ROOFING SYSTEMS

BUILT UP ROOFING SMOOTH SURFACE MASTER GUIDE SPECIFICATIONS

PART I - GENERAL

1.01 GENERAL

A. SCOPE:

To install an Tough Stuff coating system to waterproof and restore existing built up substrates to watertight and maintainable conditions.

B. RELATED WORK:

The work includes but is not necessarily limited to the following:

1. Cleaning and preparation of substrate
2. Application of primers
3. Detailing of flashings and penetrations
4. Application of base coat, mid coat and finish coat on roof surface

1.02 SUBMITTALS

A. PRODUCT DATA:

Submit schedules, charts, literature, material safety data sheets, and illustrations to indicate the performance, fabrication procedures and product variations.

B. SAMPLES:

Submit sample of cured membrane materials including reinforcing where appropriate.

C. QUALITY CONTROL:

Provide test results from the manufacturer indicating compliance with the specified criteria.

D. MAINTENANCE INSTRUCTIONS:

Provide preprinted maintenance instructions for the roof coating system.

E. WARRANTIES:

Provide a sample of Coatings International Roofing Systems’ warranty and the applicator’s warranty.

1.03 QUALITY ASSURANCE

A. QUALIFICATIONS:

Provide factory trained and authorized installers with a minimum of three years experience in installing work similar to the specified work. Submit written evidence of authorization from the manufacturer that contractor is an approved Tough Stuff applicator.

B. RESPONSIBILITY FOR PERFORMANCE:

If the requirements of the construction documents negate or restrict the specified performance, or if a conflict or ambiguity exists in the construction documents, the contractor must request a clarification of any discrepancies before proceeding with the work.

C. PRE-INSTALLATION CONFERENCE:

Before starting the work specified herein, a pre-installation conference shall be held to discuss all aspects of the project. The following parties shall be in attendance:

1. Applicator's field representative or roofing foreman
2. Manufacturer's technical representative and affected adjacent trades
3. Owner's representative
4. Architect

D. MANUFACTURER'S TECHNICAL ASSISTANCE:

Provide a representative to attend the pre-installation conference, and review existing conditions and application procedures at project startup and periodically during the progression of the project.

1.04 CODE REQUIREMENTS

A. CODE:

All work including disposal of materials shall be in compliance with applicable local building codes.

1.05 DELIVERY AND STORAGE

A. DELIVERY:

Deliver clearly labeled, undamaged materials in the manufacturer's unopened containers.

B. TIMING AND COORDINATION:

Deliver materials to allow for minimum storage time at the project site. Coordinate delivery with the scheduled time of installation.

C. STORAGE:

Store materials in a clean dry location, protected from weather and abuse.

1.06 SITE CONDITIONS

A. EXAMINATION OF EXISTING CONDITIONS:

Contractor shall examine existing conditions affecting this work and shall report all unsatisfactory conditions to the proper authority and will not proceed until these conditions have been corrected. Commencing work implies acceptance of existing conditions as satisfactory to the outcome of this work.

1.07 WARRANTY

All products used in the coating assembly must be furnished, specified, or approved in writing by Coatings International Roofing Systems. Products not supplied by Coatings International will not be covered by Coatings International Roofing Systems' warranty.

A. TERM:

The manufacturer shall warrant the specified work from the date of completion for the length of the specified warranty against becoming unserviceable from either nonconforming materials or workmanship.

B. LIMITATION:

Defects shall include, but not be limited to, the following:
1. Peeling, cracking, blistering, alligatoring, or releasing from the substrate
2. Excessive chalking or dusting
3. Leakage of water into the building

PART II - EXECUTION

2.01 CAUTIONS

Urethane coatings typically contain organic solvents and as such can be toxic and flammable. Work only in fully ventilated areas. Do not smoke when using these products or use near sparks, heat, or any open flames. Read and follow the Tough Stuff Material Safety Data Sheets (MSDS). All waste materials including empty pails must be removed from the site by the applicator and taken to a landfill authorized to receive such materials.

2.02 MIXING

Urethanes and primers will require proper mixing before application as follows:

PRODUCT MIX TIME
UR2100,UR2650 Four minutes (two part)
UP70 Four minutes (two part - five minute digest after mixing)
AC5000, AC5600, AC5900, UR1600, UR1700, UR1800 Two minute
2.03 SUBSTRATE PREPARATION

A. CLEANING:

Remove dirt and foreign material detrimental to adhesion or application of roofing. Use CL404 cleaner diluted 20:1 with water. On heavy dirt or grease, apply full strength. Broom scrub the soap solution on the membrane to loosen oxidation and dirt and rinse with a minimum 2500 pi water blaster. If there are algae growing on the surface, the cleaning must include bleach in the washing of the substrate.

B. WET ROOFING REPLACEMENT:

Locate wet insulation and remove. Replace with new insulation to match the existing roof level. Leave room at the top for 1/2” OSB to face the repair. Space joints 1/8” to leave room for expansion. The width of the plywood will be related to wind uplift requirements.

After installing the plywood, finish as follows:

  1. Prime plywood with PR3800 at 1/2 gallons/square.
  2. Fill joint with mastic (see Section 2.07) using a plastering trowel. Use the tool to level transitions between joints. Allow material to skin adequately. Reinforce joint with specifed top coat product and FA204 (4”) polyester by applying wet layer of urethene (not thickened) at approximately 1.5 gallons/square centered over joint. Set polyester liner in wet material and immediately top-roll with additional material to saturate the polyester leaving no wrinkles.
  3. Trowel the mastic at the edges between the existing roof and the plywood.
  4. If the patch is at a wall, fabricate a cant at the transition. Cant should be 1/2” thick at the corner tapering to flat over 3”(top and bottom). Use the round nose rubber trowel for best results.
  5. Finish by coating plywood with 2 coats of the specified finish coat. If the patch is part of a complete system, apply 1 coat of finish over the patch and finish the system while applying the balance of the roof system.
    Other Options: If practical, the existing system can be repaired using original methods. In other words, use hot or modified if desired.
2.04 PRIMING

Prime with AC5600 at 1 gallon/100 square feet whenever surface to be coated does not have a base coat with liner.

2.05 REPAIR OF SPLITS, CUTS, FISH MOUTHS

A. SPLITS & CUTS:

All splits must be repaired with the polyester liner.

  1. Make a minimum 2” cut perpendicular to the direction of the split and each end of the split.
  2. Apply the base coat to an area a minimum of 9” beyond all areas of the split at a rate of 1.5-2 gallons/100 square feet.
  3. Reinforce the area by applying the polyester liner to cover the split extending 6” beyond all areas of the split.
  4. Apply an additional application of the base coat at a rate of 1.5-2 gallons/square over the polyester liner and feather out the outside edges of the coating.

B. FISH MOUTHS:

  1. Cut out the fish mouths so the remaining membrane is not buckled and is laying flat. Apply the base coat to an area a minimum of 6” beyond all areas of the cut at a rate of 1.5-2.0 gallons/square. Reinforce the area by applying the polyester liner to cover the cut extending 4” beyond all areas of the cut. Apply an additional application of the base coat at a rate of 1.5-2.0 gallons/square over the polyester liner.

C. BLISTERS:

All blisters must be cut open, dried out, and resealed.

  1. Cut open the blister making an X cut and fold back the cut sections.

  2. If the blister has moisture, dry out the inside of the blister. Apply the base coat into the inside of the opened area at a rate of 1.5 gallons/square (24 wet mils thickness). Replace the flaps of the blister into the coating. If the neck is nailable, fasten the flaps. Apply the base coat over the blister and 12" wider than the blister at a rate of 1.5 - 2.0 gallons/square.

  3. Line the area with the polyester reinforcement which shall extend 9" beyond the blister area.

  4. Apply an additional application of the base coat at a rate of 1.5 - 2.0 gallons/square over the polyester liner and feather out the outside edges of the coating.
2.06 FLASHINGS - POLYESTER REINFORCED

Apply polyester reinforcement on areas of significant movement.

  1. Apply base coat to all areas at a rate of 1.5-2.0 gallons/square and shall extend 2” beyond where the fabric will be installed. Set FA200 polyester liner in wet base coat.

  2. Install an additional application of base coat at a rate of 1.5-2.0 gallons/square over the installed liner extending a minimum of 2” beyond the fabric and feather out the edges of the coating.
2.07 FLASHINGS - MASTIC MIXTURE

Round projections, machine legs, sign posts, guide wire straps, inside and outside corners, etc. can be flashed using the D200 powder additive mixed into the urethane to create a mastic mixture. The mastic mixture is also used to create cants and as a joint filler.

Mastic Mixing Ratios:

USAGE RATIO OF D200 TO URETHANE
Cants 50%
Brushable 40%
Light brush / spray 30%
  1. Trowel the mastic around the base of the penetration or at the juncture of roof to wall so that the mixture is 3" wide and a minimum uniform 1/4" depth at the center that tapers to 40 mils at the edge.

  2. Cover the installed mastic mixture with an application of base coat installed at a rate of 1.5 gallons/100 square feet.
2.08 FIELD LINER (AS SPECIFIED)

A field liner is typically installed over the entire smooth roof.

  1. Apply the base coat at 1.0-1.5 gal./sq. using notched squeegees or an applicator broom for the AC5600. Immediately install the polyester liner into the base coat.

  2. Install an additional application of the base coat at a rate of 1.0 gallon/square on top of the polyester liner using notched squeegees and back rolling to insure proper embedment and even coverage of the coating

2.09 APPLICATION OF FINISH COAT(S)
  1. Pour out finish coat(s) across the roof and spread out with the notched squeegee applicator tool. Back roll same area immediately after short nap enamel rollers perpendicular to the squeegee pattern.
  2. Apply subsequent layers perpendicular to the first coat.

2.10 DRAINS
  1. Remove the existing clamping ring collar and clean the bowl and collar.
  2. If there is existing roofing material in the drain, cut and remove all materials to eliminate restriction of water flow to the drains and to provide a clean substrate. If necessary, repair the substrate to provide a smooth transition to the roof drains.
  3. On lined areas extend the liner membrane and coating into the drain bowl and replace clamping ring.
2.11 INSTALLATION OF WALKWAYS

Apply additional layers of the urethane at 1.5 galons/square with optional aggregate. Aggregate can be added into the mixture or broadcast into the wet material.

2.12 VENTS

Place vents 5’ from outside walls every 50’ and at all inside and outside corners. Cut membrane and insulation to primary roof or to deck. Fill hole in insulation with crumbled insulation that was cut out. Place a triple bead of mastic (see Section 2.07) on the base of the vent and set vent centered over hole. Finish edge of vent with additional caulking and tool into place.

2.13 CLEANUP
MATERIAL CLEANUP SOLVENT
AC5000, AC5500, AC5600, AC5900, PR3800 Water
PR3900 Toluene
UP70 Xylene
UR1600, UR1800 Xylene
UR1700, UR1900 MEK/Xylene blend
UR2100, UR2650 Xylene
2.14 RECOAT WINDOWS
PRODUCT COAT WITHIN IF NOT, APPLY
AC5000 No Window
AC5600 No Window
AC5900 No Window
PR3800 No Window
PR3900 No Window
UP70 No Window Recoat with UP70
UR1600 No Window
UR1700 7 days Prime with PR3600
UR1800 72 hours Prime with PR3600
UR1900 No Window
UR2100 No Window Prime with UP70
UR2650 48 hours Prime with UP70

PART III - SCHEDULES

3.01 BUR - SMOOTH SURFACE MATERIALS, APPLICATION & WARRANTY

F/OR USE OVER BUR SMOOTH SURFACES & PLANED BUR WITH GRAVEL AND FLOOD COAT REMOVED

WARRANTY PERIOD SYSTEM PRIMER BASE COAT/ LINER MID COAT FINISH COAT
5 Year
(Option A/
5% Ponding)
SSBUR UR1700-5
FA240 in UR1600 or AC5600 on low areas, flashings and repaired areas UR1600 at 1.5 gal./sq. UR1700 at 2.0 gal./sq.
5 Year
(Option B)
SSBUR AC5900-5
Integrate FA240 in AC5600 at 2.5 gal./sq. OC6000 at 1.5 gal./sq. AC5000 at 1.5 gal./sq.
5 Year
(Option C / Fully Reinforced
Acrylic Resin)
SSBUR SL6000-5 Integrate FA240 in AC5600 at 2.5 gal./sq. SL6000 at 1.5 gal./sq.
10 Year
(Option A / Fully Reinforced Urethane)
RSSBUR UR1700-10
Integrate FA240 in AC5600 at 2.5 gal./sq. UR1700 at 2.0 gal./sq. UR1700 at 1.5 gal./sq.
10 Year
(Option B / Fully Reinforced Urethane)
SSBUR AC5900-10
Integrate FA240 in AC5600 at 2.5 gal./sq. AC5900 at 1.5 gal./sq. AC5900 at 1.5 gal./sq.
10 Year
(Option C / Fully Reinforced Silicone)
SSBUR SL6000-10
Integrate FA240 in AC5600 at 2.5 gal./sq. (split coat option) SL6000 at 1.5 gal./sq. SL6000 at 1.5 gal./sq.
10 Year
Warranty
(Option D / Unreinforced Urethane)
SSBUR UR1700-10
FA240 in UR1600 or AC5600 on low areas, flashings and repaired areas UR1600 at 2.0 gal./sq. UR1700 at 2.0 gal./sq.