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INSULATED & RETROFIT ROOFING MASTER GUIDE SPECIFICATIONS
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Revised April 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
2.03a SUBSTRATE PREPARATION - REROOF
2.03b SUBSTRATE PREPARATION - NEW
2.04 BASE SHEET (UNDER INSULATION ON NAILABLE DECKS WHEN USING ASPHALT)
2.05 VAPOR RETARDER
2.06 INSULATION ATTACHMENT
2.07 LINING OF JOINTS
2.08 FLASHINGS - POLYESTER REINFORCED
2.09 FLASHINGS - MASTIC MIXTURE
2.10 FIELD LINER/BASE COAT - REINFORCED SYSTEMS
2.11 APPLICATION OF FINISH COAT(S)
2.12 DRAINS
2.13 INSTALLATION OF WALKWAYS
2.14 VENTS
2.15 CLEAN UP
2.16 INTERCOAT WINDOWS
PART 3 SCHEDULES
3.01 WARRANTY & APPLICATION DATA
RELATED DOCUMENTS
PART I - GENERAL
1.01 GENERAL
A. SCOPE:
To install an Tough Stuff coating system to waterproof and restore existing concrete 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. Installation of insulation
4. Vapor barriers
5. Detailing of flashings and penetrations
6. Application of base coat, or base coat and line
7. Application of top coat, finish coat on roof surface
8. Vents
9. Metal flashings
1.02 SUBMITTALS
A. PRODUCT DATA:
Submit schedules, charts, literature, material safety data sheets, and illustrations to indicate the performance, fabrication procedures, product variations and accessories.
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 Tough Stuff warranty and the applicator's warranty.
1.03 QUALITY ASSURANCE
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 start-up and periodically during the progression of the project.
1.04 CODE REQUIREMENTS
A. CODE:
All work including disposal of materials shall be in compliance with applicable local building codes.
1.05 DELIVERY AND STORAGE
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 CONDITIONS
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 WARRANTY
All products used in the coating assembly must be furnished, specified, or approved of in writing by Coatings International, Inc. 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:
- Coverage is limited to the cost of the new system application.
- Warranty does not cover applications over wet roofing.
PART 2-EXECUTION
2.01 CAUTIONS
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 MIXING
Urethanes and primers will require proper mixing before application as follows:
| PRODUCT |
MIX TIME |
| AC5600, PR3200, PR3300, PR3600 |
None |
| UR2550, UR2650, UR2750 |
Four minutes (two part) |
| PR3500 |
One minute (two part - five minute digest after mixing) |
| PR3400, PR3450, AC5000, AC5900, UR1600, UR1700, UR1800 |
One minute |
2.03a SUBSTRATE PREPARATION - REROOF
A. CLEANING:
Remove dirt and foreign material detrimental to adhesion or application of roofing. Use CL404 cleaner diluted 20:1 with water. On heavy dirt or grease, apply full strength. Broom scrub the soap solution on the membrane to loosen oxidation and dirt and rinse with a minimum 2500 psi water blaster. If there are algae growing on the surface, the cleaning must include bleach in the washing of the substrate.
B. WET ROOFING REPLACEMENT:
Locate wet insulation and remove. Replace with new insulation to match 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:
- Prime plywood with PR3500 epoxy at 1/2 gallon/square.
- Fill joint with UR1700 mastic using a plastering trowel. Use the tool to level transitions between joints. Allow material to skin adequately not to move when coated. 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.
- Trowel the mastic at the edges between the existing roof and the plywood.
- 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.
- Finish by coating plywood with 2 coats of UR1700 or whatever finishing system is specified. If the patch is part of a complete system, apply one (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 such as hot or modified if desired.
2.03b SUBSTRATE PREPARATION - NEW
Inspect decking to ensure proper conditions for installation of the new system. Slope and deck attachment problems must be corrected by the decking contractor.
2.04 BASE SHEET (UNDER INSULATION ON NAILABLE DECKS WHEN USING ASPHALT)
Use large head annular threaded nails, ring shank nails, or specially approved mechanical fasteners designed for the specific deck, for back nailing, to fasten membranes, and to fasten base flashings.
2.05 VAPOR RETARDER
NOTE: Extreme conditions such as manufacturing process, humidity, freezers, swimming pools, laundries, greenhouses, seasonal temperature extremes, etc., must be taken into account to prevent moisture condensation in the roof assembly. The following two options must be taken into consideration with respect to the required perm rating in order to retard vapor drive. Install desired vapor retarder on the deck or on a substrate of insulation as required by the building design to prevent condensation and vapor drive into the roof assembly.
A. Bituminous Method:
- If over concrete or plywood, prime with asphalt primer at 200 square feet/gallon. Install 2 plies of glass ply felts with 3 layers of bituminous coating.
- Seal off edges and gaps around stacks and flashings with compatible flashing cement or urethane mastic to prevent bitumen drippage and air flow.
- If over concrete or plywood surfaces, prime with PR3500 primer at 1/4 gallon/square. Caulk joints in insulation with UR1700 mastic and strike smooth. Detail gaps around projections and edges with urethane mastic.
- Apply 2 layers of UR2550 or AC6000 urethane over entire surface at 1.5 gallons/square/coat.
2.06 INSULATION ATTACHMENT
A. NAILABLE OR METAL DECKS
- Install new insulation with staggered joints and boards butted together. New construction insulation should be installed in a minimum of 2 layers with the first layer perpendicular to the water flow. Fasten the first or lower layers of insulation board per Factory Mutual Research requirements.
- Fully mop or adhere with adhesives the facer, top layer, or composite board.
Option B: Mechanical Attachment (through all layers where thermal drift through plates and screws is not a factor)
- Install all layers mechanically per desired FM requirements.
B. NON-NAILABLE DECKS
- Fully adhere with adhesives or hot moppings of steep asphalt all layers of insulation. Concrete decks should be primed with asphalt sealer prior to mopping to concrete.
C. REQUIRED FACER:
All insulation will be faced or will have the facer alone as the roofing surface. Facer will be one of the following:
| FACER |
SPACING |
| 1/4” - 5/8” Silicone Impregnated GYP |
Do Not Space |
| 7/16” - 3/4” OSB |
1/8” |
| 1/2”-3/4” CDX |
1/8” |
| MANDATORY PLYWOOD AREAS |
WIDTH |
| Maximum Wind Uplift |
4’ - 12’ |
| Interior Walls |
2’ - 4’ |
| Curbs |
1’ - 2’ |
2.07 LINING OF JOINTS
A. PLYWOOD:
- Prime plywood with PR3500 epoxy at 1/2 gallon/square. Fill joints with UR1700 mastic using a plastering trowel. Use the tool to level transitions between joints. Allow material to skin.
- Reinforce joint with UR1700 and FA204 (4”) polyester by applying wet layer of UR1700 at approx 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.
B. SILICONE IMPREGNATED GYP:
- Trowel mastic on joints to fill gaps. Reinforce joints with AC5600 and FA204 (4”) polyester by applying wet layer of AC5600 at approx 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.
2.08 FLASHINGS — POLYESTER REINFORCED
2.09 FLASHINGS - MASTIC MIXTURE
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.
Mastic Mixing Ratios:
| USAGE |
RATIO OF D200 TO URETHANE |
| Cants |
50% |
| Brushable |
40% |
| Light brush / spray |
30% |
- 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.
- Cover the installed mastic mixture with an application of UR1700 installed at a rate of 1.5 gallons/100 square feet.
2.10 FIELD LINER/BASE COAT – REINFORCED SYSTEMS
- Apply the base coat using notched squeegees. Immediately install the polyester liner into the base coat in built up fashion working from the low point upwards.
- Install an additional application of the base coat on top of the polyester liner using notched squeegees and back rolling.
2.11 APPLICATION OF FINISH COAT(S)
- Apply base coat with the 3/16” notch squeegee and back roll with a 1/4” - 1/2” nap enamel roller cover – perpendicular to the squeegee pattern.
- Apply first and second finish coats perpendicular to the base coat with the 3/16” notch squeegee and back roll with a 1/4” - 1/2” nap enamel roller cover – perpendicular to the squeegee pattern.
2.12 DRAINS
- Remove the existing clamping ring collar and clean the bowl and collar. 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. On lined areas, extend the liner membrane and coating into the drain bowl and replace clamping ring.
2.13 INSTALLATION OF WALKWAYS
Apply additional layer(s) of the urethane at 1.5 gallons/square with optional aggregate. Aggregate can be added to the mixture or broadcasted into the wet material.
2.14 VENTS
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 SL6000 mastic on the base of the vent and set vent centered over hole. Finish edge of vent with additional caulking and tool into place.
2.15 CLEANUP
| MATERIAL |
CLEANUP SOLVENT |
| AC5000, AC5600, AC5900 |
Water |
| BU8000 |
Mineral Spirits |
| PR3300, PR3400, PR3450 |
Xylene |
| PR3600 |
No Clean Up Required |
| SL6000 |
Xylene |
| UR1600, UR1800 |
Xylene |
| UR1700, UR1900 |
MEK/Xylene blend |
| UR2550, UR2650, UR2750 |
Xylene |
2.16 INTERCOAT WINDOWS
PART 3 SCHEDULES
3.01 INSULATED MATERIALS, APPLICATIONS & WARRANTY
| WARRANTY PERIOD |
SYSTEM |
PRIMER |
BASE COAT/LINER |
MID COAT |
FINISH COAT |
| 10 YEAR (Reinforced / Non traffic) |
IS AC5900-10 |
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FA240 on field set in AC5600 at 2.5 gal.sq.
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AC5900 at 1.5 gal./sq.
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AC5900 at 1.0 gal./sq.
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| 10 YEAR (Reinforced / Non traffic) |
RIS SL6000-10 |
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FA240 on field set in AC5600 at 2.5 gal.sq.
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SL6000 at 1.5 gal./sq.
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SL6000 at 1.0 gal./sq. |
| 10 YEAR (Reinforced / Higher traffic) |
RIS UR1700-10 |
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FA240 on field set in AC5600 at 2.5 gal.sq.
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UR1700 at 1.5 gal./sq. |
UR1700 at 1.0 gal./sq. |
| 10 YEAR (Unreinforced / Regular Duty / 0% Ponding) |
IS UR1700-10 |
PR3500 at 1.0 gal./sq. |
UR1700 mastic with FA206 polyester on joints |
UR1600 at 1.5 gal./sq. |
UR1700 at 2.0 gal./sq. |
| 10 YEAR (Unreinforced) |
IS SL6000-10 |
PR3500 at 1.0 gal./sq. |
UR1700 mastic with FA206 polyester on joints |
UR1700 at 1.5 gal./sq. |
SL6000 at 1.5 gal./sq. |
| 15 YEAR (Unreinforced) |
IS SL6000-15 |
PR3500 at 1.0 gal./sq. |
UR1700 mastic with FA206 polyester on joints |
UR1700 at 2.0 gal./sq. |
SL6000 at 2.0 gal./sq. |
FOR ADDITIONAL INFORMATION, GO TO:
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