Electromagnetic Induction Welding

Transcription

1 Electromagnetic Induction Welding An Advanced Method of Mechanical Attachment for Thermoplastic Membrane Roof Systems DISTANCE LEARNING This course is sponsored by OMG Roofing Products, 153 Bowles Rd., Agawam, MA

2 Learning Objectives Understand electromagnetic induction welding technology. Recognize the component parts of the system and their roles. Understand the system s performance, productivity and installation steps. A look at Induction Welding Best Practices. How does induction welding 1. Optimize roof system installation 2. Optimize roof system performance 3. Optimize building owner roof management

3 Mechanical Attachment Comparisons In Seam Induction 1 set of fasteners for insulation attachment 1 set of fasteners for membrane attachment 1 set of fasteners for BOTH insulation and membrane attachment. Field attachment FEWER FASTENERS

4 How many fewer fasteners? 1,000 SQ / 12 PW = 16,228 fewer (8,114) 3,000 SQ /12 PW = 46,654 fewer (23,327) 5,000 SQ /16 PW = 78,104 fewer (39,052) 10,000 SQ /16 PW = 153,485 fewer (76,743)

5 Fewer Fasteners Induction = Fewer Fasteners 1) LESS PROPERTY DAMAGE: Fewer deck penetrations lessens the chance of a roofing fastener causing damage to underlying wires and utilities 2) ZERO MEMBRANE PENETRATIONS: No penetrating seam fasteners for membrane attachment all membrane attachment supported from under the membrane rather than fastening from the top down. 3) EFFICIENCY: Streamlined material handling and reduced total weight of roofing materials installed most important on reroof!

6 Mechanical Attachment Comparisons In Seam Multiple courses of ½ sheets installed using penetrating seam fasteners into the perimeters and corners (picture framed) to accommodate added wind uplift in these zones. Induction NO ½ sheets Added wind uplift accommodated by an increased density of fasteners installed from F/P/C. FEWER FASTENERS FEWER SEAMS

7 Prescriptive Fastening Pattern The Prescriptive Fastening Pattern for Field / Perimeter / Corner is ALWAYS supplied by Roof System Manufacturer!

8 Perscriptive Fastening Pattern Layout

9 Inductions vs In-Seam Roof Membrane Layout Traditional Method Induction ½ Sheets in Corners & Perimeter = Miles of added seaming in most vulnerable roof zones! 100% FULL WIDTH MEMBRANE ORIENTATION YOUR CHOICE! NO added seaming in corners & perimeters from ½ sheet installation.

10 How much less seaming in P & C? 1,000 SQ = 3,000 SQ = 5,000 SQ = 10,000 SQ = 2,295 less seaming 3,958 less seaming 7,071 less seaming 10,292 less seaming *5,280 in a mile NO ½ Sheets in Corners & Perimeters

11 Fewer Seams Induction = Fewer Seams In most vulnerable roof zones, the perimeters and corners 1. Roof specifiers can use full width sheets all the time 2. Fewer callbacks and less seaming to inspect during routine inspection and maintenance 3. Every inch of seaming is a legacy for future leaks 4. Reduced likelihood of property damage associated with roof leaks 5. Reduced sheet flutter 6. Solar ready installation Induction mechanical field attachment (not in-seam) is proven and suitable for solar racking installation

12 Mechanical Attachment Comparisons In Seam Membrane seam overlaps typically specified at 6 to cover penetrating seam fasteners Induction Membrane seam overlaps specified at 3 because there are no penetrating seam fasteners to cover. Monolithic FEWER FASTENERS FEWER SEAMS ZERO MEMBRANE PENETRATIONS

13 Mechanical Attachment Comparisons In Seam Membrane seams MUST be orientated perpendicular to metal deck flutes Zero flexibility Mismanaged materials Induction Membrane seams can be orientated according to installer preference; perpendicular, parallel, even diagonal to metal deck flutes Maximize materials

14 Mechanical Attachment Comparisons In Seam Limit membrane roll width to reduce sheet flutter and/or to accommodate reduced spacing between fasteners rows (FM4470) Mismanaged materials Induction Maximize membrane roll width and reduce flutter. Full width membrane across entire roof...n S E W Maximize materials

15 How much membrane is saved in sq/ft? 1,000 SQ = 3,000 SQ = 5,000 SQ = 10,000 SQ = 4,288 sq/ft less membrane 10,247 sq/ft less membrane 17,380 sq/ft less membrane 31,811 sq/ft less membrane No ½ Sheets in Corners & Perimeter All full width membrane positioned in any way across roof planners and roofers choice!

16 Electromagnetic Induction Welding Concept Definition of Technology

17 Electromagnetic Induction Welding Defined INDUCTION Electromagnetic induction is an invisible force used to generate heat in a conductor This heat is used to activate a powerful bond between thermoplastic roofing materials and coated plates, without penetrating the membrane (Over 550 F) Industrial Examples: Cooking, Yogurt, Carpet

18 Electromagnetic Induction Plates Dual Function: Insulation Attachment Membrane Attachment PVC (Black) Thermoplastic PVC coating TPO (Gold) Thermoplastic Polyolefin coating Raised circular surface is the bonding surface between plate and underside of membrane

19 System Components Portable Induction Tool Magnetic Heat Sinks Coated Plates Fasteners

20 System Components Electromagnetic induction welding tool Magnetic heat sinks Set of six per tool Coated plates TPO PVC Roofing fasteners

21 Heat Sink Magnets Heat Sink Use Once an induction weld is completed, a magnetic heat sink is placed over the welded plate for 45 seconds *6 Heat Sink Magnets / Tool Dual Function Draws heat from the plate Maintains contact between plate and membrane to promote strong bond

22 Keep Magnets Clean If debris or gauges / scratches appear Use fine grit sandpaper in circular motion to clean smooth *Best Practices WIPE!

23 Compatible Insulation & Cover Board Polyisocyanurate (ISO) DensDeck Securock Rock wool compressible insulation using a TreadSafe tube and plate SPECIAL CONSIDERATIONS If Foil Faced 1.5 minimum thickness cover If XPS/EPS ½ minimum thickness OR New Cardboard Disk insulators

24 Calibrating the Induction Welding Tool Required energy setting on induction tool ( 10 to +10) determined by ambient temperature and membrane thickness Daily calibration of tool is required to determine optimal energy setting needed to achieve 100% bond Re-calibration recommend if ambient temperature changes (+/ 15 F)

25 Electromagnetic Induction Welding Characteristics System Characteristics Performance Characteristics Typical Fastening Pattern Comparison System Benefits

26 Performance Characteristics No membrane penetrations, no seam fasteners Evenly distributed wind loads Enhanced wind uplift performance Minimizes/reduces membrane flutter Solar Ready attachment method! Mechanically attached deck in wind lab Induction welding deck in wind lab

27 The Dry-In Difference Streamlined installation process Increased productivity Faster dry-in Compressed construction schedule

28 Operational Ambient Temperature Range The induction welding system is designed to operate in ambient temperatures ranging from F. What if Fully Adhered jobs get bumped into cold weather months? Some call Induction Welding a Hybrid System Mechanically Attached with performance characteristics closer to fully adhered.

29 Standard Applications New Construction Re-roof

30 Install Insulation Install fasteners and coated plates in grid pattern One fastener/plate for both insulation and membrane Fastening patterns to meet desired FM rating supplied by roof system manufacturers Field vs perimeter vs corners

31 Chalk Lines to Mark Fastener Patterns According to supplied prescriptive fastening patterns for the field, perimeter and corners, use chalk lines to layout fastening patterns Strike chalk lines and install plates in straight lines in the same direction as membrane Grid pattern ensures proper placement of fasteners and makes locating plates under membrane easier Random placement = bad Straight lines = good

32 Use Chalk Lines to Mark Straight Rows

33 Proper Coated Plate Installation To ensure 100% bond, plates must be installed flush with insulation board Coated plates must NOT be overdriven Properly driven Overdriven will not bond well

34 Roll Out Membrane - Flexibility Any width membrane Any direction, NOT perpendicular to flutes ONLY No half-sheets and all it s ugly seaming. KEEP membrane seams 2 off a row of Induciton Plates.

35 Heat Weld Seams INSTALLATION MILESTONE: Once enough insulation has been fastened to roll out two rolls of membrane, roll out membrane and heat weld seams. Roof is now dry

36 Bond Plates to Membrane with Induction Tool Position induction welding tool directly over plate Activate fivesecond cycle Clean magnetic heat sink Apply magnetic heat sink Bond next plate

37 3-Part CSI Specification

38 3-Part Specification A formal product guide specification is available and in accordance to the Construction Specifications Institute (CSI) 3-Part Format, including MasterFormat, SectionFormat, and PageFormat, as described in the CSI Construction Specifications Practice Guide. Specification available online.