Barrel Vault/ Our Lady of Sion College, Box Hill, Melbourne Victoria

Free span 9.6mtr

Everbright E610 clear panels with silver polycool inserts was installed recently at Our Lady of Sion College, Box Hill, Melbourne to cover an outdoor area at the college. Everbright E610 was extruded and supplied in 9.97mtr curved panels and in 600mm configurations. Our panels simply clip together, making the installation process rapid, as our product only requires to be joined every 600mm on site. E610 free spanned 9.6mtr, incorporating Locking System 2.2 (see design loads). The total area was 300sqm, the curved panel length was 9.97mtr x 30mtr. The installation time on this project was two days and four men were available on site.

The standard performance data for our 74mm polycarbonate panels can be dramatically increased when introducing other materials within our panels.

This is due to our unique panel design and the two air gaps improving E610ís thermal performance and light transmissions even further. The polycool inserts are available in either a gold or silver finish.

The brief was given for a modern curved roof, minimal structural requirements and long life span. The client required a pleasant and attractive covered area for all the staff and pupils to assemble out of the elements. Another key factor was for a product with superior thermal performance, as during summer months it can reach high temperatures.

The specification was to make use of all the natural light available. Since less structure is required with our system less shadows are created, and as such the natural light translucency is at its full potential, making our system an excellent choice for this project.

For developments of this nature E610ís additional benefit, is that in the unlikely event of students climbing on the roof, our polycarbonate system will not break or the joints separate. Making E610 one of the strongest translucent materials available in the world today.

The front fix method was used on this development, which is the preferred fixing method for larger span curved projects and is different from the top fix method. The front fix method provides more strength and stability. On this particular project the structure was set at a 20 degree angle to accommodate our panels.

Front fix method for larger span curved projects;


Secure aluminium eaves angle with appropriate fixings at 200mm centres.
Tap out tab on end caps with the sleeve in the E610 tube. Usually two per panel edge.

Peel away the backing tape on the side of each panel to reveal butyl seal.

Drop single panel in position ensuring it locates inside each eaves angle starting from RIGHT to LEFT.
Drill 10mm diameter holes to face of eaves angle at 300mm centres unless otherwise specified to line up with sleeve and knocked out tab on end cap.

Slide and clip next panel onto previous, then fix polycarbonate locking bar between panels. Secure first panel to structure with the M8x30mm bolt as provided. This is fitted through the holes made in the eaves angle , through the tab of the end cap and into the sleeve inside a panel tube.

Repeat all process as above until complete roof width is installed.

Push fit all profile foam fillers, flashings and rainwater goods.

E610 fixing accessories supplied with large curved roofs;

a) Aluminium eaves angle EL16 supplied in 6mtr lengths 40mm x 40mm x 4mm.

b) M8 x30 stainless steel bolts EL26.

c) EL136 foam profile.

E610 LS2.2 Weight and dead load calculations;

Locking System LS2.2 = 10 kg/sqm with a dead load of 0.101kN/sqm.

See design loads, which shows you in more detail the different locking systems available.

E610 polycarbonate panels incorporate as standard detailing an excellent safety factor. All loading criteria are based on 0.75kN/sqm and a 50% safety factor as part of a standard specification detailing.

The geometry details on this project were:
Free span 9.6mtr/ radius 14mtr
Slope 20 degrees
Midpoint height 846mm
Curved length with eaves 9.97mtr

Our polycarbonate system give a seamless and continuous line, with no steel frame work spoiling the visual effect. E610 Integral locking bars hide the aspect of where a panel starts and where it finishes, so it becomes a continuous system giving a uniformed and conformed design feature. Creating an architectural flare, that isn't possible with any other polycarbonate system available on the market. Other systems would necessitate the need for a framed grid work support system across the entire roof. On this project our system only needed to be secured to both sides of the eaves structure, all the joints are self sealing once the integral locking bar is fitted.

The construction process with E610 is very simple and is less time consuming to install on site. We can advise that there was a significant cost saving on the structure requirements with our system on this project.

Major Advantages:

  • Superior free span capabilities (see design loads)
  • Fully Trafficable.
  • Light weight product. Each panel could be easily lifted and locked into place on site.
  • E610 supplied in one complete flat or curved 12mtr length.
  • Less structure means less shadows created and as such the natural light translucency is at its full potential.
  • Great visual architectural effect.
  • Silicone free system. No possible leakage where product is sealed.
  • Translucent so that it maximizes natural light without excessive glaze.
  • Great thermal performance and sound reduction.
  • Self cleaning dome shape profile.

This site is situated at Our Lady of Sion College,1065 Whitehorse Road, Box Hill, Melbourne VIC. This project can be viewed should adequate notice be given.

Everbright E610 major advantages at a glance:

  • Rapid installation
  • Superior free span (see design loads)
  • Can be extruded to a maximum 20.5mtr
  • Minimal additional structure required with our system
  • Strongest translucent material in the world (74mm profile)
  • 100% fully trafficable
  • Passed the AS1562.3-2006 sand bag test
  • Impact resistance
  • Intruder resistance
  • Cyclone rated
  • Superior thermal/ acoustic performance
  • Long life span
  • Coextruded UV protection layer
  • Australian manufactured
  • Unique jointing arrangement
  • Self cleaning dome shape
  • Light weight product

This project is located at , Victoria
The project can be viewed should site visits be required and adequate notice is given.

The Installation Visually

  • Project location

    Project location

  • 9.6mtr free span

    9.6mtr free span

  • Modern uniformed look

    Modern uniformed look

  • Minimal structure

    Minimal structure

  • Unique design feature

    Unique design feature

  • Simple construction

    Simple construction

  • Rapid installation

    Rapid installation