Nuratech TPE Waterproofing Membrane

Transcription

1 Nuratech TPE Waterproofing Membrane Building Product Quality Plan Nuralite Waterproofing Limited 53A Victoria Street Onehunga Auckland 1061 New Zealand phone: fax: V3 Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 1

2 TABLE OF CONTENTS 1. Nuratech TPE product range covered by BEAL appraisal Introduction Reference Documents Company QMS Policy Statement Key Risk Issues Material Quality Requirements Material Storage and Tracking Qualifying Applicator Firms able to install product Qualifying Individual Applicators of Nuratech TPE Issuing Warranty Complaint Handling Risk Management Appendix I Substrate Readiness Checklist Plywood Substrate Readiness Checksheet Concrete Substrate Readiness Checksheet ENERTHERM Substrate Readiness Checksheet Appendix II Project Signoff Form Project Sign-off Form Appendix III Warranty Example Appendix IV User Maintenance Document Nuratech Maintenance Programme Appendix V Remedial Issue Form Document Control Issued John Simmons Sept 2011 Version 2011-v1 Revised John Simmons Nov 2011 Version 2011-v2 Revised John Simmons Aug 2012 Version 2012-v3 The only person authorised to change this plan is the Managing Director, John Simmons. BEAL must be copied into each version. Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 2

3 1. Nuratech TPE product range covered by BEAL appraisal Membranes NURATECH TPE SM TPE with polyester scrim reinforced membrane for adhesive bonded or mechanically fastened roofing systems. NURATECH TPE SG TPE with polyester fleece backed membrane for bonded roofing systems. NURATECH TPE D Homogeneous roofing membrane for use on complex detailing. NURATECH TPE W A heavy duty membrane with a slip resisting surface to be welded onto an underlying waterproofing membrane layer Components NURABOND TPE CONTACT ADHESIVE NURABOND LOW FOAM PU ADHESIVE BARBED FLATBAR THERMAL BREAK INSULATION FLANGE METAL FLANGE FOR NON-INSULATED ROOFS NURATECH TPE COATED EDGE TRIM NURATECH TPE INNER CORNER NURATECH TPE OUTER CORNER NURATECH TPE STANDING SEAM/BATTEN DETAIL NURATECH TPE DRAIN NURATECH TPE SCUPPER NURAVENT Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 3

4 2. Introduction Nuralite is a privately owned New Zealand company, developing and supplying roofing and waterproofing systems for buildings and structures. For the past four decades, Nuralite has been used on many of the New Zealand s most important buildings. From award-winning homes to intricate temples, and Parliament buildings to ski lodges, Nuralite is used to waterproof the most inspiring architecture within New Zealand and throughout the Pacific. Our network of applicators provides specifiers and property managers with the highest quality service, workmanship and finish on site. We are proud to work closely with them to achieve a great result for the property owner. Nuralite systems and services are applicable to the full spectrum of buildings and structures from repairs on small remote cottages to the roofing of new hospitals, power-stations, universities and government buildings. The Nuralite organisation also maintains a team of skilled technical representatives who are prepared to demonstrate the correct application of Nuratech TPE on site or to discuss any problems which may arise regarding its use. This Quality System relates to the Nuratech TPE range of waterproofing products. Nuratech TPE membranes have a unique formulation with both thermoplastic (TP) and elastomeric (E) properties. They are durable, environmentally friendly and offer flamefree application as membrane laps are homogeneously welded using hot air. Contact info Nuralite Waterproofing Limited 53A Victoria Street Onehunga Auckland 1061 New Zealand phone: fax: info@nuralite.co.nz Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 4

5 3. Reference Documents ASTM D751: Standard Test Methods for Coated Fabrics AC75: Acceptance Criteria For Membrane Roof-Covering Systems EN 13956: Flexible Sheet For Waterproofing 05/4203: BBA Agrément Certificate New Zealand Building Code, 2004 E2/AS1 Acceptable Solution External Moisture 4. Company QMS Policy Statement Nuralite is the Flat Roof Experts. Our expertise and market leading position require us to set very high standards in order to consistently satisfy the needs and expectations of its customers. This level of quality is achieved through adoption of a system of procedures that reflect the competence of the Company to existing customers, potential customers, and the construction industry in general. Achievement of this policy involves all staff, who are individually responsible for the quality of their work, resulting in a continually improving working environment for all. This policy is provided and explained to each employee by the Managing Director. All employees are encouraged to suggest improvements in methods, materials, suppliers, and sub-contractors. The Company has established procedures for review of all activities in order to identify and evaluate all possible improvements in methods/ materials and its procedures. To achieve and maintain the required level of assurance the Managing Director retains responsibility for the Quality System. John Simmons Managing Director Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 5

6 5. Key Risk Issues Issue Likelihood Consequence Product Items supplied to us not meeting the relevant specification Very Low Large Items supplied to us not properly identified Low Small Items supplied to us damaged Medium Little Items supplied by us to a customer not properly identified Low Little Items supplied by us to a customer damaged enroute or to the worksite Low Small Items supplied not stored correctly or protected on site Low Small Installation Installation done by untrained personnel High Serious Installation done poorly High Serious Check Sheets not being properly completed by the Installer Medium Medium or Applicator on a predetermined basis Technical manual not up to date and displaying the version Low Little number Installation drawings not up to date and displaying the Low Little version number Installer or Applicator Training Manual not up to date and displaying the Issue number Low Little Process An Internal Audit of our BPQP not being carried out on a Low Medium regular basis (frequency) An External Audit of our BPQP not being carried out at least once a year Low Medium Non-current documents are referred to Low Small Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 6

7 6. Material Quality Requirements Nuratech TPE Dimensions and Weights Thickness: 1.2 mm Roll width: 2.05 m Roll length: 20 m Roll coverage: 41m2 Roll weight: 32 kg Typical Performance Weight: DIN EN g/m2 Tensile strength: DIN EN (L) 1286 (T) N/50mm Elongation at break: DIN EN (L) % 565 (T) % Tear strength: DIN EN (L) N 174 (T) N Peel strength: DIN EN (heat aged) N/50mm Low temperature flexibility: DIN EN oc <-35 Dimensional stability: DIN EN <0.5% Nurabond TPE Contact Adhesive Dimensions and Weights Solids: Approx 27% Viscosity: 600 cp Flash Point: -23 C Colour: Yellow. Odour: Solvent Nurabond Low Foaming PU Adhesive Dimensions and Weights Solids: >97% Viscosity: approx 3000 cp (DVIII, 25 C, #25, SSC) Appearance: Viscous white Liquid. Odour: Slight, Characteristic. Nuralite purchases the above material from ATAB (a subsidiary of IKO based in Belgium) who hold it in stock for use in Europe. IKO is a global leader in the manufacture and supply of quality roofing products including shingles, commercial roofing and asphaltic and bituminous waterproofing products. IKO operate more than 20 manufacturing factories throughout North America and Europe. Nuralite was had a commercial relationship with IKO for over a decade. They are the source of 90% of the products distributed by Nuralite. The Nuratech TPE material is produced by IKO Group in an ISO9001 accredited facility in Chesterfield, England. Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 7

8 The material is produced for use throughout the United Kingdom and Europe. As part of the ISO9001 requirements each master roll is checked for compliance to performance requirements. Nuralite can access the batch tests to verify continued compliance with standards. Verification of the batch testing must be done at least annually. Except for Nuravents, Nuralite does not manufacture any products as part of the Nuratech TPE system. Everything is supplied by IKO as part of a complete waterproofing solution. Nuralite will not be sourcing Nuratech TPE material from any other supplier. Nuravents Manufactured for Nuralite in Auckland by Metal Spinners Ltd. Consists of two simple metal components, the vent and lid. Nuralite Warehouse Manager to inspect each delivery for product quality and consistency Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 8

9 7. Material Storage and Tracking Material Acceptance and storage Materials and goods received, whether the property of the company or others, will, as far as practicable, be protected and their quality preserved until such time as they are transferred to a customer, or disposed of to a third party. The objective is to prevent deterioration and damage whilst in storage, or in the process of transportation, installation, commissioning or maintenance. All stores areas are maintained as secure as practical. All items received by the Company are identified and verified in accordance with the requirements of the Delivery Note and Purchase Order, and are inspected for correct identity, quantity and any signs of damage. The membrane product should be stored lying down. Pallets should not be stacked on top of another. Once delivered to site the membrane should be protected against exposure from rain and site dirt. Material non-conformance All goods received are documented and, in the event of non-conformance, the items are placed in a reject area or labeled to ensure identification. The extent of the nonconformance is noted and subject to disposition review by nominated personnel. Once non-conforming items have been noticed they are identified by location, associated documents, or specific markings to prevent their inadvertent use. All nonconforming items and customer complaints are subject to review and rectification by nominated personnel. The type and extent of non-conformity is documented in order to establish trends and identify possible areas for improvement. The corrective action required to prevent recurrence is evaluated, documented, and its effective implementation is monitored. All rectification is subsequently re-inspected to ensure complete customer satisfaction. Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 9

10 Material tracking NURATECH TPE On all internal cores of rolls are stickers which include product name, roll size, product code and production batch number. When a roll is sold the sticker is removed and attached to our dispatch docket which also records the project reference. In case of material quality issues at a later date the project location will be used to identify the relevant invoice and consequently the exact product which was supplied. Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 10

11 8. Qualifying Applicator Firms able to install product Nuralite only sells waterproofing membranes to suitably qualified firms. Before approving a business Nuralite vets them paying attention to: Credit worthiness Longevity of business Experience in waterproofing Size of business References from property owners References from building firms Nuralite interviews the proprietor about their views on customer service and approach to business. Before entering an applicator relationship a formal contract is signed by both parties (draft copy stored in folder) Our experience is that new applicators cause most problems and are most likely to fail. Consequently few businesses are accepted as new applicators and many are declined. Not every Nuralite approved Applicator will be entitled to install Nuratech as it is a new product range. Before they can price any jobs the Applicator business will need to have purchased the necessary hardware/tools and sent at least one installer on a Nuratech basic installation course. The Nuralite website will clearly identify applicators who are in a position to install Nuratech membrane. 1. Cover of Training Manual Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 11

12 9. Qualifying Individual Applicators of Nuratech TPE All individual Nuratech TPE installers will have to attend the Nuratech TPE training course prior to installing Nuratech TPE membranes. The programme will consist of a tool handling course followed by an Introduction to Nuratech TPE Training workshop run by Nuralite. At this stage Applicators will be issued with a Nuratech TPE Installation Manual and a complete set of Detail Drawings to act as reference material on future jobs. Upon completion of the course the individual will be issued with a Limited Nuratech TPE Installers ID Card, these will relate to each individual installer and will not be general to an applicator business. The applicator will be allowed to commence work but for the first three jobs will be closely monitored on site by the Nuratech Technical Department. The monitoring will cover: Material checking and storage on site Substrate readiness confirmation Product layout preparation Product installation Detailing Project signoff Following completion of a minimum of three Nuratech TPE jobs with demonstrable quality and consistency of workmanship, the applicator will be able to attend Advanced Nuratech TPE Installation. This course will reinforce the basics before introducing some theory, robotic welding machines and advanced detailing. Once this course is completed the individual will be issued with a Full Nuratech TPE Installers ID Card which will allow them to install product without direct supervision. Full records are maintained of all training undertaken and these will be kept for a minimum of 20 years. Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 12

13 10. Issuing Warranty The Warranty process provides the opportunity to close the quality circle. When the Authorised Applicator business applies for the warranty they must: Reference the job location State the products used Identify the individual who installed the product Quote the invoice number they purchased the product under Include a completed Substrate Readiness checklist Include a completed Project Signoff form Nuralite can then ensure that the correct products were used, on a suitable substrate and installed by a trained installer. Warrantees are stored electronically as a pdf and also in a database listing. Records are retained for a minimum of 20 years from issue. At least once a year, on a random basis, Nuralite will check on a completed job by every trained installer to check they are completing the paperwork thoroughly and doing the installation in a thoroughly professional manner. It is the responsibility of the applicator to provide the warranty to the end user as they only do so once the job is finished and paid for. Nuralite is investigating sending reminder letters to customers on the anniversary of their warranty so the maintain their building maintenance. 11. Complaint Handling A complaint is a serious matter which needs prompt resolution. Complaints indicate a dissatisfied customer but also flag a potential quality problem which may be systematic. Identifying the cause of the problem is critical to prevent the issue being replicated on other jobs. When a complaint is made the advisor taking the call completes a remedial issue form and passes it to the Nuratech TPE technical advisor. The advisor must arrange to visit the site with the installer with a view to identifying the cause of the complaint. A photographic record of the problem should be made a remedial instructions issued. The advisor must also consider what steps can be taken to prevent a repetition which may include: Additional training for the installer Changing the installation manual Implementing a new detail Writing an All Applicators Instruction letter Reporting back to IKO if there are concerns about the membrane Records of complaints are kept for a minimum of five years from resolution. Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 13

14 12. Risk Management Risk Responsible When Action Required Items supplied to us not meeting the relevant specification Managing Director Annually Check at Master Roll Test Results meet specification Items supplied to us not properly identified Warehouse Manager Each Shipment Visually confirm items delivered against Purchase Order Items supplied to us damaged Warehouse Manager Each Shipment Confirm that product in good condition Items supplied by us to a customer not properly identified Warehouse Manager On notification arrange for items to be returned and replaced Installation done by untrained personnel Nuratech TPE technical advisor and other advisors Site inspections Order work stopped on site Installation done poorly Nuratech TPE technical advisor and other advisors Site inspections at least annually for each individual installer Suspend approval / withhold sales of product until retrained Check Sheets not being properly completed by the Installer or Applicator Complaint handling Office Manager Warranty issued Notify Nuratech TPE technical advisor of any discrepancies Nuratech TPE technical advisor and other advisors When complaints are made Investigate the complaint thoroughly and take steps to prevent a reoccurrence Non-current documents referred to Managing Director When documents revised Archive old document versions and remove from common use Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 14

15 13. Appendix I Substrate Readiness Checklist Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 15

16 PLYWOOD SUBSTRATE READINESS CHECKSHEET Project Name: Form Completed by: Company: Area ready: Applicator CCA H3.2 Treated plywood sheets 17mm thick for roofs, 20mm thick for decks. Plywood sheets supported at 400mm centred rafters and nogs for roofs and decks. Unless otherwise specified. Sheets stagger lay (fully offset) with correct falls and no ponding. 5mm clearances from all abutments, 5mm radius to all exposed edges. All sheet edges supported, fixed 150mm on edges and 200mm through girth, edges butt-jointed with no gaps except at abutments. Sheets fixed by gluing and Stainless Steel countersunk screw fixing. Rainwater outlets and overflow recesses formed to fit outlets rebated into the surface. Sharp edges and lips removed and cavities filleted. All joints flush. Ensure only approved accessories to be used for drainage and venting. Confirm the substrate slope complies with specification. Review penetrations to minimize number and complexity. Substrate dry, clean, firm and suitable condition for laying. Notes Signed Builder: Signed Applicator: Date: Date: Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 16

17 CONCRETE SUBSTRATE READINESS CHECKSHEET Project Name: Form Completed by: Company: Area ready: Applicator Concrete cured and thoroughly dry over a minimum of 28 days. Surface smooth and clean with correct drainage falls. Ponding areas removed. Cavities and cracks filled with repair mortar, flushed off and cured. Concrete surface firm with any soft concrete or laitance removed. Roof drains and overflow recesses formed to fit rebated outlets. Smooth 5mm radius to all external edges If terminating into a chase, pre-form the chase and ensure it s straight and 20mm deep. Plinths formed for any exterior ventilation, fixtures or similar. Review penetrations to minimize number and complexity. Substrate clean, firm and suitable condition for laying the Nuralite systems. Notes Signed Builder: Signed Applicator: Date: Date: Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 17

18 ENERTHERM SUBSTRATE READINESS CHECKSHEET Project Name: Form Completed by: Company: Area ready: Applicator Sheets stagger lay (fully offset) with correct falls and no ponding. Confirm the substrate slope complies with specification. All insulation sheet joints taped with 50mm aluminium tape. Rainwater outlets and overflow recesses formed to fit outlets rebated into the surface. Ensure only approved accessories to be used for drainage and venting. Review penetrations to minimize number and complexity. Any gaps in the insulation filled to prevent thermal bridging. Material fastened with the correct quantity of IKOfix Telescopic Fixing Plates and Fixing Screws (5 per sheet normally, 10 per sheet in Extra High wind zones). All edges of insulation supported by timber to prevent damage Plinths formed for any exterior ventilation, fixtures or similar. Substrate clean, firm and suitable condition for laying the Nuralite systems. Notes Signed Builder: Signed Applicator: Date: Date: Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 18

19 14. Appendix II Project Signoff Form Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 19

20 PROJECT SIGN-OFF FORM NURATECH TPE Project Name: Sign-off below by: Company: Area covered by QC Sheet Date: Roofing membrane installation item Substrate readiness form completed Gutters correctly and neatly installed, particularly the internal corners Roof drains & overflows installed to specification and watertight Adhesive used in correct quantities. Membrane fully adhered to substrate with no evidence of bubbles or lifting. Correct quantity of fastenings used if Mechanically fastened. All laps fully welded and tidily appearance. Overall installation free of wrinkles, creases and splits Nuravents installed to specification (one every 20m²) All penetration details completed to specification including under/overflashing All non standard details installed as per pre-approved specifications (attach approved drawing) Any damage to membrane repaired to specification. Comply Y/N/Na Comments Note: Where an element identified in the above checklist is not applicable, please record N/A in the comply column. Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 20

21 Project Sign-off Form cont. Remedial action required: Note of damaged areas repaired: Signed Applicator: Date: Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 21

22 15. Appendix III Warranty Example Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 22

23 16. Appendix IV User Maintenance Document NURATECH MAINTENANCE PROGRAMME To get the longest life from a roof it must be regularly inspected & maintained. When first installed there should be inspections each spring and autumn, to enable the effects of annual extremes of weather to be checked. Following that an annual program of roof inspection and cleaning should be established by the building owner as part of general building maintenance. Roofs exposed to high levels of pollution or in close proximity to trees might require more frequent inspection. Inspections The inspection should concentrate on high risk areas such as hatches, drains and around all roof top equipment, as well as a general inspection of the entire roof. Inspections should also include the examination of the roof deck if possible from the underside for evidence of leaks, deteriorated decking, structural cracks or movement and other deficiencies. Parapets and edging should also be examined for evidence of cracking, deterioration and moisture infiltration. Damage If damage is found on the roof surface it should be repaired immediately by an approved Nuralite Applicator. They will use NURATECH component products and special techniques to achieve neat, unobtrusive reinstatement of the NURATECH. Cleaning Location, traffic level, effective drainage, and service use will dictate cleaning requirements. Sweeping clean followed by hose and broom washing of the NURATECH roof is recommended, not waterblasting. If mould does appear it should be removed with a longterm mould killer such as Nuracide. You may do this yourself or talk to your applicator if you would like them to include you in an annual program of inspections & cleaning. Five Year Authorised Service Checks To maintain your warranty, every five years you must have an Approved Applicator visit to inspect the roof and ensure it remains in good condition. The Applicator will thoroughly check the roof for signs of damage, water ingress or potential problems. These checks are inexpensive and are the best way to ensure the roof over your head stays in top condition. Applicator Date Signed Inspection 1 Inspection 2 Inspection 3 Inspection 4 Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 23

24 INSPECTION CHECKLIST 1) Surface: a) accumulation of silt or vegetation; b) areas of ponding. 2) Membrane: a) blistering, ripples, rucking, detachment; b) cracks, splits, tears, punctures, indentations; c) pimpling, pitting, crocodiling; d) pulled, unbonded laps; e) softening of surface. 3) Substrate: a) depressions in surface; b) lack of support/soft support to membrane. 4) Rainwater outlets: a) blocked; b) not bonded to membrane (if bonded type); c) clamping ring loose (if clamped type). 5) Upstands: a) damaged/detached flashings; b) sagging membrane; c) splits, cracks, tears; d) membrane unsupported at fillet; e) unbonded laps; f) blistering. 6) Eaves/verge: a) unbonded or peeling membrane; b) cracking/splitting or strain in membrane; c) displacement or signs of movement of edge trim. 7) Movement joints, upstand type: a) unsealed capping joints; b) dislodged flashing/capping; 8) Abutting construction: a) parapet copings cracked, loose, unsealed; b) damaged damp-proof course, lack of continuity in damp-proofing; c) open joints, cracking in construction; d) loose/missing pointing. 9) Roof fixtures and penetrations: a) damaged/missing flashings; b) balustrade/vent pipe, loose or missing flashing or collar; c) plant plinth damaged/missing flashing; d) lightning conductor tape, fixing loose Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 24

25 17. Appendix V Remedial Issue Form Your Name: Date: Customers Name: Phone number: Property Location: Product Used: Applicator: Date Installed: Warranty Number: Brief summary of the issue: REMEDIAL ISSUE FORM INITIAL ENQUIRY Has the applicator been and inspected the problem?: Put this form in the Remedial Cases File and ensure technical advisor is notified Nuratech TPE BPQP 2012-v3 9 Aug 2012 Page 25