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BUILT UP ROOFING - GRAVEL SURFACE MASTER GUIDE SPECIFICATIONS

Revised May 2000

PART I - GENERAL

1.01 GENERAL
1.02 SUBMITTALS
1.03 QUALITY ASSURANCE
1.04 CODE REQUIREMENTS
1.05 DELIVERY AND STORAGE
1.06 SITE CONDITIONS
1.07 WARRANTY

PART 2-EXECUTION

2.01 CAUTIONS
2.02 MIXING
2.03 SUBSTRATE PREPARATION
2.04 REPAIR OF SPLITS, CUTS, BLISTERS, DUCT LEAKS, WALLS, COPINGS
2.05 FLASHINGS - POLYESTER REINFORCED
2.06 FLASHINGS - MASTIC MIXTURE
2.07 DRAINS
2.08 APPLICATION OF BASE COAT
2.09 APPLICATION OF FINISH COAT(S)
2.10 INSTALLATION OF WALKWAYS
2.11 VENTS
2.12 CLEANUP
2.13 RECOAT WINDOWS

PART 3 SCHEDULES

3.01 BUR - GRAVEL SURFACE MATERIALS, APPLICATION & WARRANTY

RELATED DOCUMENTS


PART I - GENERAL

1.01 GENERALup.gif

A. SCOPE:

To install an Tough Stuff coating system to waterproof and restore existing built up substrates to watertight and maintainable conditions.

B. RELATED WORK:

The work includes but is not necessarily limited to the following:

1. Cleaning and preparation of substrate
2. Application of primers
3. Detailing of flashings and penetrations
4. Application of base coat, mid coat and finish coat on roof surface

1.02 SUBMITTALSup.gif

A. PRODUCT DATA:

Submit schedules, charts, literature, material safety data sheets, and illustrations to indicate the performance, fabrication procedures and product variations.

B. SAMPLES:

Submit sample of cured membrane materials including reinforcing where appropriate.

C. QUALITY CONTROL:

Provide test results from the manufacturer indicating compliance with the specified criteria.

D. MAINTENANCE INSTRUCTIONS:

Provide preprinted maintenance instructions for the roof coating system.

E. WARRANTIES:

Provide a sample of Coatings International Roofing Systems’ warranty and the applicator’s warranty.


1.03 QUALITY ASSURANCEup.gif

A. QUALIFICATIONS:

Provide factory trained and authorized installers with a minimum of three years experience in installing work similar to the specified work. Submit written evidence of authorization from the manufacturer that contractor is an approved Tough Stuff applicator.

B. RESPONSIBILITY FOR PERFORMANCE:

If the requirements of the construction documents negate or restrict the specified performance, or if a conflict or ambiguity exists in the construction documents, the contractor must request a clarification of any discrepancies before proceeding with the work.

C. PRE-INSTALLATION CONFERENCE:

Before starting the work specified herein, a pre-installation conference shall be held to discuss all aspects of the project. The following parties shall be in attendance:

1. Applicator's field representative or roofing foreman
2. Manufacturer's technical representative and affected adjacent trades
3. Owner's representative
4. Architect

D. MANUFACTURER'S TECHNICAL ASSISTANCE:

Provide a representative to attend the pre-installation conference, and review existing conditions and application procedures at project startup and periodically during the progression of the project.

1.04 CODE REQUIREMENTSup.gif

A. CODE:

All work including disposal of materials shall be in compliance with applicable local building codes.

1.05 DELIVERY AND STORAGEup.gif

A. DELIVERY:

Deliver clearly labeled, undamaged materials in the manufacturer's unopened containers.

B. TIMING AND COORDINATION:

Deliver materials to allow for minimum storage time at the project site. Coordinate delivery with the scheduled time of installation.

C. STORAGE:

Store materials in a clean dry location, protected from weather and abuse.

1.06 SITE CONDITIONSup.gif

A. EXAMINATION OF EXISTING CONDITIONS:

Contractor shall examine existing conditions affecting this work and shall report all unsatisfactory conditions to the proper authority and will not proceed until these conditions have been corrected. Commencing work implies acceptance of existing conditions as satisfactory to the outcome of this work.

1.07 WARRANTYup.gif

    All products used in the coating assembly must be furnished, specified, or approved in writing by Coatings International Roofing Systems. Products not supplied by Coatings International will not be covered by Coatings International Roofing Systems' warranty.

A. TERM:

The manufacturer shall warrant the specified work from the date of completion for the length of the specified warranty against becoming unserviceable from either nonconforming materials or workmanship.

B. LIMITATION:

Defects shall include, but not be limited to, the following:
1. Peeling, cracking, blistering, alligatoring, or releasing from the substrate
2. Excessive chalking or dusting
3. Leakage of water into the building

PART 2 - EXECUTION

2.01 CAUTIONSup.gif

Urethane coatings typically contain organic solvents and as such can be toxic and flammable. Work only in fully ventilated areas. Do not smoke when using these products or use near sparks, heat, or any open flames. Read and follow the Tough Stuff Material Safety Data Sheets (MSDS). All waste materials including empty pails must be removed from the site by the applicator and taken to a landfill authorized to receive such materials.

2.02 MIXINGup.gif

Urethanes and primers will require proper mixing before application as follows:

    PRODUCT MIX TIME
    AC5600, PR3600 None
    UR2650 Four minutes (two part)
    UP70 One minute (two part - five minute digest after mixing)
    AC5000, AC5900, UR1600, UR1700, UR1900 One minute


2.03 SUBSTRATE PREPARATIONup.gif

A. CLEANING:

Remove all loose gravel, dirt, and foreign material detrimental to adhesion or application of roofing. Power wash with a minimum 3500 psi. For greasy areas, use CL404 cleaner full strength and completely rinse until foaming stops.

B. WET ROOFING REPLACEMENT:

Locate wet insulation and remove. Replace with new insulation to match the existing roof level. Leave room at the top for 1/2” OSB to face the repair. Space joints 1/8” to leave room for expansion. The width of the plywood will be related to wind uplift requirements.

After installing the plywood, finish as follows:

  1. Prime plywood with PR3800 epoxy at 1/2 gallons/square.
  2. Fill joint with UR1700 mastic using a plastering trowel. Use the tool to level transitions between joints. Allow material to skin adequately. Reinforce joint with UR1700 and FA204 (4”) polyester by applying wet layer of UR1700 (not thickened) at approximately 1.5 gallons/square centered over joint. Set polyester liner in wet material and immediately top-roll with additional material to saturate the polyester leaving no wrinkles.
  3. Trowel the mastic at the edges between the existing roof and the plywood.
  4. If the patch is at a wall, fabricate a cant at the transition. Cant should be 1/2” thick at the corner tapering to flat over 3”(top and bottom). Use the round nose rubber trowel for best results.
  5. Finish by coating plywood with 2 coats UR1700 or whatever finishing system is specified. If the patch is part of a complete system, apply 1 coat of finish over the patch and finish the system while applying the balance of the roof system.
    Other Options: If practical, the existing system can be repaired using original methods. In other words, use hot or modified if desired.


2.04 REPAIR OF SPLITS, CUTS, BLISTERS, DUCT LEAKS, WALLS, COPINGSup.gif

A. SPLITS & CUTS:

    All splits must be repaired with the polyester liner. Spud gravel to the smooth felt.

  1. Make a minimum 2” cut perpendicular to the direction of the split and each end of the split.
  2. Apply the base coat to an area a minimum of 9” beyond all areas of the split at a rate of 3-4 gallons/100 square feet.
  3. Reinforce the area by applying the polyester liner to cover the split extending 6” beyond all areas of the split.
  4. Apply an additional application of the base coat at a rate of 3-4 gallons/square over the polyester liner and feather out the outside edges of the coating.

B. METAL EDGE FLASHING JOINTS:

Drip edge joints and metal integrated into the built-up roof will be repaired and reinforced at the lap joints.

  1. Clean the area 6" on each side of the split down to the felts.
  2. Install FA206 (6") membrane centered over the split on both sides of the metal and 3" on the field in UR1700 urethane at 2 gallons/square Immediately top coat with UR1700 urethane at 2 gallons/square.

C. BLISTERS:

All blisters must be cut open, dried out, and resealed. The gravel must be spudded down to the felts. Reapply gravel in the wet urethane after completing repair to maintain roof level.

  1. Cut open the blister making an X cut and fold back the cut sections. If the blister has moisture, dry out the inside of the blister. Apply the base coat into the inside of the opened area at a rate of 1.5 gallons/square (24 wet mils thickness).

  2. Replace the flaps of the blister into the coating. If the neck is nailable, fasten the flaps.

  3. Apply the base coat over the blister and 12" wider than the blister at a rate of 1.5 - 2.0 gallons/square.

  4. Line the area with the polyester reinforcement which shall extend 9" beyond the blister area.

  5. Apply an additional application of the base coat at a rate of 1.5 - 2.0 gallons/square over the polyester liner and feather out the outside edges of the coating.

D. COPINGS:

Detail all control joints and coat cap.

  1. Cut loose sealant at joint. Prime cap with 2 coats PR3900 at 200 square feet/gallon/coat. Caulk entire seam with Mastic (see section 2.06). Set FA204 (4") polyester liner in urethane centered over joint.
  2. Coat entire cap with 2 coats AC5900 at 1 gallon/square/coat.

E. PARAPET WALLS:

  1. Seal joints with mastic (see section 2.06).
  2. Coat wall with 2 coats AC5900 at 1.0 gallon/square/coat.

F. MACHINE DUCTS AND CONNECTIONS:

  1. Prime rusted metal with PR3900 at 1/2 gallon/100 square feet. Seal joints with mastic (see Section 2.06) and FA204 (4") polyester.

  2. Coat duct work with 2 coats AC5900 at 1.0 gallon/100 square feet/coat. Seal connections and profiles with mastic.

G. EXPANSION JOINTS:

Expansion joints will be integrated or removed and reinstalled.

  1. Integrated Joints with Rubber Flange.
    a. Prime rubber expansion joint flange with PR3800. Install FA204 (4") polyester liner in mastic (see Section 2.06) centered over joints in system. Saturate top of liner immediately with additional mastic.

  2. Metal Caps Spanning Open Expansion Joint.
    a. Remove cap to allow for installation of the flashing.
    b. Detail joints in cap with mastic (see Section 2.06) and FA206 (6") polyester. Cover liner to saturation.


2.05 FLASHINGS - POLYESTER REINFORCEDup.gif

    Install polyester reinforcement on areas of movement such as gravel stops, metal edge and building additions.

  1. Apply urethene to all areas at a rate of 1.5-2.0 gallons/square and shall extend 2” beyond where the fabric will be installed. The edges of the coating shall be feathered out.
  2. Embed the polyester liner into the coating and brush in place to remove voids and insure proper adhesion.
  3. Install an additional application of urethene at a rate of 1.5-2.0 gallons/square over the installed liner extending a minimum of 2” beyond the fabric and feather out the edges of the coating.


2.06 FLASHINGS - MASTIC MIXTUREup.gif

Round projections, machine legs, sign posts, guide wire straps, inside and outside corners, etc. can be flashed using the D200 powder additive mixed into the urethane to create a mastic mixture. The mastic mixture is also used to create cants and as a joint filler or use premade AC5500 Mastic.

Mastic Mixing Ratios:

USAGE RATIO OF D200 TO URETHANE
Cants 50%
Brushable 40%
Light brush / spray 30%

  1. Trowel the mastic around the base of the penetration or at the juncture of roof to wall so that the mixture is 3" wide and a minimum uniform 1/4" depth at the center that tapers to 40 mils at the edge.

  2. Cover the installed mastic mixture with an application of UR1700 installed at a rate of 1.5 gallons/100 square feet.

See section 3.01 for specific requirements or contact Coatings International.


2.07 DRAINSup.gif

  1. Remove the existing clamping ring and collar.
  2. If there is existing roofing material in the drain, cut and remove all materials to eliminate restriction of water flow to the drains and to provide a clean substrate. If necessary, repair the substrate to provide a smooth transition to the roof drains.

2.08 APPLICATION OF BASE COATup.gif

Apply the extended UR2650 at a rate of 5 - 8 gallons/100 square feet using a stiff bristle emulsion broom. UR2650 is extended approximately 50% with D210 ceramic or 2:1 urethane to ceramic.

2.09 APPLICATION OF TOP FINISH COAT(S)up.gif

Once the base coat has cured, immediately proceed with the installation of the top, finish coats.

  1. The two component urethane base coatings have a window of time in which the top coat must be installed. Consult the Recoat Window Chart for specifics.


2.10 INSTALLATION OF WALKWAYSup.gif

    Apply additional layer(s) of the urethane at 1.5 gallons/square with optional aggregate. Sand aggregate can be added to the mixture or broadcast into the wet material.

2.11 VENTSup.gif

    Place vents 5’ from outside walls every 50’ and at all inside and outside corners. Cut membrane and insulation to primary roof or to deck. Fill hole in insulation with crumbled insulation that was cut out. Place a triple bead of mastic (see Section 2.06) on the base of the vent and set vent centered over hole. Finish edge of vent with additional caulking and tool into place.


2.12 CLEANUPup.gif

MATERIAL CLEANUP SOLVENT
AC5500, AC5600, AC5900, PR3800 Water
PR3900 Toluene
UR1600 Xylene
UR1700, UR1900 MEK/Xylene blend
UR2100, UR2650 Xylene

2.13 RECOAT WINDOWSup.gif

    PRODUCT COAT WITHIN IF NOT, APPLY
    AC5000 No Window dot.gif
    AC5600 No Window dot.gif
    AC5900 No Window dot.gif
    PR3800 No Window dot.gif
    PR3900 No Window Recoat with PR3300
    UP70 48 hours Recoat with UP70
    UR1600 No Window dot.gif
    UR1700 7 days Prime with PR3600
    UR1900 No Window dot.gif
    UR2100 No Window dot.gif
    UR2650 48 hours Prime with UP70

PART 3 SCHEDULES

3.01 BUR - GRAVEL SURFACE MATERIALS, APPLICATION & WARRANTYup.gif

WARRANTY
PERIOD		 SYSTEM PRIMER BASE COAT/LINER MID COAT FINISH COAT
10 YEAR GB AC5900-10 dot.gif FA240 in base at coat at low areas, flashings & repaired areas.

Base Coat: UR2650 at 3.0-3.5 gal./sq. (avg.)

1. Extended (3:2) with D210 ceramic

2. Total base coat 5-8 gal./sq. after extension.		 UR1600 at 1.5 gal./sq. AC5900 at 1.5 gal./sq.
* Coverage of coating will vary greatly depending on the size and embedment of the gravel. A test area should be installed to determine coverage rates.

FOR ADDITIONAL INFORMATION, GO TO:up.gif

Master Guide Specifications

See also: