Construction Mirror Industry Features Details

Roofing and Cladding industry: Market size, Trends and Challenges

August 08, 2018

 The Indian construction industry has witnessed a significant evolution in roofing systems across different sectors. The current status of roofing industry also gives a special focus on asbestos, tile and metal roofing segments, which makes it happening ever before. With a dedicated impetus on infrastructure segment, the future of roofing and cladding segment is going to reach beyond expectation. Roofing industry in India is preparing for the next generation of ambitious projects. Growth in the infrastructure and industrial segment has been a major demand driver for roof and wall cladding industry. It has registered a double digit growth over past three years and the future of this industry is also looking bright considering the low steel penetration and high demand in construction industry. The current trend is the use of colour coated metallic roofing systems across all the major greenfield and brownfield projects. After increased awareness on hazards associated with production and usage of asbestos roofing, the roofing requirements of the Indian customers are met in the form of metallic and nonmetallic types. The major reasons for this practice are durability, high strength, economical and faster construction, design flexibility and improved aesthetics.There is also growing awareness about the advantages of sustainability and long term cost effectiveness since the future is in sustainable materials. Turnkey projects where roofing is not just a structure to cover the building but an integral part of the entire space provides support to other systems such as HVAC, lighting, energy generation and so forth.
Then there is pre-engineered buildings which have emerged and provided cost effective roofing solutions. With more optimum designs and better quality construction, the building construction costs have lowered at the same time, with quality standards.
 
Market Size and Trends
The Indian roofing industry has witnessed a sustainable growth and is preparing for its next generation of ambitious projects. A major shift is observed from clay tiles and conventional roofing systems to metal cladding solutions. Today customers are looking for architectural solutions which enable innovative shapes in addition to attractive colours. The key issues facing the roofing market at present is an emphasis on lowering costs, at any cost. This has led to sub-standard construction and deterioration on quality, increasing costs for the client in the longer run. Educating the market on the importance of quality and the advances in roofing is a trend that has developed due to this issue. Also compromising on costs also brings the problem of leaking. Unskilled labour, no expert supervision and other by-products of cheap materials lead to a building without adequate weatherproof. Another trend is the emphasis on sustainability as mentioned above and safety as well. Worker conditions and the feasibility of the structure for long use and expansion are taken into account by knowledgeable clients and roofing system providers.
The total market size of steel roofing industry is approximately 1MT. The Indian market has witnessed a major shift from asbestos and galvanized steel sheets to Zn-Al coated sheets. Asbestos consist of carcinogenic material, has low strength and cracks easily. Also, increased corporate and public awareness about climate change has resulted in new initiatives like green building concept and elimination of carcinogenic materials.Moreover, Zn-Al coated sheet provides excellent atmospheric resistance in a wide range of environment under many diverse conditions. Aesthetics, superior technology, durability, thermal efficiency are some of the significant driving factors for Zn-Al coated sheets. Performance of 150GSM Zn-Al coated material is four times longer than 275 GSM Zn coated material.
Mantri Adarsh Gram Yojna which are expected to provide long-term strength to the roofing market. There are estimated 25 crore houses in India of which 46% are considered to be homes with pucca roofs and rest made of thatch (Kutcha roofing) and clay tiles. In rural areas alone, security concerns along with increased income level has led to an increase in the desire of shifting from kuccha house to pucca house. On the other hand increased construction in urban areas and infra development activities like construction and renovation of airports, metro rails, SEZs, industrial cities and IT parks have kick-started the demand for modern, efficient roofing systems. Overall, the roofing market is witnessing healthy growth on the backdrop of consistent development in infrastructure and rising disposable income both in urban as well as rural areas.
There is a wide spectrum of roofing materials, which are used for different structural, aesthetic, economic and performance reasons. Roof designs have developed from just being a weather performance element to an architectural trademark that can be environment friendly, structurally sound, reasonably priced and aesthetically attractive. As per data, about 55% of the Indian market continues to use RCC, followed by clay tiles (18%). Fibre cement sheets contribute around 11%. The segment seeing an increasing demand is metal roofing which expects to see a growth of 30% CAGR. This growth is predominantly seen in developed states, cities and rapid urbanization. Although rural regions account for a higher number of houses in India, the roofing solutions opted by them are generally cheaper than their urban counterparts. Asbestos cement roofing installed capacity is expected to witness steady growth over the next five years. Some of the leading players in the fibre roofs have come a long way. Today’s metal roofs are attached to the structure with concealed clips, which slide to accommodate expansion and contraction. Manufacturing industries such as power, automobile, engineering goods and services including logistics, warehouses and infrastructure are large users of PEB. Leading players in the metal roofing industry are Lloyds Insulations, Tata Bluescope Steel, Kirby, Pennar and Interarch. The total market for steel roof and wall cladding industry alone is about a million tonne and has registered near to double-digit growth over the past 3 years. There also seems a major shift from galvanized steel sheets to Zn-A cement roofing sector are Everest, HIL, Vishaka and Ramco. RCC is widely used in India owing to its cost effectiveness & versatility. Since most structures that people inhabit are residential or commercial buildings, they go with reinforced cement concrete (RCC) roofs. Metal roofing as a concept was introduced a few decades back to replace asbestos cement panels. The idea gained ground with the evolution of pre-engineered steel buildings for industrial manufacturing sectors. Since then, metal coated sheets as the latter provides excellent atmospheric resistance in a wide range of environment under many diverse conditions. Aluminum products are also getting recognition in the market because of the flexibility offered to designers. Applications like flat roofing where metal profile have limitations from viewpoint of weather tightness, nonmetallic outer finishes like TPO, PVC or EPDM are offered as part of roofing assemblies.
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. These panels incorporate mineral fibre to provide thermal insulation and eliminate interstitial condensation and cold bridging. They offer rigid and lightweight construction, with no vapour or breather membranes required, and being a single unit, significantly reduce installation time. Composite panels are suitable for use on all building types in the commercial, retail and industrial sectors, providing flexibility for change of future use. They can also be installed over existing sheet-covered roofs to improve thermal insulation and weather protection. Revamping airports has led to the emergence of aluminum built-up and single ply membrane built-up roofing systems. Architectural trends have been of considerable importance to the level of demand for roofing materials in luxury housing. Over the years, architects have largely developed a preference for the use of more traditional materials such as slates and clay tiles because of the environmental and aesthetic advantages that they bring.Shingles are also becoming increasingly popular in the country. Shingles are fiberglass reinforced, high grade, mineral- stabilized asphalt based mats which are overlaid with high strength ceramic coated granules and underplayed with a mineral stabilizer cum fire retardant. They come with multiple-laminate options and in a wide variety of colors and they can be applied on sloped roof which could be of concrete,wooden or any such solid plane material.
With the Government of India’s Solar Mission, companies like Lloyd Insulations are working on a few proposals wherein PV Solar Panels are integrated with almost all types of roofs.Challenges involved are integrity of the entire roof from view point of water tightness and structural integrity of PV solar panels. The company has engineered PV solar systems with its roofing applications with importance given to cost economics and track records. Other solar technologies that can revolutionize the Indian roofing industry are the latest generation of thin film solar and photovoltaic panels that look like ordinary shingles. PV laminate is a superior method of integrating photovoltaic with metal roofing. The laminates have a peel and stick backing that enables them to be attached to the metal roofing panels in the shop or at the site. When applied directly to the standing seam metal roofing of dark colours, it is hardly discernible from ground level.
PV laminates work well in cloudy, low-light environments, capturing different light wavelengths and allowing current to flow around shaded areas of the laminate. They also perform well in coastal conditions and in industries where there is a lot of airborne dirt and particles. Moreover as they are directly applied to the metal roofing and do not require framing,they are cost effective than conventional solar panels. Solar roof tiles are lightweight tiles or shingles that look like normal tiles and the installation process is similar to that of normal roof tiles except that solar roof tiles must always be bordered by normal roofing tiles. The tiles are coated with PV cells made of amorphous silicon. They can be designed to look like conventional asphalt shingles and can be used instead of roofing materials such as asphalt shingles, standing seam metal roofing and slate or concrete tiles. Also, solar tiles can be blended with existing asphalt roofing tiles, are waterproof and designed to withstand heavy sun and natural elements. In the near future, most companies expect at least 50% of the roofs in industrial, commercial and public buildings will be with PV solar systems. Green roofs are also coming to the fore with the emphasis on sustainability and efforts to mitigate the urban heat island effect. However, they are still in nascent stages in the country due to the lack of awareness and knowledge required for installation and maintenance.
Roofing industry has witnessed a paradigm shift in the last few years. With increased investment in infrastructure projects, customers are demanding durability, flexibility along with aesthetically pleasing designs. It is observed that customers are shifting from conventional screw-down system to concealed fixed system. In screw down system, the screws are exposed to the atmosphere. Due to poor workmanship and use of low quality fasteners they often leak and rust. On the other hand, in concealed fixed system, sheet sare fixed on clips which in turn are screwed on purlins, this reduces the chances of leakages. Roofing industry in India is preparing for the next generation of ambitious projects. Growth in the infrastructure and industrial segment has been a major demand driver for roof and wall cladding industry. It has registered a double digit growth over past three years. Major shift is observed from clay tiles and conventional roofing system to metal cladding solution. Customers are looking for architectural solution which provides innovative shapes such as convex, concave in addition to new attractive colors. The future of roof and wall cladding industry is bright considering the low steel penetration and high demand in construction industry.
 
Challenges
The presence of large organized players is limited in the roofing industry. Unavailability of skilled manpower for installation, low product quality and lack of safety awareness are the increasing challenges for roofing industry. Having set several benchmarks for safety in the industry, our state-of-the-art manufacturing facilities have achieved ISO 14001:2004, environment Accreditation and OHSAS 18001:2007 on Safety system. Safety is an integral part of our core values and an essential condition for employment. We regularly educate our stakeholders – employees, customers, builders, suppliers, partners, on best safety practices.We constantly aspire to achieve “Zero Harm” for all our stakeholders in all forms of activities.
Problems with metal roofing:  Today, manufacturers recommend a minimum roof pitch of 8° for installing corrugated sheet roofing, but in many situations art deco houses had corrugated roofing installed with roof pitches of 7° or less. This may have resulted in water getting under the laps between sheets or at flashing locations and being unable to readily drain out. There may also  be ponding of water at any lower points or indentations in the roofing. If the roofing material is the original corrugated galvanised steel, it may require replacement. If this is the case, unless the roof pitch is 8° or greater, a different metal roof profile such as a trough section roofing must be installed. Trapezoidal symmetrical and unsymmetrical rib profiles and standing seam, fully supported flat sheet metal roofing materials may be used with roof pitches as low as 3°. Confirm manufacturer’s’ recommendations for minimum roof pitch for specific materials. It is important, particularly when replacing membrane with profiled metal on a low pitch, to ensure that flashings or internal gutters are extended sufficiently under the roofing material to prevent water tracking or being blown under the roofing and leaking beyond the flashing. Generally, to avoid this risk, it is advisable to replace low-pitched roof cladding with a membrane system with gutters integrated into the membrane.
Problems with built-up Roofing: The early built-up roofing had a limited life span as bituminous materials were prone to a number of problems including: hardening and cracking of the membrane; rotting of organic fibres in early the felts as the bituminous coating deteriorated allowing moisture to penetrate; differential movement between the roofing material and the substrate and insufficient elasticity in the roofing; loss of adhesion of stone chips and subsequent loss of UV-protective coating to the membrane; breakdown of the paint finish and subsequent loss of UV-protective coating to the membrane. Roofs with low pitches that were slow to drain, were more likely to suffer some water penetration through any minor breaches in the roofing membrane and this may result in eventual failure of the roofing.
Deterioration of Roof Framing: Moisture, whether from external sources or from internal condensation (see below) may lead to deterioration of timber roof framing. Roofs should be checked for evidence of sagging, which may be due to inadequate timber sizes, or rot, which may be due to moisture penetration.
Condensation and Trapped Moisture: Because art deco houses were hard lined and uninsulated, there is a risk that condensation will occur on walls and ceilings, particularly where the house is shut up during the day, and particularly where the original timber windows have been replaced with aluminium. Ensuring that the house is well ventilated, insulated if possible, and heated, will reduce the amount of condensation forming. An issue that can arise with low-slope skillion roofs is the accumulation of moisture within the roof space, which can form as droplets on the underside of the timber sarking or metal roofing. Research has shown that moisture within roof spaces is carried there by air movement from moist internal spaces into the roof space. A number of art deco houses incorporated vents into parapet walls to provide ventilation of the roof space. Where there is a membrane roofing system, some of this moisture is transferred through the permeable substrate and then condenses (on cold nights) on the underside of the membrane. As the sun warms the roofing in the morning, the moisture cannot escape back through the substrate, and bubbles form as the water tries to dry to the outside. Unless the source of moisture is removed, the bubbles will continue to expand, and because the substrate remains wet, there is an increased risk of timber damage. For metal roofing, droplets that form on the underside of the metal may drip back down onto the ceiling, which may result in damage to the ceiling and/or ceiling framing.
Problems with corrosion: Corrosion of metal components such as the roofing, fixings, flashings or accessories, may appear as the familiar red rust, or as a white discolouration on the surface of materials containing zinc, which is called white rust. It may be caused by: moisture combined with salt spray, dirt, or hydrogen sulphide from coal-burning fires or geothermal activity; contact between dissimilar metals resulting in electro-galvanic action; runoff from copper-based timber treatments. Houses/PEBs built close to the sea are likely to be affected by salt or chloride contaminants. The parts of the house most likely to be affected are the subfloor, roof cladding and flashings, window and door flashings and cladding nails.
No Underlay: It was not uncommon for walls and roofs of art deco houses to be built without any form of building paper or underlay. If  they have previously been re-roofed or reclad, underlay may or may not have been installed. Options for retrofitting underlay include to install underlay: when replacing roofing; by folding into the framing cavities for walls when the interior lining is being replaced.
Unavailability of skilled manpower for installation, low product quality and lack of safety awareness, presence of unorganized players coupled with installation issues are some of the challenges that are putting a damper in the growth of the Indian roofing industry. Again, India is a country with several geographical and weather variations across the region. Roofing solutions need to be adapted as per a region’s climate and creating customized roofing solutions that are suitable for each of these regions is a big challenge for the industry. Rising and fluctuating input costs such as that of steel also hamper the supply side of the roofing industry value chain. Under such a condition it becomes difficult for the manufacturer to develop innovative and customized products at affordable costs. The roofing industry is a dynamic industry, with new innovations, materials and tools cropping up on a regular basis. With the rising importance of roofing design and the adoption of “green” products, the sector is all geared up to go through the roof in the coming decades.

 

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