PART 3 GENERAL REQUIREMENTS

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1 Table of Contents General Applicability Re-Cover Considerations Manufacturer's Qualifications - Quality Assurance Contractor Qualifications Pre-Installation Meeting Job Site Considerations Delivery, Handling, and Storage Roof Drainage Roof Decks - General Requirements Roof Decks - New Construction or Complete Tear Off Steel Decks Poured-in-Place Structural Concrete Decks Precast Concrete Decks Pre-Stressed Concrete Decks Plank and Heavy Timber Wood Decks Plywood Decks Structural Wood Fiber Decks Poured-in-Place Gypsum Decks Poured-in-Place Lightweight and Cellular Concrete Decks Roof Decks - Re-Cover Resaturated or Coated Smooth Surface Built-Up or Modified Bitumen Roofs Non-Resaturated or Uncoated Smooth Surface Built-Up or Modified Bitumen Roofs Mineral Surface Built-Up or Modified Bitumen Roofs Gravel Surface Asphalt or Coal Tar Built-Up or Modified Bitumen Roofs Sprayed-in-Place Urethane Roofs Expansion Joints Design Recommendations Flashing Recommendations Area Dividers and Control Joints PART 3 GENERAL REQUIREMENTS Page 1

2 Vapor Retarders Vapor Retarder Installation Kraft Vapor Retarder Installation over Steel Decks Vapor Retarder Installation over Concrete Decks Vapor Retarder Installation over Wood and Structural Wood Fiber Decks Roofing Asphalt Asphalt Grades for Insulation, Base Sheets, Ply Sheets, Modified Bitumen Roofs and Built-Up Roofs Asphalt Identification Asphalt Heating and Application Wood Nailers Installation Roof Insulation Insulation Approvals, Restrictions, Minimum Thicknesses and Assemblies Roof Insulation Installation Roof Insulation Attachment Mechanical Attachment of Insulation with Screws and Plates Fastener Pullout Resistance Hot Asphalt Attachment of Insulation Cold Adhesive Attachment of Insulation Cant Strip Installation Base Sheet Base Sheet Installation Roof Membrane Hot Asphalt Applied SBS Modified Bitumen Membrane Heat Fused Applied SBS and APP Modified Bitumen Membrane Cold Process Applied SBS Modified Bitumen Membrane Slope Nailing Requirements Hot Asphalt Applied Base Sheet and Cap Sheet Cap Sheet Repair Built-Up Roof Repair Using Modified Bitumen Sheets Flashing - General Guidelines Using Modified Bitumen Membranes Roof Walkways PART 3 GENERAL REQUIREMENTS Page 2

3 Sheet Metal Flashing Installation Work Temporary Closures Test Cuts Weather Precautions PART 3 GENERAL REQUIREMENTS Page 3

4 General A. This part shall be used in conjunction with Part 4 - SBS Application, Part 6 - APP Application, Part 7 - Modified Bitumen Flashing Details, Part 8 - BUR Application and Part 9 - BUR Flashing Details to the extent that they are applicable to project design intent and application Applicability A. Full IKO Modified Bitumen and Built-Up Roofing Systems are applicable for many commercial and industrial roofing applications at a variety of roof slopes. B. Full IKO Modified Bitumen and Built-Up Roofing Systems are not applicable where any one of the following conditions exists: 1. Roofs where the structural conditions of the roof deck, or structural supports of the roof deck, are insufficient to support the load of the completed roof plus other anticipated loads as recognized by the architect, engineer, roofing professional, or building owner. 2. Non-roofing applications such as below grade waterproofing, plaza decks, pond liners, parking garages, and the like. Contact your IKO Technical Representative for further information on these applications. C. IKO Modified Bitumen and Built-Up Roofing Systems are not applicable, without additional design considerations from the IKO Technical Services Department, where any one of the following conditions exist: 1. Roofs exposed to discharge that is known to be detrimental to the roof membrane or components. 2. Buildings with large wall openings that could be left open during a wind event. Large wall openings are defined as openings that occupy a surface area greater than ten percent of the total surface area of the wall. 3. Roofs subject to regular manual or mechanical traffic. 4. Roofs that are subject to positive air pressure from below the roof deck. These include, but are not limited to: buildings with positive air pressure; roof decks that permit air infiltration; aircraft hangars; canopies; overhangs; and buildings with a large number of bay doors. 5. Cold storage building areas when the freezer or cooler insulation is used as a base to receive the roof. D. Contact the local building code official, prior to bidding, with regard to roofs that are subject to building code requirements. If there are questions after contacting the local building code official, contact IKO Technical Services Department to determine which system will meet the building code requirements or other authorities of jurisdiction. PART 3 GENERAL REQUIREMENTS Page 4

5 E. IKO Modified Bitumen and Built-Up Roofing System specifications are published for the sole purpose of defining the minimum requirements necessary to issue the IKO Limited Warranty. IKO suggests that an architect, engineer, or other design professional be consulted to address conditions beyond the scope of these installation guidelines and to insure appropriate design and application Re-Cover Considerations A. Moisture trapped within an existing roof may have a significant effect on the new system depending upon the components selected. A moisture survey should be conducted on an existing roof that remains in place, to determine the moisture content of the existing roof system. All components of the existing roof which would be detrimental to the new system due to moisture content,must be removed and replaced prior to installation of the new system. An infrared scan is highly recommended to detect wet insulation in the existing roof system. B. The structural integrity of the existing roof deck should be confirmed. An under deck internal visual review by a qualified professional may assist in finding deteriorating deck conditions that affect the structural Integrity. This internal review may also detect recently replaced deck sections and determine if structural support is adequate for these sections. Repair or replacement of defective decking should be specified as required. C. When re-covering over an existing insulated single ply roofing system (i.e. EPDM, PVC, TPO, etc.), cut the existing membrane every ten feet (10') (3 m) perpendicular to: the flutes in a metal deck; the seams in a precast concrete deck; the control joints in poured concrete deck; and to slope on a wood deck D. Occasionally, existing building features do not permit specified flashing heights to be achieved. Contact the IKO Technical Services Department for review of the proposed detail when existing doors, windows, or equipment supports do not permit termination of the new system above the anticipated high water level. E. If the existing wood nailers are to be reused, then the condition of the nailers, as well as nailer attachment, shall be confirmed as suitable for attachment of the new roofing materials. Independent pull-tests may be required. F. If the existing roof is coal tar pitch, then confirm the compatibility between the new system and the existing coal tar Manufacturer's Qualifications - Quality Assurance A. Upon request from the building owner, IKO shall supply proof of applicable requested Certifications. B. IKO Modified Bitumen and Built-Up Roofing Systems must be installed by an IKO registered applicator for any registered IKO Limited Warranty. C. For any IKO Limited Warranty, IKO reserves the right to conduct an inspection to insure compliance with IKO specifications. PART 3 GENERAL REQUIREMENTS Page 5

6 D. As every roof is different, the IKO Technical Services Department is available for consultation concerning required departures from current specifications due to unique existing circumstances. E. Any departure from current installation guidelines, without first obtaining written permission from IKO, will void any registered IKO Limited Warranty. F. IKO shall provide a limited warranty upon satisfactory completion and inspection of the roofing system, where applicable, and compliance with all limited warranty requirements Contractor Qualifications A. For IKO extended limited warranties, the roofing contractor must be an IKO registered applicator from before the beginning of the bidding process through the end of the installation. B. Upon request by the building owner, the roofing contractor should present a copy of the IKO registration. C. The roofing contractor should maintain a full time supervisor or foreman experienced with the specified roof system on site during the majority of working hours. D. The roofing contractor should maintain a work force skilled in the application of IKO modified bitumen and/or built-up roofing. The crew should be properly instructed in all applicable safety procedures including, but not limited to, proper clothing. E. The roofing contractor should maintain all equipment and tools necessary to complete the work. This includes, but is not limited to, working and readable thermometers on all kettles and tankers Pre-Installation Meeting A. The pre-installation meeting should convene within five working days prior to commencement of work in this section. B. All parties responsible for work in this section are required to attend. C. All installation procedures shall be reviewed and, where necessary, coordination with related work from other trades shall be determined. D. All outstanding issues shall be noted in writing, the responsible parties designated, and a proposed timetable for completion prepared. E. No roofing work shall begin until a Notice To Proceed is issued following the pre-installation meeting. The Notice To Proceed shall include information concerning: acceptable staging areas; suitable parking and access points; location of refuse containers; sanitary requirements; working hour restrictions; noise restrictions; and complaint resolution protocol between the roofing contractor and the building owner/general contractor. PART 3 GENERAL REQUIREMENTS Page 6

7 Job Site Considerations A. All components of the new IKO roofing system shall be protected from harmful discharges such as petroleum by-products, vegetable oil, animal fat, and other by-products which may come into direct contact with the components. B. IKO does not perform nor review dew point analyses. Therefore, IKO is not responsible for damage due to condensation. C. With the exception of initial installation, all IKO roofing system components shall be protected from direct contact with heat sources that may cause damage while in service Delivery, Handling, and Storage A. All materials shall be delivered and stored In accordance with the manufacturer's recommendations. B. When outdoor storage of insulation is unavoidable, the insulation shall be stacked on pallets a minimum of four inches (4") (100 mm) above ground level and covered with a waterproof tarp. The insulation manufacturer's packaging is not considered waterproof and shall be slit, as recommended by the manufacturer, to reduce condensation inside the packaging. C. When stocking the roof, consider the effect of loads on the structure and decking due to the placement of materials. Avoid stockpiling of materials on the roof without first obtaining permission from the building owner/general contactor D. Store all roofing materials in a dry, well-ventilated area. Remove materials only as needed for daily work. E. During winter, store roll goods in above-freezing temperatures. Store pails of adhesives, primers and mastics in accordance with the manufacturer's recommendations. F. Roll materials must be stored on end with selvage edge up. Do not double stack roll goods, skids of asphalt or Protectoboard. G. All materials damaged during storage or transport shall be removed from the job site and replaced Roof Drainage A. It is an IKO requirement that all roof surfaces have positive drainage. IKO recommends a minimum slope of one-quarter inch (1/4") per horizontal foot (12") or 2%. B. Inadequate drainage is defined as any area of the roof where water ponds for more than forty-eight (48) hours after a rainfall under conditions conducive to drying. Ponding can also result from other water sources including improperly plumbed HVAC units and condensation from steam lines. C. Damage caused by inadequate drainage or ponding water in accordance with the above definition will not be covered by an IKO registered Limited Warranty. Provisions for additional work to insure proper drainage should be considered by the building owner. PART 3 GENERAL REQUIREMENTS Page 7

8 Roof Decks - General Requirements A. A properly designed and constructed roof deck, as well as the proper interrelationship of all building components, is the responsibility of the architect, engineer, or building owner. The density, internal moisture, integrity, and other inherent elements of the deck must also be suitable to receive the roof. IKO is not responsible for any of the previously mentioned factors and assumes no responsibility under any circumstances. B. The roof deck constructions and deck surface preparation requirements which follow are provided as a supplemental guide for the architect, engineer, or building owner. IKO's acceptance of a roof deck as satisfactory to receive the IKO roofing system refers only to the deck surface and not the design, construction, structural integrity or attachment of said deck. C. Deck types not listed in this guide must be accepted, in writing, by the IKO Technical Services Department in order to be eligible for a limited warranty. D. The surface of the roof deck, regardless of type, shall be dry, clean, smooth, firm, properly constructed, properly attached, and properly designed for anticipated loads with deflection not to exceed 1/240 of the span at mid-span. E. The roof deck shall be constructed in accordance with the project specification or IKO guidelines and the roof deck manufacturer's requirements whichever is more stringent. F. All penetrations through the roof deck should be completed prior to installation of the roofing system. Projections may not penetrate cant strips around the parapet or other locations where cant strips are required. Penetrations shall not be placed closer than twenty-four inches (24") (610 mm) from the base of the parapet wall. Proper bracing required around opening as per deck manufacturer's guidelines or Steel Deck Institute (SDI) requirements and in compliance with applicable building code. G. Utility piping, such as electrical conduit or gas lines, may not be installed on the surface of the roof deck. If installed above the surface of the roof, utility piping should be installed on support blocking. H. If the roof deck slopes more than one inch (1") per foot (8%), contact IKO Technical services for wood nailer insulation stops and backnailing guidelines for membrane systems. I. Roof decks shall be designed and constructed with expansion joints in appropriate quantity and placement. Expansion joints must extend through the structural system to be functional. Expansion joints shall be incorporated to separate adjoining buildings or sections of buildings as determined by the designer. J. Thermal barriers, minimally one-half inch (1/2") (12.7 mm) thickness if necessary to meet local building code or insurance requirements, may be installed directly over the roof deck and under the roofing system assembly. PART 3 GENERAL REQUIREMENTS Page 8

9 Roof Decks - New Construction or Complete Tear Off A. When roofing over existing steel support decks, stipulations shall be made for: 1. Removal of surface corrosion and subsequent painting; 2. Repair to holes, or severely corroded sections. 3. Fastening of loose decking; and Replacement of decking that is corroded beyond repair or otherwise unsuitable as a substrate Steel Decks A. Steel decks must be a minimum of 22 gauge (0.8 mm), manufactured from mild steel, and be factory primed or galvanized to resist rusting. The top flanges of sheet panels shall be flat. B. Steel decks must comply with gauge, span, and fastening requirements listed in the current Factory Mutual Research Corporation (FMRC) Approval Guide and Loss Prevention Data Sheet 1-28, and/or as specified by the decking manufacturer. C. Wood nailers of equal thickness of the roof insulation must be provided at perimeters and projection openings to function as insulation stops and to provide a fastening base for flanges of metal curb and flashings. D. In some cases, steel decks may require the installation of an acceptable insulation or board product prior to the application of a roof membrane assembly. The rigid board must be of the minimum thickness necessary to span the flutes, as well as capable of withstanding traffic, as recommended by the manufacturer. The rigid roof boards must be securely attached to the decking. E. For Factory Mutual, (FM), compliant assemblies, the first layer of rigid insulation must be mechanically attached with approved screws and plates. Subsequent layers may be attached using adhesives, hot asphalt or all layers can be attached through the top layer with common fasteners through the deck. F. Perimeter nailers must be provided. All cant strips used in conjunction with steel roof decks must be properly secured in place. G. Any of the IKO guidelines for use over insulation may be applied over a steel deck, providing the steel deck is covered with acceptable rigid roof insulation or board products Poured-In-Place Structural Concrete Decks A. Poured-in-place structural concrete decks must have a minimum compressive strength of 3,000 PSI and be properly cured for a period specified by the concrete manufacturer, or a minimum of twentyeight days (28) prior to the application of the roofing system. PART 3 GENERAL REQUIREMENTS Page 9

10 B. All poured-in-place structural concrete decks shall provide for bottom side drying. Decks poured over non-venting forms that remain in place are not acceptable. C. All poured-in-place structural concrete decks shall be dry prior to the installation of the new roofing system. Wet decks must be permitted to dry and frozen decks must be permitted to thaw and dry. All necessary precautions must be taken to avoid entrapment of moisture. IKO shall not be responsible or liable for damage to the roofing system caused by trapped moisture under the roofing system, whether it is from the concrete deck or some other source. D. If there is any doubt concerning deck dryness, especially in the case of hot asphalt attachment, IKO recommends using the deck dryness test. When hot asphalt is used for the attachment of the insulation or base sheet, the following NRCA deck dryness test is recommended to verify dryness of the concrete: 1. Pour one (1) pint (0.5 L) of the specified bitumen that has been heated to a minimum of four hundred (400 o F) degrees Fahrenheit (204 o C) on to the concrete deck. 2. If the bitumen bubbles or foams, then the deck is not dry enough. 3. After cooling, peel the bitumen off the deck. If the bitumen can be removed cleanly, then the deck is not dry enough. E. All poured-in-place structural concrete decks shall be smooth, level, and free from dirt or contaminants. Concrete curing agents shall be checked for compatibility with roofing materials. F. All roof deck ridges, depressions, or irregularities must be leveled prior to the application of the roofing system. Grind down ridges or irregularities. Fill depressions with cement grout or other material accepted by the roof deck manufacturer. Cracks greater than one-eighth inch (1/8") (3.2 mm) in width shall be repaired in accordance with the deck manufacturer's requirements. G. All poured-in-place structural concrete decks receiving heat fused roofing materials or hot asphalt must first be primed with a suitable primer. Self-adhesive and adhesive-applied components may also require priming of the deck. Check with IKO Technical for specific applications of individual products. H. Perimeter nailers must be provided. All cant strips used in conjunction with poured-in place structural concrete roof decks must be properly secured to the structure. I. It is the responsibility of the architect, engineer, building owner, or roofing contractor to determine the suitability of the deck for direct membrane application to the concrete deck. Decks with textured finishes are not acceptable where the membrane system will be applied directly to the poured-inplace structural concrete deck. PART 3 GENERAL REQUIREMENTS Page 10

11 Precast Concrete Decks A. Precast concrete decks shall be properly cured and installed in strict accordance with the deck manufacturer's specifications prior to the application of the roofing system. Any critically misshaped sections shall be replaced. B. All IKO installation guidelines over precast concrete decks which require an IKO limited warranty must have an acceptable insulation or separation panel solidly mopped, glued or mechanically fastened over the deck. C. All precast concrete decks shall be dry prior to the installation of the new roofing system. Wet decks must be permitted to dry and frozen decks must be permitted to thaw and dry. All necessary precautions must be taken to avoid entrapment of moisture. IKO shall not be responsible or liable for damage to the roofing system caused by trapped moisture under the roofing system, whether it is from the concrete deck or any other source. D. If there is any doubt concerning deck dryness, especially in the case of hot asphalt attachment, IKO recommends using the deck dryness test as outlined in subsection Concrete Decks. E. All precast concrete decks shall be smooth, level, and free from dirt or contaminants. F. All roof deck ridges, depressions, or irregularities must be leveled prior to the application of the roofing system. Grind down ridges or irregularities. Fill depressions and top joints between precast slabs with cement grout, or other materials accepted by the roof deck manufacturer, to provide a smooth deck surface. In order to permit maximum contact surface for roofing materials to be applied, leveling shall be gradual and smooth. Cracks greater than one-eighth inch (1/8") (3.2 mm) in width shall be repaired in accordance with the deck manufacturer's requirements. G. All precast structural concrete decks receiving heat fused roofing materials or hot asphalt must first be primed with a suitable primer. Self-adhesive and adhesive applied components may also require priming of the deck. Check with IKO Technical for specific applications of Individual products. H. Perimeter nailers must be provided. All cant strips used in conjunction with precast structural concrete roof decks must be properly secured to the structure. I. It is the responsibility of the architect, engineer, building owner, or roofing contractor to determine the suitability of the deck for direct membrane application to the precast concrete deck. Decks with textured finishes are not acceptable where the membrane system will be applied directly to the precast concrete deck Pre-Stressed Concrete Decks A. Pre-stressed concrete decks shall be properly cured and installed in strict accordance with the deck manufacturer's specifications prior to the application of the roofing system. Any critically misshaped sections shall be replaced. B. All IKO installation guidelines over pre-stressed concrete decks which require an IKO limited warranty must have accepted rigid board stock solidly mopped, glued or mechanically fastened, to the deck prior to the application of a membrane system. PART 3 GENERAL REQUIREMENTS Page 11

12 C. All pre-stressed concrete decks shall be dry prior to the installation of the new roofing system. Wet decks must be permitted to dry and frozen decks must be permitted to thaw and dry. All necessary precautions must be taken to avoid entrapment of moisture. IKO shall not be responsible or liable for damage to the roofing system caused by trapped moisture under the roofing system, whether it is from the concrete deck or some other source. D. If there is any doubt concerning deck dryness, especially in the case of hot asphalt attachment, IKO recommends using the deck dryness test as outlined in subsection Concrete Decks E. All pre-stressed concrete decks shall be smooth, level, and free from dirt or contaminants. F. All roof deck ridges, depressions, or irregularities must be leveled prior to the application of the roofing system. Grind down ridges or irregularities. Fill depressions and top joints between precast slabs with cement grout, or other material acceptable to the roof deck manufacturer, to provide a smooth deck surface. In order to permit maximum contact surface for roofing materials to be applied, leveling shall be gradual and smooth. Cracks greater than one-eighth inch (1/8") (3.2 mm) in width shall be repaired in accordance with the deck manufacturer's requirements. G. All pre-stressed structural concrete decks receiving heat fused roofing materials or hot asphalt must first be primed with a suitable IKO primer. Self-adhesive and adhesive-applied components may also require priming of the deck. Check with IKO Technical for specific applications of individual products. H. Perimeter nailers must be provided. All cant strips used in conjunction with pre-stressed concrete roof decks must be properly secured to the structure. I. It is the responsibility of the architect, engineer, building owner, or roofing contractor to determine the suitability of the deck for direct membrane application to the pre-stressed concrete deck. Decks with textured finishes are not acceptable where the membrane system will be applied directly to the pre-stressed concrete deck Plank and Heavy Timber Wood Decks A. Wood shall be a minimum of one inch (1") (25 mm) thick, between four inches (4") (100 mm) and eight inches (8") (200 mm) wide, and kiln dried. Tongue and groove, or sidelap lumber, is preferred over square edge lumber. B. Confirm compatibility between roofing materials and preservatives used to treat the wood. C. All wood shall be stored on skids or raised platforms and be covered with a waterproof tarp. Wood decks shall be roofed promptly after installation. D. All wood planks must have a bearing on rafters at each end and be securely fastened to the joists or trusses. E. Any knotholes or cracks in the lumber in excess of three-eighths inch (3/8") (9.5 mm) shall be covered with strips of securely fastened sheet metal. F. Plank and heavy timber wood decks require the installation of a layer of insulation, a separation panel, or a mechanically fastened base sheet. PART 3 GENERAL REQUIREMENTS Page 12

13 Plywood Decks A. Plywood decks must be a minimum of fifteen-thirty seconds inch (15/32") (12 mm) thick with joist spacing not to exceed twenty-four inches (24") (610 mm) on center. B. Plywood decks shall be exterior grade, American Plywood Association (APA) Product Standard PS- 1. Fire retardant plywood is not acceptable. C. If plywood other than APA Product Standard PS-1 is considered, then the roofing contractor must confirm the compatibility between the roofing materials and any preservatives used to treat the plywood. D. All plywood shall be stored on skids or raised platforms and be covered with a waterproof tarp. Plywood decks shall be roofed promptly after installation. E. Joints in the plywood deck must be supported by wood framing or some other means to prevent deflection. F. The plywood deck must be secured to joists or trusses in accordance with APA recommendations. G. Plywood decks require the installation of a layer of insulation, a separation panel, or a mechanically fastened base sheet. H. When roofing over plywood decks, stipulations shall be made for: 1. repairs of holes; 2. attachment of loose decking; and 3. replacement of decking that is warped, rotted, or deteriorated beyond repair or otherwise unsuitable as a substrate Structural Wood Fiber Decks A. Structural wood fiber decks must be protected from the weather during storage and installation and must be dry when roofing is installed. B. Structural wood fiber decks must be installed in accordance with the manufacturer's specifications and with level joints. C. Structural wood fiber decks must be able to sufficiently hold fasteners and must be able to support minimum design loads as recommended by the deck manufacturer. D. Structural wood fiber deck sections which become wet or deformed shall be replaced with new decking. E. Structural wood fiber decks shall be covered with roofing immediately to avoid water damage from precipitation. PART 3 GENERAL REQUIREMENTS Page 13

14 F. Structural wood fiber decks require the installation of a layer of insulation, a separation panel, or a mechanically fastened base sheet. G. Structural wood fiber decks that incorporate composite elements such as insulation or particleboard are not accepted for use in IKO roofing systems. IKO Limited Warranties will not be issued on these deck systems Poured-In-Place Gypsum Decks A. Call the IKO Technical Services Department for information on Modified Bitumen or Built-Up Roof Systems over poured-in-place gypsum decks Poured-In-Place Lightweight and Cellular Concrete Decks A. Call the IKO Technical Services Department for information on Modified Bitumen or Built-Up Roof Systems over poured-in-place lightweight and cellular concrete decks Roof Decks - Re-Cover A. Tear-off to the roof deck is considered new construction. Refer to the appropriate part of section When IKO Modified Bitumen or Built-Up Roofing Systems are attached directly to existing smooth built-up or modified bitumen roofs, IKO is not responsible for failures due to lack of adhesion of the existing roof to the existing substrate. It is recommended that the new system be secured through the existing system into the decking using appropriate screws and plates where possible to ensure the new system is suitably attached to the structure. B. Re-cover is defined as installation of a new roofing system over an existing system. The existing roof must present a suitable surface to receive the new roofing system. C. The roof deck must be clean, dry and free of projections or depressions and comply with the minimum general requirements as outlined in Part 3, Section D. It is recommended that an Infrared Scan be performed to locate any wet insulation under the existing roof membrane. Any wet insulation shall be removed and any blisters shall be repaired. When wet insulation is removed and replaced, it must be covered with a layer of like materials of equal thickness to the layer of smooth surface built up or modified bitumen that was removed. IKO will not be responsible for diminished life and/or premature failure of the membrane assembly due to pre-existing conditions within the old assembly left in place. E. Existing flashings must be removed prior to the installation of the new flashing system. F. If the existing metal flashing is damaged or deteriorating, or otherwise not reusable, then the existing metal flashing must be removed and replaced. All existing lead flashings must be removed. All metal flashing forming part of the membrane assembly contacting the bitumen must be primed. PART 3 GENERAL REQUIREMENTS Page 14

15 Resaturated or Coated Smooth Surface Built-Up or Modified Bitumen Roofs A. Smooth surface built-up or modified bitumen roofs that have been resaturated or coated require the installation of a layer of insulation, a separation panel, or a mechanically fastened base sheet. The first layer may be an IKO No. 25 Glass Base Sheet, or a layer of Protectoboard. B. The initial layer of insulation or base sheet must be mechanically fastened. If both a layer of insulation and base sheet are used, then they may both be mechanically fastened using a common fastener. Alternately, successive layers of insulation or base sheet may be hot asphalt, or cold applied into place. C. If hot asphalt is used for the attachment of the base sheet or recover board, then the existing surface must first be primed with an ASTM D 41 or CGSB 37-GP-9 IKO asphalt primer and installed in accordance with the manufacturer s recommendations Non-Resaturated or Uncoated Smooth Surface Built-Up or Modified Bitumen Roofs A. Smooth surface built-up or modified bitumen roofs that have not been resaturated or coated may have an IKO Modified Bitumen or Built-Up Roofing System installed directly over the existing surface providing the following conditions are satisfied: 1. Any wet insulation has been removed and any blisters have been repaired. When wet insulation is removed and replaced, it must be covered with a layer of like material or built-up roof of equal thickness to the layer of smooth surface built-up or modified bitumen that was removed. It is recommended that an Infrared Scan be performed to locate any wet insulation under the existing roof membrane. 2. The existing roof does not have areas of loose alligatoring on the surface. 3. The existing roof does not have large splits or cracks in the surface. 4. The existing roof is primed with an ASTM D 41 or CGSB 37-GP-9 IKO asphalt primer. B. The asphalt primer shall be permitted to dry prior to the installation of the roofing system components. C. If insulation or a separation panel is required and installed as per manufacturer s recommendations. D. If insulation, or a separation panel, and a base sheet are required, then they may be mechanically fastened with a common fastener. The first layer may be an IKO Base Sheet, or a layer of Protectoboard Mineral Surface Built-Up or Modified Bitumen Roofs A. Mineral surface built-up or modified bitumen roofs that have not been resaturated or coated may have an IKO Modified Bitumen or Built-Up Roofing System installed directly over the existing surface providing the following conditions are satisfied: PART 3 GENERAL REQUIREMENTS Page 15

16 1. Any wet insulation has been removed and any blisters have been repaired. When wet insulation is removed and replaced, it must be covered with a layer of modified bitumen or built-up roof of equal thickness to the layer of smooth surface built-up or modified bitumen that was removed. 2. The existing roof does not have areas of loose alligatoring on the surface. 3. The existing roof does not have large splits or cracks in the surface. 4. The existing roof has all roof cement removed. 5. The existing roof is primed with an ASTM D 41 or CGSB 37-GP-9 IKO asphalt primer. B. The asphalt primer shall be permitted to dry prior to the installation of the roofing system components. C. If insulation or a separation panel is required, then the first layer must be mechanically fastened or hot asphalt attached to the primed surface. D. If insulation, or a separation panel, and a base sheet are required, then they may be mechanically fastened with a common fastener Gravel Surface Asphalt or Coal Tar Built-Up or Modified Bitumen Roofs A. Gravel surfaces on built-up roofs must be removed, the high spots must be removed, and the depressions filled. B. Any wet insulation shall be removed and any blisters shall be repaired. When wet insulation is removed and replaced, it must be covered with a layer of like material or built-up roof of equal thickness to the layer of gravel surface built-up roof that was removed. C. Conditioned surfaces of BUR systems meant to receive a new membrane must be dry, smooth, free of debris, large voids (over 1/8 ) (over 3.2 mm) and sufficiently stable so as not to impede the performance of the new assembly. D. Gravel surfaces on built-up roofs require the installation of an accepted insulation and base sheet or a single layer of Protectoboard. The initial layer of insulation and base sheet shall be mechanically fastened with a common fastener and plate. E. A mechanically fastened recovery board a minimum of one-eighth of an inch (1/8 ) thick, (recommended to be 1/4 thick), is required over the existing roof if the roof is not smooth, or the existing roof is coal tar pitch. All loose gravel must be removed. F. If removing the existing membrane causes surface damage to the existing insulation, then a recover board must be installed over the existing insulation to provide a smooth surface. Caution: Fastener penetration of the existing roof and roof deck may cause a flow of coal tar/bitumen into the building. PART 3 GENERAL REQUIREMENTS Page 16

17 Sprayed-In-Place Urethane Roofs A. Sprayed-in-place urethane roofs are not acceptable substrates for IKO Modified Bitumen or Built-Up Roofing Systems. Sprayed-in-place urethane roofs must be removed to the deck prior to the installation of the new roofing system Expansion Joints A. The design, location, and use of expansion joints are the responsibility of the architect, engineer, or building owner Design Recommendations A. Although design, location, and use of expansion joints are the responsibility of the designer, engineer, or building owner, IKO strongly recommends expansion joints whenever: 1. The length of the building exceeds two hundred feet (200') (61 m), or 2. Steel framing or structural steel changes direction or elevation, or 3. Roof decking changes direction such as "L", "U", or "T" configuration, or 4. The roof deck material changes from one material to another, or 5. Additions are connected to an existing building, or 6. Canopies, overhangs, or loading docks junction into the main structure, or expansion joints are provided in the structural system. The above list is not all-inclusive as it does not define all possible conditions that would require an expansion joint Flashing Recommendations A. All metal/elastomeric composite expansion joint covers that penetrate the membrane shall be elevated on curbs a minimum of eight inches (8") (200 mm) above the surface of the roof. B. Roof level expansion joints must be waterproof, monolithic, and factory vulcanized. Standard of quality referenced herein is Redline by Situra Inc. Call the IKO Technical Services or Situra Inc,for information on acceptable roof level expansion joints relative to IKO roofing systems. 1. Redline, (Situra brand name ), is installed typically in an asphaltic based medium. Apply the base coat of the asphalt medium directly to the substrate and embed the Redline waterproof expansion joint material and making sure that the bottom polyester fleece is in full contact with the hot asphalt bitumen. Press the Redline material into the hot asphalt to ensure a continuous and even bond. PART 3 GENERAL REQUIREMENTS Page 17

18 2. Spread and even coat of asphalt on the top surface of the Redline expansion joint ensuring the top white polyester fleece is completely covered and strip in felt plies. The system is to be wholly encapsulated between plies in an asphalt/bitumen compatible roofing/waterproofing system with flood coat ( mopping is acceptable ) of asphalt bitumen. The joint shall not obstruct water flow across its surface and shall form a continuous monolithic waterproof barrier. 3. Always lay the Redline expansion joint material only in lengths of 10 feet (3m) or less to allow for full contact with the hot bitumen adhesive. Do not lay Redline into cold asphalt. Application temperatures for hot asphalt bitumen referenced elsewhere in this guideline shall apply to the Redline product as well. C. Expansion joints shall be continuous and shall not be terminated before the break in the structure. D. For expansion joints to function properly, construction ties must be removed Area Dividers and Control Joints A. Area dividers and control joints are not expansion joints, however, they do serve the same purpose in some applications. Area dividers are an acceptable alternative to expansion joints if they are installed where expansion joints were not included in the original design. Area dividers shall be designed and installed using the same criteria as expansion joints Vapour Retarders A. A vapor retarder installed to the roof deck beneath the roof insulation is a part of the roofing specification. The need, design, use, and placement of a vapor retarder must be determined by an architect, engineer, or building owner. B. Use of a vapor retarder should be investigated if any of the following conditions exist: 1. A project where outside average January temperature is below forty (40 F) degrees Fahrenheit (5 C) and where interior relative humidity of forty-five (45%) percent or greater is anticipated. 2. A project where construction components or processes may reasonably expected to create moisture after the roof is installed. C. Refer to the (NRCA) National Roofing Contractors Association Roofing and Waterproofing Manual or the (CRCA) Canadian Roofing Contractors Association Reference Manual for recommendations on vapor retarders or consult the current issue of the (NBC) National Building Code Vapor Retarder Installation A. Vapor retarders are only effective in reducing transmission of moisture vapor if properly installed and are not damaged or punctured during installation. B. The vapor retarder must be properly sealed at all laps, and penetrations. Penetrations must be flashed or enveloped. C. All punctures in the vapor retarder must be repaired prior to installing the roof insulation. PART 3 GENERAL REQUIREMENTS Page 18

19 D. The surfaces to be combined must be smooth, dry, and free from dust, dirt, grease, oil, or other foreign matter. E. Insulation boards should be installed immediately over the vapor retarder to avoid damage to the vapor retarder during construction of the roof Kraft Vapour Retarder Installation over Steel Decks A. The vapor retarder may be installed between two layers of board stock or directly over the steel deck. 1. Vapor retarder installation between two layers of board stock: a. The bottom layer must be a nominal thickness as dictated by code. The bottom layer must be mechanically fastened or cold applied. Typically the bottom board product is a gypsum board suitable for exterior applications. Starting at the low point of the roof, chalk a line on the first layer for alignment of vapor retarder plies. b. Attach a single ply of IKO ArmourGard Vapor Retardant above board stock with hot asphalt at the rate of thirteen (13 lbs.) pounds per one hundred square feet (100 ) (.68 kg/m²) in continuous ribbons two to three inches (2 to 3 ) (50 to 76 mm) wide at not more than six inches (6 ) (150 mm) aligned on center parallel to the deck flutes. c. Apply successive plies in shingle fashion and overlap previous layer side laps two inches (2 ) (50 mm). Stagger adjacent end laps a minimum of twenty-four (24) inches (610 mm). d. Attach the top layer of insulation with hot asphalt at the rate of twenty-five (25 lbs.) pounds per one hundred square feet (100 ) (1.2 kg/m²). A. Vapor retarder installation directly to the steel deck: a. Starting at the low point of the roof, chalk a line on the steel deck for alignment of vapor retarder plies. b. Attach a single ply of IKO ArmourGard Vapor Retardant with ArmourGard Vapor Retardant Adhesive at the rate of two hundred and fifty square feet (250 ) per gallon (0.16 L/ m 2 ). As an option, IKO Cold Gold Adhesive may be used in continuous ribbons, half inch (1/2 ) (12.7 mm), wide, spaced not more than twelve inches (12 ) (300 mm) on center. The ribbons shall be applied in parallel fashion on top of steel deck flutes. c. Apply successive plies in shingle fashion and overlap previous layer side laps two inches (2 ) to four inches (4 ) (50 mm to 100 mm) depending on the profile of the steel deck. Stagger adjacent end laps a minimum of twenty-four inches (24 ) (610 mm). PART 3 GENERAL REQUIREMENTS Page 19

20 d. Attach the insulation over the vapor retarder in accordance with the project specification or manufacturer s recommendation. B. Self-Adhesive Vapor Retarder (MVP) directly on steel deck: a. Prime steel flutes with IKO S.A.M Adhesive and allow to dry. Note that priming is only required when the primary layer above is not mechanically attached to the decking. b. Align vapor retarder sheets over male flutes starting at the low point of the roof. c. While aligned, remove release film from backside of the vapor retarder and press vapor retarder into full contact with male flutes. Press areas in contact with the decking to ensure a fully bonded contact patch. d. Align successive sheets of vapor retarder with the first. Always join laps over a male flute. Overlap sides by two inches (2 ) (50 mm) minimum and stagger end laps from each other by a minimum of twenty-four inches (24 ) (610 mm). End laps spanning the female flutes may require support. Cut appropriate pieces of insulation and place within the flute so that a level continuous surface supports the endlap e. Ensure vapor retarder has sufficient material at all roof edges, penetrations and curbs to affect a proper seal forming a continuous barrier throughout.. C. Vapor Retarders over attached board products: a. The board product must be attached to the steel deck in accordance with the manufacturer s recommendations. It may be by mechanical or adhesive-applied method. b. All manner of vapor retarder membranes can now be applied over the board surface for vapor control. Membranes can be modified bitumen, built-up with felts and asphalt or other such membranes compatible with the balance of the roofing assembly. c. Most board products serving this purpose are primarily used as a thermal barrier or as a base for thicker membrane vapor retarders. Typically used is a gypsum board of half inch (1/2 ) (12.7 mm) thickness or five-eighths inch (5/8 ) (15.9 mm) thickness. Check with the board manufacturer for specific recommendations as to the nature of the membrane intended, priming requirements and compatibility with various heatfused, hot mopped or cold applied membranes Vapor Retarder Installation over Concrete Decks A. Prime the deck with an ASTM D 41 or CGSB 37-GP-9 IKO asphalt primer, at the rate recommended by the manufacturer and permit to dry prior to the application of the roofing system. B. Do not apply asphalt primer within four inches (4 ) (100 mm) of precast concrete panel joints, cracks, or roof openings. C. Over concrete panel joints, install a minimum six inch (6 ) (150 mm) wide strip of a Modiflex base PART 3 GENERAL REQUIREMENTS Page 20

21 sheet centered over the joint and spot attach to the deck on one side with hot asphalt. D. Starting at the low point of the roof, chalk a line on the concrete deck for alignment of vapor retarder plies. E. Attach a single ply of IKO ArmourGard Vapor Retardant with hot asphalt at the rate of thirteen pounds (13 lbs.) per one hundred square feet (100 ft 2 ) (.68 kg/m2) in continuous ribbons two to three inches (2 to 3 ) (50 to 76 mm) wide and not more than six inches (6 ) (150 mm) apart. F. Apply successive plies in shingle fashion and overlap previous layer side laps two inches (2 ) (50 mm). Stagger adjacent end laps a minimum of twenty-four inches (24 ) (610 mm). G. Hot asphalt attach the insulation board stock at the rate of twenty-five (25 lbs.) pounds per hundred square feet (100 ft 2 ) (1.2 kg/m2). Use Type II or Type III roofing asphalt only for attachment of the vapor retarder and board products. H. Attach the insulation in accordance with the project specification or manufacturer s recommendations. I. For concrete decks all manner of vapor retarders can be applied so long as they are compatible with the balance of the roofing system assembly. These membranes can be modified bitumen, mopped in hot asphalt, heat fused or glued in place, self-adhering modified bitumen sheets or felt and hot asphalt built up membranes. In all cases suitable surface preparation is required. Contact IKO Technical Services for specific requirements Vapor Retarder Installation over Wood and Structural Wood Fiber Decks. A. Mechanically fasten one ply of acceptable base sheet, using the appropriate number and type of fasteners as well as the fastener pattern as per design requirements or base sheet manufacturer s recommendations. B. Starting at the low point of the roof, chalk a line on the base sheet for alignment of vapor retarder plies. C. Attach a single ply of IKO ArmourGard Vapor Retardant with hot asphalt at the rate of thirteen (13 lbs.) pounds per one hundred square feet (100 ft 2 ) (.68 kg/m2) in continuous ribbons two to three (2 to 3 ) inches (50 to 76 mm) wide at not more than six inches (6 ) (150 mm) in center parallel to the deck joints. D. Apply successive plies in shingle fashion and overlap previous layer side laps two inches (2 ) (50 mm). Stagger adjacent end laps a minimum of twenty-four inches (24 ) (610 mm). E. There are many different membranes which can apply to wood decks. Ensure that the vapor retarder is compatible with the roofing assembly prior to application. F. It is not recommended to apply liquid adhesives in full coats directly over wood decks where the risk of bleed-through to the interior is high. A mechanically attached sheet should be attached first to prevent this. Liquids can then be safely applied over the fastened sheet. G. It is recommended to secure the first layer of a roofing assembly over a wood deck as it can be PART 3 GENERAL REQUIREMENTS Page 21

22 removed in the future without removing the wood decking. Assemblies adhered directly to wood decking may prohibit this from happening when re-roofing is necessary Roofing Asphalt A. IKO roofing systems require the use of ASTM D 312, or Canadian Standards Association (CSA) A123.4 asphalt, for the application of roof insulation, base sheets, ply sheets, and cap sheets. Consult IKO Technical Services for specific asphalt type to be used. B. IKO is not responsible for the performance of roofing asphalt not supplied by IKO Asphalt Grades for Insulation, Base Sheets, Ply Sheets, Modified Bitumen Roofs and Built-Up Roofs A. CSA A123.4 Type II or III can be used for insulation, base sheet, ply sheet, and cap sheet mopping on slopes one inch (1") (25 mm) per foot (8%) or less. For slopes greater than one inch (1") (25 mm) per foot (8%), Type III must be used. CSA A123.4 Type III asphalt may be used for slopes up to and including three inches (3") per foot (25%). Mopped flashing membranes on vertical surfaces must be terminated by mechanical means at and beyond twenty-four inches (24 ) (610 mm) above the roof surface. B. ASTM D 312 Type III and CSA A123.4 Type III asphalt have a softening point between one hundred and ninety-four and two hundred and five ( F) degrees Fahrenheit (90-96 C) and is applied between four hundred and twenty-five (425 F) degrees and four hundred and fifty (450 F) degrees Fahrenheit ( C). The maximum heating temperature is five hundred (500 F) degrees Fahrenheit (260 C). C. ASTM D 312 Type II and CSA A123.4 Type II asphalt has a softening point between one hundred and sixty seven and one hundred and eighty one ( F) degrees Fahrenheit (75-83 C) and is applied between four hundred and twenty-five (425 F) degrees and four hundred and seventy-five (475 F) degrees Fahrenheit ( C). The maximum heating temperature is five hundred (500 F) degrees Fahrenheit (260 C). D. Easy-Melt 200 is a CSA A123.4 Type III asphalt. It has the same properties as indicated in part B above. E. Modi-Melt SEBS is a premium Type III modified asphalt that conforms to all requirements of ASTM D6152 and UL55A for use with glass felts, modified membranes, insulation and coverboards with slopes of 0:12 to vertical application [up to sixteen inches (24 ) (610 mm)] Asphalt Identification A. IKO recommends and endorses an identification system for mopping grade asphalts and the use of such identification information. This information should be printed on the asphalt packages or bills of lading covering bulk asphalt and should include: 1. Type III or IV per ASTM D 312 or Type II or III per CSA A Flash Point (FP) per ASTM D 92. PART 3 GENERAL REQUIREMENTS Page 22

23 3. Equiviscous Temperature Range (EVT) Asphalt Heating and Application A. IKO requires that all mopping grade asphalt to be applied at the EVT range specific to the application method as printed on the asphalt cartons or bills of lading. B. Asphalt at the point of application shall be the EVT plus or minus twenty-five (25 F) degrees Fahrenheit (13 C). A viscosity of one hundred and twenty-five (125) centipoise should be achieved for hand mopping, and seventy-five (75) centipoise for mechanical spreaders. Under no circumstances shall the asphalt temperature be less than four hundred and twenty-five (425 F) degrees Fahrenheit (219 C) at the point of application, for the formation of the water proofing membrane. C. Asphalt for base sheet, ply sheet, or cap sheet applications shall be applied at the rate of twentyfive (25 lbs.) pounds per one hundred square feet (100 ft 2 ) (1.2 kg/m²) plus or minus twenty (20%) percent. Maximum temperature of three hundred and ninety (390 F) degrees Fahrenheit (199 C) for polyisocyanurate insulation at the rate twenty-five pounds (25 lbs.) per one hundred square feet (100 ft 2 ) (1.2 kg/m²). D. The asphalt shall be applied no more than three feet (3') (1 m) in front of the roll of base sheets, ply sheets, or cap sheets at all ambient temperatures. E. Thermometers on kettles and tankers should be checked periodically to ensure accuracy and proper asphalt heating temperatures. F. Do not heat asphalt beyond the finished blowing temperature for more than four (4) hours, and never above its flash point. G. Do not keep heated tankers above three hundred and twenty-five (325 o F) degrees Fahrenheit (163 o C) over nights, holidays, or weekends. H. The kettle operator shall be fully trained regarding safe operation of the kettle and have the required clothing, personal protective equipment, and fire protection equipment. I. Do not mix coal tar pitch with asphalt and do not mix different types of asphalt Wood Nailers Installation A. On new construction or complete tear-off projects, wood nailers must be kiln-dried structural grade number two (#2) or better. For re-cover projects and new construction projects where a poured-inplace deck is specified, wood nailers must be pressure treated for rot resistance (i.e. "Wolmanized" or "Osmose K-33") number two (#2) or better lumber. Asphaltic, creosote, or field treatment for rot resistance lumber is not acceptable. B. Wood nailers are required at the following locations: PART 3 GENERAL REQUIREMENTS Page 23

24 1. At all roof edges where parapet walls or adjoining walls are not present to serve as insulation stops. 2. At all locations where sheet metal is used and not fastened directly to the roof deck or fastened at a fastener spacing greater than six inches (6") (150 mm) on center over the insulation. The minimum fastening rate for penetration pockets or pitch pans is two (2) fasteners per horizontal flange. 3. At sixteen feet (16') (4.9 m) on center, and perpendicular to the slope, on insulated roof decks with slopes between one inch (1") and two inches (2") (8% to 17%) to the horizontal foot. 4. At eight feet (8') (2.4 m) on center, and perpendicular to the slope, on insulated roof decks with slopes between two inch (2") and three inches (3") (17% to 25%) to the horizontal foot. 5. At four feet (4') (1.2 m) on center, and perpendicular to the slope, on insulated roof decks with slopes greater than three inches (3") (25%) to the horizontal foot. 6. At all other locations as required by system details. 7. Wood nailers shall be installed as specified by the project designer or as required in these specifications and details. C. The system designer shall specify that the attachment of wood nailers shall be in accordance with the manufacturer s recommendations. D. Wood nailer height shall match the total thickness of the specified insulation and shall be installed with a one-eighth inch (1/8 ) (3.2 mm) gap between each length and each change of direction. If applicable, wood nailers shall be tapered to be flush at the point of contact with the insulation Roof Insulation A. The purpose of roof insulation is to provide a smooth, clean, dry, and firmly attached substrate to receive the roofing system while providing insulating value against the transmission of heat and cold. Roof insulation is not a part of the roofing membrane. B. The selection of insulation type and thickness are the responsibility of the architect, engineer, or building owner. C. The insulation manufacturer must notify IKO, in writing, that their insulation meets all of the requirements outlined in this section. D. IKO reserves the right to accept or reject any roof insulation as an acceptable substrate for attachment of an IKO roofing system. E. Sprayed-in-place polyurethane foam is not an acceptable substrate to receive an IKO roofing system. F. The roof insulation must not be exposed to the elements. PART 3 GENERAL REQUIREMENTS Page 24

25 G. The roof insulation must be manufactured for use as roof insulation. H. The roof insulation must be able to withstand normal construction traffic without crushing. I. On metal decks, the roof insulation must be strong enough to span the flutes without breaking under typical rooftop traffic. Contact the insulation manufacturer for maximum flute spanability on steel roof decks. J. The insulation manufacturer must accept responsibility for any manufacturing defects that occur in the insulation. K. Heat fused modified bitumens should not be directly torched to combustible insulations or insulations with combustible facers. L. Insulation thickness requirements may vary for building or energy code compliance. Consult the local building code official for current requirements. M. All roof insulation manufactured in four foot (4') by eight foot (8') (1.2 m by 2.4 m) size must be mechanically fastened according to FM requirements. In multi-layer insulation assemblies, the first layer of insulation must be mechanically fastened on metal decks. Note that in some cases adhesives can be applied to metal decking. N. Where insulation is required by design to be in excess of four inch (4") thickness (100 mm), it is recommended to use thinner boards in multiple layers. The first layer must be adhesive or mechanically attached. Subsequent layers can be hot asphalt applied or adhesive applied. Alternatively, all layers can be loose and a single mechanical fastener driven through all layers into the decking Insulation Approvals, Restrictions, Minimum Thickness and Assemblies A. The insulation shall be accepted by FM and classified by Underwriters Laboratories (UL/ULC). B. Insulation installation requirements and recommendations may vary by application or region. Consult the insulation manufacturer for the most current requirements and recommendations. C. If an insulation other than one supplied by IKO is specified, then the insulation manufacturer must recommend and market the specific insulation type and thickness for the proposed IKO roofing system. D. Listed insulation thicknesses are minimums in a fully supported application. Consult the insulation manufacturer for maximum flute spanability of a specified thickness over a specific metal deck configuration. At no time shall flat stock board polyisocyanurate insulation go below one inch (1") (25 mm) in thickness. PART 3 GENERAL REQUIREMENTS Page 25

26 E. Wood fiberboard insulation must meet Federal Specification LLL-1-535, ASTM Specification C 208, CAN/ULC S706 and American National Standards Institute (ANSI) AHA A Minimum thickness is seven-sixteenths inch (7/16") (11 mm). F. Perlite insulation must meet Federal Specification HH and ASTM Specification C 728. Minimum thickness is one-half inch (1/2") (12.7 mm) as an overlay and three-quarter inch (3/4") (19 mm) as a single layer. G. Fiberglass insulation must meet Federal Specification HH and ASTM Specification C 726. Minimum thickness is one-half inch (1/2") (12.7 mm) as an overlay and fifteen-sixteenths inch (15/16") (23.8 mm) as a single layer. When mechanically fastening fiberglass insulation boards, plastic plates are required unless hot asphalt overlay of a minimum of one-half inch (1/2") (12.7 mm) wood fiberboard, perlite, or fiberglass roof insulation, or one-eighth inch (1/8") (3.2 mm) Protectoboard is used. H. Expanded polystyrene insulation must meet ASTM Specification C 578 and CAN/ULC-S701 with a minimum one pound (1lb.) density (0.45 kg). All expanded polystyrene insulation must be processed from modified EPS resin. All expanded polystyrene insulation must be aged a minimum of seven (7) days prior to shipping. All expanded polystyrene must have a seven-sixteenths inch (7/16") (11 mm) wood fiberboard, perlite, or fiberglass roof insulation, or one-eighth inch (1/8") (3.2 mm) Protectoboard over the expanded polystyrene and the joints of the overlay must be taped or sealed in all directions. Individual board thickness should not exceed three inches (3") (76 mm) in mechanically fastened roofing applications. I. Polyisocyanurate must meet ASTM C1289 and/or CAN/ULC-S704. Minimum thickness is one inch (1") (25 mm). Polyisocyanurate must have a minimum of seven-sixteenths inch (7/16") (11 mm) thick wood fiberboard, perlite, or fiberglass roof insulation, or minimum one-eighth inch (1/8") thick (3.2 mm) Protectoboard as a coverboard. Tapered insulation thickness may be below the one inch (1") (25 mm) thickness. In areas where this occurs, the polyisocyanurate shall be fastened at a rate of one (1) fastener and plate for every two square feet (2 ) (0.61/ m2) of board area. Individual board thickness should not exceed four inches (4") (100 mm) in mechanically fastened roofing applications. J. Perlite/Polyisocyanurate composite must meet Federal Specification HH and ASTM Specification C 728 for perlite and ASTM C 1289 and CAN/ULC-S704 for polyisocyanurate. Minimum thickness is one inch (1") (25 mm). If this board is to be hot asphalt attached, then it shall be installed with the perlite side up. If this board is installed with the perlite side down, then a minimum of seven-sixteenths inch (7/16") (11 mm) thick wood fiberboard, perlite, or fiberglass roof insulation, or minimum one-eighth inch (1/8") thick (3.2 mm) Protectoboard is required as a coverboard over the polyisocyanurate. K. Perlite/Polyisocyanurate/Perlite composite must meet Federal Specification HH and ASTM Specification C 728 for the perlite and ASTM C 1289 and CAN/ULC-S704 for polyisocyanurate. Minimum thickness is one and one-half inches (1 1/2") (38 mm). L. Cellular glass insulation must meet Federal Specification HH-1-551E and ASTM Specification C 552. Minimum thickness is one inch (1") (25 mm). Cellular glass must have a minimum of one-half inch (1/2") (12.7 mm) wood fiberboard, perlite, or fiberglass roof insulation over the cellular glass and/or minimum one-eighth inch (1/8") thick (3.2 mm) Protectoboard. PART 3 GENERAL REQUIREMENTS Page 26

27 M. Perlite/Expanded Polystyrene Composite must meet Federal Specification HH and ASTM Specification C 728 for the perlite and Federal Specification HH-1-524C and ASTM C 578 for the polystyrene. If this board is to be hot asphalt attached, then it shall be installed with the perlite side down. If this board is installed with the perlite side down, then a seven-sixteenths of one inch (7/16") (11 mm) wood fiberboard, perlite, or fiberglass roof insulation, or one-eighth of one inch (1/8") (3.2 mm) Protectoboard is required over the polystyrene. In either case, the joints of the overlay (perlite side down) or the joints of the composite (perlite side up) must be taped or sealed in all directions. Minimum thickness is one and one-half inches (1 1/2") (38 mm). N. Wood Fiber/Expanded Polystyrene Composite must meet Federal Specification LLL-1-535b Class C and ASTM Specification C 208 for the wood fiber and Federal Specification HH-1-524C and ASTM C 578 for the polystyrene. Minimum thickness is one and one-half inches (1 1/2") (38 mm). O. Protectoboard/Expanded Polystyrene Composite must meet Federal Specification HH-1-524C and ASTM C 578 and/or CAN/ULC S701 for the polystyrene. Minimum thickness is one and one-half inches (1 1/2") (38 mm). P. Rockwool must meet Federal Specification HH-I-526C and ASTM C 726. Minimum thickness is one inch (1") (25 mm). Rockwool must have a suitable coverboard over top or be specifically manufactured to receive a base sheet membrane directly. Q. IKO Protectoboard (asphalt core board), minimum thickness one-eighth of one inch (1/8") (3.2 mm). Protectoboard is a re-cover overlay board consisting of a mineral-fortified asphaltic core between two layers of high-strength reinforcing glass fiber mat. R. Phenolic foam insulation in an existing roof assembly is not an acceptable substrate for IKO roofing systems. S. Gypsum and Light-Weight Concrete decking must be reviewed by IKO Technical Services for suitability to receive an IKO roofing system Roof Insulation Installation A. Install only as much insulation as can be covered with the completed roof the same day. B. Do not install wet, damaged, warped, or defective insulation. C. Install insulation boards in staggered joint fashion in one direction. If there are multiple layers of insulation, then all joints between layers must also be staggered. D. Install insulation boards so that the sides and ends of the boards make contact along the entire length and width. Do not kick insulation boards into place. E. Gaps between insulation boards that exceed one quarter inch (1/4 ) (6.4 mm) must be filled with similar insulation material). F. Fit insulation neatly around all penetrations and nailers. PART 3 GENERAL REQUIREMENTS Page 27

28 G. Tapered insulation is recommended around all drains to create a sump for drainage. Mitering insulation is required at drain sump points. It is recommended that drain sumps be located a minimum of half an inch (1/2 ) (12.7 mm) below the finished roof surface. H. Insulation boards shall be mitered and filled at the ridges to prevent open joints. I. Insulation boards must be firmly attached to the roof deck or base sheet with screws and plates, hot asphalt or adhesives. Use only acceptable fasteners with a minimum three inch (3 ) (76 mm) diameter plates when mechanically fastening insulation. J. Install saddle or cricket systems in accordance with insulation manufacturer s instructions. K. Torch applied roofing membranes may not be applied directly over plastic fastening plates. L. When hot asphalt is applied directly over an insulation board that is directly over extruded or expanded polystyrene, then all joints of the top layer of insulation shall be taped or sealed Roof Insulation Attachment A. Positive attachment of roof insulation over an acceptable substrate is required. Insulation shall be attached in accordance with the requirements of the insulation manufacturer. Local building codes, insurance underwriters, and other authorities having jurisdiction may require additional fastening to satisfy separate requirements. IKO is not responsible for damage to roofing membranes or flashing from movement or wind uplift due to inadequate attachment of roof insulation to the roof deck. B. Install fasteners vertically to ensure proper thread engagement into the deck. C. Do not over-drive fasteners to the point where the fastening plates cup and the insulation dimples. D. Do not under-drive fasteners so that the fastener head is exposed above the fastening plate. E. Do not drive fasteners into any utility lines such as electrical, conduit or gas pipes. F. Three inch (3 ) (76 mm) diameter metal or plastic fastening plates are required when mechanically attaching insulation. Do not use plastic fastening plates for assemblies requiring a torch applied cap sheet. G. To compensate for anticipated increased wind loads for corners and perimeters, it may be necessary to increase fastener densities. Consult the insulation manufacturer for specific recommendations Mechanical Attachment of Insulation with Screws and Plates A. All mechanical fasteners and plates used to attach insulation shall meet the corrosion resistance requirements of FM Standard 4470 and must be accepted by IKO prior to installation. B. Nail attachment of roof insulation to a nailable deck is not acceptable. C. The following minimum penetration requirements shall apply to mechanical fasteners used to fasten into each deck type. Penetration is measured from the top surface of the deck and includes the PART 3 GENERAL REQUIREMENTS Page 28

29 tapping point of the fastener. Steel - three-quarter inch (3/4") (19 mm) Concrete - one inch (1") (25 mm) Plywood or Wood Plank one inch (1") (25 mm) D. Thermal bridging can be expected at every fastener and plate when a single layer of insulation is mechanically fastened directly under the roofing membrane. Thermal bridging can be avoided by using two layers of insulation. The first layer shall be mechanically fastened to the roof deck, and the second layer of insulation shall be hot asphalt or adhesives attached to the first. The second layer of insulation shall be off-set and hot asphalt or adhesive attached to the first. See Attachment diagrams following this page PART 3 GENERAL REQUIREMENTS Page 29

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