INSTALLATION MANUAL & QUALITY CONTROL CHECK LISTS

Transcription

1 NURATECH TPE INSTALLATION MANUAL & QUALITY CONTROL CHECK LISTS THIS MANUAL WAS PRESENTED TO WHO ATTENDED TRAINING ON 2012

2 TABLE OF CONTENTS NURATECH TPE - INSTALLATION MANUAL Qualifying Individual Applicators of Nuratech TPE... 4 Health and Safety... 5 Project Administration/Supervision... 6 Nuratech Products... 7 Nuratech TPE Membranes... 7 Storage Guidelines... 8 Cleaning Regime... 8 Tools and Equipment... 9 System Accessories Substrate Readiness Plywood Substrate Readiness Checksheet Concrete Substrate Readiness Checksheet ENERTHERM Substrate Readiness Checksheet Installing the Nuratech Adhering Nuratech SM Mechanically Fastened Roofing System PU Adhered Roofing System Joints and Installation Peel Tests Hand Welding Cross Joints Nuratech upstand rails Adhering Upstands Pipe Flashing Rainwater Outlets Parapet Outlets Internal Corner (horizontal fold) Internal Corner (vertical fold) External Corner Rooflights Roof Trims Nuratech Roof Trims Internal Corner Nuratech Roof Trims External Corner Day Joints Project Sign-off Form Nuratech Maintenance Programme v3 Page 2

3 Nuralite roofing and waterproofing systems are intended for application by skilled tradesmen and these notes are a technical guide to the application of the Nuratech range. The Nuralite organisation also maintains a team of skilled technical representatives who are prepared to demonstrate the correct application of Nuratech on site or to discuss any problems which may arise regarding its use. Please note that Nuratech has a very long warranty period and every precaution must be taken to avoid any possible weakness. Application according to these guidelines must be insisted upon by both the specifying Authority and the Applicator to ensure that full benefits of the warranty period are maintained. Warranty The product comes with a 20 year material defects warranty. Applicators can apply for the warranty at the completion of install the job but the warranty application must include a completed Substrate Readiness Checklist (pg 12/13) and Project Signoff form (pg 39). OTHER REFERENCE DOCUMENTS This manual forms one part of the full technical documentation for the Nuratech TPE system. You must familiarize yourself with the following: Other manuals Nuratherm Insulated Roof installation manual Technical literature (available at Nuratech TPE detail drawings Material Safety Datasheets Technical Datasheets Specifications Generic Nuratech TPE specifications Project specific specification TECHNICAL ADVICE For advice on unusual or abnormal conditions or details, please contact Nuralite Waterproofing Ltd, Auckland phone: or info@nuralite.co.nz 2012 v3 Page 3

4 QUALIFYING INDIVIDUAL APPLICATORS OF NURATECH TPE 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 training is performed by Neville Boreham, an experienced installer who has been trained in Nuratech installation by the manufacturer in England. The Nuralite website will clearly identify applicators who are in a position to install Nuratech membrane. 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 v3 Page 4

5 HEALTH AND SAFETY An applicator s wellbeing is paramount. Do not enter a worksite, commence work or continue working if: 1. You have not been adequately trained by your employer 2. You have not been briefed about the workplace hazards by the site manager 3. You do not have proper clothing, footwear, safety & workplace equipment. 4. You witness unsafe practices or you believe the workplace is unsafe. Use your commonsense and speak up if anything concerns you. A few points of particular relevance to Applicators are: 1. Applicators must wear protective clothing including a hard hat and suitable footwear. In particular, heat resistant gloves must be worn. Footwear should have soft, non-slip soles. 2. First aid equipment must be provided on site and work personnel trained in first-aid procedures. 3. Nuratech TPE is welded using electric powdered hot air tools. Take care to ensure the risk of electric shock is minimized by using serviced equipment, avoiding wet conditions and having correct, RCP protected, electric supply. 4. Experience and training for working at height is important, including understanding restraint procedures. Nuratech systems are normally applied to either roofs or decks, which are usually 2.5m or more above the ground. All work carried out in such situations require sufficient safety and protection to avoid falls. 5. All applicators must have a current Site Safe passport v3 Page 5

6 PROJECT ADMINISTRATION/SUPERVISION Nuralite & you, the applicator, are in a partnership designed to achieve the installation of many high quality Nuratech systems. Nuralite works hard to get jobs specified by Architects. The Applicator is responsible for the quality control and the installation of the Nuratech membrane systems and quotations. All work will rapidly dry up if the application is not performed in a professional manner. Not only must the workmanship be high quality, but the service and support to the builder and project manager should equal that to ensure we all get repeat business. Nuralite recommends a pre-inspection and/or a pre-job meeting of all parties involved with the Nuratech system to identify any areas of concern. It is important for a successful installation to resolve and clarify any issues or project requirements, work programme and issues with other trades, the project documentation required product storage, and site health and safety matters. Before commencing work, the Applicator must determine: That all the building consents have been issued and the specifications and detailed drawings are workable and suitable for the project That there is nothing that will compromise the Applicator s required responsibility under the NZ Building Code or your ability to follow these instructions and thus issue a warranty on your workmanship That no existing conditions at the site prevent the Applicator from performing in a professional and safe manner That the product to be installed is as per the official consent documents. If you have any concerns about the project, your working conditions or the substrate preparations then raise them with the site manager, your employer or a Nuralite representative. All applicators have the right to refuse to commence work until they are satisfied they can complete the job safely and to the highest standards v3 Page 6

7 NURATECH PRODUCTS The Nuratech system has a number of varieties which are selected based on factors such as the desired look, the climate, exposure to foot-traffic and possibility of moisture coming up through the substrate. NURATECH TPE MEMBRANES 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. The Nuratech range is provided in three standard colours; pure white, light grey and dark grey. Nuratech TPE is produced in a range of different membrane types designed for specific applications: Nuratech SM Polyester scrim reinforced membrane for adhesive bonded or mechanically fastened roofing systems. The membrane is adhered with Nurabond TPE Contact adhesive or mechanically fastened in the overlap using IKOfix Stress Plates and IKOfix Screws, the fixing passes through the insulation and vapour control layer (if present) into the deck. Overlaps are hot air welded. Nuratech SG Polyester fleece backed membrane for bonded roofing systems. The membrane is bonded to the substrate using Nurabond low foaming PU Adhesive. Side laps are hot air welded. End laps are butt jointed and waterproofed with a cover strip v3 Page 7

8 STORAGE GUIDELINES Once delivered to site the membrane should be protected against exposure from rain and site dirt. When stored in clean & dry conditions the Nuratech membrane needs no additional cleaning. CLEANING REGIME For new or already clean TPE No action needed For lightly soiled TPE Wipe off any debris / water For heavily soiled TPE Wipe off any debris / water Wash / scrub membrane with soapy water Allow to dry 2012 v3 Page 8

9 TOOLS AND EQUIPMENT Hot Air Hand Welders Quality hot air hand welding tools are available from Leister (Triac PID). These tools are lightweight and have a digital temperature display showing set and actual air temperatures up to maximum 600 C. The recommended welders have stepless electronic temperature control and are available in both 110v and 230v. Automatic Hot Air Welders Suitable machines are available from both Leister (Varimat) and weigh approximately 25kg. The digital temperature display shows set and actual air temperatures up to a maximum 660 C. Maximum welding speeds are between 57metres per minute. These machines have stepless electronic temperature and welding speed control. The independent suspension pressure roller ensures consistent distribution of pressure on uneven substrates. Nozzles A 40mm wide nozzle should be used where stresses occur on the membrane laps e.g. in the field zone. The 20mm wide nozzle is used for welding laps located at intricate detailing e.g. internal corners, and are interchangeable with the hand welders outlined above. Seam Pressure Roller 40mm wide silicone roller for providing pressure to welded laps. Penny Pressure Roller 6mm brass roller for providing pressure to welded detailing. General Tools Nuratech TPE membranes are generally cut using scissors although a flat bladed knife can be advantageous at detailing. A wire brush is required to remove polymer deposits from welding nozzles. Wide paintbrushes or compatible application rollers are suitable for application of Nurabond Contact Adhesive. A chalk line should be used to mark the membrane prior to cutting. Tape measures should be used to ensure consistency of lap widths. Welded seams should be checked using a suitable seam check tool v3 Page 9

10 SYSTEM ACCESSORIES A range of ancillaries is available to complement the Nuratech TPE membranes: Nuratech Coated Metal Nuratech coated metal is a steel sheet precoated with homogeneous TPE membrane. The coated metal is fabricated offsite to form perimeter details such as drip edges and upstands. The TPE membrane surfacing to the metal enables Nuratech TPE Membranes to be heat welded to preformed edge details to ensure the perimeters are fully sealed and waterproofed. Nurabond Low Foam PU Adhesive Nurabond PU Adhesive is a ready to use, high performance, single component, moisture curing polyurethane adhesive for bonding fleece backed polymeric single ply membranes to rigid insulation and other suitable substrates. The adhesive is cold applied and has been specially developed to allow safe and rapid bonding of suitable membranes. Nurabond TPE Contact Adhesive Nurabond TPE Contact Adhesive is a ready to use synthetic rubber based, contact adhesive for adhering TPE roofing membranes onto various substrates. It is easy to apply using brush or roller and is specifically used to adhere Nuratech TPE membranes to various substrates at upstands and details IKOfix Telescopic Fixing Plates and Fixing Screws Polypropylene telescopic fixing tubes for fixing membranes and insulation in warm roof buildups, used in conjunction with the appropriate fixing screws. Using fixing tubes reduces thermal bridging and can offer cost savings when fixing through large insulation thicknesses. The telescopic effect means they can also protect the fixing from damage caused by foot trafficking. Nuratech D Homogeneous roofing membrane for use on complex detailing v3 Page 10

11 Pressure Plates NURATECH TPE - INSTALLATION MANUAL Metal pressure plates suitable for membrane and insulation applications. Flat plates are used for rigid / flat surfaces and those with a deeper recess are suitable for compressible substrates. Termination Bars & Clamping Strips Metal clamping and termination bars for mechanical fixing of Nuratech membranes at perimeters. Nuratech TPE Standing Seam Profile Nuratech Standing Seam Profile is a preformed profile used to simulate a metal standing seam joint. The profile is manufactured from homogeneous TPE and is heat welded. Nuratech TPE Scuppers and Drains A range of TPE fabricated drains and scuppers are stocked by Nuralite. These accessories are made of the same TPE resin as the membrane itself so they can be completely welded together. Premshield Flashing Tape A bituminous self-adhesive waterproofing tape protected by a metal film in aluminium reinforced with a polyester film. The adhesive bituminous compound is protected, until use, by a silicone release film v3 Page 11

12 SUBSTRATE READINESS Many poor jobs are found to result from membranes being laid on top of a badly constructed substrate. Before you start work laying all Nuralite systems, you must ensure that the substrate is ready. It is better to sort out any issues up front rather than debating the matter latter when things have gone wrong. Being a thin membrane, any problems with the substrate will be clearly visible through the finished product. The substrate finish must be of the highest standard before commencing work. REMEMBER: ONCE YOU START WORK YOU HAVE ACCEPTED THE SURFACE! Minimum Falls 1:30/2 for roofs 1:40/1.5 for decks 1:100/0.5 for gutters (Seek better than minimum falls if possible) DECK SURFACE PLYWOOD a. The top surface of the plywood should be sanded and plugged, to a minimum standard of C. b. Plywood substrate must be 17mm thick for roofs, 20mm thick for decks, and must be treated (CCA) H3.2 grade. Do not use LOSP-treated (light organic solvent preservative) or CuN treated (copper nitrate) plywood. c. Roofs and decks must be supported at 400mm centre maximum (including noggins & rafters), plywood sheets must be laid across supports and joints staggered (brick pattern), unless otherwise specified. d. Sheets must be glued and then fixed with Grade 316 Stainless Steel 10 gauge countersunk screws. Screw edges every 150mm} about 20mm from the edges Screw centres every 200mm} throughout the plywood sheet e. Confirm the sheets are be dry to the touch and check sheet edges show no signs of moisture having been absorbed. DECK SURFACE CONCRETE a. Minimum cure 28 days. Curing membranes removed. b. Edges arrised, drainage outflows rebated. c. Surface clean and dry. Dryness demonstrated by leaving a rubber mat on the concrete in sunlight for one hour and then checking for condensation. DECK SURFACE ENERTHERM a. Ensure there are no gaps between sheets or around penetrations b. Tape all the joints between the sheets using 50mm aluminium tape. c. Enertherm 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) v3 Page 12

13 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: Date: 2012 v3 Page 13

14 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: Date: 2012 v3 Page 14

15 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: Date: 2012 v3 Page 15

16 INSTALLING THE NURATECH Substrate Material? Plywood or Enertherm Concrete or existing Nuralite or Nuraply sheets Project Type? Standard Residential or Commercial Large simple Commercial or Green/Recyclable NURABOND TPE CONTACT ADHESIVE MECHANICALLY FASTEN NURABOND LOW FOAM PU ADHESIVE NURATECH TPE SM NURATECH TPE SM NURATECH TPE SG 2012 v3 Page 16

17 ADHERING NURATECH SM When the Nuratech SM membrane is to be adhered to the substrate the Nurabond TPE Contact Adhesive is used. Ensure the substrate is solvent resistant, absorbent, dry and free from oil and grease. Ensure the ambient air temperature is above 5 C. When using Enertherm insulation board as a substrate ensure that the longest dimension is fully supported and attach the thermal insulation boards to the deck in accordance with Nuralite s recommendations. Ensure that all Enertherm insulation boards are laid with staggered joints and the boards are clear from debris. Ensure that all board joints are sealed with a self-adhesive foil faced aluminium tape. lf adhering over plywood etc ensure all deck fasteners are flush with the deck surface. Adhesive Installation Guidelines 1. Before use, thoroughly stir the Nurabond Contact Adhesive. Replace the container lid when work is interrupted. 2. Confirm the adhesive is in good condition by stirring it and checking the smooth viscosity of the product as it drains off the stirrer. 3. Using a sheepskin roller apply a primer coat of Nurabond Contact Adhesive to the prepared substrate surface, priming only the area of substrate where the membrane will be laid the same day. Allow adhesive to dry. If the substrate is PIR insulation then all the board joints are to be taped using self-adhesive foil faced tape prior to the primer coat is applied. 4. Unroll the Nuratech SM over the primed substrate and fold back approximately half its length. 5. Apply Nurabond Contact Adhesive with a sheepskin or similar roller to the underside of the Nuratech SM membrane ensuring the weld area is kept free of adhesive and allow to become tacky. 6. Carefully roll out the Nuratech SM over the previously primed surface and roll with water filled roller or soft broom. 7. Fold back other half of the roll of Nuratech SM and repeat the procedure. 8. Unroll the next roll of Nuratech SM, ensuring the end laps are staggered and the side overlaps the previously installed sheet by 50mm. 9. Repeat the adhering process. 10. Fully hot air weld the 80mm side lap, allow to cool completely. 11. Mechanically check the integrity of the cooled weld by running a 4mm wide screwdriver (with rounded edges) along the seam applying pressure into the seam. lmportant Notes Nurabond contact adhesive must only be applied to 100% dry substrates. Failure to do so could result in the membrane disbonding. Ensure that membrane and Insulation is stored correctly prior to use and that all substrates are completely dry prior to adhering to them v3 Page 17

18 Do not allow the adhesive to get wet when still in the tin, as this will render the adhesive useless. Only lay insulation that can be covered that day. Flat bars should be installed around all perimeter and internal upstands at the end of each day. MECHANICALLY FASTENED ROOFING SYSTEM 1. Carefully unroll the Nuratech SM out over the previously prepared substrate. If installing on a profiled metal deck ensure that the membrane is perpendicular to the direction of the deck sheet. 2. Allow membrane to relax prior to installing fixings (approx 10 mins depending on ambient temperature). 3. Install the IKOfix fasteners, using an appropriate installation tool 30mm from the rear edge. Fasteners must be installed at the fixing centres specified by NURALITE for the specific project. Nuralite should always be consulted as to the number, type and layout of the fixings. Ensure that the appropriate fastener is used with the deck. lf installing a mechanically fastened system over an existing deck, then a pull out test will be required to establish the suitability and amount of fasteners to be used. Torque clutches must always be used when installing fasteners to ensure that the fasteners are installed to the correct torque and not over tightened. 4. Unroll the next roll of Nuratech SM ensuring the end laps are staggered and the side overlaps the previously installed sheet by 110mm. 5. Mechanically check the integrity of the cooled weld by running a 4mm wide screwdriver (with rounded edges) along the seam applying pressure into the seam. 6. In corners and other areas where additional fastening is required install IKOfix fasteners through the roof sheet and cover with a 200mm wide strip of Nuratech SM. Hot air weld both sides and ends. 7. At upstands and at all roof penetrations secure the Nuratech SM membrane with a toothed bar. 8. Cover 10mm gap in the toothed bars with a 50mm x 50mm piece of Nuratech SM and weld to the roof sheet. 9. Waterproof the toothed bar with the upstand flashing hot air welded to the roof sheet v3 Page 18

19 Due to the nature of the SM membrane when being mechanically fastened it is not uncommon, especially during warmer periods, for the membrane to expand and ripple directly after being installed. The membrane expansion and rippling effect can be reduced during warm weather by following these guidelines: Position the membrane and mechanically fasten one end on both sides of the sheet. Pull the sheet taught from the other end and mechanically fasten the sheet on both sides. Once taught install the remainder of the fasteners. Once the membrane has been installed ensure that all membrane seams are welded, this will help with the membrane settling process. By the end of each day install all perimeter and internal toothed flat bars. Ultimately, the membrane will begin to settle and tighten up resulting in a smooth ripple free appearance. The rippling will have no detrimental effect on the performance of the membrane or affect the Nuratech product warranty. Depending on the wind uplift loads at the perimeter of the roof or the deck table intermediate rows of fasteners may be required by Nuralite. The Nuratech SM System provides two options for dealing with this scenario: 1" Option Install a row of IKOFix fasteners through the centre of the SM sheet at the required fixing centres. Once installed cover the row of fasteners with a 200mm wide cover strip that is then welded both sides to the field sheet. 2" Option Use a 1m wide sheet of SM fastened with the IKOFix fasteners at the required centres v3 Page 19

20 PU ADHERED ROOFING SYSTEM 1. Before use thoroughly stir the Nurabond PU Adhesive. Replace the container lid when work is interrupted. If required warm the Nurabond PU adhesive in warm water. Confirm the adhesive is in good condition by stirring it and checking the smooth viscosity of the product as it drains off the stirrer. 2. Allow membrane to relax prior to installing fixings (approx 10 min depending on ambient temperature). 3. Unroll the Nuratech over the prepared substrate and fold back approximately half its length. 4. Using a sheepskin or similar roller apply a coat of Nurabond PU to the substrate surface, coating only the area of roof where the membrane will be laid. The PU adhesive must be given time to activate prior to applying the membrane. On activation i.e. the point at which the adhesive will afford the highest bond strength, the surface of the adhesive starts to change from pink to opaque. The maximum adhesive exposure time is 15 minutes. Do not apply more adhesive than can be covered in this time; The membrane must be applied before surface curing or skinning of the adhesive has started. Applying the adhesive from the central area of the sheet out towards the edge of the sheet will help to avoid contamination of the side lap with adhesive. Any adhesive spillage on the seam area must be cleaned off immediately, as failure to do so will result in a poor quality seam weld. This adhesive is not suitable for sealing lap joints. Lap joints should be welded with hot air. 5. Carefully roll the Nuratech into the coated surface and roll with water filled roller or soft bristled broom. 6. Fold back other half of the roll of Nuratech and repeat the procedure. 7. Unroll the next roll of Nuratech ensuring the end laps are staggered and the side overlaps the previously installed sheet by 50mm. 8. Repeat the adhering process. 9. Fully hot air weld the 50mm side lap and allow to cool completely. 10. The butt-jointed end laps are covered with a 200mm minimum wide strip of Nuratech SM membrane. Laid equidistant over the joint, the perimeter of this strip should be hot air welded into position. 11. Mechanically check the integrity of the cooled weld by running a 4mm wide screwdriver (with rounded edges) along the seam applying pressure into the seam v3 Page 20

21 Due to the nature of the SG membrane when being adhered it is not uncommon, especially during warmer periods, for the membrane to expand and ripple directly after being adhered. The membrane expansion and rippling effect can be reduced during warm weather by following these guidelines: Once applied spray the PU adhesive with fine water mist which accelerates the curing period. This ensures that the membrane adheres quicker and reduces the rippling effect. Once the membrane has been installed ensure that all membrane seams are welded, this will help with the membrane settling process. By the end of each day install all perimeter and internal flat bars. Ultimately, the membrane will begin to settle and tighten up resulting in a smooth ripple free appearance. The rippling will have no detrimental effect on the performance of the membrane nor affect the Nuratech Product warranty. Coverage Rates for Nurabond PU Adhesive Nurabond PU Adhesive consumption is dependant upon a number of factors including ambient temperature and the smoothness of the substrate but will generally range between g/m2. At 20 C, onto a smooth substrate e.g. plywood, the adhesive coverage rate is approximately 150g/m2 i.e. one 15kg tin is sufficient to bond 100m2 of membrane. At 20 C, onto a medium textured surface e.g. sand surfaced bituminous membrane, the adhesive coverage rate is approximately 300g/m2 i.e. one 15kg tin is sufficient to bond 50m2 of membrane. At 20 C, onto a rough textured surface e.g. mineral surfaced bituminous membrane, the adhesive coverage rate is approximately 500g/m2 i.e. one 15kg tin is sufficient to bond 30m2 of membrane. Nurabond PU Adhesive sets within 6 hours and the minimum application temperature is +5 C. Below this temperature, the viscosity of the adhesive increases making it more difficult to apply and therefore greatly increasing consumption. In addition the adhesive activation time, i.e. the time between having applied the adhesive and laying the membrane will also increase, resulting in far slower membrane application speeds. The adhesive cures through a reaction with moisture in the air and as such the relative humidity should be minimum 30%. In hot summer conditions, when the relative humidity is below 30%, it will be necessary to lightly moisten the substrate with a fine spray of water prior to applying the adhesive v3 Page 21

22 JOINTS AND INSTALLATION PEEL TESTS 1. Optimum welding quality can be ensured by Test weld prior to actual welding. Seam check during welding. Seam check after welding. Before welding the membrane a peel test must be carried out to determine the optimum welding parameters for that day. Subsequent test welds should be carried out if outside temperature dramatically changes. Peel tests should be performed for each piece of hot air welding equipment used. 2. Peel test across the seam The fully cooled welded seam must not separate within the final weld zone. 20mm wide strips are cut across the welded seam and care is to be taken to only cut the top layer. When machine welding the test weld must not separate within the whole width of the weld. 3. Peel test along the seam The fully cooled welded seam is tested by pulling the top layer of the seam. This will also establish if a continuous weld has been achieved in the final weld zone v3 Page 22

23 HAND WELDING NURATECH TPE - INSTALLATION MANUAL When hot air welding Nuratech the overlap should be clean and dry. The following minimum system overlaps are required. Adhered 60mm, Mechanically Fastened 120mm TACK WELD The tack weld prevents movement of the overlap. PREWELD The preweld acts as a continuous air trap, ensuring minimal heat loss during the final weld stage. Always roll the pressure roller fully across the seam. A distance of 20mm should be kept between the roller and nozzle. Position the welding nozzle at the rear of the overlap allowing for a 30mm lap to remain once welded (see illustration). FINAL WELD The final weld ensures that the overlap is watertight. SEAM CHECK The seams are to be checked once they have completely cooled. Seams are checked using an approx 5mm wide probe with rounded edges called a "Seam Probe". A "Seam Probe" is used progressively by the NURATECH TPE applicator, to constantly test the fused and rolled NURATECH TPE lap joints, as the rolls are laid, tooled and detailed. A "Seam Probe" is also used for later site testing if required, by simply probing along lap joints, to locate any unfused points or "fishmouths" in the lap joints. A seam check is not a leak test but will help to identify weak welds. GENERAL INFORMATION ON WELDING NURATECH MEMBRANES Nuratech SM and SG can be welded at temperatures ranging from 200 C to 600 C. The appropriate temperature should be selected depending on individual speed preferences and ambient conditions. Nuratech D should be welded at temperatures between 200 C and 400 C, allowing for greater control when dealing with intricate or difficult details v3 Page 23

24 CROSS JOINTS NURATECH TPE - INSTALLATION MANUAL 1. Mitre the lower layer of overlap seam as illustrated. Round off corner to top overlap layer. Fully weld subsequent layers of membrane to fieldsheet. Note: Care should be taken at point of potential capillary (see illustration below) NURATECH UPSTAND RAILS 1. A 10mm clearance is needed between the bar ends due to expansion and contraction of the bar. 2. Cover the bar ends with a sacrificial piece of Nuratech. This will help protect the membrane flashing from sharp edges v3 Page 24

25 ADHERING UPSTANDS 1. A primer coat of Nurabond TPE Contact Adhesive is applied evenly with a brush or compatible application roller. The primed substrate must be allowed to dry fully before further coats or membrane is applied. When primer is dry apply a complete coat of Nurabond TPE Contact Adhesive. Note: Insulation boards will require their joints taped before starting. 2. Nurabond TPE Contact Adhesive is now applied to the back of the Nuratech membrane with a brush or compatible application roller. Residual adhesive should be removed. Care should be taken not to apply adhesive in areas of seam to be hot air welded. 3. When the solvent has evaporated, position the Nuratech membrane onto the prime substrate. The evaporation time will depend on the weather conditions, amount of adhesive applied and type of substrate being adhered to. An indication of when sufficient solvent has evaporated is by the finger test (see diagram). Adhesive strands should be approximately 10mm. 4. Once the membrane has been applied to the substrate surface must be rolled to ensure all air pockets are removed and that intimate contact is achieved between the membrane and substrate v3 Page 25

26 PIPE FLASHING NURATECH TPE - INSTALLATION MANUAL 1. Cut a hole in the Nuratech field membrane. This needs to be slightly larger than the pipe diameter. 2. Cut a hole in the Nuratech D base plate apron 10mm smaller than the pipe diameter. NB. The outer diameter should be large enough to cover any additional fasteners. 3. Pull the base plate apron over the top of the pipe. TIP: Warming up the inner hole with a hot air gun will help this process. 4. Once in position the base plate apron will create a 10mm upstand around the pipe. 5. Hot air weld the outer edge of the base plate apron to the field sheet. TIP: Welding temperature for Nuratech D should be approximately 220 C. 6. Cut out a pipe collar flashing to suit the pipe dimensions. A 20mm (min) vertical overlap and 15mm (min) horizontal overlap should be allowed for. It is advised to prepare the horizontal overlap prior to installation (as illustrated). Pre-bend the horizontal overlap using a silicone seam pressure roller v3 Page 26

27 7. Once prepared, position the pipe collar flashing around the pipe and tack weld into position. 8. Hot air weld the vertical pipe collar seam. 9. Hot air weld the horizontal seam to the apron base plate. 10. Completed detail Once completed, the top of the pipe is to be clamped with a mechanical restraint and sealed using Nuratech bond & seal mastic. Sealed surfaces should be primed prior to sealing with bond and seal activating cleaner v3 Page 27

28 RAINWATER OUTLETS 1. Position the outlet on top of the Nuratech membrane and mechanically fix through the membrane into the substrate using the appropriate fixings. On mechanically fastened systems additional fasteners and pressure plates may be required around the outlet. 2. A membrane flashing is required to ensure the waterproof integrity between the fieldsheet and the outlet. The membrane must be sufficiently sized to allow for a pre weld and final weld onto the field sheet (80mm min overlap). The welded areas are illustrated. 3. Once cut, position the rainwater outlet flashing. Allow the inner diameter hole to be 5mm (minimum) larger than the outlet opening (as illustrated). 4. Hand weld the membrane flashing to the Nuratech outlet. 5. Hand weld the membrane flashing to the fieldsheet v3 Page 28

29 PARAPET OUTLETS NURATECH TPE - INSTALLATION MANUAL Option A Two matching Nuratech D pieces should be cut as illustrated. One piece should be welded to the outlet first. Then the second piece can be positioned and welded to the outlet. Once this operation is completed the outer edge can be welded to the fieldsheet and upstand flashing. Option B Weld the two Nuratech D pieces to the outlet prior to installing it. Remember to leave the fixing points of the outlet free from weld and complete outer edge welding after the outlet has been installed. Once secured the Nuratech cloak can be welded to the fieldsheet and upstand membrane v3 Page 29

30 INTERNAL CORNER (HORIZONTAL FOLD) 1. Adhere Nuratech SM membrane into corner ensuring that the membrane is tight into all angles. TIP: 20mm nozzle advised. TIP: For corners that are not 90 degrees, allow for an oversized membrane flashing that can then be trimmed. Form internal fold as illustrated. 2. Form a 45 degree mitre and crease fold with a silicon roller. 3. Hot air weld the gusset TIP: Allow the gusset to completely cool before moving onto the next stage. 4. Weld lower flap to fieldsheet. 5. Hot air weld the remainder of the gusset. TIP: The critical weld is at the internal fold. 6. Complete the weld from the corner outwards v3 Page 30

31 INTERNAL CORNER (VERTICAL FOLD) 1. Cut and adhere into position the Nuratech SM membrane. Ensure that sufficient material is allowed for on the vertical corner return. (see illustration). If the corner is not square, allow for an oversized membrane flashing and trim back. Ensure membrane is tight into all angles. 2. Form a 45 degree mitre and crease fold with a silicone roller. Hot air weld the gusset. TIP: Allow the gusset to completely cool before moving onto next stage. 3. Hot air weld the Nuratech SM membrane flashing overlap to the adjacent flashing and fieldsheet. TIP: Work away from the internal angle. 4. Hot air weld the remainder of the gusset. TIP: The critical weld is at the internal fold. 5. Completed corner v3 Page 31

32 EXTERNAL CORNER NURATECH TPE - INSTALLATION MANUAL 1. Make a cut in the Nuratech SM membrane in line with the vertical corner. 2. Warm up the Nuratech SM membrane flashing along the vertical edge and dress the membrane around the corner, avoiding ripples. 3. Hot air weld the Nuratech SM membrane flashing overlap to the field sheet. 4. Prepare a corner patch from Nuratech D approx 20mm larger than the required dimensions. Round off the corner before tack welding into position v3 Page 32

33 5. Tack weld the rounded corner into position. Allow for a minimum of 20mm on the vertical surface. NOTE Hot air weld Nuratech D at approx 250 C. 6. Trim the corner patch in line with outer edge of the upstand flashing. 7. Hot air weld the top of the raised section of the corner patch to the upstand flashing. Now weld either side of the raised corner to the adjacent angle. TIP: Allow Nuratech D to cool fully before proceeding to next stage. 8. Hot air weld the remainder of the corner detail. 9. Completed detail. TIP: Care should be taken on the capillaries (see illustration) 2012 v3 Page 33

34 ROOFLIGHTS NURATECH TPE - INSTALLATION MANUAL 1. Adhere Nuratech D to the rooflight kerb using Nuratech Contact Adhesive. Confirm the membrane has bonded to the substrate before proceeding. Ensure that there is sufficient membrane overlap either side of the rooflight (see illustration). Cut out the corner as illustrated. Once trimmed allow for min 30mm extra membrane to return around rooflight corner. 2. Warm up the Nuratech D and adhere to the adjacent surface. Ensure that areas to be hot air welded are free from adhesive. 3. Ensure that there is sufficient membrane either side of the rooflight. Trim excess membrane and allow for a thumb sized tab of material in the base of the corner (as illustrated). 4. The corner is now ready for welding. TIP: It is advised that all four corners are prepared as outlined previously prior to welding. 5. Pre-weld the vertical and horizontal seam starting from the internal angle each time. The protruding thumb tab should be welded first v3 Page 34

35 6. The final weld can now be completed. Start the vertical and horizontal weld from the thumb tab. 7. Completed detail v3 Page 35

36 ROOF TRIMS NURATECH TPE - INSTALLATION MANUAL 1. Weld Nuratech SM membrane directly to Nuratech trim. Ensure membrane is positioned a minimum of 5mm from the outer edge of the trim. 2. Insert butt strap between joint of Nuratech trims. Leave a 10mm expansion gap between trims as illustrated. Trim Fixing Guide a. General trims on adhered upstands - fix at 250mm centres. b. Trims used as mechanical restraint - fix at 150mm centres. c. Trim used as part of a mechanically fixed upstand - fix at 150mm centres. d. Fixings should be staggered on wide horizontal surfaces. 3. Apply a 30mm strip of Premshield Flashing Tape over expansion gap. This will help to provide a clean line on the pre-weld. 4. A Nuratech D strip should be welded to the face of the trim. NOTE Welding temperature for Nuratech D should be approx 250 C. Face Fixing Guide 2012 v3 Page 36

37 a. 50mm - 90mm deep trims - 0.6mm butt strap plate needed. b. 90mm - 120mm deep trims - face fixed at each end. c. 120mm - 150mm deep trims - face fixed at one metre spacings. In the event that Face Fixing is not possible: a. If a suitable face fixing cannot be achieved then face fixings can be substituted for additional 0.6mm galvanised butt straps. b. 50mm - 90mm deep trims - each end and in the centre of the trim. c. 90mm deep trims - at 500mm spacings including each end. Trims protected from wind damage by guttering may not need additional face fixing. If in doubt please consult Nuralite Technical Services Department on +64 (09) Complete the remaining weld of the Nuratech D strap. 6. Complete butt strap detail. 7. Hot air weld the fieldsheet or upstand flashing directly to the trim. NOTE Care should be taken to ensure a capillary is not created when passing over the butt strap v3 Page 37

38 NURATECH ROOF TRIMS INTERNAL CORNER 1. Mark mitre on Nuratech metal and cut out excess to fit internal corner. TIP:: Ensure drip return is cut directly below fold point so that a straight corner can be formed. To ensure accuracy, transfer cutting point with a right angled straight edge. 2. Internal corner once cut. 3. Fold Nuratech roof trim to form corners and fix to substrate. 4. Cut and adhere Nuratech SM membrane to substrate. Ensure membrane is free from adhesive in the section to be welded to Nuratech trim. Once in position weld Sectraplan SM membrane to the trim and fieldsheet. TIP:: Before folding the membrane onto the horizontal surface of the parapet, heat up the Nuratech membrane at the point of the fold with the hot air welder. This will help to create a clean, neat edge v3 Page 38

39 5. Cut and position patch as illustrated using Nuratech D membrane only. 6. Hot air weld down the Nuratech D corner patch v3 Page 39

40 NURATECH ROOF TRIMS EXTERNAL CORNER 1. Mark a line on Nuratech metal and cut to fit external corner. TIP:: Ensure drip return is cut directly below fold point so that a straight corner can be formed. To ensure accuracy, transfer cutting point with a right angled straight edge. 2. Fold the Nuratech roof trim to form external corner and fix to substrate. Cover the remainder of the corner by inserting a section of Nuratech metal as illustrated. 3. Cut and adhere Nuratech SM membrane to the substrate. Ensure membrane is free from adhesive in section to be welded to Nuratech trim. Cut Nuratech D patch and weld into position as illustrated. To ensure coverage, cover cut edge of trim. 4. Weld one side of the Nuratech SM membrane to the Nuratech metal. Create a 45 degree fold in the Nuratech SM membrane. Hot air weld the pocket together and allow to fully cool before continuing. 5. Hot air weld the remaining side of Nuratech SM membrane to the Nuratech trim. Ensure mitred pocket is fully welded v3 Page 40

41 DAY JOINTS NURATECH TPE - INSTALLATION MANUAL Day joints help to protect from water ingress under incomplete areas roof. The day joints should be installed when work is either interrupted due to adverse weather or at the end of each working day. Nuralite would always recommend good roofing practice and promote that only areas that can be completed that day should be laid and that detail work is completed as roof progresses. The diagrams below show typical methods of sealing day joints v3 Page 41

42 PROJECT SIGN-OFF FORM 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 preapproved 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 v3 Page 42

43 Project Sign-off Form cont. Remedial action required: Note of damaged areas repaired: Signed: Date: 2012 v3 Page 43

44 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 long-term 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 v3 Page 44

45 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 2012 v3 Page 45