SECTION 07570

SWD Urethane Company

COATED FOAM ROOFING SYSTEM

Part 1 GENERAL

SUMMARY

 

Section Includes: Coated foam roofing, as shown on drawings and specified herein.

 

1.01  SYSTEM DESCRIPTION:

 

  1. Roofing System shall be UL-790 (ASTM E-108) Class A and conform to UBC Sections 1501-1510 and UBC Code Standard 15-2. System shall meet UL-1256 Construction Methods #136, #I81 and #206. Roofing System shall meet UL-1897 Standard for Wind Uplift and UL-2218 Standard Impact Resistance. Roofing System shall meet required ICC Revised AC-12/ASTM C-1029/ASTM D-6083 approval criteria, and/or, FM Global approval standards, and "Energy Star" Guidelines and CRRC Requirements.
  2. SWD “Quik-Shield®”/"Ever-Gard" Roofing System shall be Class B over Combustible Deck and conform to ASTM Test Standards, ICC and UBC Requirements.
  3. 1. 10 Year Warranty System

                                              a.     One inch (minimum) of sprayed Polyurethane Foam (additional inches may be added and /or sloped depending upon desired insulation value) on the deck surface with 25 mil thickness of white, reflective 100% acrylic roof coating with #9 white limestone granules or #11 ceramic granules imbedded into or on top of the wet coating at (50) pounds per 100 square feet. The roof system will provide a 10-year, no-leak warranty.

                                             b.     Low cost sustainable foam roof system is easily maintained, repaired and upon inspection, may be re-coated with elastomeric protective coating after 10 years.

 

1.02  SUBMTTTALS

 

  1. Product Data: Submit manufacturer's material specifications, installation instructions and evidence of UL, ICC, CRRC, California Title 24, "Energy Star" and/or FM ratings for roofing system.
  2. Provide specimen copy of the applicable warranty for this project, as specified herein.
  3. Submit evidence that Coated Foam Insulating System is approved in accordance with UL-790 Class A Testing.
  4. Submit evidence that Coated Foam Insulated Roof System Is approved in accordance with UL-2218 Impact Resistance Testing.
  5. Submit evidence that Coated Foam Insulated Roof System is approved in accordance with UL Reports P-733, P-826 or P-904 for Hourly Fire Resistance Design Ratings on specific decks, where applicable.
  6. Submit evidence that polyurethane foam with HFC 245fa blowing agent in Coated Foam Roof System is approved in accordance with Montreal Protocol and U.S. EPA non-depleting ozone requirement.
  7. Submit evidence that top coatings on Coated Foam Insulated Roof Systems are approved in accordance with "Energy Star" and CRRC Solar Reflectance and Thermal Emittance Testing.

 

1.03  QUALITY ASSURANCE

 

  1. Qualifications:
    1. Manufacturer: Company specializing in manufacturing products, specified with minimum 5 years documented experience.
    2. Applicator: Roofing applicator with 5 years experience in work of similar scope and nature to that specified and approved by manufacturer of roofing material and certified or licensed by manufacturer.
  2. Pre-Installation Conference:
    1. Convene a pre-installation conference to review roofing specifications and procedures with the architect, contractor, roofer and other trades relative to the work, prior to ordering materials.

 

1.04  DELIVERY, STORAGE AND HANDLING

 

  1. Delivery:
    1. Deliver materials to site intact with labels showing UL.
    2. Deliver so that stocks of materials on the site will permit uninterrupted progress of the work.
  2. Storage and Handling:
    1. Adequately protect against damage while stored at the job-site.
    2. Comply with manufacturer's instructions.

 

1.05  PROJECT/SITE CONDITIONS

 

  1. Polyurethane foam shall not be sprayed during inclement weather and when the following conditions exist:
    1. If surface temperature is above 160 degrees F or below 40 degrees F or when the dew point is less than 5 degrees F above the surface temperature.
    2. If surface moisture is present.
    3. If wind velocity is above 12 miles per hour, windscreens are required; for wind velocity at or above 25 miles per hour, work shall be suspended.

 

1.06  WARRANTY

 

  1. Warranty: Furnish written 10 Year No Leak Warranty on Coated Foam Insulated Roof System. Warranty shall cover repairs necessary to maintain roofing work in a water-tight condition during the warranty period. Warranty is to cover workmanship, materials and repair during the period covered.

 

Part 2. PRODUCTS

 

2.01 MANUFACTURERS

 

  1. Roofing products shall be manufactured by the following accepted manufacturers:
    1. SWD Urethane Company, Mesa, Arizona – Polyurethane Foam & Acrylic Coating
    2. Stabond – Los Angeles, California – Primer/Sealer

 

2.02 MATERIALS

  1. Primer/Sealer:
    1. Neoprene based primer formulated to be airless sprayed and designed expressly to enhance adhesion of SWD Urethane foam to various surfaces-
    2. SWD-1000 Primer/Sealer is acceptable.
    3. SWD – 2000 Primer / Sealer is acceptable in California.
  2. Polyurethane Foam Roofing/Insulation:
    1. Two component rigid foam, designed to be applied with foam dispensing equipment, meeting the following Minimum Physical Properties:

                                              a.     Property                                  Procedure                    Values        

Density, pcf nominal *               D- 1622                       2.5 - 3.0

Compressive, psi                        D-1621                         50

Tensile, psi                                 D-1623                        85

Shear, psi                                   D-273                          50  

Closed Cell Content %               D-2865                         95

Permeance, per/inch                   E-96                            2-3

R Value                                      C- 177                         6.8

k-Factor (initial)                         C- 177                         0.148

           

a.     Polyurethane Foam Density and Compressive Strength shall be uniform and consistent with specification. Minimum Physical Properties shall not allow for multiple foam densities or compressive strengths to be applied within multiple inches of specified foam.

b.     Polyurethane Foam shall contain EPA-approved 245fa blowing agent and meet U.S. non-ozone depleting requirements of the U.S. EPA mandate blowing agent is acceptable.

c.     SWD Urethane Company, SWD 125 “Quik-Shield”® Polyurethane Foam with HFC 245fa blowing agent is acceptable

  1. Protective Coating:

a.     SWD 1929F “Kool-Kote”™ 100% acrylic elastomeric UL 723 Class I Rated white coating meets EPA "Energy Star" and CRRC guidelines for Solar Reflectance and Thermal Emittance and can be applied by brush, roller or conventional airless spray equipment with the following  Minimum Physical Properties:

b.     Property                                  Procedure                                Values

Solids Content

      By Weight                               ASTM D-1353                       70%    

By Volume                              ASTM D-2697                       60%

Solar Reflectance                     ASTM E-903                          83%

Thermal Emittance                         ASTM E-408                          95 %

Ultimate Tensile Strength:

                  Psi                               ASTM D-412                         280

Elongation at Break:

                  Psi                               ASTM D-412                         355

Permeance

      Perms @ 20 mils                     ASTM E-96                            3.5

Hardness:

      Shore A Durometer                 ASTM D-2240                       60

All Tests Required                        ASTM D-6083                       pass

Colors:                                                                              Grey, Buff, White

Note: SWD Urethane Company is an original "Energy Star" partner and approved by CRRC.

 

c.     Dry film thickness shall be 25 mils application with #9 limestone granules or #11 ceramic granules embedded at 50 Ibs per 100 square feet.

d.     Base coat and top coat should be contrasting colors to ensure adequate thickness and coverage.

e.     SWD Urethane Company "Kool-Kote"™ 1929F Acrylic Elastomeric Coatings are acceptable.

      Note: This material complies with all the requirements of ASTM D-6083 standard specification for liquid applied acrylic coating used in roofing.

 

Part 3. EXECUTION

 

3.01 EXAMINATION

 

  1. Verification of Conditions:
    1. Roofing contractor shall examine the roof deck, flashings and other surfaces that are to receive roofing materials, prior to the application, to ensure that surfaces are true, even, dry, clean and in proper condition to receive the roofing system.
    2. All penetrations through roofing including drains, scuppers, miscellaneous pipe, vent penetrations and electrical conduits shall be completed prior to starting of work. Post-installation of penetrations after roofing section is completed requiring repairs, shall constitute costs added above contracted scope of work.
  2. Application of roofing material shall constitute the roofing contractor's acceptance of surfaces and flashings to receive the materials.
  3. Coordinate with other work, which affects, connects with or will be concealed by this work.

 

3.02 PREPARATION

 

  1. General Area:
    1. Notify the owner's representative and visitors to the job-site of potential fugitive overspray.
    2. Cars, etc. should be moved or covered to prevent inadvertent spraying. Contractor shall coordinate traffic with subcontractor during roof operations.
    3. Use appropriate barricading methods to shelter walking traffic from the work area's equipment and overspray.
    4. Mask work area as necessary to protect building walls, adjacent structures and vegetation, etc. from possible overspray.
  2. Surface Preparation for Different Roof Decks:
    1. Built-up roof or other existing roofs (Retro-fit).

                                              a.     All loose gravel, dust and residue shall be removed using power-vacuum equipment, power-sweeper, air-blowing or other suitable means. (Special conditions may be required if asbestos products are a part of roof removal.)

                                             b.     The existing roof shall be thoroughly inspected for adhesion between felts, insulation and deck. Areas of poor adhesion should be fastened. Blisters, buckles, wrinkles and fish-mouths shall be cut out and/or fastened.

                                              c.     Remove or re-fasten all loose base flashing, counter-flashing and gravel-stops, as required.

    1. Metal Deck:

                                              a.     The metal roof deck shall be constructed of minimum 22-gauge steel. Construction shall conform to local building codes.

                                             b.     Ferrous Metal: Sandblast iron and steel surfaces, which are not primed, shoppainted, or otherwise protected- Remove loose rust and primer from shop-primed iron and steel surfaces by scraping or wire brushing.

                                              c.     Non-Ferrous Metal : Clean galvanized metal, aluminum and stainless steel surfaces, as recommended by the manufacturer issuing the warranty.

                                             d.     If the metal surface is free of loose scale, rust, weathered or chalking paint, it can be cleaned using compressed air-jet, vacuum equipment, hand or powerbroom to remove loose dirt. Grease, oil or other contaminants shall be removed with proper cleaning solutions.

                                              e.     Fluted metal decks require a suitable method of covering or filling the flute prior to polyurethane foam application. Flutes may be covered with a suitable board stock, special polyester tape, pro-cut board stock or spray-applied polyurethane foam. Where a fire barrier is required, apply Type X gypsum board, mechanically-fastened to the metal surface, to meet local building code requirements.

                                              f.     Metal flutes up to three (3) inches in width, may be taped with 4" clear adhesive tape then sprayed with a minimum of ½” of foam.

    1. Concrete Deck:

                                              a.     Remove loose dirt, dust and debris by using compressed air, vacuum equipment or a broom. Oil and grease from release agents or other contaminants shall be removed with proper cleaning solutions.

                                             b.     All joint openings in concrete decks that exceed ¼” shall be grouted or caulked by others, prior to application of polyurethane foam.

                                              c.     Priming is required on concrete surfaces and it is recommended that due to hydration that is present, poured concrete decks be permitted to cure for twenty-eight (28) days prior to the application of sprayed polyurethane foam.

                                             d.     Sprayed polyurethane foam is not recommended for application to lightweight or insulating concrete materials unless underlayment and/or vent pans are installed. (Check with manufacturer prior to installation of PUF roof system over lightweight concrete).

    1. Wood Deck:

                                              a.     Deck must meet building code requirements for resistance to wind uplift.

                                             b.     Plywood shall contain no more than 18% water, as measured in accordance with ASTM Standards. Plywood shall be exterior grade not less than 1/2" thick, nailed firmly in place.

                                              c.     Plywood joints in excess of ¼”, shall be taped or filled by others with a suitable sealant material, prior to application of polyurethane foam.

                                             d.     Deck shall be free of loose dirt, grease, oil or other contaminants prior to priming or foam application. Remove loose dirt or debris by use of compressed air, vacuum or broom. No washing shall be permitted.

                                              e.     Tongue & Groove Sheathing or Planking: Due to the frequency of joints,  possibility of variable openings and effects of aging and shrinking, these surfaces must be overlaid with a minimum of ½” thick exterior grade plywood or other suitable covering with a minimum 1" foam thickness.

    1. Other Surfaces (i.e. Mineral Fiber Board, Gypsum Board)

                                              a.     Such materials used over fluted metal decks must be installed with mechanical fasteners or adhesives.

                                             b.     Fasteners shall be installed to meet Factory Mutual wind uplift criteria or the appropriate local building code criteria.

                                              c.     Boards shall be firmly butted together along edges without gaps or openings. Joints exceeding ¼” shall be caulked by others with a suitable sealant material.

                                             d.     Care shall be taken to prevent mineral or gypsum board from getting wet in storage on the job-site and after installation, prior to being protected by foam. Moisture exposure may damage these materials and require replacement.

                                              e.     Remove loose dirt and debris by using compressed air, vacuum or broom. No power-broom is permitted due to possibility of damage. The installed materials shall be protected from spills of contaminants

 

3.03 INSTALLATION - GENERAL

 

  1. Install all materials in strict compliance with all published safety, weather or applicable instructions from the manufacturer and/or regulations of local, state and/or federal agencies, which have jurisdiction.
  2. No work shall be commenced over defective area until advised in writing by architect of the action to be taken in such areas.
  3. Spray polyurethane foam for new construction projects, shall be installed when the deck, parapet walls, rough openings and curbs are completed. The type of skylight used will determine when skylights should be installed and galvanized roof jacks and vents (No lead), drains and electrical penetrations shall be in place prior to foam installation. No trades-people shall be allowed to work on the roof when the spray polyurethane foam and coatings are being installed- HVAC units shall not be installed until after the foam and coating roof system is in place.
  4. Substrate shall have sufficient structural strength and integrity without substrate deformation, and sufficient slope-to-drain per code requirements of 1/4 inch/foot to eliminate excessive ponding water. Excessive ponding is defined as "an area of 100 square feet or more which holds in excess of 1/2" of water, as measured 48 hours after a rainfall" per The NRCA Roofing and Waterproofing Manual - Fourth Edition.
  5. Metal: Install metal foam-stop at all roof edges, as required.
  6. Crickets and Cants:
    1. The required drainage slope gradients are required to meet the various drainage sources.
    2. Crickets may be constructed as follows:

                                              a.     Using ½” CDX plywood and structural lumber adhered mechanical1y to the substrate and vertical walls installed by others.

                                             b.     Using spray polyurethane foam (within certain sloping requirements).

                                              c.     Using tapered insulation board which shall be secured to the substrate with an adhesive recommended by the tapered board manufacturer or with mechanical - fasteners.

    1. Cants formed with spray polyurethane foam shall transition from the deck surface up the parapet wall.
  1. Parapets:
    1. The polyurethane foam shall extend a minimum of 4" and/or to 12" up the vertical wall at a thickness of ¾ inch to 1 ½  inch at the cant.
    2. If it is required that polyurethane foam extend all the way up the parapet wall then foam termination shall be detailed via straight line and tapered foam or optional sheet metal flashing that is acceptable to architectural standards.

 

3.O4 INSTALLATION – PRIMER/SEALER

 

  1. All surfaces should be clean and free from moisture, oil, grease, loose particles, dust, debris and any other materials that shall prevent maximum adhesion.
  2. Spray primer/sealer to decking at a rate of 1/2 gallon per 100 square feet.
  3. Application of spray foam over primer shall be per manufacturer's recommendations.

 

3.05 INSTALLATION - POLYURETHANE FOAM

 

  1. SWD 125 “Quik-Shield”® foam shall be applied in minimum 1/2" thick passes to achieve the specified thickness ±1/4 inch.
  2. Spray only the area each day that can be completed to the specified thickness that same day. Before resuming spraying operations on subsequent days, inspect the exposed leading edge of the foam for possible surface moisture that could cause blistering. The foam edge shall be considered dry when there is no indication of moisture when blotted with an absorptive material.
  3. Surface texture and quality" Cured polyurethane foam shall range from a smooth to heavy "orange peel" finish. Textures described as "popcorn" or "tree bark" surfaces, which exhibit crevices, voids and widespread defects, are not acceptable.

 

3.06 INSTALLATION - PROTECTIVE ELASTOMERIC COATING

 

  1. Preparation:
    1. Foam surface and adjacent surfaces to be coated, shall be completely free of degraded foam, foam over-spray, grease, oil or other contaminants which would interfere with proper coating adhesion.
    2. Surface shall be dry and frost-free before coating. Do not apply coating materials when surface temperature is less than 50 degrees F.
    3. Any physical damage to the polyurethane foam shall be repaired before coating.
    4. Operator should wear soft-soled shoes to avoid damaging the skin of the foam.
    5. An additional application of base coat shall be applied where foam surface has been sanded, planed or trimmed and the skin removed prior to applying normal base coat to the entire area.
    6. The SWD 125 “Quik-Shield”® polyurethane foam shall be inspected for suitability of base coat application, prior to application of the protective coating and be free of UV oxidation and contaminants.

B.    Base Coat:

    1. SWD 1929F Kool-Kote Coating shall be a contrasting color from the top coat to insure adequate coverage.
    2. Shall be applied on the same day, as the polyurethane foam application, when possible.
    3. The polyurethane foam shall be inspected for UV oxidation if more than 72 hours has elapsed prior to application of base coat.
    4. Spray-apply elastomeric base coat over insulation at the rate of 1 gallon per 100 square feet in one application.
  1. Top Coat:
    1. SWD 1929F Kool-Kote Coating shall be a contrasting color from the base coat to ensure adequate coverage.
    2. Do not apply top coat until base coat has cured properly. Normally, 24 hours is sufficient time for the base coat to properly cure.
    3. Spray-apply elastomeric top coat over the base coat at the rate of one additional gallon per 100 square feet. A 3rd gallon may be added if required.
    4. Coating shall extend up and over all polyurethane foam on vent pipes, parapets and other penetrations and shall terminate a minimum of 4 inches above the foam. All top coat termination points shall be straight-lined on walls, parapets, vent pipes and other penetrations.
  2. Granules:
    1. Granules when specified, shall be broadcast into wet top coat while it is being applied at the rate of 30 pounds per 100 square feet.
    2. Shall consist of #11 ceramic granules or #9 limestone granules.

 

3.07 CLEANING

 

  1. Remove and dispose of excess materials, equipment and debris from premises during work and/or upon completion of work.
  2. Leave work in clean condition in accordance with general condition requirements.