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Exploring DECK Roofing Panels

When it comes to renovating an old roof or installing a new one, primarily in industrial constructions, there are various options to choose from. Notably, the installation of sandwich panels or DECK Roofing stands out. In other posts, you will find everything you need to know about Sandwich Panels and the different products we offer at Panel Sandwich Group, so next, we will focus on explaining what DECK Roofing is and what it is used for.

Before beginning, it is necessary to specify that there is no type of roofing that is better than another: both are very good solutions for your industrial roof, so the choice will depend on the specific needs of each project.

What are DECK Roofing Panels?

The upper enclosure of a building is one of the most important areas to achieve good insulation and optimal waterproofing conditions in a construction, factors very important if we want to improve energy efficiency inside. And DECK Roofing is a solution that encompasses all of this.

Support Sheet + Insulation + Waterproofing

It is a type of flat roof used mainly in industrial projects to cover the top of a construction, as well as in all kinds of non-residential buildings such as sports centers, warehouses, hypermarkets, or shopping centers. Its main function is to cover and insulate buildings and constructions, and its use is especially recommended in cases where there is a minimum slope between 1% and 5% (depending on the roof configuration).

Composition of DECK Roofing Panels

At Panel Sandwich Group we receive this product arranged in three independent construction elements that can vary. This type of roofing is formed by an integral system composed of the following levels:

DECK Roof CompositionDECK Roof Application

1. Interior Sheet/Profiled Sheet

The base that supports the entire load of the roof is the profiled sheet, which is anchored with suitable mechanical fixings to the structure. That is, it is the plate responsible for bearing the weight of the entire roof.

The choice of steel thickness and profile will depend on the distance between supports and the load to bear.

It is composed of materials that offer great resistance to the passage of water vapor, preventing condensation in the insulation package of the roof and ensuring that it maintains its properties.

2. Thermal and Acoustic Insulation

Depending on the requirements related to thermal insulation, acoustic properties, fire reaction, or compression resistance, we can choose between the different types of cores and thicknesses.

In the following table, we have gathered responses to various properties of the materials we use to ensure the insulation core of our panels (Rock Wool and Polyisocyanurate).

Basic CharacteristicsRock WoolPolyisocyanurate
Thermal ResistanceGoodExcellent
Compression ResistanceFairGood
Fire ReactionExcellentFair
Vapor ReactionLowFair
Water AbsorptionGoodExcellent
Acoustic BehaviorExcellentFair

DECK Roofing Panels with a Rock Wool core, in addition to providing good thermal and acoustic insulation, also offer fire protection since it is a completely non-combustible material, with an excellent fire reaction. These sheets may come without coating or with coatings such as glass veil or finished in oxidized asphalt.

As for DECK Roofing Panels with a Polyisocyanurate (PIR) core, they consist of rigid PIR sheets that are lighter than Rock Wool and offer better thermal insulation. There are multiple options for the coating of both sides: glass veil, asphalt finish, aluminum, Kraft paper, among others.

3. Waterproofing

It involves a waterproofing sheet or membrane that acts as a waterproof coating to ensure total watertightness across the entire roof surface. For the transverse and longitudinal overlap of the plates, they are joined together by heat or flame welding.

In order to achieve the highest level of waterproofing possible, we have different solutions for the DECK Roofing: Bitumen Modified Sheet or Asphalt Sheet is the best solution when an excellent bond to the substrate, ease of adapting new elements on the roof, and greater thickness are required. Its use is increasingly less in favor of Synthetic Sheets.

On the other hand, Synthetic Waterproofing Sheets can be of two types depending on their composition: with PVC membranes or with TPO membranes.

Applications of DECK Roofing Panels

As previously discussed, the use of DECK Roofing was limited to constructions such as supermarkets, commercial buildings, logistics centers, or factories, typically in new construction. Its insulation system was also used in roof rehabilitations of industrial buildings.

The use of DECK Roofing in new constructions is primarily due to the following factors: its easy assembly, dry installation, the continuous insulation it provides (avoiding thermal bridges),and its accessibility (the roof is accessible in case of maintenance of installation equipment or specific points such as skylights, drains, etc.).

Currently, improvements in material performances and, consequently, in construction systems, allow achieving high values of acoustic insulation without impacting the environment. Therefore, the use of this type of roofing is no longer limited only to commercial and industrial buildings but has expanded to other construction typologies such as conference and exhibition halls, cinemas, multipurpose halls, sports centers, or auditoriums, among others.

Many clients contact us asking when DECK Roofing is better compared to other alternatives. At Panel Sandwich Group, we advise and guide our clients to try to resolve all their doubts. Here are five scenarios where DECK Roofing is the best alternative:

  • When the roof has a large surface area:

DECK Roofing is especially recommended in very large buildings such as large logistics centers, hypermarkets, airports, etc. It is very useful when openings for smoke outlets or natural lighting are needed.

  • If we want a flat roof or with slopes less than 3%:

DECK Roofing allows the construction of large surface roofs that do not require a steep slope.

  • When we need it to support certain installations:

In many cases, the roof needs to encompass smoke outlets, skylights, ventilation ducts, ..., or need to be used to include installations such as solar panels or ventilation systems. In these cases, DECK Roofing is ideal because it can support these loads without risk.

  • If we need total waterproofing without joints:

The DECK system includes a membrane or waterproofing sheet that makes it even more watertight.

  • When you want a green roof:

There are DECK Roofing options that allow for a green roof finish. This is a very interesting option in the world of sustainable construction.

Installation of DECK Roofing Panels

It is worth remembering that the installation of a metal DECK roof is a fairly simple process. However, at Panel Sandwich Group we recommend that the assembly be carried out by professionals as they will not only determine the conditions of the work area, but also the best way to install them.

Good installation conditions will ensure that the DECK Roof meets its basic requirements:

  • That it has a strong and quality metallic support.
  • That it includes an insulation system.
  • That at least one layer of waterproofing can be performed.

We also advise our clients that, in the case of the installation of non-walkable DECK Roofing or hard-to-access roofs, to leave a space where personnel can be placed for maintenance. In this way, it will avoid damaging it in the future.

Next, we explain the basic installation process of DECK Roofing:

1º We start the assembly by fixing the roof to the main structure with self-drilling screws. The importance of this first step is to prevent water from entering.

2º The insulation board must also be fixed with self-drilling screws. For a perfect finish and fit, Panel Sandwich Group suggests the use of washers.

To ensure maximum safety in the assembly process, at Panel Sandwich Group we recommend the installation of lifelines on our DECK Roofing. This is a horizontal anchorage device whose function is to significantly minimize any forces that have been generated in the structure in the event of a fall. Thanks to these systems, the protection that makes it possible to transit, stay, and perform work at heights of at least two meters is provided.

Where to Install DECK Roofing Panels?

Traditionally, these types of roofs are used in commercial buildings, logistics centers, supermarkets, and industrial warehouses, mainly in new construction, although the thermal insulation and waterproofing system can also be used in the rehabilitation of existing industrial-type roofs.

Currently, the construction systems and materials used provide significant improvements in their performance such that they contribute to environmental improvement and also, achieve high values of acoustic insulation.

In this way, the use of this roof is no longer limited to commercial and industrial buildings, where its use is logically still valid, and these systems can also be used in other constructions like cinemas, exhibition and conference palaces, sports centers, multi-purpose pavilions, auditoriums, and airports, for example.

Installation of PVC Waterproofing SheetsInstallation of TPO Waterproofing Sheets

Advantages of DECK Roofing Panels

After learning more about DECK Roofing, it is necessary to compile and mention the most notable advantages they offer:

  • Great thermo-acoustic insulation capacity: perfect for maintaining comfort inside the building.
  • High resistance to compression and weight: they are ideal for supporting heavy installations such as air conditioning equipment or solar panels. They also withstand weather conditions well and have good fire-resistant behavior.
  • Lightness compared to other materials.
  • Quick and easy assembly: its lightness makes installation very easy. Additionally, the installation of the different materials can be performed simultaneously.
  • Easy maintenance: this process is very simple and practical.
  • Versatility: it adapts to various geometric shapes and offers a wide variety of finishes. It is ideal for combining with skylight designs. Likewise, it perfectly combines both with air conditioning and ventilation systems.
  • Waterproofing: It is a watertight roof. That is, by not presenting joints, the risk of leaks is much lower, something that is reinforced with the presence of the waterproofing layer.
  • Good quality-price ratio. An aspect to highlight of the choice of a DECK roof is that it turns out to be an economical investment in the medium to long term.
  • Continuous finish.
  • Materials respectful of the environment.
  • Durability: Excellent resistance to atmospheric agents and aging.

If you would like to learn more about DECK Roofing or about any product from Panel Sandwich Group, do not hesitate to contact us through our sales team. You can do so through this form that appears on our website or by calling the phone number +1 904 512-3122