SPECIFICATION GUIDE FOR DURAGARD IV SEAMLESS INSULATED ROOFING SYSTEM
YOUNG BUILDERS ROOFING
“Standing behind our work and our word since 1972” Professional Applicators of Roofing Waterproofing Coatings Caulkings & Sealants 1315 East Gibson Lane, Building A-2 Phoenix, Arizona 85034 602-944-4485 FAX 602-254-4445
License Nos: ROC C-42 78510 ROC L-42 78508
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TABLE OF CONTENTS PART 1 – GENERAL SCOPE . . . . . SUBSTITUTIONS . . . . PRODUCT . . . . . SUBMITTALS . . . . QUALITY ASSURANCE . . . PRE-INSTALLATION CONFERENCE . REGULATORY REQUIREMENTS . DELIVERY, STORAGE, AND HANDLING ENVIRONMENTAL/SITE CONDITIONS INSPECTIONS . . . . PART 2 – MATERIALS PRIMER . . . . URETHANE FOAM INSULATION FIRE HAZARD CLASSIFICATION MEMBRANE COATING . . AGGREGATE . . . FLUID APPLIED FLASHING . EQUIPMENT . . . EQUIPMENT SAFETY . . PERSONAL PROTECTION . PART 3 – EXECUTION APPLICATION . . . PREPARATION . . . SUBSTRATE PREPARATION . PRIMER . . . . MEMBRANE COATING PREPARATION MEMBRANE COATING APPLICATION AGGREGATE . . . VERTICAL SURFACES . . FIELD QUALITY CONTROL . CLEAN UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 7 7 8 8 9 9 9 9 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 4 4 5 5 5 6 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 2 2 3 3 3 3
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SECTION 07540 COATED FOAMED ROOFING PART 1 – GENERAL 1.1 Scope – Work Specified Herein A. All labor, materials, transportation, storage facilities, equipment and services necessary to furnish and install spray applied monolithic rigid polyisocyanurate urethane foam insulation waterproofing and cementitious protection systems including all accessories and devices necessary to complete the roof installation as specified and indicated in the plan documents. B. Drawings and general provisions of the contract, including General and Supplementary Conditions and Division 1 specification sections, apply to this section. C. Related Sections Include: 1. 2. 3. Division 6 Section: Carpentry – Wood nailers and curbs Division 7 Section: General Sheet Metal – sheet metal flashing and trim and roof specialties and accessories Division 9 Section: Gypsum sheathing as applicable
D. Intent of the Specification The intent of this specification is to establish a level of quality and minimum standards for the products acceptable for use on this project. 1.2 Substitutions A. For roofing systems not specified herein, the Manufacturer or Contractor must obtain prior approval from the Architect before his/her product will be allowed to be bid on this project. Products not specifically approved for use on this project within this specification must be submitted for prior approval at least seven days prior to bid date. B. Submit to the Architect two (2) weeks prior to the initially scheduled bid date two (2) 24”x24” samples and Material Tech Data Sheets exhibiting equal or greater physical properties than the specified system. Submit evidence that the proposed substitution has been tested as a composite roof covering in accordance with: UL 790 Class “A” (UBC 32-7 Standards), Class A spread of flame in accordance with E108-82 (UL Class “B” as it applies to a minimum 1” thickness when applied over combustible decking), Factory Mutual Class I for Severe Hail Resistance (FM-4470), and supported by ICBO with current ICBO evaluation report designation. 1.3 Product The Duragard/Diathon roof system (UL Class A Classification Nos. R-1400, R-6986, R-6935 and ICBO Evaluation report #3129) is an acceptable product.
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1.4
Submittals A. Submit evidence that the polyurethane insulation, together with the waterproofing membrane has been tested as a composite roof covering in accordance with: i. ii. iii. iv. v. UL 790 Class-UBC 32-7 Standards Class “A” for spread of flame in accordance with E108-82 UL 1256-85 (UBC 17-4) roof deck construction assembly wind uplift ratings ICBO Data in accordance with the ICBO ES Acceptance Criteria for Membrane Roof Covering Systems Factory Mutual 4470 – Factory Mutual Class I for Severe Hail Resistance
B. Submit technical data sheets on polyurethane foam, protective coatings, and primers. C. Submit manufacturer’s application or installation instructions D. Submit contractor/applicator certification from polyurethane foam supplier and/or protective coatings manufacturers as evidence of contractor/applicator qualification and experience. E. Submit sample warranty: shall be the standard ten (10) year manufacturer and contractor warranty. F. Submit evidence that system constituents are VOC compliant G. Submit evidence that polyurethane foam insulating system is 95% Freon-free, environmentally safe HCFC type product. Foam must be approved per UL 723 testing. 1.5 Quality Assurance A. Protective Coating Manufacturer Qualifications: 5 years of successful installations and a minimum 1 million square feet on which its acrylic products have been used in conjunction with the specified polyurethane foam and cementitious protective topping. B. Contractor and Applicator Qualifications: Engage a contractor with at least one applicator that has successfully completed, within the last 5 years, 1 million square feet of cementitioustopped acrylic-coated foam roofing assemblies. 1.6 Pre-installation Conference A. Two weeks prior to installing the specified roofing system, conduct a conference at the project site to comply with Division 1 Section requirements. Notify participants at least five working days prior to the conference. B. The conference shall include the architect, contractor, roofing superintendent, roofing project manager, roofing applicator, deck installer and installers whose work interfaces with or affects roofing, including installers of roof accessories and roof mounted equipment.
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C. The conference shall include discussions related to substrates (decks); mechanical equipment curbs and other roof deck penetrations, drainage and drain assemblies and conditions of other construction that will affect the roofing application. Discussions should also include conditions that may be affected by possible fugitive overspray during the application of the spray applied polyisocyanurate insulation. D. Minutes of the conference shall be documented by the prime contractor and distributed to all parties involved. 1.7 Regulatory Requirements A. Polyurethane foam insulation and protective coating shall have been tested by Underwriter’s Laboratories and shall bare a UL 790 Class “A” label for fire resistance. B. The Class “A” certification shall apply to a combustible deck with no less than 1 inch thickness of polyurethane foam, top coated with the protective coating system as set forth within. C. Insure all system constituent material containers are UL labeled and covered by Underwriter’s Laboratories’ follow up service agreements. 1.8 Delivery, Storage and Handling A. Packing and Shipping: Deliver materials to site in manufacturer’s original unopened containers with labels intact. B. Storage: Insure adequate protection from damage during storage. All material shall be protected from excessive heat and cold in accordance with manufacturer’s printed instructions. C. Handling: Per manufacturer’s written instructions. D. Provide manufacturer’s representative written verification those products approved are products installed on the job. E. Urethane insulation and waterproofing materials, aggregates, and protective coatings shall be processed and applied, using only that equipment specifically designed for this application. 1.9 Environmental/Site Conditions Environmental/site requirements: Air temperature/surface temperature shall be as recommended by the polyurethane foam manufacturer’s printed technical guidelines. 1.10 Inspections
A. Manufacturer’s representative is to provide a “pre-project inspection report” prior to any work commencing. B. At the completion of the roofing project, manufacturer’s representative is to provide a completed project inspection report. 3
C. Roofer shall assume responsibility for acceptance of the substrate (decks) by application of the roofing.
Part 2 – MATERIALS 2.1 Primer In cases where a system warranty is required, the primer should be United Coatings Uniseal primer. 2.2 Urethane Foam Insulation: A. Urethane foam insulation shall be Flexible Products 241-27 two-component spray applied urethane foam specifically manufactured for roofing. B. Foam thickness shall be a minimum ____” (+ 1/8 ”) at field areas and a minimum ¾ inch at the parapet wall areas. Application shall result in a high quality seamless layer of rigid urethane insulation meeting the following requirements: *Density in Place: ASTM D-1622 @ 74 F 2.7-3.0 lb./ft Compressive Strength: ASTM D-1621 @ 74 F 40-45 psi Tensile Strength: ASTM D-1623 @ 74 F 60 psi “K” Factor: ASTM C-518 0.14/0.16 “R” Factor Aged: ASTM C-518 6.25 inch Closed Cell % ASTM-2856 95+ Dimensional Stability: ASTM D-2126 @ 160 F Net Change 1% Surface Burning: Tunnel Test per UL 723 ASTM E-84 Flame Spread: ASTM E-84 30 Smoke Density: ASTM E-84 >450 (*) Density requirements are specifically given as guidelines only. The physical properties of the foam shall prevail over density. These physical properties are listed, as minimum required regardless of density. 2.3 Fire Hazard Classification: A. Roof system shall meet UL 790 requirements as a Class “A” roof covering when used with the protective coatings as specified. Thickness: Flame spread: Smoke Density: At specified thickness Less than 75 Waived
B. Polyurethane foam shall be the correct grade for the time of year that the installation occurs.
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2.4
Membrane Coating: A. Fluid applied membrane waterproofing shall be United Coatings Diathon/Duragard single component two-coat application and specifically manufactured for use with the approved system. The total dry film thickness shall be 25 mils. The application of the fluid applied membrane waterproofing system shall result in a high quality seamless, pinhole-free membrane meeting the following minimum physical requirements:
Solids by Weight Solids by Volume Tensile Strength Elongation: Permeance Permeability Hardness Hail Resistance
ASTM D-2369 ASTM D-2697 ASTM D-412 ASTM D-412 ASTM E-398 ASTM E-398 ASTM D-2240 FM – 4470
70% (+2) 60% (+2) 250 psi (+20) @ 75 F (24 C) 440 psi (+20) @ 0 F (-18 C) 280 % @ 75 Fahrenheit 320% @ 0 Fahrenheit 3.0 Perms @ 20 mils 0.06 Perm Inches 55 to 65 Shore A Factory Mutual Class I Severe Hail Resistance
2.5
Aggregate Aggregate shall be washed, screened, and sized specifically for use in the specified system.
2.6 2.7
Not Used Fluid Applied Flashing Fluid applied flashing at vertical surfaces (equipment curbs, vents, pipes and parapet walls) shall be United Coatings “Diathon” and applied over the specified and pre-designated (by virtue of plans and designated details) polyurethane foam. The fluid applied membrane coating shall be applied in a three-coat application at the rate of 1-1/4 gallons per coat. Each coat shall be applied in contrasting colors. The total average dry film thickness shall be 30 mils. The application of the fluid applied membrane coating shall result in a seamless membrane with the following performance properties: Base Coats Color Tensile Strength Elongation Hardness Shore “A” Tear Resistance Fire Resistance Top Coat
ASTM D-412 ASTM D-412 ASTM D-2240 ASTM D-1004 UL 790
Grey White 250 psi 250 psi 280% 380% 55-60 55-65 130 130 Class A and ICBO rated
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2.8
Equipment A. Use equipment specifically designed for the proportioning and dispensing of two-component urethane foam or coating systems. B. The primary heaters shall be the means of actually controlling the temperature of the chemicals. C. The hose heating element(s) shall maintain the liquid temperature between the proportioner and the gun. D. Ensure that the hose thermometer is in good working condition at all times during the application so that there is proper viscosity necessary for premium mixing of the two components. E. Take extreme precautions necessary to not contaminate the roof’s surface while cleaning the spray equipment.
2.9
Equipment Safety As with most mechanical equipment, certain safety precautions must be taken when any equipment is used or serviced. Please contact the manufacturer of the equipment to be utilized for this project for safety guidelines that pertain to the type of application specified for this project.
2.10
Personal Protection Protective equipment such as OSHA approved safety goggles/glasses, protective gloves; functional respirator must be worn at all times while using the equipment necessary for the application of the specified roof system. In poorly ventilated areas, it is recommended that a fresh air-type respiratory system be used.
PART 3 3.1
EXECUTION
Application A. Examine substrates that are to receive sprayed urethane foam roofing for deficiencies. Deficiencies found shall be documented and submitted to the architect through the designated contractor. B. Inspect substrate to ensure no contaminants exist that will interfere with the complete and total adhesion of the spray applied urethane foam to the substrate. The substrate shall be free of loose particles, rust, scale, grease, dirt, latents or other contaminants. C. Verify that roof openings and roof penetrations are in place, set and braced and that roof drains are properly secure in position. 6
D. Verify that wood nailers are in place and secured. E. A dry surface is one that is free of visible moisture and that when tested with a moisture meter registers a reading of less than ten percent. F. Urethane foam shall not be applied to a designated substrate if the deck temperature is within five degrees of the dew point. G. Sprayed foam shall not be applied on a roof substrate surface having a measured temperature of less than fifty degrees unless foam specifically formulated for low temperature application is employed. In this event, the minimum permissible measured substrate temperature will be thirty-five degrees. H. Do not proceed with installation until unsatisfactory conditions have been corrected. 3.2 Preparation A. Document and submit to the responsible parties engaged the potential for fugitive overspray. B. In a conspicuous manner, place barricades to adjacent areas of the designated work are to ensure that all vehicular traffic is eliminated. This is in an effort to minimize the potential for overspray. C. Vehicles and vehicular equipment shall be moved and/or covered in an effort to minimize the potential for overspray. D. Supply and install protective covering as necessary to protect pedestrian walkways, building walls, plant life, and adjacent buildings from the potential of overspray. E. Upon completion of the finished product, no evidence of the roof installation shall be visible from the ground level other than intentional design plans. 3.3 Substrate Preparation A. Concrete “T” joints shall be prepared utilizing the following method: a. Apply a minimum 6” wide (length as necessary) and minimum 56 mil self-adhering sheet membrane (Bituthene 3000/Polygard 650 are acceptable) over the entire length of each panel. Overlap each side of the joint a minimum 2 inches. b. The substrate must be primed to protect it and to increase bonding of the foam insulation. Allowable types and required design loading must comply with applicable codes. B. Metal decks shall be prepared utilizing the following methods: a. The metal roof deck shall be constructed with minimum 22-gauge steel and defection shall be less than 1/240 of the span. Construction shall be in accordance with local building codes. b. Clean and prime per the manufacturer’s printed instructions. 7
c. If the metal surface is free of loose scale, rust, weathered or chalking paint, it can be cleaned using compressed air, vacuum equipment, hand or power broom to remove loose dust or dirt. Grease, oil, or other contaminants shall be removed with the proper cleaning solutions as recommended by the manufacturer. d. Fluted metal decks require a suitable method of filling the flutes prior to the application of the polyurethane foam. Flutes may be covered with mechanically fastened board stock, special polyester tapes or spray applied foam. C. Gypsum board or isocyanurate board shall be installed utilizing the following methods: a. Board stock shall be fastened to the metal decks with Factory Mutual approved fasteners and plates or UL approved Insta-stick adhesive. b. Comply with UL 1256 (UBC 17-4) for roof deck construction assembly wind uplift. 3.4 Primer A. Spray apply primer to the designated substrate at the rate of one gallon per 300 square feet. B. Sprayed urethane insulation: a. Sprayed urethane insulation shall be metered to material supplied specifications through proportioning equipment that provides thermostatically controlled material and spray gun shall be temperature controlled. b. Surface texture of the installed foam shall range from a smooth to medium coarse (orange peel) finish. Surface textures that may be defined as “popcorn” or “tree bark” are not acceptable. C. Filleting of foam to parapet walls, vents, roof mounted equipment curbs, etc., shall provide a relatively smooth transition to the roof deck and shall be of uniform cross-section thickness and shall meet all other foam surface requirements. D. All areas, which fail to meet specification requirements with respect to thickness, foam quality, etc., shall be repaired and re-sprayed at the expense of the foam applicator. E. Spray apply urethane foam insulation in minimum lifts of ½” to achieve the specified thickness. The finished foam surface shall be of sufficient overall uniformity and pitch (slope) as necessary to avoid ponding water. F. The substrate shall provide a minimum of ¼” per foot slope. It is the roofing contractor’s and the general contractor’s responsibility to confirm that the substrate slope requirements have been met per design and have been provided by the installation of the substrate. G. Substrates that are not warped at drain areas to facilitate water drainage or on metal and concrete decks, crickets shall be manufactured utilizing the spray applied polyurethane foam insulation. Refer to the roof diagram, roof framing diagram, elevations, and details to confirm the installation of spray-applied crickets. H. Terminate foam application _____” above the finished roof surface at parapet walls. 8
3.5
Membrane Coating Preparation A. Verify urethane insulation to be coated is free from defects such as contaminants, UV degradation, or other foreign matter, which will inhibit a successful bond of the coating and the urethane foam insulation. B. Repair all physical damage to the urethane foam insulation prior to the application of the fluid applied membrane coating. C. All areas of repair shall have an additional coat of the specified fluid applied membrane coating applied at the rate of 1-1/2 gallons per 100 square feet. 3.6 Membrane Coating Application A. Spray apply fluid applied membrane base coat over prepared insulation at a rate of 1-1/2 gallons per 100 square feet. Color of base coat to be grey. B. Spray apply fluid applied membrane top coat over completed base coat at the rate of 1-1/2 gallons per 100 square feet. Color of top coat to be white. C. The total dry mil thickness of the completed membrane, exclusive of the aggregate, shall be 25 mils. A dry mil thickness of less than 22 at any tested location of the finished membrane shall be cause for rejection and locations shall be recoated to achieve the required thickness.
3.7
Aggregate A. Broadcast Shasta #9 limestone aggregate into final fluid membrane top coat at a rate of 65 pounds per 100 square feet. B. To ensure uniformity, broadcasting shall be completed by means of mechanical granulation equipment. Hand distribution is unacceptable.
3.8 3.9
Not Used Vertical Surfaces A. Protective coating membranes at vertical surfaces: Pipe penetrations, parapet walls, mechanical curbs, etc., shall receive a 3-coat application of fluid applied membrane coating for a total dry mil thickness of 30 mils. Apply each coat at a rate of 1-1/4 gallons per 100 square feet. Base coat to be light grey, intermediate coat to be grey, and top coat to be white. B. Terminate membrane coating system 2 to 4 inches above urethane foam insulation at all through-roof penetrations to create a self-flashing termination. C. Utilize Daily Quality Control Report forms as necessary to document weather conditions and completed application dry mil thickness. D. If due to unforeseen conditions the urethane foam insulation remains uncoated for more than 72 hours, the uncoated urethane foam insulation must be inspected by the manufacturer’s representative to determine the necessity of primer application. 9
3.10
Field Quality Control
A. Roofing Manufacturer’s Obligation a. The manufacturer’s representative for the materials specified on this project shall make inspections as outlined by the manufacturer and as required to provide the specified warranty. b. In addition to the inspections required for the warranty, the following inspections are required: i. ii. iii. B. Core Sampling a. The owner reserves the right to take random core samplings to determine if the urethane foam meets the minimum physical requirements as specified and for proper adhesion to the substrate. b. Core samples, if required, shall be cut by the contractor prior to the application of the fluid applied membrane coating system. c. Cost associated with the cutting of core samples, and necessary repairs of cutout sections shall be borne by the roofing contractor. d. Cost associated with testing the in-place density shall be borne by the owner. Tests shall be performed by an independent laboratory in accordance with ASTM D-1622. 3.11 Clean up During the course of the work and upon completion of the work, remove and dispose of excess materials, equipment and debris away from the premises. Leave work area in clean condition in accordance with Division 1 Section of Closeout Procedures. Preliminary substrate inspection A minimum of one unannounced spot inspection Final completed roof inspection
END OF SECTION 7540
Last Revision: 1/10/2009
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