INSTALLATION

GUIDE


DURATILE ROOFING SYSTEM



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The Duratile Roofing System

Duratile Incorporated is pleased to introduce an innovative roofing system which is
wholly owned and manufactured on our beautiful island of Barbados. Our new facility in
Lears Quarry, Lears, St. Michael features state-of-the-art equipment and processing
technologies to provide you with the highest quality product.

Duratile Slate Roofing replicates the classic look of natural slate and adds prestige
and character to any architectural style of building. The low gloss variegated color and
natural slate colors enhance the design of your home. The unique hinged ridge cap
system allows the flexibility to accommodate roof angles from 5 - 90. This range of
movement allows a single component to adapt to a variety of roof pitches. With the
Duratile Roofing System, you will get the beauty you want plus the performance you
demand.

Duratile Slate Roofing is manufactured from a durable plastic composite material
extending your roofs life cycle substantially. Thanks to our extensive Research and
Development efforts, which have resulted in a proprietary resin compound, the product
exhibits superior structural integrity and impact resistance. The color through process
eliminates the need for painting or protective sealant throughout the life of the product.

Duratile Slate Roofing, while providing the look and texture of slate, is lighter in weight
than traditional slate or clay tile systems and therefore requires no additional structural
reinforcement when replacing conventional roofing nor does it require you to undo any
structural requirements for the new applications.

The Duratile Roofing System provides economical and ecologically sound roofing
solutions for today and the future of our island.






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TABLE OF CONTENTS

General Construction Guidelines

General Application Details ......................................................................................................... 4
Slopes (Roof Pitch) ........................................................................................................................ 5
Decking........................................................................................................................................... 5
Self Adhering Membrane ............................................................................................................. 5
Underlayment ................................................................................................................................ 6
Torch Down Membrane ............................................................................................................... 6
Sheet Metal Flashing..................................................................................................................... 6
Vent Stacks .................................................................................................................................... 7
Roof Vents...................................................................................................................................... 7
Adhesives & Sealants .................................................................................................................... 7
Fasteners ........................................................................................................................................ 8
Compatibility ................................................................................................................................. 8

The Duratile Roofing System

General Installation Details

Starter Course ............................................................................................................................. 12
Flashing Requirements ............................................................................................................... 14
Valleys .......................................................................................................................................... 14
Hip Details ................................................................................................................................... 15
Ridge Details ................................................................................................................................ 16
Ridge / Hip Intersections ............................................................................................................ 18
Changes In Roof Pitch ................................................................................................................ 19
Projections And Penetrations .................................................................................................... 20
Chimneys ..................................................................................................................................... 21
Dormers ....................................................................................................................................... 22
Skylights ....................................................................................................................................... 24
Roof Vents.................................................................................................................................... 25
Vent Stacks .................................................................................................................................. 25
Continuous Ridge Vents ............................................................................................................. 26




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GENERAL CONSTRUCTION GUIDELINES

The design of the roof is probably the most important consideration relating to the
performance of any roofing system. Typically, the steeper the roof pitch, the better the
performance of the roof design in adverse conditions. On the island of Barbados this is
extremely important in that we often endure severe storms with high winds and the
associated wind driven rain.

For your house to remain dry and un-damaged during these occasions of adverse
weather, Duratile has designed the slate shingle with weather resistant features such as
drain channels to prevent water migration into your home. To insure that the most
weather tight roof may be installed on your home, Duratile has developed this
installation manual which recommends the most current thinking in weatherproofing
your structure.

While many of the recommendations supplied in this manual are not necessarily
required by code, it is suggested that these recommendations be adhered to provide the
best long term performance for your roof installation.

At minimum, all installers of the Duratile Roofing System shall be fully familiar with and
equipped to install the product in a fully qualified manner and acceptable to the architect
specifying the roofing system and the general contractor responsible for the finished
product.
GENERAL APPLICATION DETAILS

Regardless of the style of roof the Duratile Roofing System is being installed on, the
following basic application details must be observed:

Roofing tiles must be doubled at all eaves.
Butts of the first course of tiles should project 3/4" beyond the fascia at all
rakes and eaves.
Spacing between adjacent roofing tiles should be a minimum of 1/8" and a
maximum of 1/4".
Install a minimum of two (2) fasteners per tile. Use fastener guide openings
wherever possible for the required exposure in the succeeding course.
It is recommended that in situations where a fastener opening is not readily



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available (such as cut tiles fitting valleys, hips, ridges etc.), a 3/16" diameter hole
be drilled for fastening to minimize stress in the tile and to allow movement
caused by expansion and contraction.
Joints in any one course should be separated 6" from joints in the adjacent
courses.
SLOPES (Roof Pitch)

The Duratile Roofing System may be applied on any roof with a slope of 15 or greater.
The standard roofing tile may also be applied to exterior walls utilizing acceptable
construction practices as outlined in this manual.
DECKING

The Duratile Roofing System should be applied over solid decking 3/4" thick or greater.
Deck sheathing may consist of composite board panels, such as oriented strand board,
plywood or wood planking. In re-roofing applications the existing roof must be
completely removed down to the deck. The deck must be solidly fastened to the
building structure in accordance with applicable building codes and provide a smooth
base for application of the roofing tiles.
SELF ADHERING MEMBRANE

It is recommended, but not required, that a self-adhering waterproofing membrane be
applied at all eaves, hips, ridges and roof projections.

The self-adhering membrane should be comprised of modified asphalt with a consistent
layer of adhesive applied to one side, with a release paper applied to the underside.
The membrane shall be comprised of a substrate material and rubberized asphalt with a
1/4" bead of asphalt running continuously down each side of the roll.

Self-adhering membrane should be applied at the eaves extending 36" up the slope to a
line not less than 12" beyond the face of the exterior wall. The membrane shall overlap
the apron flashing at the eaves to prevent water damage under the flashing.

Self-adhering membrane should be applied at ridges and hips extending a minimum of
18" either side of the centerline of the ridge or hip.



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Self-adhering membrane should be applied to all roof projections and penetrations in a
manner which will prevent water damage to the roof, for example around dormers,
skylights, vents, chimneys etc...
UNDERLAYMENT

Underlayment is recommended to be 30# plain roofing felt, type II, organic or in
accordance with the local code of jurisdiction and installed to the manufacturers
specification.

Install one ply of underlayment over the entire surface of the roof with the exception of
cut-out areas for vents etc..

Lay underlayment horizontal to the roof slope with a minimum headlap of 2" and a
sidelap of 4" or in compliance with manufacturers specifications. Fasten or staple
underlayment sufficiently to hold in place until roofing tiles are installed.
TORCH DOWN MEMBRANE

The islands reside in a very harsh environment which is hot and subjected to a great
deal of wind driven rain. The recommendation for underlayment contained in this
manual are at best a minimum requirement for the climate.

Duratile Inc. strongly recommends that the homeowner considers applying torch down
membrane over the entire roof prior to installing the roofing shingles.

This approach will provide the most weather tight installation as well as maximize the
functioning life of the roof.
SHEET METAL FLASHING

All sheet metal flashing shall be a minimum of 26 ga stainless steel, 16 oz. copper or
0.032" aluminum.

Install sheet metal flashing along eaves, rake edges, valleys, ridges, hips and all roof
projections and penetrations.

Sheet metal flashing work shall be manufactured in accordance with the best standard



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practices of the industry; with joints locked, cleated, caulked as required, and exposed
edges hemmed. Allowance shall be made in all work for expansion and contraction
without compromising the waterproofing integrity of the structure.

Mitered corners shall be straight and profiles level as required to suit the specific site
conditions, with flat surfaces free of distortion and face nailing.

All free edges of metal flashing shall be reinforced by a fold of at least " wide, set out
slightly and presenting a straight line and neat finish.

Form flashing in the longest possible lengths to minimize water migration and allow for
appropriate expansion and contraction.

All flashing should be fabricated in a shop where possible, with proper sheet metal
tools. Lock seams should be provided for all corners and intersections where possible.
VENT STACKS

It is recommended that soil vent pipes be installed with a pre-manufactured self-
flashing base and sealed to the vent pipe projection with an elastomeric seal or boot.
All vent flashings shall be installed in accordance with the manufacturers
recommendations.
ROOF VENTS

Roof or ridge vents shall be pre- manufactured from aluminum, galvanized steel, copper
or plastic, sized to comply with the appropriate building code.

Ridge vents shall have waterproof ends, caps and connectors as required to complete
the installation in a manner recommended by the manufacturer.
ADHESIVES & SEALANTS

The contractor should ensure that all construction adhesives and sealants used in the
installation of the roof comply with appropriate codes and are compatible with the
roofing system.




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A list of approved sealants and adhesives may be obtained from Duratile Inc..
FASTENERS

It is recommended that each Duratile Roofing Tile be attached with two non- corrosive
screws of sufficient length to fully engage the roof substrate. These fasteners may be
applied either manually or with pneumatic nailing equipment.

The recommended length for these screws follows:
3/4" starter course
1" first course
1 1/4" main course
1 3/4" caps and hips

Where fastening may be marginal such as around chimneys, valleys, hips, ridges etc.,
use a recommended construction adhesive in addition to screws to ensure that the tiles
are properly secured to the roof.

Approved fasteners are to be manufactured from electro-galvanized steel, ASTM 641,
Class 1; Type 304 or 316 passivated stainless steel, copper or aluminum.
COMPATIBILITY

The roofing contractor must ensure that all materials used in conjunction with the
installation of the roof are compatible with the Duratile roofing system and each other.

Failure to use compatible materials with a life span equal to the roofing shingles will not
only shorten the life of the roof but may void the warranty offered by Duratile Inc.

All installations must comply with the current Barbados building code and any
appropriate updates to this code.




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THE DURATILE ROOFING SYSTEM

The Duratile roofing system consists of a standard roofing tile and a unique hinged ridge
cap.

The standard roofing tile has nominal dimensions of 12" X 16". The slate look tile
features a rain gutter on the upper face to minimize water migration under each
succeeding course. Nailing points are through molded for convenience and layout
reference marks are incorporated into the face to assist in installation
(Figure 1).

The rear side of the roofing tile is cored to minimize the weight. Cut locations for both
the starter course and the half shingles are adjacent to molded rib in place structures
(Figure 2).














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The diagram below (Figure 3) illustrates the typical tile layout required for a weather-
tight roofing installation.


The hinged ridge cap consists of two parts, left and right halves (Figure 4).

As with the standard roofing tile, the ridge cap incorporates rain gutters and through
molded nailing points.

The rear side of the roofing tile is cored to minimize the weight. Reference marks are
molded into the rear surface to assist in cutting major reference angles used in
construction of a building (Figure 2).




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The tapered hinge pin allows the ridge cap to rotate up to 90 to provide installation
adjustment to fit a variety of roof styles (Figure 5).


The diagram below (Figure 6) illustrates the typical tile layout required for a weather-
tight roofing installation.

GENERAL INSTALLATION DETAILS

For the most attractive visual appearance, the contractor should mix tiles from different
bundles to take advantage of minor variations between batches and ensure random
shading on the finished roof surface.




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After the roof surface has been prepared inclusive of flashing, self- adhering membrane
and underlayment, the installation of the tiles may begin.

STARTER COURSE

The starter course consists of the upper portion of the tile (see figures 1 & 3). The
contractor should save the lower portions of the tile for use at hips, ridges and valleys.

Install the starter course by cutting one tile in half and then alternating with a full width
tile extending beyond the eaves and rakes by 3/4" ( Figure 7 ). Each starter tile should
be fastened with two (2) 3/4" screws in a parallel line with the eaves.

It is recommended that a 3/16" diameter hole be drilled for each screw to prevent
fastening stress build-up in the tile and to allow for expansion and contraction should
the provided fastening points not be suitable for the particular installation.

It is further recommended that the starter course of tiles be additionally fastened to the
roof with a compatible construction adhesive to ensure weather tightness. With the
starter course installed, the first of tiles may be installed, starting with a full tile,
extending 3/4" beyond the eaves and rakes in the prescribed manner using two (2) 1
screws per tile.





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It is recommended that a compatible construction adhesive be applied between the
starter course and the first course of tiles to ensure weather tightness.

Install the second course of tiles by cutting a tile in half vertically and install at the
appropriate exposure. Alternate this with a full tile for the succeeding course over the
joints in the underlaying tile. The second and all remaining courses are fastened with
two (2) 1 1/4" screws each." (Figure 8).



Install the roof tiles with 6" of exposure on most roof slopes. An exposure of greater
than 6" but not exceeding 6 " may be used for roofs with a slope greater than 45.
The exposure markings on the tile allow the exposure to be defined by the tile below.
Do not install on roofs with a slope of less than 15 without first consulting with a
qualified engineer.

Provide 1/8" - 1/4" gap between tiles in the same course to compensate for any
movement in the roof surface or expansion of the roofing tiles.





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FLASHING REQUIREMENTS

Most roof leaks occur where water is channeled off the roof or where the roof abuts a
vertical wall or chimney or where projections such as soil pipes pierce the roof structure.
At these points metal valleys saddle and flashings are used in conjunction with the
roofing tiles to keep the structure dry.

Structural members that protrude through the roof should be flashed at all intersecting
angles to prevent leakage. All base flashing should extend under the roofing tiles and
up vertical surfaces and should be covered by a second layer of flashing (counter
flashing).

Flashings should be stainless steel, copper or aluminum (as defined in the General
Construction Guideline section of this manual). The architect or contractor should
ensure that the selected flashing materials have the same longevity as the roofing tile.
VALLEYS

It is recommended but not required, that one ply of self-adhering membrane be installed
in all valleys. The membrane should be extended 30" up the slope from the centerline
of the valley.




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Install the sheet metal valley flashing over the self-adhering membrane where applied.
The sheet metal flashing should extend not less than 12" up the slope from the valley
centerline. Cut and fit the tiles to provide a slight taper in the exposure in the exposure
of the flashing toward the head (top) of the valley (Figure 9).

Overlap the sheet metal flashing sections a minimum of 4". All joints should be crimped
or sealed with a compatible construction adhesive to ensure weather tightness.
HIP DETAILS

It is recommended but not required, that one ply of self-adhering membrane be installed
on all hip ridges prior to installing underlayment.

Intersecting roof sections at hips must be capped to ensure a weather tight roof joint.
The Duratile hinged ridge cap is designed to accomplish this task. The 6" exposure
incorporated into this unit matches the recommended roofing tile exposure creating a
visually unified finished roof.

The roof tiles of each course are trimmed to the appropriate angle creating a finished
hip centerline. The tiles creating this intersecting joint should maintain a gap of 1/8"-
1/4" between tiles to compensate for expansion and contraction.

Each course of intersecting tiles should be flashed at the joint to maintain weather
tightness. The flashing should be bedded in a compatible construction adhesive prior to
installing the cap (Figure 10).




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Installation of the hinged cap will complete the hip construction. The hinge pin on the
right hand cap should have a bead of sealant spread along the centerline prior to
installation.

Spread a bead of construction adhesive the full length of the roof course
(Figure 11), approximately 4" on either side of the hip centerline and screw the hinged
cap on the course with two (2) screws on each side. The screws for the cap installation
must be longer than the screws used on the roof tiles (1 3/4"long).

To complete the hip installation, spread a bead of color matched sealant the entire
length of the hip on the open side of the hinge.


RIDGE DETAILS

It is recommended but not required, that one ply of self-adhering membrane be installed
on all ridges over the underlayment and extending down slope a minimum of 16" prior to
installing the flashing.

Sheet metal flashing should be applied over the ridge prior to installing the ridge cap.
The flashing should be bent to conform to the ridge angle and extend down either side



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from the centerline a minimum of 3"

It is recommended that a bead of compatible construction adhesive be applied parallel
to the ridge and approximately 2 1/2" either side of the centerline of the ridge. For
maximum weather tightness it is desirable to spread a bead of compatible construction
adhesive under the final course of tiles at the ridge prior to fastening the tile with two (2)
screws.



Installation of the ridge may now be completed by applying the hinged ridge cap.

Beginning at one end of the roof, install the first hinged cap with the tapered tail facing
the far end of the roof. The hinge pin on the right hand cap should have a bead of
sealant spread along the centerline prior to installation.

Spread a bead of construction adhesive the full length of the roof course (Figure 11),
approximately 4" on either side of the hip centerline and fasten the hinged cap on the
course with two (2) screws on each side. The screws for the cap installation must be
longer than the screws used on the roof tiles (1 3/4" long).

Repeat this process for each successive ridge cap until the full ridge is completed. The
final cap should be trimmed to mate with the far roof rake taking care to ensure that only
the slate textured portion of the cap is exposed.




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To complete the ridge installation, spread a bead of color matched sealant the entire
length of the ridge on the open side of the hinge.

RIDGE / HIP INTERSECTIONS

Roof styles which feature intersections of hips at the ridge of the roof require additional
care to ensure weather tightness. In these instances, the installer should start the ridge
installation at the intersection point rather than at the open end of the ridge.

There are two (2) basic methods of creating a visually attractive and weather tight
juncture (Figure 13).



Both approaches will provide an acceptable closure for the intersection, though, the
Mitred approach requires more care to ensure a weather tight closure.

The lap joint is the easiest to construct and provides the most reliable weather seal.

For either type of intersection, follow the recommended procedures outlined in the hip
and ridge installation sections.






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CHANGES IN ROOF PITCH

There are many architectural styles which require changes in the roof pitch or require an
intersection with a side wall. Each of these conditions poses a unique set of
requirements to ensure weather tightness of the structure.

(Figures 14 - 17) illustrate recommended approaches to addressing these requirements.
All these conditions require proper flashing and appropriate underlayment to circumvent
water migration.

Whether these recommendations are followed is optional on part of the contractor.
However, the contractor must follow accepted industry practices and ensure the building
remains structurally sound and weather tight.







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PROJECTIONS AND PENETRATIONS

Many architectural styles incorporate projections from the roof line such as dormers,
and almost all roof lines incorporate some form of penetration through the roof surface.

It is recommended but not required, that one ply of self-adhering membrane be installed
in conjunction with the required flashing for these applications. In projections such as
chimneys and dormers, it is recommended that the membrane should be extended 4"-6"
up any vertical wall.



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It is advisable to utilize a compatible construction adhesive as well as mechanical
fastening when installing the required flashing for these applications.
CHIMNEYS

Chimneys are constructed in different forms and locations depending on the
architectural style of the building and local building practices.

(Figures 18-20), illustrate the most common styles and placement of the roof. Each
type exhibits its own unique flashing requirements to ensure weather tightness.

All chimneys should be flashed on all four sides with the flashing extending up the
vertical face of the chimney 6" and out onto the roof a minimum of 4". All base flashing
should have a headlap of 4" minimum and it is recommended that a construction
adhesive be used at all lap joints to minimize water penetration.

Counter flashing should be installed over the base flashing and the roofing tiles on the
down slope side of the chimney.

It is recommended that chimney saddles (Figure 20) be installed on chimneys where the
upper side of the roof slope exceeds 30"

A minimum space 1/4" must be allowed between the vertical flashing face and the
roofing tile courses to allow for expansion and contraction.

It is recommended that a compatible construction adhesive be used in conjunction with
nails on each tile immediately abutting the chimney.
Chimneys also tend to leak internally. It is the responsibility of the contractor to ensure
that the internal structure and flashings of the chimney weather tight and in good repair.






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DORMERS

Many architectural styles utilize dormers to add interior space and to provide visual
interest to the roof line.

It is recommended but not required, that one ply of self-adhering membrane be installed
in conjunction with the required flashing for these applications. In projections which
include vertical walls, it is recommended that the membrane should be extended 4"-6"
up any vertical wall.



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Standard dormers (Figure 21) require flashing techniques common to both valleys and
wall intersections. Refer to these sections for approved construction details. The only
unique flashing element is the counter flashing required on the downslope side of the
dormer.

Recessed dormers (Figure 22) provide a more challenging set of flashing requirements.



In addition to the valley and sidewall intersections, the contractor must provide a
weather tight floor and sidewalls for the recessed area of the dormer.

Typically the floors are formed from galvanized sheet steel, copper or aluminum. The
side walls must extend up the building structure a minimum of 6". All corners must be
welded, soldered or crimped and caulked in accordance with appropriate building
codes. The floor surface should have a downward slope of 1" per 12" of run.




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The bottom edge of the floor pan should extend downslope a minimum of 4" with the
lower edge hemmed "

Additional counter flashing should extend out on the extended roof surface a minimum
of 6" and downward to cover the vertical wall of the floor pan by 4".


NOTE: Current techniques utilizing rubberized continuous membranes may be used in
place of a sheet metal floor when locally available and comply with appropriate building
codes.
SKYLIGHTS

Skylights (Figure 23) are utilized in many buildings to bring additional natural light into
the interior of the building. Opening models also offer the additional benefit of providing
ventilation.

When installing skylights, the builder or contractor should select a pre- manufactured
unit of reputable quality and ensure that the unit is installed to the manufacturers
specifications.

Trim roof tiles neatly around the base of the flange allowing a minimum of 1/4"
clearance for movement and secure to the roof with two (2) screws per tile.

It is recommended that a compatible construction adhesive be used in conjunction with
the screws to ensure weather tightness.





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ROOF VENTS

Very often roof vents (Figure 24), are required to improve air flow throughout the
building. A major function of roof vents is to remove heat build up in the roof peak and
to remove condensation build-up in the upper portions of the building.

There are many styles of metal and plastic pre-manufactured roof vents available.
When installing roof vents, the builder or contractor should select a pre- manufactured
unit of reputable quality and ensure that the unit is installed to the manufacturers
specifications.

Trim roof tiles neatly around the base of the flange allowing a minimum of 1/4"
clearance for movement and secure to the roof with two (2) screws per tile.

It is recommended that a compatible construction adhesive be used in conjunction with
the nails to ensure weather tightness.



VENT STACKS

Vent stack and pipe flashings should consist of a self-flashing base with a friction fit
elastomeric boot which seals the pipe and locks securely on the flange. When installing
the flange, the contractor should ensure that the flange extends 6" onto the roof surface



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and is secured in accordance with appropriate building codes.
Trim roof tiles neatly around the base of the flange allowing a minimum of 1/4"
clearance for movement and secure to the roof with two (2) screws per tile.
It is recommended that a compatible construction adhesive be used in conjunction with
the nails to ensure weather tightness.


CONTINUOUS RIDGE VENTS

Many buildings are constructed with pre-manufactured continuous ridge venting for
improved air flow in the structure.

There are basically two (2) styles of vents commonly in use today. The shingle over
style (Figure 26), allows the hinged ridge cap to be installed directly over the venting
system. This type of vent minimizes the visual presence of the venting system as the
roof appears to be of one material.

The second style of continuous vent is the filter vent type. This vent system is usually
manufactured from either metal or rigid plastic and is constructed with its own flashing
as part of the vent system. The unit attaches directly over the roof ridge and takes the
place of the conventional ridge cap.



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Either type of venting system may be selected. The contractor should be familiar with
the selected venting system and ensure that the installation is carried out in accordance
with the manufacturers specifications and in compliance with the appropriate building
codes.

Duratile Inc. is confident that if the guidelines contained in this manual are followed,
and that the installation is performed in a professional manner, your new Duratile
Roofing System will provide many years of trouble free use.

Not only will your roof be trouble free; the appearance of natural slate will increase the
curbside appearance of your home and improve its value in the ensuing years.

You are not only purchasing a high quality roof for your home, but investing in the future
well-being of your island.