn when walking on the
roof.
When moving around the roof, avoid avoid buckling
the tiles by placing weight on the balls of the feet, di-
rectly over the batten, in the pans of tiles.
Traffic on the roof should be kept to a minimum to avoid
possible damage to the tiles. Panels should be installed
by working progressively from the top of the roof to the
bottom, so that completed sections are not crossed
more than necessary to complete the installation.
INSTALLATION UNDER EXTREMELY
COLD CONDITIONS
Gerard roofs can be installed in areas that are subject
to lengthy periods of extreme cold. Special care is
needed during installation in winter conditions to pre-
vent damage to the surface coatings:
1. Tiles and accessories should be warmed (stored
in a warm place or lightly warmed – NOT OVER-
HEATED) before either cutting or bending.
2. The use of nailing guns is NOT recommended in
very cold conditions.
3. The use of a nail punch to drive in the final 5 mm
of the nail is recommended.
INSTALLATION MANUAL | 4
1 IMPORTANT
INSTALLATION MANUAL | 5
2 TOOLS
INSTALLATION MANUAL | 6
3 GERARD TILES
INSTALLATION MANUAL | 7
4 ACCESSORIES
190 106
110
405 30
42 0 0
190 4
4
5
190
40
5
40
165
2000
490
2000 1308
30
64
84 950 16
130 1
2000 0
20200
31
87 29
25 90
15 57
10
INSTALLATION MANUAL | 8
4 ACCESSORIES
30
235 178
10 12
92 232
130 62 62
10
ROOF ESCAPE WINDOW
VALLEY
Length of cover: 2300 mm
2400
210 20
20
SANITARY VENT GAS FLUE OUTLET
COWL VENT G2 TUBE TILE 1 PIPE
G15-45 ISO G125
TOUCH-UP KIT
INSTALLATION MANUAL | 9
5 ROOF STRUCTURE
INSTALLATION MANUAL | 10
6 LAYING THE UNDERLAY
INSTALLATION MANUAL | 11
7 BATTENS
COUNTER BATTENS
Counter battens (Ventilation Space Battens) provide
a ventilation space between the underlay and
the roof covering (refer to page 10; ROOF
STRUCTURE/ Ventilation Space). Rafters should be
lined up before the roofer begins work (this is the
builder’s responsibility). When re-roofing, counter
battens should be lined up. The recommended
counter batten dimension is 50 x 80 mm.
The minimum counter batten height is 25 mm.
TILE BATTENS
Rafters can be set at various centres depending on Option 1: Ridge batten - installation with bracket
the type of construction and the local regulations.
In most situations, the following batten sizes are
recommended based on rafter spacing.
RIDGE BATTEN
Install the top ridge batten onto the ridge bracket
(Option 1) or along the batten under-structure
(Option 2). The height of the top ridge battens
can vary depending on the slope of the roof.
This setup must be accurate as the barrel will be
installed onto the ridge batten. To provide an air
outlet (refer to page 10; ROOF STRUCTURE/ Ventilation
Space) a gap must be ensured between the ridge batten
and the upstand of the top tile. Spacers (pieces of
wood) can be installed on both sides of the ridge batten
(Option 2) to provide this opening (refer to page 31;
RIDGE/ Installation).
INSTALLATION MANUAL | 12
7 BATTENS
Option 1: Hip batten - installation with bracket Option 1: Protection flashing going behind the gutter
Option 2: Hip batten - installation with batten understructure Option 2: Protection flashing going into the gutter
INSTALLATION MANUAL | 13
7 BATTENS
VALLEY 2 3 10 30 8 9
Measure and construct the valley very
carefully as it is an important part of
the roof. The following details suggest
two ways that the valley lining may be
fitted. Local practice, building
regulations and site conditions will
dictate the final method used. If not
regulated by local legislation, it is
recommended to use a valley made
from approx. 50 cm wide, painted
aluminium-zinc alloy coated steel or
aluminium sheet. This is of particular
importance in areas prone to harsh
winters. Secure the valley with a clip.
Never nail inside the valley.
1. INSTALLATION OF THE VALLEY
ON THE LEVEL OF THE COUNTER
BATTEN SPACE
Tile battens are installed over the 2 Tile Batten
valley. The advantage of this method 3 Ventilation
is a free choice of valley width. As the Space Batten
greater part of the valley is concealed
beneath the tiles, it allows the use of
8 Underlay
wider valleys maintaining the aesthetic 9 Rafter
appearance of the roof. This is of 10 Valley
particular importance in the case of 30 Clip
extreme winter conditions and low
pitches, where a wider valley helps
overcome the consequences of ice
damming.
INSTALLATION MANUAL | 14
7 BATTENS
2 Tile Batten
3 Ventilation
Space Batten
8 Underlay
9 Rafter
10 Valley
30 Clip
INSTALLATION MANUAL | 15
7 BATTENS
The most critical factor in laying the tiles is accurately 1. An intermediate batten is obligatory for roof slopes
setting out the tile battens. If this is not done accurately of 15° to 30°. The distance between the main battens
then the tiles will not fit together correctly. is 368 mm. The intermediate batten is positioned
at a distance of 185 mm to 190 mm from the lower
All measurements should be made from the front of edge of the lower main batten.
the battens. This is the surface where tiles will be fixed
to the battens. The batten spacings for all profiles are 2. For slopes above 30°, an intermediate batten
listed below: is recommended, but is not obligatory.
m
D 6 8m
=3
D
0 mm
19
5 to
D 18
INSTALLATION MANUAL | 16
7 BATTENS
INSTALLATION PROCEDURE
Measure up from the eaves edge (D-3 mm) to establish
the position of the second batten. Use the measuring
rod to measure the subsequent battens in direction
from the eaves to the ridge.
Use coloured string to mark the position of the marking
nails. If the rafter length does not accurately suit a full
course of tiles, the top course will have to be cut and
bent to fit, requiring the space between the top batten
to the ridge to be less than usual.
Lay the battens in rows across the rafters against the
marking nails, which will be removed after fixing
the battens.
D
D-
3
m
m
INSTALLATION MANUAL | 17
8 TILE INSTALLATION
2 Tile Batten
3 Ventilation Space Batten
5 Ridge Batten
7 Ridge Bracket
8 Underlay
9 Rafter
18 Thinner Support Batten
INSTALLATION MANUAL | 18
8 TILE INSTALLATION
bottom shingle
bottom tile
top tile
bottom tile
INSTALLATION MANUAL | 19
8 TILE INSTALLATION
TILE LAYING
Start installation from ridge towards the eaves. Lay the Tiles are laid by lifting both tiles in the course above
second course of tiles from the top from gable end to and sliding the next course under the nose of the tiles
gable end, turning the edge of the end tiles up against already in place. Starting from the course already laid,
the barge battens (refer to page 34; BOX BARGE/ lay the tiles two courses at a time from end to end.
Installation). Nail these tiles in position through the flat The person laying the tiles should be two courses
of the back edge sitting on the batten. ahead of the person nailing.
1.
2.
Stagger the tile laps down the roof, using parts of tiles
4.
at the gable end.
3.
8.
2.
7.
1. 6.
5.
9.
INSTALLATION MANUAL | 20
8 TILE INSTALLATION
mm
app. 150 m 150
m app.
m m
app. 150 m 150
m app.
app. 150 m m m
150
m app.
m
0m
app. 150 m . 15
m app
m
app. 150 m 0m
m . 15
app
m
app. 1 0m
50 m m . 15
app
INSTALLATION MANUAL | 21
9 NAILING TECHNIQUE
INSTALLATION MANUAL | 22
10 NAIL POSITIONING
The correct positions for nailing different profiles are DIAMANT TILES
shown below. Correct nailing ensures good holding of
the tile and ample penetration of the nail, at the same Nails should be approximately 60 - 65 mm to the side
time restricting nail penetration to a maximum of two of the centre of the pan of the tile and close to the
thicknesses. bottom of the downturned flange.
tile
pe r
ts 4
poin
ing
Nail
Edge of tile B
Edge of tile A
Tile B
Tile A
m
Nail -6 5m
60
Lap 60 mm Centerline of pan
Bottom tile
INSTALLATION MANUAL | 23
10 NAIL POSITIONING
CLASSIC TILES
Nails should be approximately 60 mm to the side
of the centre of the pan of the tile and close to the
bottom of the downturned flange.
er tile
s4p
g point
Nailin
Tile B
Tile A
Lap 63 mm
Nail 60 mm
INSTALLATION MANUAL | 24
10 NAIL POSITIONING
HERITAGE TILES
Nails should be approximately 60 mm to the side
of the centre of the pan of the tile and close to the
bottom of the downturned flange.
er tile
s4p
g point
Nailin
Tile B
Tile A
Lap 63 mm
Nail 60 mm
Bottom tile
Centerline of pan
INSTALLATION MANUAL | 25
10 NAIL POSITIONING
MILANO TILES
Nails should be approximately 10 mm to the side of
the section of tile that rises. Milano Tiles need to be
nailed at the front and back of each tile where the tiles
lap. Place weight on the nose of the tile being nailed
so that the lap is held firmly down. Then place nails at
every second module along nose of the tile.
4p er tile
gp oints
Nailin
Edge of tile B
Nail Edge of tile A
Tile B
Tile A
Lap 122 mm
Nail
10 mm
Bottom tile
INSTALLATION MANUAL | 26
10 NAIL POSITIONING
SENATOR SHINGLE
Nails should be spaced approximately 300 mm apart.
Care is required at the lap of the shingle to ensure that
the nail is placed outside of the hidden water channel.
Edge of shingle B
Edge of shingle A
Shingle B
Shingle A
INSTALLATION MANUAL | 27
10 NAIL POSITIONING
CORONA SHAKE
Nails should be spaced approximately 300 mm apart.
Care is required at the lap of the shake to ensure that
the nail is placed outside of the hidden water channel.
e
er sha k
s4p
g point
Nailin
Edge of shake B
Edge of shake A
Shake B
Shake A
Lap 60 mm
Nail
60 mm
Bottom shake
INSTALLATION MANUAL | 28
11 EAVES FLASHING
1 Tile
2 Tile Batten
3 Ventilation Space Batten
8 Underlay
11 Eaves Flashing
12 Mesh
13 Eaves Guard Flashing
Nail
INSTALLATION MANUAL | 29
12 RIDGE
CUTTING AND
BENDING TILES
Measure the distance (A) from the last tile to the 1. Place the full tile in the long tile bending attachment,
spacers on the ridge batten (refer to page 12; which can be bolted to the bender. Line up the marks
BATTENS/ Ridge Batten). When installing the ridge showing the bend line and bend the tile upwards. It
without the use of spacers, the width of the air outlet is important to bend the tile first to avoid distortion
must be deducted from the measurement. Add 40 when cutting.
mm to the measurement for a standard up-stand and
2. Cut the tile along the marked cutting line using the
mark the tile to be cut.
guillotine, hand shears or metal cutting saw (refer to
The height of the upstand can vary depending on the page 4; IMPORTANT/ Cutting with a Saw).
pitch of the roof.
3. When making the gap for the air outlet without use
A longer turn up on the last tile (at low pitches) of spacers (refer to page 31; RIDGE/ Installation), the
facilitates fixing the tile into the ridge batten. upstand of the tile needs to be bent so that it makes
a step.
Cutting Line
min. 40mm
Bending Line
INSTALLATION MANUAL | 30
12 RIDGE
INSTALLATION 1 2 3 4 5 6 7 18 8 9
Install a thinner support batten at the
ridge when the top course is less than
the full width. This keeps the slope of
the top tile course the same as the
other tiles on the roof. The thickness
of the support batten depends on the
width of the top row tile. Fix all the cut
tiles by nailing into the ridge batten in
4 places through the small bend on
the turn up. This will leave space for
ventilation (refer to page 10; ROOF
STRUCTURE/ Ventilation space).
An air outlet can also be ensured
by installing spacers (refer to page
12; BATTENS/ Ridge batten). When
installing the ridge using spacers, nail
through the turn up and through the
spacer.
The barrels are fixed from the top
using screws or nails. The position of Intersection drawing of Option 1
the fasteners should be at the ends of
the barrels (at the overlap).
1 Tile 7 Ridge Bracket
2 Tile Batten 8 Underlay
3 Ventilation Space Batten 9 Rafter
4 Barrel 18 Thinner Support Batten
5 Ridge Batten
6 Air Outlet
Spacer
Nail
INSTALLATION MANUAL | 31
13 HIP
CUTTING AND
Hip Batten
BENDING TILES Last matching corrugation
INSTALLATION MANUAL | 32
13 HIP
INSTALLATION 1 2 3 4 5 6 7 8 9 14
Fix all the cut tiles by nailing through
the small bend on the turn up into the
hip batten. This will leave a space for
ventilation (refer to page 10; ROOF
STRUCTURE/ Ventilation space).
An air outlet can also be ensured by
installing spacers (refer to page 13;
BATTENS/ Hip batten). When installing
the hip using spacers, nail through the
turn up and through the spacer. Add
one or more nails through the front
edge into the tile batten, starting from
the bottom course.
The barrels are fixed from the top
using screws or nails into the hip
batten. The position of the fasteners
should be at the end of the barrel
(at the overlap).
Intersection drawing of Option 1
Spacer
Option 2: Hip batten with spacers
Nail
Option 1: Hip batten with air outlet
INSTALLATION MANUAL | 33
14 BOX BARGE
CUTTING AND
BENDING TILES
Gable Batten Cutting Line
Before the installation of the Box
Barge, it is essential that the edge Bending Line Last matching corrugation
of the end tile is turned up against
the barge batten (refer to page 12;
BATTENS/ Gable). For measuring,
cutting and bending the tiles, follow
the same procedure as at the hips
(refer to page 32; HIP/ Cutting and
Bending Tiles).
Cut and bend the tiles according to
the measurements: Basic dimension
INSTALLATION MANUAL | 34
14 BOX BARGE
INSTALLATION 17 15 16 3 9 14 8 1 2
Tiles are cut, bent and fastened
in place, nailing the turn up to the
gable batten.
Begin by laying the Box Barges
at the eave and temporarily tack the
barge covers in place, working up the
barge board. The overlap should be
100 mm.
INSTALLATION MANUAL | 35
14 BOX BARGE
75 mm
3. Bend the Box Barge along the Step 1: Right view
Bending line (dotted blue line) (Step
3 to Step 5).
25
m m
10
15 mm
0 mm
m
25 m
90° 90°
90°
10°
90°
INSTALLATION MANUAL | 36
14 BOX BARGE
4. Place the Box Barge End in its final Option 1: Step 3 Option 1: Step 4
position (Step 4).
90°
m
15 m
INSTALLATION MANUAL | 37
15 VALLEY
INSTALLATION MANUAL | 38
15 VALLEY
INSTALLATION 1 2 3 30 10 8 9 14
Cut and bend the tiles at the
Valley as straight as possible to
obtain a straight line. The last
tile should be nailed into the tile
batten as close to the batten end
as practicable. Never nail into
the Valley gutter.
1 Tile
2 Tile Batten
3 Ventilation
Space Batten
8 Underlay
9 Rafter
10 Valley
14 Ventilation Space
30 Clip
INSTALLATION MANUAL | 39
16 WALL FLASHING
INSTALLATION MANUAL | 40
16 WALL FLASHING
1 Tile
2 Tile Batten 21 Side Flashing
3 Ventilation Space Batten 22 Render
8 Underlay 23 Warmth Insulation
9 Rafter 25 Sealant
14 Ventilation Space 26 Side Wall Starter Flashing
INSTALLATION MANUAL | 41
17 TOP WALL FLASHING
INSTALLATION MANUAL | 42
18 MILANO RIDGE WALL FLASHING
INSTALLATION 1 2 3 4 5 6 7 29 18 8 9
Install a thinner support batten at the
ridge when the top course is less than
the full width (refer page 31; RIDGE/
Installation). Cut tile approximately
30 mm from the ridge batten. The flat
on the back of the tile then needs to
be turned up approximately 25 mm.
This brings the tile shape back to its
shaped profile and provides a bar-
rier against any wind-driven rain. In-
stall Milano Ridge Wall Flashing. The
flashing is fixed from the top into the
top course tile using screws and by
nailing through the small bend on the
turn up into the ridge batten. When
installing the ridge using spacers, nail
through the turn up and through the
spacer (refer to page 31; RIDGE/ In-
stallation). The barrels are fixed from
the top using screws or nails.
Nail
INSTALLATION MANUAL | 43
19 CHIMNEY FLASHING
1 Tile
2 Tile Batten
3 Ventilation Space Batten
9 Rafter
27 Chimney Flashing
INSTALLATION MANUAL | 44
19 CHIMNEY FLASHING
1 3 2 27 27 28 9
1 Tile
2 Tile Batten
3 Ventilation Space Batten
9 Rafter
27 Chimney Flashing
28 Board
INSTALLATION MANUAL | 45
20 INSTALLING ACCESSORIES
Nail Nail
Nail Nail
Nail
INSTALLATION MANUAL | 46
20 INSTALLING ACCESSORIES
Step 1 Step 2
Step 3 Step 4
INSTALLATION MANUAL | 47
20 INSTALLING ACCESSORIES
Nail
Nail
INSTALLATION MANUAL | 48
20 INSTALLING ACCESSORIES
PLATFORM, STEPS
Install the base plate first, then drill the holes into the
tile and install the tile. Finally install the platform or
steps.
Platform Steps
Washer
Washer
INSTALLATION MANUAL | 49
21 MANAGEMENT OF THE WORK SITE
The following outlines some simple methods for 1. Box Barges: determine the length of the barges.
estimating the quantity of tiles and accessories Divide the lineal coverage per accessory (i.e. 1.9
required for a roof. m) to calculate the number of units required.
INSTALLATION MANUAL | 50
NOTES
INSTALLATION MANUAL | 51
EUROPEAN OFFICES
European Head Office Adriatic Region Ukraine / Belarus / Kazakhstan /
AHI Roofing Kft. AHI Roofing Adriatic Azerbaijan / Georgia
Fehérvári út 28/14 Dunajska cesta 129 Phone: (+38) 0504476297
8100 Várpalota SI-1000 Ljubljana www.ahiroofing.com.ua
Hungary Slovenia
Phone: (+36) 88 552 800 Phone: (+386) 1 56 00 730
Fax: (+36) 88 552 888 Fax: (+386) 1 56 00 735
Email: office@gerardroofs.eu Email: info@ahiroofing.si
www.gerardroofs.eu www.gerardroofs.si
www.gerard.hu