PART I - GENERAL

1.01 GENERAL

A. SCOPE:

To install a Tough Stuff coating system to waterproof and restore existing single ply membranes to watertight and maintainable conditions.

B. RELATED WORK:

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

1. Fastener and shrinkage repairs
2. Cleaning and preparation of substrate
3. Application of primers
4. Detailing of flashings and penetrations
5. 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, product variations and accessories.

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 Tough Stuff 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 of in writing by Coatings International, Inc. 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:

1. Coverage is limited to the cost of the new system application.
2. Warranty does not cover applications over wet roofing.
   

PART 2-EXECUTION

2.01 CAUTIONS

A. SAFETY:

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
AC5600, PR3200, PR3300, PR3600	None
UR2550, UR2650, UR2750	Four minutes (two part)
PR3500	One minute (two part - five minute digest after mixing)
PR3400, PR3450, AC5000, AC5900, UR1600, UR1700, UR1800	One 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 psi water blaster. If there are algae growing on the surface, the cleaning must include bleach in the washing of the substrate.

B. DEFECTS & SHRINKAGE:

1. Fastener Back out: Examine existing system for loose or backed out fasteners. Remove and replace as needed.
2. Membrane Shrinkage: Membrane shrinkage must be relieved and membrane must be reanchored mechanically to maintain or exceed original wind rating design. Missing flashing membrane due to shrinkage and relief (wall will be short) can be cut to the new mechanical termination at the base and replaced with the urethane flashing system.
3. Perimeter Replacement: Defective or wind damaged systems from 4’-12’ on the outside perimeter will be replaced and converted to urethane systems. Anchor OSB either mechanically or with adhesives to the outside perimeter of the roof and at all machine curbs and projections. Width will be determined by the potential for uplift relative to the buildings position. Placement guidelines are as follows:

LOCATION	WIDTH
Outside Edge	4-12 feet (12 ft. for maximum requirements)
Interior Walls	4 feet
Machine Curbs	2-4 feet
Vents	2 feet

Install 1/2” OSB over the membrane if the edge is high and apply system directly to the OSB. Remove existing roof and insulation at the perimeter if the edge is low and install new insulation to match roof level. Face the top layer of insulation to be 1/2” OSB with new system again installed directly to the OSB. Tuck the existing roof under the OSB detail. Install plywood edge with screws and plates per FM I-90.

After installing the plywood, finish as follows:

1. Prime plywood with PR3500 epoxy at .5 gallon/square.
2. Fill joint with UR1700 mastic using a plastering trowel. Use the tool to level transitions between joints. Allow material to skin adequately. Reinforce joint with UR1700 and FA204 (4”) polyester by applying wet layer of UR1700 (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 with 2 coats UR1700 or whatever finishing system is specified. 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.

2.04 PRIMING

Certain substrates may require the use of a primer to achieve proper adherence of the base coat to the substrate.

MEMBRANE	PRIMER	COVERAGE
EPDM	AC5600 PR3300, PR3600 PR3450	.50 gal./sq. .20 gal./sq. .33 gal./sq.
CPE, CPA, PVC	AC5600 PR3300, PR3600 PR3450	.5 gal./sq. .20 gal./sq. .33 gal./sq.
Hypolon, PIB	AC5600 PR3300, PR3600 PR3450	.50 gal./sq. .20 gal./sq. .33gal./sq.

2.05a SEAM AND FLASHING REINFORCEMENT-POLYESTER REINFORCED

Membranes with seam failure require all field fabricated seams and flashings to be reinforced with polyester liner material. On other single ply substrates, all defective seams as determined by seam probing shall require lining.

1. Apply a base coat of material over the seam area several inches wider than the polyester liner. The coating shall be installed at a rate of between 1.0-1.5 gallons/square (16-24 wet mils).
2. Roll the 4“-6” wide polyester liner into the wet substrate and brush it into the coating. Feather out the outside edges of the coating.
3. Install an additional layer of coating over the installed polyester liner at an application rate of 1.5 gallons/square (24 wet mils). Allow the repaired seams to tack prior to the application of the base coat for the field of the roof or additional layers.
4. Apply finish layer of seam area at 1.5 gallons/square (24 wet mils) if seam restoration is self standing. If the roof is being completely coated, do not apply second finish coat over seams.
   

2.05b SEAM AND FLASHING REINFORCEMENT-MASTIC METHOD

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. Brush a light 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.

2.06 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. Apply the base coat to an area a minimum of 6” beyond all areas of the split at a rate of 1.5-2.0 gallons/square.
2. Reinforce the area by applying the polyester liner to cover the split extending 6” beyond all areas of the split.
3. 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.
   
   

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 split at a rate of 1.5-2.0 gallons/square.
2. Reinforce the area by applying the polyester liner to cover the split extending 4” beyond all areas of the split.
3. 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.

2.07 FIELD LINER (OPTION AS SPECIFIED)

A field liner is typically installed over marginal stability membranes subject to cracking.

1. Apply the base coat at a rate of 1.0-1.5 gal./sq. using notched squeegees or the 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 gallons/square on top of the polyester liner using notched squeegees and back rolling to insure proper sealing and even coverage of the coating.

2.08 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 the same area immediately after short nap enamel rollers perpendicular to the squeegee pattern.
2. Apply subsequent layers perpendicular to the first coat.

2.09 INSTALLATION OF WALKWAYS

1. Apply additional layer(s) of the finish at 1.5-2.0 gallons/square with optional aggregate. Aggregate can be added to the mixture or broadcast into the wet material.
   

2.10 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 SL6000 mastic on the base of the vent and set vent centered over hole. Finish edge of vent with additional caulking and tool into.

2.11 CLEANUP

MATERIAL	CLEANUP SOLVENT
AC5000, AC5600, AC5900	Water
BU8000	Mineral Spirits
PR3300, PR3400, PR3450	Xylene
PR3600	No Clean Up Required
SL6000	Xylene
UR1600, UR1800	Xylene
UR1700, UR1900	MEK/Xylene blend
UR2550, UR2650, UR2750	Xylene

2.12 INTERCOAT WINDOWS

PRODUCT	COAT WITHIN	IF NOT, APPLY
AC5000	No Window
AC5600	No Window
AC5900	No Window
BU8000	No Window
PR3200	24 hours	Recoat with PR3200
PR3300	48 hours	Recoat with PR3300
PR3400	6 hours	Recoat with PR3400
PR3450	6 hours	Recoat with PR3450
PR3500	24 hours	Recoat with PR3500
PR3600	48 hours	Recoat with PR3600
SL6000	No Window
UR1600	No Window
UR1700	7 days	Prime with PR3600
UR1800	72 hours	Prime with PR3600
UR1900	No Window	/td>
UR2550	5 days	Prime with PR3600
UR2650	48 hours	Prime with PR3600
UR2750	4 hours	Prime with PR3450

PART III - SCHEDULES

3.01 SINGLE PLY MATERIALS, APPLICATION & WARRANTY