The Evolution of Roofing. Helene Hardy Pierce GAF

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1 The Evolution of Roofing Helene Hardy Pierce GAF 1

2 Discuss both low- and steep- pitch roof solutions for hot-humid climates and high-velocity hurricane zones, review evolution of roofing methods and materials, new vs. replacement roofs.

3 So let s talk about roofing membranes

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5 The Roofing System Membrane System Wind/Fire Traffic Bldg. Use Access Secondary Use Maintenance

6 Structural Deck Deck Ability to attach Moisture Movement Slope Movement relative to walls Air leakage

7 Insulation Insulation Number of layers Attachment Compatibility Fastener location Durability to traffic Coverboard or not Joints staggered

8 Membrane System Type Mechanically attached Hot asphalt Heat welding Fully adhered Membrane Number of layers Type Vapor Retarder Need Type Attachment Compatibility

9 Details

10 Critical to ANY Installation

11 Evolution WHERE DID WE COME FROM? 11

12 From Tar Pits to TPO BUR

13 Indians would use surface bitumen to waterproof

14 From 1896

15 Bitumen Pitch Asphalt Type I Type II Type III Type IV 2/12+ Rubberized Dead Level Applications Steep Slope Applications

16 Plies Type IV Fiberglass Type VI Fiberglass Fiberglass Reinforced Polyester Reinforced

17 NRCA Members CARE Sponsored by:

18 Surfacing Protection UV Degradation Roof Top Traffic Wind Damage Aggregate Mineral Surface (Granulated) Coating

19 BENEFITS Multi-ply Waterproofing Surfacing Options

20 BENEFITS Multi-ply Waterproofing Surfacing Options LIMITATIONS Labor Fumes Temperature

21 BENEFITS Multi-ply Waterproofing Surfacing Options LIMITATIONS Labor Fumes Temperature MISPERCEPTIONS Old Technology Not Energy Star/Reflective No Longer Available

22 From Tar Pits to TPO EPDM BUR

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24 EPDM Since 1960 s Went down quickly-large panels Very economical-gravel ballast More versatile-building movement Cleaner than BUR

25 BENEFITS Very Stable Membrane Large Sheet Size Taped Seams Perform Well LIMITATIONS MISPERCEPTIONS

26 BENEFITS Very Stable Membrane Large Sheet Size Taped Seams Perform Well LIMITATIONS Low Reflectivity Taped/Glued Seam vs. Heat Fused/Welded Single Ply MISPERCEPTIONS

27 BENEFITS Very Stable Membrane Large Sheet Size Taped Seams Perform Well LIMITATIONS Low Reflectivity Taped/Glued Seam vs. Heat Fused/Welded Single Ply MISPERCEPTIONS Most Are Ballasted Black Energy Efficient Not Puncture Resistant

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29 From Tar Pits to TPO PVC EPDM BUR

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31 PVC Introduced in early 1970 s Heat welded seams Highly reflective - white Very chemical resistant High fire resistance

32 BENEFITS Reflective Heat Welded Seams Chemical Resistance LIMITATIONS MISPERCEPTIONS

33 BENEFITS Reflective Heat Welded Seams Chemical Resistance LIMITATIONS Red Listed by some High Temperature Single Ply MISPERCEPTIONS

34 BENEFITS Reflective Heat Welded Seams Chemical Resistance LIMITATIONS Red Listed by some High Temperature Single Ply MISPERCEPTIONS Shatters Shrinkage Impact Resistance

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36 From Tar Pits to TPO PVC Modified Bitumen EPDM BUR

37 Polymer Modified Bitumen APP SBS Modified Bitumen

38 APP... Atactic Polypropylene Developed in Italy, introduced to US in late 70 s Excellent inherent flexibility and stability Heat ( Torch ) Applied

39 SBS... Styrene Butadiene Styrene Developed in Northern Europe Excellent flexibility and elongation characteristics Hot Applied Cold Applied Torch Applied Self Adhered Applied

40 BENEFITS Multi-ply High Abuse/Puncture Easy Repair/Maintenance LIMITATIONS MISPERCEPTIONS

41 BENEFITS Multi-ply High Abuse/Puncture Easy Repair/Maintenance LIMITATIONS Labor Open Flames (APP) Cost MISPERCEPTIONS

42 BENEFITS Multi-ply High Abuse/Puncture Easy Repair/Maintenance LIMITATIONS Labor Open Flames (APP) Cost MISPERCEPTIONS Old Technology Not Energy Star/Reflective Durability in High UV

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44 From Tar Pits to TPO EPDM PVC Modified Bitumen TPO BUR

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46 TPO Introduced in late 1980 s Heat welded seams Highly reflective - white Cost effective High UV/heat formulations

47 BENEFITS Reflective Heat Welded Seams Cost LIMITATIONS MISPERCEPTIONS

48 BENEFITS Reflective Heat Welded Seams Cost LIMITATIONS Chemicals Weather - Adhered Single Ply MISPERCEPTIONS

49 BENEFITS Reflective Heat Welded Seams Cost LIMITATIONS Chemicals Weather - Adhered Single Ply MISPERCEPTIONS Length on Market Performance Impact Resistance

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51 From Tar Pits to TPO EPDM PVC Modified Bitumen TPO BUR

52 Installation Evolution Primarily Single Ply Membranes

53 Not As Simple As a Few Years Ago Today 2000 Mechanically Attached Fully Adhered* Ballasted RhinoBond Attachment Self Adhered Ballasted Fully Adhered Mechanically Attached

54 Fully Adhered Mechanically Attached Ballasted Solvent Based Low VOC Water Based Low Rise Foam 2 Part RhinoBond System Self-Adhered Installation Methods

55 Mechanically Attached Cost effective Most common installation method No sprayers or additional capital investment No odors Up to 50% faster installation than fully adhered smooth membranes Membrane carries wind load Wide application temperature

56 Mechanically Attached Limitations/Considerations Deck type/holding power Insulation thickness Tapered insulation difficulty* Impact resistance Need for an air barrier Moisture Roof as a platform * Note: tapered with any mechanical attachment increases difficulty

57 Ballasted Low labor cost No sprayers or additional capital investment No odors Ballast provides wind resistance Minimal fastening required Ideal for very wide sheets High impact resistance

58 Ballasted Limitations/Considerations Deck type capacity for load Availability of quality ballast Leak detection Wind resistance code restrictions Roof as a platform

59 Fully Adhered Bonding Adhesive No sprayers or additional capital investment Excellent wind uplift performance Familiarity with workers Solvent, low VOC, and water based adhesives Uniform, smooth appearance Ability to bury fasteners

60 Fully Adhered Bonding Adhesive Limitations/Considerations VOC content of adhesive Weather limitations for both application AND storage Open time largest installation time Material costs Wet decks and adhesives don t play well

61 Fully Adhered Fleece-Back Laid in Wet Fast installation time low labor cost Excellent wind uplift performance Low odor/voc compliant No open cure times Uniform, smooth appearance Ability to bury fasteners Excellent impact resistance

62 Fully Adhered Fleece-Back Laid in Wet Limitations/Considerations Material costs Wet decks and adhesives don t play well Substrates Cure times

63 Fully Adhered Low Rise Foam & 2 Part Adhesives Fast installation time low labor cost Excellent wind uplift performance Low odor VOC compliant Uniform, smooth appearance Ability to bury fasteners Excellent impact resistance

64 Fully Adhered Low Rise Foam & 2 Part Adhesives Limitations/Considerations Depending on adhesive, equipment cost can be high Material costs Wet decks and adhesives don t play well Substrates

65 Rhinobond System Moderate material cost No open cure times No need for half sheets at perimeter and corners Less flutter than MA systems Less fatigue on fasteners Wide application temperature

66 Rhinobond System Limitations/Considerations Equipment cost (however, can increase speed with second machine) Deck type/holding power Tapered insulation difficulty Impact resistance Need for an air barrier? Moisture Roof as a platform

67 Self-Adhered No sprayers or additional capital investment Excellent wind uplift performance No odors/no adhesives No open cure times Ability to bury fasteners

68 Self-Adhered Limitations/Considerations Material cost Single layer of insulation Self-adhered lap vs. heat welded lap Aesthetics

69 Market Evolution

70 Technology Transition

71 Technology Transition digging a little deeper P&S

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73 REGARDLESS OF MEMBRANE, Still Need Good Bones!!!

74 Don t Forget the 20 Questions! Identify the poison pills Rule out what won t work Drill down to better options These questions should identify WHAT won t work, WHAT will work, and WHAT are the best options for the specific property and WHY, based on the needs of the building owner

75 Roofing System Checklist Cost Low labor cost Low capital investment Cost effective Speed of installation Performance High impact resistance Redundancy Wind resistance High reflectivity Fire slope System Traits Fully adhered Uniform appearance Ability to bury fasteners No open cure time VOC compliant Low or no flutter Low odor No open flames Wide application window Traffic resistant Maintainable

76 Roofing System Checklist Cost Low labor cost Low capital investment Cost effective Speed of installation Performance High impact resistance Redundancy Wind resistance High reflectivity Fire slope System Traits Fully adhered Uniform appearance Ability to bury fasteners No open cure time VOC compliant Low or no flutter Low odor No open flames Wide application window Traffic resistant Maintainable SE Specific Wind Ambient Conditions Energy Code Dirt/algae Pick-Up Phasing Deck Preferences Radiative Properties

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78 PART IV: Theory Is Nice But Let s Look at Reality

79 Real World Specifics New Construction Concrete Deck Iso Insulation What Comes to Mind What is concrete poured over? Concrete = Adhered Is the deck flat? What kind of concrete?

80 Probably Not Perhaps Better/Best Cost to fasten into concrete Time Tapered Insulation? Vapor Retarder - Access Owner Preference Wind Limitations Availability of Ballast Attachment Ease Wind Uplift Vapor Retarder + Think Water

81 Real World Specifics Existing Standing Seam Metal Deck Want to Add Insulation What Comes to Mind Attachment to what? Wind Performance Fire Performance This is NOT a traditional 22 gauge metal deck

82 Highlights Retrofit Over Metal Retrofit means existing metal building may well have been built with earlier/different strength limits Deflection limits for total load of L/60, whereas for membrane roofing deck deflection should be no more than L/240 (4 times less deflection allowed)

83 Highlights Retrofit Over Metal Retrofit means existing metal building may well have been built with earlier/different strength limits Deflection limits for total load of L/60, whereas for membrane roofing deck deflection should be no more than L/240 (4 times less deflection allowed) Most existing wind uplift ratings based on 22 gauge or thicker metal deck with 33 or 80 ksi yield strength FM 1-31 on Panel Roof Systems may be a good source of recommendations

84 (Probably) Not Perhaps Better Weight - ballasted Deflection for fully adhered Into secondary support structure Only with structural evaluation Only into secondary support structure Only with structural evaluation

85 Real World Specifics Metal Deck Replace due to Blow Off 85 Building Height What Comes to Mind Wind performance Parapet walls? Type of steel deck? Exposure C or D?

86 (Probably) Not It s all about wind performance Check out FM Data Sheets don t think you can get there! Best Solution Well attached insulation + fully adhered membrane

87 Real World Specifics Roof as a Platform Solar What Comes to Mind Type of solar system Roof area to be covered? Age of existing roof? Ability to perform maintenance? Impact resistance?

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89 So let s talk about steep slope roofing

90 Age of Roof at Time of Remodeling Project, Homeowner Survey n=559 90

91 The State of the Roofing Industry Top 5 complaint industry to the BBB Over 50% of contractors go out of business within 5 years Millions of dollars wasted Owners distrustful Some bad contractors

92 Tear Off Expose existing or potential problems Rotted decks Mold growth Damaged framing Missing underlayments Flashing system deteriorated

93 Components of a Steep Slope Roof 1. Shingles/seal tabs/4 or 6 nails 2. Underlayment 3. Self-adhered underlayment/ice dam protection 4. Starter strip/rake edge 5. Ventilation, balanced 6. Hip/ridge products 93

94 Leak Barriers

95 Leak Barriers

96 Ventilation Federal Housing Administration 1. 9/10 homes are not properly ventilated 2. 1/300 Net Free Ventilated Area Ratio 3. Ventilation System must be balanced

97 Inadequate Ventilation Mold High energy consumption Premature material wear Rotted decks

98 Ventilation Non Vented Outside 170 Rooftop Attic

99 Ventilation Vented Outside 170 Rooftop Attic

100 Ventilate for Longevity For every 10C increase, activation energy doubles. (Arrhenius Equation) 100

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103 Georgia Tech Ridge and soffit vents are best ventilation source US Dept. Of Housing Proper venting prevents ice dams Plywood Associations Proper ventilation is required for decking Shingle Manufacturers Ventilation is required for warranties

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109 Asphalt Shingles

110 Today s Asphalt Shingles Wide Range of Styles and Colors Affordable Easy to Maintain Lightweight Easy to Install Title 24 Options/Cool Roofing Options

111 Asphalt Shingles Historically Speaking Laminate Shingles Strip Shingles 80% 80+%

112 Asphalt Shingles Regardless of Style or Color Shed Water Fire Resistant Durable Wind Resistant Code Compliant

113 Wind Testing Can Be Either D7158 or D3161 Comparison of ASTM D7158 and ASTM D3161: Wind speed ASTM D7158 ASTM D mph -- Class A 90 mph Class D Class D 110 mph -- Class F 120 mph Class G mph Class H --

114 Documentation of Code Compliance Third-party certification:

115 Wind Driven Rain Test Summary Florida Building Code Test Protocol TAS- 100 Minimum slope specified by the manufacturer No water infiltration through the sheathing; no blow-off/tear-off or release of the shingle or portion thereof

116 Wind Driven Rain Test Summary 15 min wind/water 10 min off 35, 70, 90, & 110 mph 8 /hour rain event

117 Wind Driven Rain Test

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122 Questions? Thank you for your time and attention!

123 THANK YOU! Contact: