Recent developments in infrastructure projects as well as modern architectural practice has given Lloyd Insulations India opportunities to introduce new roofing and wall cladding concepts in the Indian market
Growth story in Roofing & CladdingEarlier, metal roofing was only used in industrial buildings with conventional concepts like screwed down corrugated metal roofing. The airport revamping program by Airport Authorities of India has changed its conventional thinking in view of large roofs involved and modern architectural features. This has given opportunities to introduce new concepts like aluminium built-up roofing systems as well as single ply membrane built-up roofing systems both of which need specialisation.
Today, Lloyd Insulations offers almost all type of roofing and wall cladding systems in India which are available in international markets. Because of this, the Company is in a position to offer roofing solutions for buildings with minimum slope (up to 2 per cent) and for buildings with steep slopes (in the range of 1:10 to 1:3). Based on shape, size and contour of the roof; Lloyd Insulations engineers all types of roofing systems keeping in mind necessary wind load resistance and weather tightness of the building envelope.
It offers specialised aluminium built-up roofing system which can address thermal as well as acoustic performance requirements in functional buildings, like airports, commercial complexes, supermarkets etc. The recent example of the same is Terminal 1C at MIAL GVK domestic airport at Mumbai. This concept offers designers a clean finish by providing single length roof sheets as per the building requirements in curved shapes, both concave and convex.
For buildings with very low slopes like MIAL GVK’s Terminal II international airport project, Lloyd Insulations introduced single ply TPO built-up membrane roofing system with structural decking, fibre reinforced gypsum boards, PIR insulation boards, vapour barriers and weather tight covering of fully adhered Thermo Plastic Olefin (TPO) membrane. This roofing system is also designed for specific thermal, acoustic and fire performance requirements in line with FM and UL guidelines.
To support green movement in the country, the Company introduced special grade of Lloyd Sandwich Panels with metal facings with core of Rockwool or PIR (Poly Isocynurate foam) to offer a ‘Zero ODP’ material. Both the materials are top in the list of green building resource index.
Conventionally, sandwich panels were used for wall cladding application in vertical orientation.  Recently, Lloyd Insulations introduced very special product in Lloyd Sandwich Panel system which can be laid horizontally with plain architectural grade metal facing of desired colour. It has recently completed such application for Ferero Rocher, Italy for their chocolate manufacturing unit at Imsofer Manufacturers (India) Pvt. Ltd. in Baramati. This horizontally laid Lloyd panel system concept can also replace aluminium composite panels which are used in building applications for architectural finish. This system offers an added advantage of heat and acoustic insulation with excellent architectural finishing.All of its new concepts afford great flexibility to architectural community to freely design buildings without compensating for any performance requirements. At the same time, the Company is able to achieve total weather tightness which is of prime importance.
Innovations in the Roofing & Cladding marketAll above referred roofing and wall cladding concepts are fairly new in Indian market and may not to be considered innovative as they have already been used for quite a long time in European, American and Middle East markets. India is lagging behind, perhaps because we started using metals in our buildings very late and also due to hesitation to change our conventional mindset towards building construction. There are certain concepts like copper roofing which are quite innovative but from the point of functional requirements and economics, there would be restrictions for using the same for large projects. Retrofitting of old buildings has definitely given the Company a chance for innovation in this sector. Depending upon the actual condition of the building, it designs tailor made system for such applications with various options – like, three choices of standing seam roofing –both with steel and aluminium, ‘KLIP FIX’ non punctured roofing, TPO membrane system with best solar reflective index and to minimise heat island effect.
Lloyd Insulations also introduced concepts like EIFS Exterior Insulation Finishing System which can be used with conventional wall cladding application. EIFS is designed to result in thermal insulated, protected, decorative exterior lagging system. High density water repellant mineral wool, rigid polyurethane foam either as slabs or in-situ sprayed form are featured as insulant, to be protected externally with mineral or synthetic plastic. The thickness of insulation can be designed in line with R Value requirements as per ECBC or IGBC norms. Apart from the insulation layer to achieve the requisite standards of thermal performance, the system incorporated provides weather proof finish of a plaster or rendering. It can also comprise bricks, slabs, tiles or decorative board as well.
Material being used for extreme climatic conditionsThis aspect is very sensitive as far as India is concerned. The environmental conditions up in north are totally different than environmental conditions down in south same is the case with east and west coast. If a designer designs without keeping in mind the environmental factor while designing roofing and wall cladding application, serious failures may occur in terms of damage of architectural finishes, weather tightness etc. For inland applications, colour coated galvanised steel products are highly popular and affordable, although they offer restricted architectural features. Owners also prefer colour coated zinc aluminium products which have a proven track record of last 10-12 years in Indian market. For severe environmental conditions, aluminium is considered as the best option. But it is quite expensive compared to above referred options. At the same time when designers want to impart architectural features, aluminium which offers great flexibility and becomes the only choice to convert designs into reality. Use of non-metal components like TPO membranes is feasible for roofing system in low slope roofing applications.
Types of materials is in demand & their durabilityCurrently, for roofing and wall cladding application colour coated galvanised and colour coated zinc aluminium coated products are very popular in Indian industry. Aluminium products are also getting recognition in the market because of the flexibility offered to designers. Sandwich panels with metal facing are also receiving good acceptability from industrial as well as commercial sectors due to their providing ‘one-step’ solutions to insulation and weather tightness.
Green productsLloyd Ins ulations India has worked on prestigious projects like the American Consulate, new office complexes at Bandra Kurla complex wherein the insulation products of company like Rockloyd rockwool building insulations and super foam polyurethane products got prestigious approval from overseas building operation divisions of US government. The Company has been selected for another high profile project by Bayer for their ‘zero emission’ building at Noida.
The Rockwool insulation products are the first choice of designers in the field of green buildings, because of their being based on naturally occurring raw materials. Lloyd sandwich panel system incorporates fire-safe polyisocynurate foam core with zero ozone depletion potential. Today, it offers roofs with high solar reflective index and also ‘Green Roofs’ (roof garden) to drastically limit heat island effect and thereby earn high carbon credits and LEED rating.
Lloyd Insulations’ projects in India The Company is currently working on and almost on the verge of finishing roofing and cladding works for Imsofer at Baramati (a division of Ferero Rocher, Italy) wherein Loyd PIR sandwich panels are featured.
There are total 5 buildings in this project which are temperature controlled and all have Lloyd TR PIR panels used for roofing.  These panels are manufactured with Traperoidal colour coated metal sheets on weather exposed side with 100 mm thick polyisocynine foam core and slightly ribbed colour coat metal facing on the bottom side.
For wall cladding in all buildings architectural grade horizontally laid Lloyd PIR sandwich flat panels are used in 3 colour combinations. The panel thickness used is 100 mm. The outer facing of panel is flat PVDF colour coated galvanized steel with 100 mm PIR core and slightly ribbed colour coated liner. The panel joints are designed in such a manner that no where fastener is used to fix the panels are visible. Due to this reason, this system is also called as ‘secret fastener’ system or ‘hidden fastener’ system.
The total area for roofing and  wall cladding is around 45,000 sq. mtrs. and Lloyd Insulations’ job value is around Rs. 12 crore. The Company has almost completed work in all the buildings and total time required to finish the work is around 6-7 months.
Contact:
Abhijeet P. KaleDeputy General Manager – Technical & MarketingLloyd Insulations India Limited386, Veer Savarkar Marg, PrabhadeviMumbai – 400025.Tel: +91-22-30480129