CHAPTER

6
Single-Ply Roofing
he single-ply membrane roofing system was developed in Europe in the late 1950s, partially in response to difficulties in obtaining asphaltic materials for conventional roofing systems. Single-ply membranes were first introduced in the United States in the mid-1960s by European manufacturers. Since their first appearance in our country, single-ply materials have become increasingly popular. Whether imported from Europe or produced domestically, these products have proven themselves in a wide variety of climates over more than four decades of use. Built-up roofs (BUR) are literally constructed on the roof by the contractor, using component materials such as felts and asphalt (Fig. 6-1). Thus, they are subject to problems caused by weather, worker error, and material inconsistencies. Single-ply membranes, however, are flexible sheets of compounded synthetic materials that are manufactured in a factory to strict quality control requirements. This process minimizes the risks inherent in BUR systems. Primary among the many physical and performance properties that these materials provide are strength, flexibility, and long-lasting durability. The prefabricated sheets are inherently flexible, can be used with a variety of attachment methods, and are compounded to provide watertight integrity for years of life. These various factors are

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F I G U R E 6 - 1 A single-ply installation.

the reason for the popularity of single-ply systems, which account for up to 40 percent of the commercial roofing market. There are many different single-ply roofing products. Although their chemistry and composition are complex, the Single-Ply Roofing Institute (SPRI) classifies them into three main groups: thermosets, thermoplastics, and modified bitumens. Each of these types of singleply membranes includes of a number of individual products.

Casting Thermosets
Single-ply thermoset materials are chemical crosslinkages of polymer that cannot be changed once the sheet material is cast. Two types of thermosets are used for roofing: vulcanized, or cured, elastomer and nonvulcanized, or noncured, elastomer. The advantages associated with elastomeric roofing include performance, cost benefits, conservation, the substitution of materials, and adaptability to a wide range of roof configurations. The membrane is able to elongate and accommodate movement in the substrate. The

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extension or elongation of certain systems at room temperature can be as high as 700 to 800 percent. Elastomeric membranes can bridge nonworking joints and cracks in the substrate without cracking and splitting, provided they are not bonded or are reinforced at these locations. The ability of the membrane to remain flexible at low temperatures is another feature. Some elastomeric membranes remain flexible at temperatures as low as 50F, whereas conventional bituminous membranes become brittle within a range of about 0 to 45F. Some elastomeric membranes retain their ability to elongate at low temperatures, although the elongation is reduced from that at room temperature, or approximately 68F. Some elastomeric roofing systems weigh less than 10 pounds per 100 square feet of roof area. This is a minimal weight when compared to that of smooth-surfaced bituminous systems, which weigh approximately 150 pounds per square foot. Roof designs for many modern buildings must be architecturally attractive and functional. These roofs include a variety of configurations, such as domes, barrels, and hyperbolic paraboloids. Conventional materials usually are not suitable for these shapes. Elastomeric membranes are able to conform to a variety of shapes and contours. This makes them suitable roofing materials for these modern architectural designs. In addition, some elastomeric roof membranes are available in a variety of colors that can enhance the attractiveness of roofs. Colors can also be reflective, which reduces the absorption of solar radiation and results in lower roof temperatures.

Vulcanized Elastomers
Ethylene propylene diene terpolymer (EPDM) and chlorinated polyethylene (CPE) are the two most popular vulcanized elastomers.
ETHYLENE PROPYLENE DIENE TERPOLYMER (EPDM)

This thermoset membrane is compounded from rubber polymer and is often referred to as rubber roofing. The American Society for Testing and Materials (ASTM) classifies this material as an M class polymer. The M in EPDM is sometimes taken to mean monomer, which is technically incorrect.

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Ethylene and propylene, derived from oil and natural gas, are the organic building blocks of EPDM. When these are combined with diene to form the basic rubber matrix, the result is a long-chain hydrocarbon with a backbone of saturated molecules and pendant double bonds. The practical translation is that ethylene, propylene, and diene combine to form a large molecule that is very stable when exposed to sunlight, heat, ozone, and moisture. These molecules can be cured, or vulcanized, into a rubber sheet that permits elongation of more than 400 percent without structural damage. In other words, EPDM is the binder material, or the basic rubber matrix that gives the final membrane rubber properties. Carbon black, oils, processing aids, and curatives are added to increase tensile strength, flexibility, mixing, and dimensional stability. Features that contribute to the popularity of EPDM single-ply roofing systems include:
I Long-term weatherability, including excellent resistance to tem-

perature extremes, sunlight, ozone, and moisture

I Ease, speed, and cleanliness of installation I Flexural stability; an elongation factor enables EPDM membranes

to accommodate roof deck movement and displacement

I Compatibility with a wider variety of polystyrene insulation

products than asphaltic materials

I Ease of maintenance I Proven long-term performance

Another feature is adaptability. Various application techniques, such as ballasted, fully adhered, and mechanically fastened, allow EPDM roofing systems to be applied to virtually any roof surface: flat, spherical, curved, or slanted. EPDM also offers reroofing flexibility. When the roof deck is moisture-free, EPDM can be installed over existing roof membranes in reroof situations. Finally, code and standardization progress by the Rubber Manufacturers Association (RMA), Underwriters Laboratories, Inc. (UL), and Factory Mutual (FM) contribute to the demand.

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Ballasted: Ballasted systems are the most common for rubber-based, single-ply roofs. The thermal insulation and rubber membrane are loosely laid over the roof deck and then covered with ballast, which is usually round, washed river rock as specified by ASTM. The major advantages of this method include low installation costs, ease of installation, a UL Class A fire rating, and separation of the membrane from the deck, which allows for maximum independent movement. Fully Adhered: This is the second most popular application method (Fig. 6-2). Ideal for contoured roofs, sloped surfaces that cannot withstand the weight of a ballasted system, or reroofing applications over existing material, fully adhered membranes are completely bonded to the substrate using contact adhesives. Major advantages include their light weight, durability, ease of maintenance, and aesthetically clean, smooth appearance.

F I G U R E 6 - 2 Apply adhesive on a fully adhered EPDM roof.

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Mechanically Fastened: With this method, the membrane is loosely laid over the substrate and then anchored to the deck using fasteners. Many types of mechanically fastened systems are available. Most common are those attached directly to the deck. Nonpenetrating systems are also available. Mechanically fastened systems are lightweight, easy to install, and relatively inexpensive. As discussed later in this chapter, a recent development in EPDM is a sheet that can be heat welded.
CHLORINATED POLYETHYLENE (CPE)

CPE exhibits properties of both vulcanized and nonvulcanized elastomers. CPE is manufactured as a thermoplastic, but over time it cures as a thermoset. This means that most CPE systems are typically hot-airor solvent-welded. The features and benefits of CPE are discussed in greater detail in the nonvulcanized, uncured elastomers section.

Polychloroprene or Neoprene
Neoprene is a generic name for polymers of chloroprene. It was the first commercially produced synthetic rubber and exhibits resistance to petroleum oils, solvents, heat, and weathering. It is available in sheet and liquid-applied forms, and in weathering and nonweathering grades. Weathering grade is black; nonweathering is light-colored. Nonweathering grade must be protected from sunlight, normally by applying a coating of usually chlorinated polyethylene. Neoprene formulations are no longer widely used for roofing.

Nonvulcanized, Uncured Elastomers

The manufacturing process differentiates these uncured elastomeric membranes from vulcanized polymers. During the production of vulcanized polymers, combinations of chemicals, primarily polymers, fillers, and additives, are processed together and cured by heating so that chains of molecules are permanently crosslinked. This curing method results in a thermoset membrane with low tensile strength and high elongation values. In the field, cured elastomers must be applied and repaired with adhesives. New chemical bonds cannot be formed. Nonvulcanized, uncured elastomers, in contrast, are manufactured without any crosslinks between chains of polymer molecules. Although

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exposure to the elements can naturally cure some of these polymers during their lifespan, all nonvulcanized elastomers can be heat-welded during the initial installation. The generic classification of polymers known as nonvulcanized elastomers includes chlorosulfoned polyethylene (CSPE), chlorinated polyethylene (CPE), polyisobutylene (PIB), and nitrile alloy with butadiene-acrylonitrile copolymers (NBP).
CHLOROSULFONED POLYETHYLENE (CSPE)

CSPE, sold under the DuPont trademark Hypalon, is a polymer that has enjoyed increased popularity over the years because of its attractive white appearance and energy-efficient, heat-reflective properties. Other factors contributing to the popularity of CSPE and other rubberbased, single-ply roofing systems include
I Long-term weatherability; excellent resistance to temperature

extremes, sunlight, ozone, and moisture

I Ease, speed, and cleanliness of installation I Reduced labor costs in many cases I Flexural stability; accommodation of deck movement and dis-

placement
I Routine reroof installation over existing moisture-free mem-

branes
I Compatibility with many insulation materials I Code and standardization progress by the RMA and others I Ease of maintenance I Proven long-term performance

Another benefit is adaptability. Application techniques allow rubber-based roofing systems to be applied to virtually any roof surface: flat, spherical, curved, or slanted. CSPE is a saturated polymer that contains chlorine and sulfonyl chloride groups attached to a polyethylene backbone. It is an elastomeric material. Typical elongations range from 200 to 400 percent, depending on the type and amount of reinforcing fillers present in the

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compound. This means that CSPE can stretch far beyond its original length and return to its original configuration without loss of structural integrity. Actually, a unique feature of CSPE is that it is manufactured as a thermoplastic, but over time it cures as a thermoset. This means that most CSPE systems are typically hot-air- or solvent-welded. The advantages of welded seams include relatively quick procedures, good strength, and the lack of additional seaming material. There are two primary methods of application for CSPE rubber-based, single-ply systems, each of which offers certain advantages in specific applications. Mechanically fastened. The membrane is loosely laid over the substrate and then anchored to the deck using fasteners. Many types of mechanically fastened systems are available. The most common are those that attach directly to the deck. Nonpenetrating systems also are available. Advantages include the fact that the systems are lightweight, easy to install, and relatively inexpensive. Fully adhered. Ideal for contoured roofs or sloped surfaces that cannot withstand the weight of a ballasted system, fully adhered membranes are completely bonded to the substrate with contact adhesives. The major advantages include the fact that these systems are lightweight, durable, and easy to maintain. They also have an aesthetically clean and smooth appearance. Only a handful of CSPE systems are installed using the ballasted technique popular with other rubber-based roofing systems because most building owners prefer not to cover the attractive white membrane. In fact, CSPE systems are often specified because of their attractive white exterior.
CHLORINATED POLYETHYLENE (CPE)

This material is formulated around its prime polymers and blended with pigment and processing aids, which serve as release agents and antioxidants. In fact, one manufacturer produces 15 grades of cured and uncured raw CPE polymer. CPE made its roofing debut in 1967. Prior to that, it emerged in various military and civilian applications, most notably as a pond liner.

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The majority of todays CPE roof membranes are offered in an uncured composition and are reinforced with a polyester scrim by individual roofing manufacturers. Standard thicknesses are 40 to 48 mils. Both CPE and CSPE normally are formulated without plasticizers because of their inherent flexibility as an elastomer. As closely related elastomers, CSPE and CPE share similar behavioral characteristics. An aged CSPE, however, cannot be heat-welded. Adhesives must be applied if field repairs are necessary. The methods of application are the same for CPE and CSPE.
POLYISOBUTYLENE (PIB)

PIB is usually a 60-mil membrane made from synthetic rubber polymer, or polyisobutylene, pigments, fillers, and processing aids within several quality-control parameters that relate to thickness, density, elongation, hardness, and so on. The underside of the membrane is generally laminated with a 40-mil, needle-punched, nonwoven, rot-proof polyester fabric. The membrane is finished with a 2-inch-wide, self-sealing edge material that is protected by a strip of release paper. PIB is compatible with hot asphalt and shows excellent resistance to weathering, radiant heat, and ultraviolet (UV) light. Used primarily as a final waterproofing membrane over existing flat or low-sloped roof assemblies, PIB can also be used as a waterproofing membrane for new-construction roof assemblies. PIB is a lightweight system that requires no ballast. It can be installed quickly and economically. PIB passes ULs Class A fire rating and FMs I-90 wind-resistance rating. These systems offer both the building owner and the roofing contractor numerous advantages. The self-sealing edge offers assured seam strength, long-term waterproofing, lower installation costs, faster application per worker hour, and no need for special capital equipment. The fact that the system is unballasted can eliminate the need to structurally reinforce the building before it is reroofed. PIB also minimizes the deck load and eliminates the logistics of adding 1000 to 1200 pounds of gravel for every 10-foot-square area. PIB has a short but successful history in the United States. As more people become familiar with the system, realize that it is a solution for

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many roofing problems, and view the evidence of product support and longevity, the PIB system continues to show steady growth in the single-ply market.
NITRILE ALLOYS (NBP)

These membranes, as thermoset elastometers, are compounded from butadiene-acrylonitrile copolymers, nonvolatile polymeric plasticizers, and other patented ingredients. These membranes typically are made by coating the compound on a heavy-duty polyester fabric. They range in thickness from 30 to 40 mils. Seams are hot-air welded. Used for almost 30 years for such diverse products as exterior door gaskets and footwear, NPB is recognized for its weather-protectant and waterproofing capabilities. The material exhibits good chemical resistance and low-temperature flexibility, but is sensitive to aromatic hydrocarbons.

Heating Thermoplastics
When heat is applied to a thermoplastic, its polymer chains slide freely over one another. This makes the plastic more pliable and heat weldable. When returned to ambient temperature, the polymer chains again intertwine and regain their original properties. This process can be repeated again and again with the same results, which explains why seaming is so excellent and easily done with a thermoplastic. Thermoplastic roofing systems tend to be lighter in color, which can add value in terms of aesthetics. They are especially popular in multitiered roofing that can be seen from above by building occupants or neighbors. The two most common chlorinated hydrocarbon thermoplastics are polyvinyl chloride (PVC) and CPE.

Polyvinyl Chloride (PVC)

PVCs, originally produced in Germany more than 30 years ago, are among the most versatile thermoplastics for industrial and commercial applications. PVC is synthesized from vinyl chloride and is a member of a larger group of polymers designated as vinyls. These poly-

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mers are composed of intertwined molecular chains. This, in part, is what gives PVC its unusually good physical properties. PVC is one of the easiest materials to use. In its uncompounded state, PVC is a rigid material. Historically, PVC has been used in residential and commercial piping, plumbing, window frames, and exterior siding. When blended with plasticizers, PVC becomes soft and pliable. The use of the proper plasticizers enables membranes based on PVC to be used over a wide temperature range without substantial change. Because PVC is a plastic and not a rubber, it is unaffected by ozone. Ingredients are added to PVC to protect the polymer during processing and manufacture, or to achieve specific requirements such as increased flame retardance, resistance to microbiological attack, and resistance to UV light. PVC is an excellent choice when high performance and economy of cost are the primary factors in roof selection. PVC is forgiving. Installation mistakes can be easily corrected, and alterations, such as the addition of air-conditioning systems at a later date, are easily accomplished. For this reason, PVC conforms to nonstandard details with exceptional ease. With regard to seam integrity, thermoplastic roofing membranes can be welded together with heat or solvents. Once welded, they develop bond strengths that equal or surpass the strength of the base material. PVC membranes can be installed by three different methods: loose-laid, partial bonding, and fully adhered. The simplest installation procedure is to loosely lay the material on the substrate. Attach the membrane only around the perimeter of the roof and at any penetrations. The insulation does not need to be fastened in place, as the roofing system is ballasted to resist wind uplift. Since the membrane is not attached to the substrate, stresses in the substrate are not transferred to the membrane. Gravel ballast must be of sufficient size and free of sharp edges, so that it does not puncture the membrane. The partial bonding method uses elements of both the loose-laid and fully adhered systems. Firmly fasten insulation material beneath the membrane to the substrate. Then mechanically fasten round plates firmly to the substrate in a predetermined pattern and spacing. Finally, bond the membrane to the pattern. Partial bonding allows the membrane to float free over a crack or joint in the substrate. This distributes stress in the membrane between adhered areas. It is not

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intended to serve as or replace an expansion joint. On partially adhered systems, there are voids between membranes and substrates. If moisture enters the void and vapor pressure builds, blistering can occur. The fully adhered method completely fastens the roofing system to the roof deck. For sheet systems, total bonding is usually achieved by applying an adhesive. The substrate for adhesive-bonded systems must be smooth, clean, dry, and free from dust, dirt, grease, oil, wax, and loose particles. Many manufacturers recommend that the substrate be primed before adhesive is applied to achieve greater bond. Contact adhesives are typically used in total bonding. They are applied to the top surface of the substrate and the bottom of the sheet. Some sheets are self-adhering, however, so that the bottom of the sheet adheres to the substrate without an adhesive. The fully adhered method is suited to reroofing projects when the old roofing is not removed. It can also be used on steep roofs that cannot contain ballast and where partial bonding allows the membrane to sag between fastening points. Mechanically fasten a layer of hardboard or insulation to the deck, since PVC is incompatible with asphalt or coal tar. The system designer must consider all roofing materials when specifying PVC. Common roof materials like asphalt and coal-tar pitch cannot come in contact with PVC single-ply roofing. If they do, the PVC membrane may fail. All PVC roofing manufacturers stress that the membrane must be completely isolated from any contact with bituminous materials. Even fumes from coal tar must be avoided. Bituminous materials have the effect of leaching the plasticizers out of the PVC, leaving it weak and brittle. Polystyrene insulation must not come in direct contact with PVC, since it can rapidly extract the plasticizers from the membrane. The treatment used for wooden blocking and nailers must be carefully considered because only waterborne wood preservatives can be used.

Chlorinated Polyethylene (CPE)

Thermoplastic elastomers, such as CPE, are unique in that they have elastomeric properties, have rubber-like elasticity, and are easy to

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install, like PVC. In fact, CPE can be applied in the same manner as PVC. Welds can be made with heat or solvent and detailing is accomplished easily because of the thermoplastic-like properties of CPE. With noncuring elastomers, such as CPE, the chemical properties are such that the polymer chains are designed not to crosslink during the materials useful lifetime. Such a material has most of the desirable performance properties of a true rubber and easily conforms to any subsequent alteration to the roof. Such membranes seam almost as easily after being in place several years as when they were initially installed. Noncuring elastomers exhibit a mix of the qualities of both rubber and thermoplastic. CPE resin in a pure form offers a soft membrane with poor physical properties. In order to be used as a roofing material, CPE polymer must be enhanced with other reinforcing chemicals, such as processing aids that ease polymer processing and stabilizer packages that protect and enhance the polymer when it is installed on the roof. CPE offers the best chemical resistance of any conventionally available, single-ply roofing material. Depending on the given application, CPE is resistant to acetic acid, asphalt, bleach, chlorine, coal tar, fuel oils, animal fats and oils, fertilizer, sulfuric acid (acid rain), and a broad range of other corrosives. An excellent all-around choice as a roofing membrane, CPE has superior resistance to weathering, UV radiation, ozone, and microbiological attack. In addition, CPE has good fire resistance qualities.

Featuring Modified Bitumen Roofing

Modified bituminous roofing (MBR) systems have their technical roots in Italy, France, and Germany. They first appeared on the American market in 1975. Consisting of asphalt, a conventional base material, and any one of a number of polymeric modifiers, MBR membranes bridge the gap between conventional hot-applied BUR and nonconventional single-ply membranes. MBR systems cover the full range of inplace system specifications. These systems currently are being applied using loose-laid, partially attached, and totally adhered methods, and as protected membrane

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systems. In addition, MBRs can be applied over a wide range of roof decks and roof insulations. The requirements for deck selection, roof insulation, vapor retarder application, drainage, and flashing details that apply to conventional hot-BUR applications are generally applicable to most MBR systems as well. This makes the selection of an MBR system particularly attractive to the roofing contractor who might be skeptical of other singleply systems application requirements and techniques. The MBR system is also versatile in its application method. These systems can be applied by hot-asphalt application, heat-welding or torching, or cold adhesive. Some systems have self-adhering properties. Again, this versatility provides the roofing contractor with a wide range of application choices that can be tailored to specific job requirements. The MBR membrane is similar to hot-BUR systems, but represents a refinement in conventional asphalt technology. Though both systems have distinct softening points and proper installation temperatures, MBRs are composite sheets modified by either plastic or elastomeric material, such as atactic polypropylene (APP), styrene block copolymer (SBC), styrene-butadiene-styrene (SBS), or styrene-butadiene-rubber (SBR). Both the SBR-modified and APP-modified bitumen systems produce good lap-joint strength. Lap-joint construction for the APPmodified membranes normally is accomplished by torching. SBR- and SBS-modified membranes normally are adhered using hot asphalt as the adhesive. They also can be torched, although the APP-modified systems are more conducive to torching. The APP modification allows the bitumen material to flow easily when heat is applied directly, thus the term torching felt. Like BUR membranes, the MBR membrane consists of layers of modified asphalt that waterproof a reinforcing material. The reinforcing in MBR might be glass-fiber mats, polyester scrim, or a combination of the two. Each type of reinforcing material imparts different properties to the membrane. The manufacturing process usually dictates the location of the reinforcing material within the membrane. Membranes with reinforcing material sandwiched in the center are the easiest to fabricate. Properties of the reinforcement material, how-

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ever, also affect its location. Because polyester is not UV resistant, it must be buried in the mat, but not too close to the bottom because heat causes it to shrink and melt. Glass-fiber reinforcement material generally is placed close to the top of the mat to serve as a wearing surface. It resists foot traffic and UV degradation and provides a fire rating. One argument against this location is the potential for delamination during application. Manufacturers using both types of reinforcement put the glass fiber at the top and the polyester in the middle. Roofing contractors like reinforcement in the middle because the top melts slightly when the next layer is applied, which fuses it to the bottom of the layer above. MBR membranes range in thickness from 40 to 60 mils. Some MBR membranes are best covered. For example, SBS must be covered at all times because its UV and ozone resistance is low. Most surfacing consists of granules provided by the manufacturer. This granule surfacing does not add much weight to a system. Other coverings include manufacturer-installed metals or applied coatings of acrylics, asphalt emulsions, or fibrated aluminum. Of these, fibrated aluminum is the most popular because of its reflective properties. The differential movement of metal applied over asphalt is solved by fabricating tiny expansion joints into the metal. UV-resistant APP can be left uncoated. It usually is coated, however, to promote longer life. Coatings include fibrated aluminum, acrylics, and asphalt emulsions. Mineral surfacings are available, too, but generally are used only for their aesthetic effect. Surfacings also are used to achieve fire ratings because most systems, with the notable exception of glass-fiber-reinforced membranes, cannot attain a fire rating alone. MBR systems generally are applied in either a single-ply or multi-ply application (Fig. 6-3), frequently using conventional organic or fiberglass felts as the base ply. Currently, the heat welding and hot-asphalt mopping application methods seem to enjoy the most prominence. MBR systems are suitable for application in new construction as well as reroofing jobs. Because of their superior load-elongation behavior, MBRs are frequently applied directly over existing conventional roofing materials. This is possible only if the existing substrate is not badly deteriorated or heavily moisture laden.

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4" lap Nailable deck sheathing paper (if required) Nails

18" 11" Felt 37" Drainage 3" lap Asphalt 11" 36" Endlaps staggered 3" apart (min) 4" endlap 9" 3" lap 24" 9" 18" Asphalt 37" Felt

F I G U R E 6 - 3 MBR can be applied with multiple sheets.

Preparing the Roof

The following are some general guidelines for the care and use of single-ply membrane materials. (See also Fig. 6-4.)
I Deliver materials in the manufacturers original unopened pack-

aging with labels intact.

I Store materials onsite under protective coverings and off the

ground.
I Do not store material on the deck in concentrations that impose

excessive strain on the deck or structural members.

I Proceed with roofing work only when existing and forecasted

weather conditions permit installation in accordance with the manufacturers recommendations and warranty requirements.
I Take special precautions, as recommended by the manufacturer,

when applying roofing at temperatures below 40F.

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Item Deliver materials in the manufacturers original unopened packaging with labels intact. Store materials onsite under protective coverings and off the ground. Do not store material on the deck in concentrations that impose excessive strain on the deck or structural members. Proceed with roofing work only when existing and forecasted weather conditions permit installation in accordance with the manufacturers recommendations and warranty requirements. Take special precautions, as recommended by the manufacturer, when applying roofing at temperatures below 40F. Do not torch-fuse membranes directly to flammable substrates. Check with the manufacturer about application requirements. Check with the manufacturer about slope requirements. The National Roofing Contractors Association (NRCA) recommends that all roofing materials be installed on roofs with positive slope to drainage. If UL-classified roofing membranes are required, carefully evaluate the manufacturers test data to determine compliance with code or other fire-related performance characteristics. Ensure that edge nailers, curbs, and penetrations, including drain bases, are in place and properly secured before starting the job so that the roof system can be installed as continuously as possible. Ensure that the insulation or base ply is positively attached to the roof deck.

F I G U R E 6 - 4 Preparing the roof.

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Item Ensure that the bonding agent used to assemble laps and to adhere the single-ply membrane to the roof substrate is permitted by and acceptable to the material supplier. Ensure that positive attachment is achieved with partially adhered and mechanically fastened MBR systems that preclude a continuous film. Ensure that the roof membrane is applied in such a way that water can run over, or that the membrane has sidelaps and/or endlaps. Check that sheets are aligned so that minimum required end- and sidelap widths are maintained. Check that membrane laps are watertight. Repair voids and fishmouths within the lap as soon as possible. Install temporary water cutoffs at the end of each days work. Remove them before installing additional insulation or membrane. Apply surfacings, when required, in accordance with the membrane suppliers requirements and so that the entire membrane surface is covered.

F I G U R E 6 - 4 (Continued)

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I Do not torch-fuse membranes directly to flammable substrates. I Check with the manufacturer about application requirements. I Check with the manufacturer about slope requirements. I The National Roofing Contractors Association (NRCA) recom-

mends that all roofing materials be installed on roofs with positive slope to drainage.
I If UL-classified roofing membranes are required, carefully

evaluate the manufacturers test data to determine compliance with code or other fire-related performance characteristics.
I Ensure that edge nailers, curbs, and penetrations, including drain

bases, are in place and properly secured before starting the job so that the roof system can be installed as continuously as possible.
I Ensure that the insulation or base ply is positively attached to

the roof deck.

I Ensure that the bonding agent used to assemble laps and to

adhere the single-ply membrane to the roof substrate is permitted by and acceptable to the material supplier.
I Ensure that positive attachment is achieved with partially

adhered and mechanically fastened MBR systems that preclude a continuous film.
I Ensure that the roof membrane is applied in such a way that

water can run over, or that the membrane has sidelaps and/or endlaps.
I Check that sheets are aligned so that minimum required end-

and sidelap widths are maintained.

I Check that membrane laps are watertight. Repair voids and fish-

mouths within the lap as soon as possible.

I Install temporary water cutoffs at the end of each days work.

Remove them before installing additional insulation or membrane.

I Apply surfacings, when required, in accordance with the mem-

brane suppliers requirements and so that the entire membrane surface is covered.

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Applying Substrate Materials

Suggested substrate materials for MBR systems include light steel, which does not have the weight of gravel or ballast; primed concrete, which requires torch welding, particularly when not insulated; mechanically fastened base sheets; and uninsulated assemblies when the deck is wood, gypsum, lightweight insulating concrete, or cementitious wood fiber. MBR is not recommended for roofs where there are concentrations of acids, hydrocarbons, or oils. It also is not cost effective for wide-open spaces because large rolls of EPDM can be installed less expensively. The condition of the substrate is crucial to the performance of the membrane. The surface of the deck must be clean, firm, smooth, and visibly and sufficiently dry for proper application. There are different preparation requirements for new construction, replacement, or recovering over each type of substrate. To avoid defects and litigation, the material supplier and the roofing contractor can be responsible only for acceptance of the surface of the substrate that is to receive the roofing system. Design considerations and questions about structural soundness are the responsibility of the owner or the owners representative. Put this in the contract. If there is a question about the suitability of the deck and/or its surface, reach an agreement with the material supplier, the roofing contractor, and the owner before proceeding with the work. When a primer is required, coat the surface with an amount sufficient to cover the entire surface. The amount required varies, depending on the nature of the surface. Allow the primer to dry before the membrane is applied. If visual examination indicates deficiencies in primer coverage, apply additional primer for complete coverage and then allow it to dry before applying the membrane. The existing roof surface must be suitable to receive a single-ply membrane. Both the NRCA and the RMA recommend putting a recover board over existing gravel-surfaced roofs before the membrane system is applied. Remove loose and protruding aggregate by spudding, vacuuming, or power brooming to achieve a firm, even surface to receive the recover board.

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When the existing roof is smooth or mineral-surfaced, refer to the material suppliers specifications. Some specifications permit fully adhering by heat welding, hot mopping, or adhesives. Others require base sheets over the existing roof, while still others permit spot mopping, strip attachment, and/or mechanical fastening.

Laying Insulation
Manufacturing tolerances, dimensional stability, application variables, and the nature of insulation boards make it difficult to obtain tightly butted joints. Some variance is expected, but the spacing between insulation boards should range from no measurable space to no more than 14 inch or the space specified by the material supplier. Fill insulation gaps between adhered or mechanically fastened insulation boards in excess of 14 inch with roof insulation. Reduce gaps between loosely laid insulation boards by adjusting the boards or adding insulation. If the insulation boards appear to be out of square, make a diagonal measurement to confirm the squareness. Do not use defective material. When composite-board, polyisocyanurate foam-board, polyurethane foam-board, perlitic board, or wood fiber-board insulation is used as the insulation substrate under a torch-applied MBR membrane, install a base sheet as the first layer below the roof membrane. This protects the insulation substrate from the flame and heat of the torch. Lap each base sheet a minimum of 2 inches over the preceding sheet; endlaps should be a minimum of 4 inches. Adhere the base sheets to the insulation in accordance with the manufacturers specifications.

Fastening Insulation and Base Plies

Various mechanical fasteners are used to apply insulation and base plies. They also can be used to attach the single-ply membrane to the roof deck and to attach flashing materials. The fasteners often are specified by type, number, and spacing distance to fulfill the attachment functions. Practical considerations often prevent exact spacing, such as 6 inches on center. Reasonable variances from specified spacing distances are expected, but the minimum number of fasteners specified should be used.

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The fastener type and spacing should be as specified by the material supplier with the understanding that the spacings are average values and the spacing between any two fasteners can vary. Should fastener deficiencies be discovered, install additional fasteners as needed and space them appropriately. On all nailable roof decks, install a base sheet as the first layer below the roof membrane. This base sheet serves as a separating layer between the nailable deck and the roof membrane. Lap each base sheet a minimum of 2 inches over the preceding sheet. Endlaps should be a minimum of 4 inches. Fasten the base sheets according to the manufacturers recommendations.

Applying Single-Ply Materials

As stated earlier, there are several attachment methods, depending on the single-ply material. System configurations change from specification to specification and are predicated not only on the manufacturers procedure, but on site conditions. This can and does leave some questions about the proper method to use. Nonetheless, fundamental procedures for the correct installation of all single-ply membranes remain the same, regardless of the system or specification. The strength and waterproofing characteristics of singleply membrane systems depend on the construction of the laps and seams between membrane sheets and between the membrane and flashing materials. Lap dimensions typically are specified as an amount of overlap between adjacent sheets. Because of the many construction variables already mentioned, some variance can occur. An overlap exceeding the specification is not considered detrimental. The material suppliers minimum lap values must be maintained, however, so as not to affect the strength and waterproof integrity of the membrane. Fabricate membrane laps so that they are watertight. Repair voids and fishmouths within the lap. Products are frequently supplied with laying lines. Use these lines to position the subsequent course of material for compliance with nominal lap requirements. Because of the variation in substrates,

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products, and systems, refer to the material suppliers specifications for minimum requirements. If the product does not have laying lines, use the material suppliers stated lap dimension as the minimum lap requirement. If examination reveals insufficient lap width, install a strip no narrower than twice the required lap over the deficient lap. Use the appropriate attachment method. Check all laps of heat-welded systems for adequate bonding. Seal any unbonded area. Several factors determine the point at which work begins. For water runoff, begin work at a high point on the roof and move toward the low point. This prevents any drainage water from overnight rains from working its way under the new roof. Always shingle membrane laps with the flow of water or parallel to the flow of water. Consider the deck type. Metal decks have corrugations that fall in 6-inch modular spacings. As with rigid insulation, fasten the membrane to the top of the flutes to meet Factory Mutual Engineering (FME) specifications. Because the exposed width of most full rolls of exposed membrane is 6712 inches, the edge of the sheet eventually falls between the flutes when the membrane is run parallel to the flutes. When this happens, trim the excess back to the nearest flute top (Fig. 6-5A). When the membrane is run perpendicular to the metal deck corrugations, the amount of trimming and membrane waste is less than it would be if the membrane ran parallel to the corrugations (Fig. 6-5B).

Applying Thermoset Materials

Thermoset single-ply material can be applied loose-laid and ballasted, partially adhered, or fully adhered. Always roll out the sheet and allow it to relax. Inspect the sheet for defects as it is being rolled out. To seal the laps, fold the sheet back onto itself and clean the underside of the top sheet and the upperside of the bottom sheet with the recommended solvent to remove dirt and talc from the lap area. Apply adhesive evenly to both surfaces and allow it to set according to the manufacturers application instructions. Then roll the top sheet over the bottom sheet in a manner that minimizes voids and wrinkles. Apply pressure to the lap to ensure contact.

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Top view

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Top view Direction of membrane run

108'

6' max.

Direction of membrane run

Up to 108'

W a s t e 3"

3" Side view Side view

F I G U R E 6 - 5 (A) Membrane running parallel to metal decking might require trimming

along entire length of roll. (B) Membrane running perpendicular to the metal deck corrugations. The maximum trim is across the width of the roll.

LOOSE-LAID AND BALLASTED METHOD

With this method, the membrane is placed on a substrate without bonding and held in place by ballast. NRCA recommends that consideration be given to mechanically fastening or spot adhering the first layer of insulation to the roof deck under loosely laid roof systems. Only enough mechanical fasteners or adhesive need be used to hold the insulation boards in place during installation of the roofing membrane and to prevent stacking or displacement. Attach the second layer of insulation, if used, to the first layer with a compatible adhesive. As an alternative procedure for nailable roof decks, both layers can be mechanically fastened to the deck at the same time. Adhesive application quantities, mechanical fastener spacing, lap dimensions, and other minimum installation requirements vary from manufacturer to manufacturer. Over cellular glass insulation and any other insulation substrate where rough surfaces, protrusions, or sharp edges might affect the service of the membrane, install a separation sheet between the insulation and the roof membrane. Fasten the separation sheet only often enough to hold the sheets in place until the roof membrane is applied. Roll out and align the sheet so that it overlaps the previous sheet by the required lap width. Seal all membrane laps together. Fabricate laps to shed water whenever possible.

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First layer preformed roof insulation board EPDM sheet Separation layer (if required)

Adhered seams Second layer preformed roof insulation board Ballast

F I G U R E 6 - 6 Loose-laid membrane system.

Ballast the loose-laid membrane with rounded stone, such as washed river gravel (Fig. 6-6). The amount of needed ballast varies with the location and height of the building. Substitute concrete pavers for rounded stone ballast if a protective underlayment is installed to protect the roof membrane from the abrasive surface of the paver.
PARTIALLY ATTACHED SYSTEMS

There are three generic ways to partially attach a thermoset (EPDM) membrane (Fig. 6-7). For the first method, roll out the sheet and align it so that it overlaps the previous sheet by the required lap width. Install mechanical fasteners with large washers or install bars with mechanical fasteners through the membrane and into the deck. Cover these fasteners or bars with membrane pieces that are bonded to the membrane in a manner similar to the methods used for sealing laps. Then seal all membrane laps together. For the second method, roll out the sheet and install mechanical fasteners with large washers or bars with mechanical fasteners through the membrane within the area of the lap and into the deck. Seal all membrane laps together so that the fasteners are covered.

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Individual or bar-type mechanical fastener covered with membrane piece Separation layer (if required)

First layer preformed roof insulation board

EPDM sheet

Adhered seams Individual or bar-type mechanical fastener installed under lap

Second layer preformed roof insulation board

Proprietary nonpenetrating fastening system

F I G U R E 6 - 7 Partially attached roof system.

For the third method, mechanically fasten a proprietary fastening system in a predetermined pattern over the separation layer if used. Install the roof membrane over the fasteners. Roll out and align the sheet so that it overlaps the previous sheet by the required lap width. Sandwich the membrane between the parts of the fastening system by installing the second part of the mechanical fastener. Seal all membrane laps together.
FULLY ATTACHED SYSTEMS

For sheet systems, total bonding is usually achieved by applying an adhesive. The substrate for adhesive-bonded systems must be smooth, clean, dry, and free from dust, dirt, grease, oil, wax, and loose particles. Prime the substrate before applying the adhesive to achieve a greater bond. Contact adhesives usually are used in total bonding. They are applied to the top surface of the substrate and the bottom of the sheet. Some sheets are self-adhering, however, so that the bottom of the sheet adheres to the substrate without an adhesive. To apply a fully attached or total-bonded application, roll out the sheet and align it so that it overlaps the previous sheet by the required lap width. Fold the sheet back onto itself and coat the bottom side of

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First layer preformed roof insulation board Contact adhesive EPDM sheet Second layer preformed roof insulation board

Adhered seams

F I G U R E 6 - 8 The mechanics of a fully adhered

roof system.

the membrane and the top side of the deck with adhesive. Avoid getting adhesive on the lap joint area. After the adhesive has set according to the adhesive manufacturers application instructions, roll the membrane into the adhesive in a manner that minimizes the occurrence of voids and wrinkles. Repeat this for the other half of the sheet. Take care to adhere the very middle of the sheet (Fig. 6-8). Then seal all membrane laps together. Fabricate caps to shed water wherever possible.

Seaming Single-Ply Materials

A single-ply system is only as strong as its seams. There is more than a little truth to this cliche, especially with elastomerics. Unlike hot BUR, elastomeric and plastomeric sheets are preformed in the factory. Most of the problems with these systems can be traced back to field workmanship, of which lap seaming is a critical part. Most contractors feel that poor workmanship is the most common reason for single-ply roof failure. Industry experts are inclined to agree.

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Most rubber-based, single-ply membranes require adhesive for lap seaming. A new generation of adhesives and sealants that speed application and improve the performance of rubber-based systems is providing simplified design, ease of inspection, proven performance, and low maintenance.

Bonding Adhesives
All-purpose bonding adhesives, geared toward roofing applications, adhere EPDM, neoprene, and butyl roof membranes to wood, concrete, metal, and certain insulation surfaces. These are contact-type adhesives. Their use involves the application of a uniform coat to the back of the rubber membrane, as well as to the surface to which it is to be bonded. These successful products have earned wind-test ratings from FM and are accepted by most code authorities. Manufacturers advise that the mating surfaces be dry, clean, and free from oil, grease, and other contaminants. The best working temperatures are 40F or above. Many EPDM suppliers currently use one-part butyl adhesives to seal their 45- and 60-mil membranes. These adhesives normally give consistent peel strengths in the range of 3 to 412 pounds per inch. The application of one-part butyls is somewhat less forgiving than that of other adhesive systems, however. The open time or window, defined as the time from when the seam can first be closed to when it no longer grabs, is shorter and varies with weather conditions. Keep in mind that onepart butyl requires a heavier adhesive coating. It can skin over and give a false indication that it is dry. In addition, it has been found that improperly stirring the adhesive results in less-than-adequate peel strengths. Butyl cement begins to cure when exposed to heat and moisture. Once a can of adhesive is opened, do not reseal it or use it again because a substantial thickening of the cement occurs in about 48 hours. On the other hand, if butyl goes bad, the applicator knows it because the material does not stick. The pass/fail criteria for other adhesives are not as obvious.

Splicing Adhesives
There are lap splicing adhesives for EPDM, neoprene, and butyl membrane roofing. These adhesives provide long-lasting, weather-

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resistant bonding between the single-ply membranes used in various systems. Technology in the last five years has further enhanced the long-term performance of these adhesives. The size of the splice determines the application. In most cases, for flashing and expansion joint applications, the minimum splice width is 3 inches. These also are contact adhesives that must be applied to both of the surfaces being bonded. The splice area must be dry and completely free of dust, talc, and other contaminants. The best working temperatures are between 40 and 120F.

Sealants
Adhesive-seamed, cured, and uncured elastomer membranes all require the use of a lap sealant at the seam edge. Most adhesives are vulnerable to moisture until fully cured. Some materials take as long as a week to become fully moisture resistant. In addition to sealing out moisture and other contaminants, the sealants absorb thermal expansion and resist fatigue, vibration, and biological attack. They are ideal for sealing roofing protrusions, cracks, duct work, and exterior seams. In order to allow the solvents to escape from inside the seam, do not apply the lap sealant for at least 2 hours. If rain is imminent or there is a need to leave the jobsite, apply the lap sealant earlier rather than later. Repairing minor blistering in the caulked edge is always easier than dealing with ruined seams. It is also easy to wander off the membrane edge when you install the lap sealant. Because of this, it is important to tool the sealant. Ideally, one worker should install the material, while a second worker follows behind and tools the edge. If one waits too long to tool, the material can harden and start building up on the tool. Sometimes a primer is applied to the sheet before the adhesive to enhance seam performance. Unlike splice or primer washes, the solvent is applied at full strength. The combination of primer and neoprene adhesive usually offers performance similar to that of one-part butyl. To apply the adhesive system, first use a splice cleaner on the seam. After the area dries, roll the primary butyl adhesive over the entire width of the splice. Next, apply a bead of inseam sealant tube on top of

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the butyl and roll the seam closed. Finally, secure the splice with a lap sealant. The inseam sealant is also designed to serve as a redundant adhesive. If the installer misses a small section of the seam with the butyl, the inseam sealant should still adhere to the EPDM and seal the seam. Because the sealant has a greater mass than the butyl adhesive, it is capable of filling any voids or gaps in the seam created by an uneven substrate. Be aware that the inseam sealant does not have the green strength to hold the seam together during setup time. Therefore, the butyl adhesive must be installed in conjunction with the sealant to avoid fishmouths at the edge of the seam.

Tape
Butyl-based tape offers the extra mass of adhesive needed when three layers of membrane come together, called a T-joint. According to many roofers, the tape is somewhat more sensitive to dust, dirt, and contaminants than the liquid adhesive. Applying the liquid adhesive with a bristle brush can lift contaminants into the adhesive mass. On the other hand, tapes have speed and labor-saving advantages, if the applicator is skilled. While many tapes used in the past were made of uncured material, todays tape adhesives are cured. Uncured tapes move independently of the roof during expansion and contraction. Cured tape is able to move with the sheet.

Heat Welding
Until recently, one of the easiest ways to tell if an applied single-ply membrane was thermoset or thermoplastic was to look at the seams. Thermoset seams were installed with adhesive tape or sealer, while thermoplastic seams were usually heat-welded. Several manufacturers are now producing a hot-air weldable EPDM membrane, however, which eliminates the use of adhesives or tapes. One product consists of a patented blend of polypropylene and vulcanized rubber. The polypropylene gives the membrane heat-welded characteristics and greater oil resistance, while EPDM and carbon black protect the polypropylene from UV degradation. During manufacture, a codispersion between the EPDM and polypropylene takes

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place,with the molecular crosslinking of the polypropylene already in the EPDM formulation. Another heat-weldable EPDM is made of polypropylene and a thermoplastic rubber. A coextrusion process causes the crosslinking of the two materials, with the top layer containing more vulcanized rubber and the bottom layer more polypropylene. The 45-mil membrane is mechanically fastened in seam using 2inch-diameter washers set 18 inches on center. A UL Class 90 winduplift rating and Class B fire rating (smooth surfaced) have already been achieved. Tear strength is a consideration in a nonreinforced, mechanically attached sheet. The crosslinking process gives the membrane a 360-pounds-per-square-inch tear strength across the sheet, which is where wind uplift forces are greatest, according to the manufacturer. CSPE, as mentioned earlier in the chapter, is heat-welded.

Applying Thermoplastic Materials

PVC, CPE, and PVC blends can be installed by loose-laid, partially attached, or fully adhered methods.

Using the Loose-Laid Method

On all nailable roof decks, install a separator sheet as the first layer below the roof membrane to serve as a separating layer between the nailable deck and the roof membrane (Fig. 6-9A and B). Lap each separator sheet a minimum of 2 inches over the preceding sheet. Endlaps should lap a minimum of 4 inches. Fasten the separator sheets only as necessary to hold the sheets in place until the roof membrane is applied. Roll out the sheet over the separator sheet and inspect the membrane for defects. Align the sheet so that it overlaps the previous sheet by the required lap width. Seal all membrane laps together using either heat welding or chemical fusion. Fabricate laps to shed water wherever possible. Apply pressure to the lap to improve the bond. Carefully inspect lap edges. Repair unsealed areas, voids, and fishmouths. Generally, manufacturers require that exposed membrane edges be finished with a sealant. Fasten all membrane perimeters, terminations, and penetrations as required by the manufacturer.

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Nailable deck PVC sheet

Heat-welded or chemically fused laps Separator sheet Ballast

A
First layer preformed roof insulation board PVC sheet Separator sheet (if required)

Ballast the loosely laid membrane with rounded stone, such as washed river gravel. The amount of ballast needed varies with the location and height of the building. Concrete pavers can be substituted for rounded stone ballast, provided that a protective underlayment is installed to protect the roof membrane from the abrasive surface of the paver.

Using the Partially Attached Method

There are three generic methods for partially attaching thermoplastic membranes (Fig. 6-10). For the first method, mechanically fasten Second layer Heat-welded or preformed roof chemically fused laps PVC-coated metal discs in a predeinsulation board termined pattern over the separator sheet. Roll out the membrane Ballast and inspect it for defects. Heat weld or chemically weld the B F I G U R E 6 - 9 (A) Loosely laid PVC sheet membrane to the PVC-coated metal discs as the membrane is over a nailable deck. (B) Loosely laid PVC over an insulated deck. rolled out onto the deck. Align the sheet so that it overlaps the previous sheet by the required lap width. Then seal all membrane laps using heat welding or chemical fusion. Fabricate laps to shed water wherever possible. Apply pressure to the lap to improve the bond. The second method calls for the installation of mechanical fasteners with large washers through the membrane and into the deck. Cover these fasteners with membrane patches and heat weld or chemically fuse the patches to the membrane. Seal the membrane laps using heat welding or chemical fusion. Fabricate the laps to shed water and apply pressure to the lap to improve the bond.

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The third method follows the same initial steps. Roll out and inspect the membrane and seal the laps using heat welding or chemical fusion. Fabricate the laps to shed water, and apply pressure to the lap to improve the bond. Then place continuous metal bars in a pre-engineered pattern on top of the membrane and mechanically fasten them to the nailable roof deck. Cover the bars with membrane patches that are heat welded or chemically fused to the membrane.

Mechanical fastener covered with membrane piece PVC sheet Sheet welded to mechanically fastened PVC disk

Nailable deck

Heat-welded or chemically fused laps

Bar-type fastener covered with membrane piece

Separator sheet

F I G U R E 6 - 1 0 Partially attached PVC roof

system.

Using the Fully Adhering Method

Wood plank or plywood deck

PVC sheet There are two generic methods Water-or for fully adhering thermoplastic solvent-based adhesive membranes (Fig. 6-11). For solvent-based adhesives, roll out the sheet and inspect it for defects. Align the sheet so that it overlaps Heat-welded or chemically fused laps the previous sheet by the required lap width. Fold the sheet back onto itself and coat the bottom side of the membrane and F I G U R E 6 - 1 1 A fully adhered PVC roof the top side of the deck with system. adhesive. Avoid getting adhesive on the lap joint area. After the adhesive has set according to the manufacturers application instructions, roll the membrane into the adhesive in a manner that minimizes the occurrence of voids and wrinkles. Repeat this for the other half of the sheet. Carefully adhere the middle of the sheet. For water-based adhesives, follow the steps for solvent-based adhesives, but avoid getting the adhesive on the lap joint area when you

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coat the deck. After the adhesive sets according to the manufacturers application instructions, roll the membrane into the adhesive in a manner that minimizes the occurrence of voids and wrinkles.

Seaming Thermoplastics
PVC, CPE, and the PVC blends are inherently heat weldable with typical lap seam strengths of more than 20 pounds per inch. While hot-air and solvent welding procedures are quicker than adhesive seaming, a considerable amount of applicator skill is still required. For example, CPE exhibits a higher melting temperature than most PVCs and a narrower welding window. It is especially important to conduct test welds when ambient roof conditions change substantially. There are two basic types of welders available: automatic and hand. The automatic welder rides on the top sheet, which is being welded to the bottom sheet. For this reason, it is possible to start welding in one of two roof corners: the upper right-hand corner or the lower left-hand corner (Fig. 6-12). To determine these two corners, face the same direction as the run of the membrane. The roof corners to your upper right and lower left are the possible starting points. Automatic welding machine Use the hand welder to weld seams when automatic welding is Upper right not possible, such as near a paraWelder pet wall or curb detail. Hand start position welding is also used for many and direction flashing details, applying memof travel brane patches, and repairing poor or unfinished machine-welded Second First seams (Fig. 6-13). full full sheet sheet When the gun heats the membrane to a semimolten state, use a hand roller to bond the lap seam. A number of interchangeable nozzle tips are designed to match Lower left any hand-welding situation. For F I G U R E 6 - 1 2 Welding can begin at one heavily reinforced PVC blends, of two points on the roof, the upper right applying pressure at the right or the lower left. temperature is crucial to a good

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F I G U R E 6 - 1 3 A hand welder in use.

lap seal. Because there are several models and designs, always follow the adjustment procedures (Fig. 6-14) outlined in the service manual (see App. A for vendors).

Checking Welded Seams

Working conditions vary from job to job, from day to day, and even from hour to hour. Varying conditions require different heat and speed settings on the welding machine. Because conditions vary, it is extremely important that you inspect all welded seams with care. Make adjustments to welder speed, temperature, and setup as needed. Wait several minutes before testing seam strength, since even good welds can be separated while they are still hot. A good weld is one where the top sheet does not separate from the bottom sheet without damaging the membrane. Proper seam width is approximately 112 inches. The welded seam should be smooth and continuously bonded without voids or air pockets. The lap edge should be bonded completely together. Check for gaps in this seam by running a cotter-pin puller along the seam. The automatic welder usually misses the first few inches of a seam, so pull back the lap after it has cooled and mark off the area that requires hand welding. If there are voids in the weld seam, or if the

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F I G U R E 6 - 1 4 Making an adjustment on a hand

welder.

finished seam is weak, it probably means that the hot-air nozzle did not have enough time to heat the membrane to the necessary molten state. To correct this problem, slightly lower the machines welding speed and make another test run. Other problems, such as dirt on the membrane, moisture on the membrane, or variances in the power supply, also can produce voids and poor bonding. Inspect the welded seam and the area around the weld. A light browning or burning of the membrane indicates that the nozzle is overheating the weld area. To correct this, increase the welding speed slightly and test again. If the membrane still burns at the highest speed setting, lower the nozzle temperature by adjusting the heat control dial. Brown streaks at the edge of the overlap usually are caused by the outer edge of the nozzle dragging heated dirt and membrane particles across the membrane. To prevent this, clean the nozzle with a wire brush. Pinch wrinkles can be pulled into the membrane sheets when the automatic welder is not set up properly. If pinch wrinkles occur, review the setup and operating procedures given earlier in this section and those provided with the welder. Repair pinch wrinkles with membrane patches.

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Applying Modified Bitumen Materials

MBR can be applied using torch-applied, hot-mopped asphalt or a selfadhered method.

Torch-Applied or Heat-Weld Method

To apply the membrane, roll out the sheet and inspect it for defects. Align the sheet so that it overlays the previous sheet by the required lap width and then reroll it. Heat the underside of the roll to soften the bitumen coating. Take care not to overheat the top surface of the sheet. Most torch-applied membranes come with a factory-installed burnoff film. This film is usually polyethylene, though it can be polypropylene. Burn-off films are applied as a release agent and as a compatible material that blends with the MBR coating when heated. This creates an excellent cohesive bond at the lap or seam. Films also facilitate bonding to other surfaces. Some torch-down products incorporate talc or sand as a release instead of burn-off films. To obtain flow of the MBR coatings, apply heat to the burn-off film surface in sufficient amounts to soften and melt the coating. When the roll is unwound you should see a flow ahead of the roll and at the sidelap that minimizes voids and wrinkles. At the sidelap and all seams, flow should be from a minimum of 14 inch to a maximum of 12 inch. It should be continuous and uninterrupted. No flow at all indicates that insufficient heat was applied. A flow more than 12 inch indicates that too much heat was applied. Take care to ensure proper lap alignment. Membrane laps are sealed together as the sheet is adhered to the deck. Fabricate laps to shed water wherever possible. Check all seams for proper bonding. Check any lap or seam that has no flow for integrity. Some manufacturers require that all seams be buttered or troweled. In most cases, however, this is not necessary. Any installation areas that have an observable flow in excess of 1 2 inch are not likely to have bonding surfaces. This yields the maximum effect because of excess coating flow. In some cases, the coating can be almost completely forced away from the bonding surfaces, which reduces maximum bonding potential.

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Excess heat also can affect polyester-reinforced membranes. These membranes are susceptible to stretch and thermal breakdown if too much heat is applied. Polyester burns and melts, which dramatically reduces performance characteristics. Fiberglass-reinforced membranes do not stretch under heat. They can, however, experience thermal breakdown of binders, which can result in a loss of performance characteristics.

Hot-Mopped Method
Roll out and inspect the sheet. Then align the sheet so that it overlaps the previous sheet by the required lap width. Reroll the membrane. Apply a mopping of hot asphalt immediately in front of the roll. Follow the guidelines for heating asphalt as predicated by the equiviscous temperature (EVT) printed on the carton or wrapper, or review Table 5-1. Never heat the asphalt to its flash-point temperature. Align the membrane plies carefully. Stagger or offset endlaps a minimum of 3 feet. Apply the first membrane course at the lowest point of the deck. This prevents water from flowing against the lap seams. Mop consistently at about 25 pounds per square. The mopping action should be continuous and uninterrupted when fully adhered systems are installed. Do not feather or taper moppings. When applying the hot-asphalt-applied MBR membrane, advance the roll into hot asphalt that has been applied no more than 4 feet in front of the roll. Moppings more than 4 feet from the advancing roll can cool and cause false bonding. Check all laps and seams for proper bonding. Fabricate the laps to shed water whenever possible. Flow from the mopping asphalt at laps and seams should be from the torch-applied membrane. Use a thermometer to check asphalt temperatures at each point before application. For added protection and aesthetics, mineral granules can be sprinkled on the asphalt flow at all laps and seams while the asphalt is still hot. Other materials can also be used to surface MBR membranes. In addition to their primary function to protect the membrane from the elements, these surfacings often serve to increase the fire and impact resistance of the roofing system. Liquid-applied surfacing materials vary in physical properties and in formulation. Surfacing materials and aggregate are applied by vari-

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ous techniques, such as hand spreading and mechanical application. They also are applied on a variety of roofs in many climatic conditions. These factors and others preclude a high degree of uniformity in applying liquid-applied surfacing materials and aggregate over a roof area. Hot-asphalt-applied membranes come with a sand release that is used as an antiblocking agent and as a surface that facilitates adhesion to the asphalt. Hot-asphalt-applied MBR membranes are always SBSmodified bitumens with a sanded bonding surface.

Self-Adhered Method
Cold adhesives are used with some MBR membranes to bond the sheet to the substrate. Use the adhesive specified by the material supplier. During the application of a fully adhered system, you should observe a continuous, firmly bonding film of adhesive. The adhesive should flow out from the membrane to form a seal. If aesthetic appearance is a factor or is dictated by specification, matching granules can be used to cover the flow-out area. When using the fully self-adhered application, prime the surface of the roof deck with asphalt primer and allow it to dry. Primers are not required if a base sheet is used. Roll out the sheet, inspect it for defects, and align it so that the membrane overlaps the previous sheet by the required lap width. Then reroll it. Remove the release paper from the underside of the membrane and roll the membrane over the primed surface in a manner that minimizes voids and wrinkles. Take care to ensure proper lap alignment. Membrane laps are sealed together as the sheet is adhered to the deck. Fabricate laps to shed water whenever possible. Apply pressure to both the membrane and lap areas to ensure contact. In a partially adhered membrane application, MBR compounds, asphalt, and adhesives are used to secure the roof assembly to the structure. These materials are installed in a configuration prescribed by the material supplier, such as spot or strip bonding. They often are specified by amount and spacing distances. Practical considerations often prevent the application of the exact amount and spacing, such as 12 inches in diameter and 24 inches on center of the bonding agent. Reasonable variances are expected.

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The application should result in a firmly bonded membrane. The spacing of the bonding agent should be specified by the material supplier. The design team and owner should understand that the spacings are average values and that the distance between any two adhesive locations can vary. Correct deficiencies by installing an additional bonding agent as needed. Space appropriately. Determine the scope of the discrepancy and take appropriate remedial action.

Flashing at Terminations
Single-ply membrane terminations at roof edges, parapets, and flashing are treated in a variety of ways depending on the material used.

Cured Elastomeric Membrane Flashing

Cured elastomeric membrane that is identical to the roof membrane material can be used as flashing material. Cut the membrane to size and coat the bottom side of the flashing membrane and the area to be flashed with adhesive. After the adhesive has set according to the manufacturers application instructions, roll the membrane into the adhesive in a manner that minimizes the occurrence of voids and wrinkles. Exercise care that the flashing does not bridge where there is a change of direction, i.e., where the parapet wall intersects the roof deck. Seal joints where the cured elastomeric membrane flashing material meets with roof membrane in a manner similar to that used for membrane laps. Apply pressure to the laps to ensure contact.

Uncured Elastomeric Membrane Flashing

Uncured elastomeric membrane can be used in lieu of cured elastomeric material. It is especially suited for penetrations, corners, and other flashings where the membrane must be formed or must change direction. The uncured membrane is used in a manner similar to cured membrane material. Upon curing, however, it permanently shapes to conform to the substrate being flashed.

PVC-Coated or PVC-Clad Metal Flashing

PVC-coated or PVC-clad metal can be used as flashing material. The flat metal stock is cut and fabricated to the proper shape to meet field

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requirements. The sheet metal pieces should not exceed 10 feet in length. Fasten the metal in place with fasteners typically spaced 4 to 6 inches on center. Round the corners and the edges of the sheet metal flashing to protect the membrane from punctures or chafing. Cover the gap with tape. Splice the two pieces of metal together with a minimum 5-inchwide piece of PVC membrane. Center the piece on the gap so that it extends from the top of the metal flashing and out onto the field of the roof. Either heat weld or chemically fuse the PVC membrane to the PVC-clad or PVC-coated metal flashing.

Reinforced PVC Membrane Flashing

Reinforced PVC membrane flashing can be used in lieu of PVC-coated or PVC-clad metal flashing provided the membrane is first mechanically fastened to the nailable roof deck at the flashing. Fasten the reinforced PVC membrane flashing at its upper edge, and shape it to conform to the parapet wall, curb, or edging. Then extend the reinforced flashing onto the field of the roof a minimum of 4 inches. Heat-weld or chemically fuse it to the roof membrane. Endlaps are to be a minimum of 4 inches. Heat-weld or chemically fuse them to the adjoining piece of flashing. Various PVC flashing details are shown in Fig. 6-15.

MBR Flashing Systems

MBR flashing materials are applied using a variety of methods, including heat welding, hot asphalt, and adhesive applications. The degree of heat required for appropriate heat welding, the variables affecting the application rates and temperatures of any asphalt used, and the amount of adhesive used are subject to many variables, including weather conditions, job conditions, material type, and application method. In addition, the material suppliers requirements must be considered. Membrane termination follows the same basic procedure at roof edges, parapets, and other flashing applications as the BUR materials described earlier. It can be handled in one of three ways. Torch-applied MBR membranes can be used as flashing material for masonry, concrete walls, curbs, or other noncombustible substrates. Cut the membrane material to size and prime the wall or curb and the area of the roof membrane to be flashed. Place the MBR flashing membrane

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CPE coated metal drip edge with hemmed edge Continuous hook strip 22-ga. galv. secure with annular ring nails 6" on center CPE seam sealer Heat-welded lap Annular ring shank nails 4" on center 5" max.

Wolmanized wood nailer secured to deck; min. 5" wide

Roof deck Insulation

Cool-top roof membrane

A
Always reuse existing through-wall counterflashing Fasten 8" on center Varies with existing conditions CPE coated metal Provide a cant bend into metal Seam sealer Heat-welded lap Cool-top roof membrane 5" flange with hemmed edge fastened 4" on center using annular ring nails

Roof deck Existing insulation Existing roof New insulation

B
F I G U R E 6 - 1 5 (A) CPE-coated metal drip edge.
(B) Installing coated metal flashing under existing wall counter. (C) Heated vent-pipe flashing.

bottom-side up onto a plywood or other suitable platform. Heat the underside of the membrane with a torch to soften the coating bitumen. Set the heated membrane material to the wall or curb in a manner that minimizes the occurrence of voids and wrinkles. Take care that the flashing does not bridge where there is a change of direction, such

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Urethane or polysulfide caulking by others Stainless steel hose clamp

One-piece CRSI CPI boot

Vent pipe

Min 4 CBSI coated plates and screws equally spaced max. 12" on center around the pipe 2" heat-welded lap

Cool-top roof membrane

CPE seam sealer

Roof deck

Insulation

F I G U R E 6 - 1 5 (Continued)

as where the parapet wall intersects the roof deck. Seal the joints where the MBR flashing material meets with the roof membrane in a manner similar to that used for membrane laps. Apply pressure to the laps to ensure contact. Hot-mopped MBR membranes can also be used as flashing material. Follow the directions for torch-applied membranes. Instead of torching, apply hot asphalt to the area to be flashed and then to the underside of the membrane. Seal the joints where the MBR flashing material meets with the roof membrane in a manner similar to that used for membrane laps. Apply pressure to the laps to ensure contact. The third method is to use self-adhered MBR membranes as flashing material. Cut the membrane material to size and prime the wall or curb and the area of the roof membrane to be flashed. Remove the

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release paper and set the membrane to the wall or curb in a manner that minimizes the occurrence of voids and wrinkles. Take care that the flashing does not bridge where there is a change of direction. Seal the joints where the MBR flashing material meets with the roof membrane in a manner similar to that used for membrane laps. Apply pressure to the laps to ensure contact. Locate the flashing terminations a minimum of 8 inches above the level on the roof. Counterflashing should follow the material suppliers specifications. Some material suppliers have a maximum height limitation for flashings. Refer to the material suppliers recommendations. A cant strip can be installed to modify the angle between the roof deck and the vertical surface. For heat-welded applications, make cant strips from a flame-resistant material and cover them with a base felt. Consult the manufacturers instructions for recommendations regarding the use of cant strips. Install the membrane before the flashing is applied and above the plane of the roof, above the cant, and up the vertical surface as specified by the material supplier. Do not run the roof membrane up the vertical surface to act solely as a base flashing. Remove and reinstall areas of loose, inadequately or improperly bonded flashings using the same materials used in the original application. Cut out, rebond, and reinstall laps that are inadequately bonded. Carefully inspect flashing seams; repair unsealed areas, voids, and fishmouths. Smoothly finish exposed edges or torch-applied MBR membrane with a hot, rounded trowel.

Surfacing Single-Ply Roofs

Some MBR membranes have factory-applied surfacings that provide weather resistance or improve the appearance of the roof membrane. Some membranes require that the surfacings or coatings that provide these properties be applied in the field. The following is a description of the more common surfacing options for MBR systems. Ballast. Loosely laid MBR systems require the use of ballast to build resistance to wind-uplift forces. The ballast is usually rounded

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stone, such as washed river gravel. The amount of ballast needed varies with the location and height of the building. Concrete pavers can be substituted for rounded stone ballast, provided that the roof membrane is protected from the abrasive surface of the paver. Aggregate. For fire resistance, the application of a flood coat and aggregate surfacing can be required. The aggregate should be essentially opaque and a nominal 38 inch in diameter. Embed the aggregate in a flood coat of hot asphalt. Mineral granules. For fire resistance, some membranes require the field application of mineral granule surfacing. For each roof square, embed approximately 50 pounds of No. 11 roofing granules in an emulsion coating that has been applied to the membrane at the approximate rate of 2 gallons per roof square (see manufacturers instructions). Emulsion coatings. For aesthetics, some membranes require the application of an asphalt emulsion top coating. Application rates and techniques vary from manufacturer to manufacturer. Reflective coatings. Fibered and nonfibered aluminum/asphalt coatings can be applied to most smooth-surfaced MBR membranes. Application rates and techniques vary depending on the manufacturer. Factory-applied/self-surfaced membranes. Some MBR membranes might not require the field application of additional surfacing materials. These include membranes with factory-applied mineral granules or metal foils and some smooth-surfaced systems.