Roofing 101/Single-Ply Technologies. Provider # K031 Course # C102

Transcription

1 Roofing 101/Single-Ply Technologies Provider # K031 Course # C102

2 Carlisle Construction Materials Major Manufacturer of Building Components 50+ years Mfg. Roofing Products (White and Black Membranes) Air Barriers Waterproofing Insulations Skylights Garden Roofing

3 Carlisle SynTec is a Registered Provider with The American Institute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for both AIA & non-aia members are available on request. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation. Thank you! This presentation is protected by US and International Copyright laws. Reproduction, distribution, display and use of the presentation without written permission of the speaker is prohibited. Carlisle Construction Materials 2014

4 Flat/ Low Slope Assemblies Deck Types Air and Vapor Barrier Insulation/ Underlayment Single Ply Technology (EPDM, PVC, TPO, Fleece backed membranes) Edge Metal Wind Design Warranty Review

5 Flat/ Low Slope Assemblies

6 Deck Types Poured Gypsum Concrete Steel (Most Common) Structural Concrete (Most Common) Lightweight Insulating Concrete Cementitious Wood Fiber Wood Plank or Plywood

7 Air and Vapor Barrier Self Adhered Torch Grade Loose laid poly Fluid Applied

8 Vapor drive in Buildings

9 Vapor Retarder Vapor Retarder? Rule of Thumb (both yes): 1. Jan. Average Low is 40 F or less 2. Operating Interior Relative Humidity 45% or greater Typical Indoor RH Offices: 30-50% Hospitals: 30-55% Department Stores: 40-50% Swimming Pools: 50-60% Underside of steel deck w/o any insulation

10 Exterior Average Low 40 F Detroit, MI

11 Vapor Retarder Criteria Apply on warm side of insulation Perm Rating should approach zero perms Completely seal at sides and end laps; flash at openings Compatible with roofing materials and roof system components

12 Air infiltration at columns was determined

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14 Moisture suction test retrieved over 22 gallons of water Water was discolored and had a stale odor

15 Moisture Infiltration Operational Generated Moisture Construction Generated Moisture

16 Examples of Excessive Moisture Drain leaders missing

17 New Construction Projects & Project scheduling/ Construction Practices

18 Condensation / Frozen Moisture White membranes fall frequently below dew point increasing the level of condensing of moisture

19 Affects of Condensation Wet Facer found beneath membrane Gaps between Insulation

20 Affects of Condensation

21 Addressing Condensation

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26 Insulation Type Polyisocyanurate Expanded Polystyrene Extruded Polystyrene Cover boards/ High Density Boards

27 Polyiso Rigid Insulation Panel R Value of 6 per inch Fiberglass vs paper facers Flat/tapered boards available

28 Uplift Testing Performance

29 EPS/XPS Low to High Compressive Strength R-Value of 4.17 to 5 per inch Tapered/Flat

30 Cover Boards Options: ½ HD Fiberboards ½ Glass Mat Gypsum ½ Fiber-Reinforced Gypsum ½ HD Polyisocyanurate

31 US Non-Residential Roofing Market

32 U.S. Non-Residential Roofing Market

33 Cold Climate 2013 Industry Membrane Mix BUR /MB 10.7% TPO 26.6% EPDM 44.4% PVC 18.4%

34 2016 Low Slope Roofing Membrane Market 34

35 Warm Roofing Geographic Location for membrane color Cool Roofing

36 National 2013 Industry Membrane Mix BUR /MB 20.6% EPDM 22.7% PVC 17.1% TPO 39.6%

37 Membrane Performance

38 THERMOSETS & THERMOPLASTICS THERMOSET: EPDM, Butyl & Polyepichlorohydrin THERMOPLASTIC: TPO & PVC

39 Thermoset EPDM

40 Weatherability Xenon Arc Testing Radiant 0.7 W/m2 80 C Passes ASTM D4637 w/ 7,560 kj/m2 Testing beyond the ASTM 60-mil EPDM Black 41, mil EPDM Black Reinforced 35, mil EPDM White 25,200

41 Dimensional Stability 100 F Temperature Change Rene Dupuis PhD PE Structural Research Inc.: EPDM is the most dimensionally stable membrane when temperatures change Measured Load induced by temperature change EPDM Other Membranes 2-lbs per inch 8 to 15-lbs per inch

42 Long Term Performance of EPDM Membrane T. Trial Study 2004 Evaluate aged membranes with 16 to 26 year exposure 33 samples from 9 different states ( adhered and ballasted ) Independent testing by Architectural Testing Inc.

43 Tear Resistance- Adhered Samples 21.9 kn/m ( 125 lbf/in. ) ASTM D Tear Strength (kn/m) Age (years)

44 Ultimate Elongation- Ballasted Samples 400 min. 200% ASTM D Elongation (%) Age (years)

45 EPDM Roofing Systems Evolution; It is all in the seams and the details!

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49 Old Technology - Parapet/Curb

50 Bridging

51 New Technology - Parapet/Curb w/ RUSS

52 Angle Change Securement 1970 s Wood nailing strips 1980 s Plastic/rubber nailing strips 1990 s Reinforced rubber strips

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54 Old Technology Gravel Stops

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58 Thermoplastic PVC & TPO

59 Membrane Construction Membrane is composed of three layers PVC/TPO-Compounded Top Ply Reinforced Scrim PVC/TPO-Polymer Bottom Ply

60 Typical 60 Mil Fabric Reinforced Top Ply Yarn - Reinforcement Bottom Ply

61 Yarn - Reinforcement

62 Yarn Reinforcement

63 Typical 60 Mil Fabric Reinforced Top Ply Yarn - Reinforcement Bottom Ply

64 PVC Membrane Polyvinyl Chloride Strengths: Durability & pliability Heat welded seams Recyclability No shelf life Variety of accessories & colors

65 PVC Roofing Strengths: Long track record supported by numerous domestic manufacturers Chlorine in PVCprl resistance

66 PVC, KEE & KEE HP Understanding the Materials

67 Formulations: PVC vs. KEE PVC = Liquid Plasticizers KEE = Solid Plasticizers

68 Molecular Weight

69 KEE Chemical Name: Ketone Ethylene Ester Also Known As: Ethylene Interpolymer Developed in 1973 Addition to Liquid Plasticizers Solid, High Molecular Weight Polymer Does not migrate out

70 KEE ADVANTAGES Enhance UV Protection Reduced UV Degradation Increased Flexibility Longer Service Life

71 KEE Advantages Improved Aesthetics Less Dirt Pickup

72 KEE Advantages PVC KEE

73 KEE Advantages

74 KEE Flashing Accessories Molded Pipe Flashing Split Pipe Boot Split Square Tubing T-Joint Covers Flashings Outside Corners Inside Corners Sealant Pocket

75 Application Air Quality PVC KEE

76 Optimal Amount of KEE Direct Relationship with amount of KEE added & closing of the welding window.

77 KEE vs. KEE HP Higher molecular weight Cold temperature flexibility Greater thermal stability Less dirt pickup Easier melting compound Wider window of weldability Greater margin for error

78 Cold Temperature Flexibility KEE KEE HP -51 F

79 Sample A Sample B Sample C KEE HP Sample 22,680 kj/ m² 22,160 kj/ m² 18,900 kj/ m² 25,200 kj/ m²

80 KEE HP at 20x 25,280 kj/m² KEE at 20x 22,680 kj/m²

81 TPO Auto Industry since early 80 s Roofing installations as early as 1990 Stable laboratory physical properties Good Puncture Resistance Wide Sheet Technology

82 Weathering Package A B C D E

83 Industry Issues Energy

84 Today s Energy conflicts

85 Factors Impacting Energy Performance Heating Vs. Cooling Insulation Levels Building Internal Loads Mechanical System Windows (Solar Gain) Deflected Heat

86 Energy End-Use Intensities Building Type Space Heating % of total Space Cooling % of total Education 41% 6% Health Care 23% 4% Retail & Service 40% 8% Office 25% 9% Public Assembly 47% 6% Warehouse & Storage 41% 2% All Buildings 32% 7%

87 ASHRAE Standard 90.1 Energy Standards for Commercial Buildings ASHRAE, 8 Climate Zones ASHRAE : American Society of Heating Refrigerating and Air-Conditioning Engineers

88 ASHRAE* Insulation R-Value

89 Heating & Cooling Degree Days Location Heating Cooling Barrow, AK 20,226 0 Duluth, MN 10, Minneapolis, MN Chicago, IL St. Louis, MO Atlanta, GA New Orleans, LA Miami, FL

90 Cool Roofs - Benefits

91 Cool Roofs - Concerns

92 Energy Cost Comparison Buffalo, NY Zone HDD 511 CDD $45,000 $40,000 $35,000 $30,000 $/Yr $25,000 $20,000 $15,000 $10,000 $5,000 Black roof White roof $ R value

93 Energy Cost Comparison Ithaca, NY Zone HDD 318 CDD $45,000 $40,000 $35,000 $30,000 $/Yr $25,000 $20,000 $15,000 $10,000 $5,000 Black roof White roof $ R value

94 Energy Cost Comparison Syracuse, NY Zone HDD 483 CDD $45,000 $40,000 $35,000 $30,000 $/Yr $25,000 $20,000 $15,000 $10,000 $5,000 Black roof White roof $ R value

95 ASHRAE R-Value Increase 2004 to 2012 ASHRAE : American Society of Heating Refrigerating and Air-Conditioning Engineers Insulating Values for Non-Residential Buildings R-Value Climate Zones

96 Making the right Roof Color choice Dark Roofs Reflective Roofs Reflective membranes fall below dew point frequently and remain below dew point for longer periods

97 Unified Facilities Guide Spec 2012

98 What about Heat Islands? The kind of man who demands that government enforce his ideas is always the kind whose ideas are idiotic. -- H.L. Mencken Governments routinely ignore the Law of Unintended Consequences Rarely does one size/solution fit all

99 Stanford Study Cool roofs contribute to global warming Effects of Urban Surfaces and White Roofs on Global and Regional Climate (pg 21) 20 yr. simulation of converting all roofs to white Results showed local cooling however, feedbacks of the local changes resulted in gross global warming Local cooling of 0.02K but global temperature increase of 0.07K

100 Stanford Study A second simulation using 1992 land use data resulted in a similar conclusion. (pg 21) Local cooling but global warming due to white roofs White roofs may INCREASE global warming Menon & Oleson studies found that white roofs increased space heating in the annual average more than they decreased air conditioning (pg 5)

101 Stanford University Study Cool roofs contribute to global warming Effects of Urban Surfaces & White Roofs on Global & Regional Climate (pg 21) 20 yr. simulation of converting all roofs to white Results showed local cooling however, feedbacks of the local changes resulted in gross global warming Local cooling of 0.02K but global temperature increase of 0.07K

102 Sun Heat Rays deflected & Reheat Same Particles

103 CCM Air Temperature Study July 7 thru Aug 16 Carlisle, PA Temperature Recorded at ; (0 ) Data Recorded: 9:00 AM -12:00 PM - 3:00 PM - 5:00 PM

104 Air Temperatures above black & white roof membranes 30 Day Average

105 Factor in cleaning costs ORNL Study 35-50% drop in reflectivity in the first 3 years could be expected in a white membrane depending on location

106 Impact on Energy Performance? Discoloration

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110 Energy Cost Comparison Rochester, NY Zone HDD 620 CDD $45,000 $40,000 $35,000 $30,000 $/Yr $25,000 $20,000 $15,000 $10,000 $5,000 Black roof White roof $ R value

111 Energy Cost Comparison Buffalo, NY Zone HDD 511 CDD $45,000 $40,000 $35,000 $30,000 $/Yr $25,000 $20,000 $15,000 $10,000 $5,000 Black roof White roof $ R value

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115 Virginia Energy Savings Calulations

116 Comparative Roof Testing Jamesville, NY o o o o

117 Thermal Performance Study Onondaga County Correctional Facility Jamesville, NY o o

118 Based on Total Energy Costs

119 Other Considerations Increased Insulation Levels Multiple Insulation Layers Reduce Thermal Bridging

120 ASHRAE Standard 90.1 Energy Standards for Commercial Buildings ASHRAE, 8 Climate Zones ASHRAE : American Society of Heating Refrigerating and Air-Conditioning Engineers

121 ASHRAE* Insulation R-Value

122 Insulation: Single vs. Multiple Layers Gap Energy Loss 1/8" 10% 1/4" 18%

123 Thermal Bridging - Heat Transfer Analysis

124 Energy Improvement Select a balanced approach! Increase insulation levels Use multiple insulation layers Reduce thermal bridging when possible Assess heat deflection & solar gain when using reflective membranes Assess vapor drive within the roofing assembly Roof color is geographically sensitive Carbon footprint should be based on total energy consumption (heating/cooling)

125 Roofing Systems

126 Membrane Roofing Systems Mechanically Fastened Adhered Specialty Systems

127 Mechanically-Fastened Typical Application 1. Reinforced Membrane 2. Fasteners and plates 3. Acceptable Insulation 4. Approved Roof Deck

128 Mechanically Fastened Application Securement of the membrane within the seams

129 Plate Welded System Insulation Attachment & Membrane Securement PVC Coated Plate TPO Coated Plate

130 Plate Welded System Layout Plates & Fasten Insulation Layout membrane & weld by Heat Induction to plate Weighted Magnets over each plate until cool

131 Induction Welding Highlights

132 No seam fasteners No perimeter sheets Fewer fasteners Dry-in larger areas faster Highlights

133 Adhered Roofing System

134 Adhered Membrane Typical Application 1. EPDM, TPO or PVC Membrane 2. Fasteners and plates 3. Contact Adhesive 4. Acceptable Insulation 5. Approved Roof Deck

135 Insulation Fastening Density

136 Thermal Bridging at Joints and Fasteners

137 2-Part Urethane Adhesive Spray Applied Adhesive Ribbon Applied Adhesive

138 Membrane Placement

139 Membrane Adhesion

140 Alternative Adhesion Methods

141 Low VOC Options Adhesives Low VOC Adhesive Not Water based! Different solvents < 250 gpl VOC Zero VOC Urethane Adhesives Insulation & Membrane attachment

142 Pre-Applied Membrane Adhesive

143 Fleece Backed Adhered Typical Application 1. Fleece backed Membrane 2. Adhesive: 2-part urethane or cold process 3. Acceptable Insulation 4. Approved Roof Deck

144 Membrane Attachment Spray Application Extruded Application

145 Membrane Attachment

146 Recovery and Restoration Options Typical Application 1. Fleece Backed Membrane 2. Asphalt / Cold Applied or 2 part low rise foam 3. Existing Primed Smooth BUR Roof 4. Existing Insulation 5. Approved Roof Deck

147 Asphalt Mopping

148 Cold Applied System

149 Single Ply Restoration - Finish

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151 Metal Roofing Existing smooth BUR, SBS and Single Ply

152 Polyurethane Wood Surfacing Urethane Concrete Coatings Hybrids Detail Restorations

153 SBS details Complete Roof Systems

154 Restoration coating on mod bit with co-op purchase Job C 2000 Sqs Cost $2.85 million = $14.25 sq. ft. Fleeceback membrane on EPDM Job BPS 1000 Sqs < $7 sq. ft. Fully adhered EPDM + 2 polyiso & coverboard in low rise foam over existing roofing on metal deck Job W 5000 Sqs < $10 sq. ft.

155 Metal Roofs - Fastener / Attachment Loose or stripped fasteners need to be replaced. Horizontal seams need to be tight to minimize movement. Loose or stripped fasteners need to be replaced. Horizontal seams need to be tight to minimize movement.

156 Metal Roof Restoration Seam Details

157 Metal Roofs - Spray Finishes Thermo fluid systems can be sprayed, brushed or rolled.

158 Reroofing Over Existing System Benefits:

159 Metal Edging Wind Performance

160 The Cost of the Problem 60% of litigation claims originate from the roof area 60% of roof warranty claims are attributed to metal edge failures

161 Metal Edging buckled Metal Edge Buckled

162 Metal Edge First Line of Defense

163 No Continuous Cleat

164 Shop Fabricated With Continuous Cleat Failure at 90 psf

165 Pre-Fabricated Metal Edging Failure at 242 psf ANSI SPRI ES-1

166 Wood Nailer Securement

167 FM 1-49 Wood Nailer Securement

168 Fastening Enhancement at Corners FM 1-49

169 Wind Codes

170 Determination Uplift 5 Factors: Building Height Building Location (Local Wind Speed) Exposure Category ( B, C, or D ) Openings (Partial or Enclosed) Risk Category I, II, or III/IV (Building)Use)

171 ASCE ( IBC-2012 Chapter 16 ) Calculates uplift pressure in the field, perimeter and corner areas Requires extensive calculation to determine design uplift pressures

172 Manufacturer s Assistance Published Documents: ASCE 7 FM PLPDS 1-28 ANSI/SPRI WD-1 Uplift web-based calculators:

173 Manufacturer s Assistance Testing Tested Assemblies Uplift Pressures Written documentation from Manufacturer: Certification of the uplift rating for the specified assembly from lab testing FM 4470 ANSI/FM 4474 UL 1897

174 The Design Process 1. Determine the building s Uplift Pressure ASCE 7 Calculations 2. Review assembly Tested Pressures ANSI/FM Compare to confirm Correct Assembly Tested Pressures > Calculated Pressures 4. Consider Warranty Options Potential Cost Increases

175 Building Code Wind Warranty Building codes do not require a wind speed warranty on roofs, only that they meet the design pressures Other components (I.e., walls, windows, structural, etc.) must also meet the design pressures, but do not carry any wind speed warranty Warranty wind speed is not based on uplift testing which are static laboratory test that could lasts only 5 10 minutes Uplift Pressures Wind Warranty

176 Roofing Warranty

177 Warranties Wording to avoid / What to look for

178 Warranties What to Look For! System Warranty covers all material/labor No Dollar Limitation no cap on warranty Not Pro-Rated will not depreciate Transferable not limited to original owner

179 Periodic Inspection associated costs Warranty Reserve who backs it Maintenance Requirement associated costs Warranties What to Look For! Additional Coverage hail, puncture, etc. Wind Speed Coverage indicated?

180 Beaufort Wind Speed Scale No. Category MPH 7 Moderate Gale (near gale) Fresh Gale (gale) Strong Gale Whole Gale (storm) Storm (violent storm) Hurricane

181 WARRANTY OVERVIEW Preferred Warranty Coverage 10, 15, 20 and 30 year duration Fully Covers labor and material costs Not be limited to the original cost Transferable and no owner s signature. Wind Coverage up to 120 mph peak gusts Special coverage for hail & accidental punctures Managed by separate warranty reserve

182 History of Wind Speed Warranties Beaufort Wind Speed Scale

183 Wind Speed Warranty Coverage How it could be mentioned within the warranty No wind speed coverage..(0-mph) Windstorms...(64 72-mph) Full Gale Force (46 mph) Gale Force (46-mph) Gales Excluded (31-mph)

184 Warranty Coverage Comparisons Example Original Cost of Roof: $100,000

185 Architectural Specification Warranty Section Warranty A. Special Warranty: Manufacturer s standard or customized form, without monetary limitation, in which manufacturer agrees to repair or replace components of membrane roofing system that fail in materials or workmanship within specified warranty period. 1. Special warranty includes membrane roofing, base flashings, etc. 2. Warranty period: 20-years from date of Substantial Completion 3. Warranty Wind Speed: 90-mph Do not rely upon Performance Requirements to cover warranty wind speed.

186 This concludes the American Institute of Architects Continuing Education Systems Course Thank you for participating! Questions? Remember your AIA membership number is needed for reporting purposes. Please leave your membership number at the door.

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189 Services: CANNAN ALEXANDER & SCOTT Roof Inspections, Evaluations and Infrared Services Energy & Life Cycle Cost Analysis System design & consultation Specification and Detail Support Contractor Training Pre-bid, pre-construction and in-progress inspections Dan Cannan Brock Alexander Kevin Scott David Fitzpatrick Kevin Sullivan Paige Holenbeck Brandon Clark

190 Infrared Scans

191 Core Cuts

192 Roof Reports

193 Spec & Detail Support