Master Contract Specificationscoated Foamed Roofing 07 57 00

MASTER CONTRACT SPECIFICATIONSCOATED FOAMED ROOFING 07 57 00

PART 1 GENERAL

1.01SUMMARY:

A. RELATED DOCUMENTS:General provisions of contract, plans, details and scope of work as supplied by roofing system manufacturer.

1. DESCRIPTION OF WORK:

1. This specification covers the silicone roofing system which consists of a seamless sprayed-in-place urethane foam insulation covered with a silicone coating and a layer of ceramic granules for use as an insulated roofing system for both new construction and retrofit roofing.

2. The roofing system shall be installed in accordance with the roofing system manufacturer's requirements, local building codes, and FMGlobal's requirements for a Class 1 roof as though they were a part of this specification.

C.OTHER WORK THIS SECTION INCLUDES:

1.Preparation of Substrate.

2.Sprayed-in-place Polyurethane Foam (SPF) Insulation.

3.Silicone Roof Coating.

4.Roofing Granules.

5.Walkways.

1.02SUBMITTALS:

A.Specification Development - The owner/specifier shall supply to the roofing system manufacturer’s representative:

1.A draft copy of the project specification, including the roofing section, roofing warranty requirements, and roofing drawings. This shall be completed before project goes out to bid.

2.This draft specification shall be reviewed for general technical acceptance and eligibility for issuance of a warranty. A letter confirming an appropriate application, drawings and specification, based on the current available information, will be delivered to the owner’s representative at their request.

B.Any alternate products shall be submitted to the owner and/or owner’s representative 10 days before bid date to allow time for product review. Submittals shall include: all appropriate technical data sheets, manufacturer’s references, warranty, follow-up inspection policy and outline, material safety data sheets, and a typical, physical sample (3' x 3') to be used as a standard of quality. Manufacturer shall supply list of geographically appropriate work and list of work of similar size and scope to substantiate their period of performance, see 2:02A.1.

C.Applicator shall submit to owner’s representative at or before time of bid:

1.Reference projects with contacts, substantiating years of experience and completion of minimum prior work submitted by applicator.

2.Provide specimen copy of warranty.

3.Submit Underwriters Laboratory, UL 790 Class A, FMGlobal, and local building code approvals as required.

1.03QUALITY ASSURANCE:

A.APPLICATOR QUALIFICATIONS: Must be a current Approved Applicator for the selected roofing system manufacturer. The Applicator must exhibit 5 years and a minimum of 500,000 sq. ft. experience with the roofing systemand projects of a similar scope and nature. If requested, the Qualified Applicator must furnish the roofing system manufacturer’s Qualified Applicator’s Certificate or other evidence showing him/her to be a Qualified Applicator. The roofing applicator shall perform all the work of this section. Subcontracting installation of the silicone coating/polyurethane foam is not allowed.

B.INSPECTIONS: It is the Qualified Applicator’s responsibility to inspect the roof prior to the start of the application to determine what preparation steps are necessary. The preparation steps may include, but are not limited to the following:

1.Removal of wet insulation or felts,

2.Removal of loose gravel,

3.Sand blasting, priming, and repair of flashing,

4.Expansion joints and drain details, and

5.The general condition of the roof and the steps required to prepare the roof prior to the start of the application. The roofing system manufacturer will review the Job Approval form.

C.A PRE-BID CONFERENCE: Shall be conducted one week before bid date. Its purpose shall be to discuss any details of the project not adequately covered within the specification; to allow bidding applicators a period of access to the roof areas; and to review the normal flow of activities at the facility. There will be no other access to the roof area without the consent of the owner's representative. All bidding applicators must attend this Pre-Bid Conference. A list of those companies present will be recorded.

D.INSURANCE CERTIFICATION: Assist Owner in preparation and submittal of whatever roof installation acceptance certification may be necessary in connection with fire and extended coverage insurance on roofing and associated work. Installation must comply with FMGlobal Class 1 requirements and 1-60 or 1-90 requirements as applicable.

E.PREROOFING CONFERENCE: Prior to installation of roofing and associated work, meet at project site with general contractor; installer and his project foreman and safety representative; roofing system manufacturer; installers of related work; Architect; and JCPenney representative. Record discussions and agreements and furnish copy to each participant.

F.EQUIPMENT: The equipment for the application of the foam shall be as recommended and approved by the polyurethane foam component manufacturer. The equipment for the application of the silicone coating shall consist of an airless spray unit recommended or approved by the silicone coating manufacturer or rollers or power rollers which may be used for one component product.

G.COMPLETED INSPECTIONS: Completed roofing application will be inspected by an independent inspection firm designated by the warranty provider on a periodic basis.

1.04PROJECT / ENVIRONMENTAL CONDITIONS:

A.Proceed with roofing work only when existing and forecasted weather conditions will permit work to be performed in accordance with manufacturer's recommendations and warranty requirements.

B.The following minimum weather conditions must be present at the beginning of the application. If weather conditions change during the application and the stated conditions are not met the application must be stopped until such time as all the specified conditions are met. No application may proceed during inclement weather (rain, snow, fog, mist).

1.For Foam Application

a.The substrate must be free of ice, frost, surface moisture or visible dampness.

b.The substrate and ambient air temperatures must be 50°F or higher.

c.The relative humidity must be low enough to permit the production of foam with good cell structure. A relative humidity of 80% or lower is preferred. The ambient temperature must not be within 6 degrees of the dew point at time of SPF application.

d.When wind speeds exceed 10 miles per hour or adversely affects the quality of the SPF, windscreens shall be used during the application of the polyurethane foam to prevent overspray onto surfaces not intended to receive foam. Under no circumstances shall the polyurethane foam be applied when wind speeds exceed 25 miles per hour.

1. For Silicone Coating Application

a.The foam must be free of ice, frost, surface moisture or visible dampness.

b.The air temperature must be 50°F or higher.

c.The wind velocity must be 15 mph or lower unless a suitable windscreen is used.

d.When wind speeds exceed 10 miles per hour or adversely affects the quality of the SPF, windscreens shall be used during the application of the silicone coating to prevent overspray onto surfaces not intended to receive coating. Under no circumstances shall the silicone coating be applied when wind speeds exceed 25 miles per hour.

1.05DELIVERY, STORAGE AND HANDLING:

1. Deliver materials to the site in their original, tightly sealed containers, all clearly labeled with manufacturer's name, product identification, safety information, and batch or lot numbers where applicable. Provide labeled materials which have been tested and listed by UL for application indicated, for "Class A" rated material/system, for noncombustible decks.

1. Safely store materials in their original containers out of the weather and where the temperatures are within the limits specified by the manufacturer.

1. All materials shall be stored in compliance with applicable fire and safety requirements.

1. Protect materials from damage during transit, handling, storage and installation. Applicator shall provide secure site storage trailers.

1.06WARRANTY:

A.The SPF Roof System manufacturer's 15-Year Full System Warranty shall be issued upon completion, inspection and acceptance of the project. Any repairs covered by the warranty are without cost to the Owner throughout the term. The warranty shall be comprehensive with no proration and no cap for repairs.

B.The warranty agreement must be presented to the owner or his/her authorized representative for review and signature prior to the start of any work. The signed warranty agreement should then be forwarded to and approved by the roofing system manufacturer prior to the start of the application.

1.07SEQUENCING AND SCHEDULING:

A.All preparation work such as gravel removal, and blasting, priming, vacuuming, etc., must be completed in the areas adjacent to and within 100 feet of the planned foaming and coating application.

1. The spray polyurethane foam shall be installed when the deck, parapet walls, rough openings, and curbs are completed. The type of skylights used will determine when skylights should be installed. Plumbing vents, drains, and electrical penetrations should all be in place.

1. There should not be any trades-people working on the roof when the spray polyurethane foam and silicone coating are being installed.

1. The work should be planned in order to adhere to the following maximum and minimum time intervals between application steps.

APPLICATION STEP / MIN. INTERVAL / MAX. INTERVAL / SUGGESTED INTERVAL
Between foam & Silicone Base Coat / 1 hour / 24 hours / Same day
Between Silicone Base & Top Coat / 1hour / 48 hours / Same or next day
Between Silicone Top Coat & Granules / - / 5 minutes / Immediately

PART 2 - PRODUCTS

2.01GENERAL: Subject to product compliance, provide one of the following seamless roofing systems.

A.BASF: BASF Elastospray 81305 Series Sprayed-in-place Polyurethane Foam (SPF) Insulation / BASF

S-5000 Silicone Roof Coating

B.General Electric Company/Resin Technology Company: Resin Technology Company Sprayed-in-place Polyurethane Foam (SPF) Insulation / GE Silicones SCM-3400 Silicone Roof Coating.

C. BASF/Foam Enterprises, Inc. / Premium Foam PF-241 Series or FE–303 Series Sprayed-in-place Polyurethane Foam (SPF) Insulation / FE- Coat 3000 Series Silicone Roof Coating.

2.02SUBSTRATE PRIMER:

A.Gypsum board – if kept clean, with little dust, will not require a primer.

B.For B.U.R., concrete, wood, brick, metal (ferrous, not rusted) - option - to be selected by Specifier. The primer must be as approved by the roofing system manufacturer.

C.For non-ferrous metals (cleaned aluminum, galvanized copper, etc) - a primer shall be required, as approved by the roofing system manufacturer.

D.Cut-back asphalt primers are not to be used.

2.03POLYURETHANE FOAM INSULATION:

A.Insulation: The choice of foam to be used shall be based on application conditions (deck and air temperature), the type of substrate, and must be approved for use in a warranted roof system by the warranty provider.

B.Actual thickness of insulation shall be such that the coefficient of transmission of the insulation only, excluding roofing and ceiling construction, shall be as shown in the table below. The aged "R" value shall be determined in accordance with ASTM 1289-02. The number of degree days shall be as listed in the latest edition of the National Climatic Data. If location is not listed, use closest listed location.

Greater than 6000 degree days / 6000 degree days or less
u=.05 (6 month conditioned R=20) / u=.07 (6 month conditioned R=14.3)
16.6 LTTR / 12.1 LTTR

C.The cured sprayed-in-place polyurethane foam shall have the following properties:

PROPERTY / VALUE / TEST METHOD
Density, pcf, min / 3.0 / ASTM D-1622
Compressive strength, psi / 50 / ASTM D-1621
Closed-cell content, percent, min / 95 / ASTM D-2856
K-factor, aged, max / 0.16 / ASTM C-518
Dimensional Stability, 28 days,
158°F, 100% R.H., percent volume change, max / +8% / ASTM D-2126
Flame spread, max / 75 / ASTM E-84

2.04SILICONE COATINGS:

A.The silicone roofing membrane shall consist of a minimum two coats of an elastomeric, liquid applied material, domestically engineered and produced. The two coats shall be of contrasting colors. The minimum two-coat thickness shall be 25 dry mils. Membrane shall be manufacturer's white color, unless noted otherwise in the contract documents.

1.The silicone coating will be a product proven through actual roof performance for a period of time equal to, or longer, than the term of the requested warranty.

2.The manufacturer shall have an established program to rapidly respond to any required warranty repair, if the original applicator is unable to perform standard repairs.

1. The coating shall have the following minimum properties:

PROPERTY / VALUE / TEST METHOD
AS SUPPLIED:
Solids Content
by weight, percent / 77 / ASTM D-2697
by volume, percent / 62 / ASTM D-2697
Specific Gravity at 77°F (25°C) / 1.23 / ASTM D-1293
Flash Point, Pensky-Martin, closed cup, °F °C, min. / 100 (37.8)
Tack-Free Time, hours / 1
Dry Time, hours / 3.5 / ASTM D-115
Volatile Organic Content (VOC, g/l) / 290 / ASTM D-3960/EPA Method 24
AS CURED:
Durometer Hardness, Shore A,points / 45 / ASTM D-2240
Tensile Strength, die C, psi / 400 / ASTM D-412
Elongation, percent / 150 / ASTM D-412
Permeability1, perms / 3.7 / ASTM E-96
Water Absorption, percent / 0.5 / ASTM D-471
TemperatureStabilityRange, °F(C°) / -35 to 302°
(-37 to 150)
Weatherometer,
Carbon-Arc, 4,000 hours / Not observable
QUV, 10,000 hours / degradation

20 mils at 100°F (37.8°C) and 90 percent relative humidity.

2.05GRANULES:

1. Granules shall be number 11 screen size, ceramic-coated roofing granules, as approved by roofing system manufacturer. Color to best match topcoat. Quartz or silica aggregate such as #2 unground silica may be used as an acceptable alternative. This product will have natural color variations, color should be selected to match topcoat.

1. The use of granules is required for all applications unless an exemption is approved by the roofing system manufacturer.

2.06SEALANT: If silicone sealants or caulking are required for detail work or to seal the surface after samples are taken, shall be as approved by the roofing system manufacturer. The color of this sealant, if exposed, shall closely match that of the topcoat.

2.07PROTECTIVE COVERING / WALKWAYS: Weather-resistant, breathable, resilient pad composed of synthetic rubber strands shall be installed to create additionally protected roof areas. This product shall be as approved by the roofing system manufacturer.

2.08ACCESSORIES AND MISCELLANEOUS MATERIALS:

A.All accessories and miscellaneous materials, such as but not limited to, flashings, drain flashings, flashing accessories, primers, sealants, etc must be compatible with the silicone and foam materials and shall be as approved by the roofing system manufacturer. Accessories made of polyethylene and polypropylene should not be used.

B.For products requiring the use of a primer for maximum bonding, consult the roofing system manufacturer for recommendation regarding compatibility.

C.BOARD STOCK: Only types of boardstock approved by the roofing system manufacturer shall be used. When boardstock is used, it may be necessary to install an asphalt base sheet before application of the foam. See the roofing system manufacturer for requirements.

D.When required, asphaltic base sheets shall be 43-pound asphalt saturated and coated organic base sheet. Lighter base sheets must not be used.

D.ISO BOARD: Shall be a closed-cell, polyisocyanurate foam core integrally laminated to heavy, black (non-asphaltic) glass fiber reinforced felt facers, as approved by the roofing system manufacturer. Expanded polystyrene boardstock should not be used under any circumstances.

E.MEMBRANE FASTENERS: STEEL DECK: Corrosionresistant, self-tapping, self-drilling screw with low profile head and corrosionresistant, factorymade plate as approved by roofing system manufacturer.

1.Screw and plate type fastener to be FMGlobal approved.

2.Fasteners to be of sufficient length to penetrate top flange of deck by 3/4".

F.NAILERS: Nailers are to be #2, or better, and pressure treated with a salt preservative. Wolmanized treatment is approved. Asphaltic or creosote preservatives not permitted.

PART 3 – EXECUTION

3.01INSPECTION:

A.Verify all surfaces to receive polyurethane foam insulation are clean, dry and free of dust, dirt, debris, oil, solvents and all materials that may adversely affect the adhesion of the polyurethane foam.

B.Verify all roof penetrations and flashings are properly installed and secured. The metal roof deck shall be securely fastened. The existing fasteners may need to be tightened and/or new fasteners shall be required.

C.Do not begin applying polyurethane foam insulation until substrate and environmental conditions are satisfactory.

3.02SURFACE PREPARATION:

A.Built-Up Roof Membrane

1.Remove all loose and poorly imbedded aggregate surfacing material, if present, by use of a wet vacuum, power broom, hand broom, power vacuum, and/or other suitable means. Do not accumulate large amounts of aggregate surfacing material in one location that may overload the roof deck structure.

2.Remove all wet insulation under existing built-up roof membrane. Clean and dry the area and install new similar compatible insulation, or apply polyurethane foam insulation to the level of the adjacent existing membrane.

3.Repair all built-up roof membrane defects, such as blisters, ridges, splits, punctures and felt delaminations, by cutting, removing, nailing or properly adhering to form a solid substrate. BUR repairs shall be made using hot process BUR or modified bitumen products, cut-back products shall not be used. Make sure the adjoining roof materials around these defects are dry.

4.Remove all loose stones, dust, dirt, debris and other contaminants from the built-up roof membrane that may impair the adhesion of the polyurethane foam.

5.Primer: Install primer per roofing system manufacturer's recommendations. Make sure all surfaces are clean and dry prior to primer and/or polyurethane foam application.

B.Metal Decks

1.The metal roof deck should be a minimum of 22-gauge and be securely installed to conform to local building code requirements. Deflections shall not exceed 1/240 of the span.

2.Remove any loose scale, rust and weathered or chalking paint using a wire brush, scraper, sand blasting or other suitable means. Prime if necessary and as recommended.

3.Remove all dust, dirt and debris using air, a hand or power broom and/or a power washer. Other contaminants such as oil and grease must be removed with appropriate cleaning solution, and rinsed with clean water. (New metal will have a thin film of milling oil on it, which must be removed.)

4.Fluted metal roof decks should be covered with a polyester tape securely adhered to the metal deck over the flutes, or by mechanically fastened gypsum, urethane, perlite or fiberglass board per FMGlobal recommendations for local wind uplift resistance. The boards shall be firmly butted together along all edges. Any joints greater than ¼ inch shall be taped prior to foam application.

5.Factory painted metal surfaces will not normally require an additional application of primer.