Built-up roofing solutions with rigid insulation boards on concrete decks for new-build and refurbishment E-a5

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1 Cl Sfb (27-9) Rn7 M2 December 2004 Built-up roofing solutions with rigid insulation boards on concrete decks for new-build and refurbishment E-a5 Fesco, Fesco S, Retrofit, Retrofit S, Fesco Fillet, PF, PUR, EPS under-s 1b 2b 2c Solutions 1a 2a 1 Fully bonded roofing a. roof maintenance or service access b. maintenance access walkways 3a 3b Ballasted roofing a. roof maintenance b. roof maintenance or service access c. service roof Pedestrian access roofs a. pavers on paving supports b. tiling or paving slabs 4 Roof gardens 5a 5b 6a 6b 5 Car park roofs, a. light-weight vehicles b. heavy vehicles or window cleaning equipment support 6 Mastic asphalt roofing a. new build (except car parks) b. total refurbishment or car park decks 7 7 Refurbishment over existing built-up roofing

2 Solutions 1 Fully bonded roofing suitable for use in new build and refurbishment projects resists frequent foot traffic both during and after installation resists heat (torch application, hot bitumen ) increases the service life of the waterproofing 1a. roof maintenance or service access fully-bonded waterproofing Fesco fully bonded in hot bitumen to the vapour barrier 1b. maintenance access walkways reinforced walkway membrane fully-bonded waterproofing Fesco fully bonded in hot bitumen to the vapour barrier Alternatives: - single thickness Fesco S fully bonded in hot bitumen with torch-applied waterproofing - several s fully bonded in hot bitumen with lower of PF, PUR or PIR 2

3 2 Ballasted roofing protects the waterproofing from perforation no separation with loose-laid waterproofing resists heat (torch application, hot bitumen ) increases the service life of the waterproofing protects lower of organic insulation (PF/PUR/EPS) 2a. roof maintenance with walkway of pavers on a bed of concrete or stone paving slabs loose-laid waterproofing Fesco loose-laid, or bonded with hot bitumen or cold adhesive to the vapour barrier Alternative: - Fesco or Fesco S, with lower of PF, PUR or EPS, in independent or fully-bonded system 2b. roof maintenance or service access with walkway of pavers on a of EPS concrete or stone paving slabs protections: EPS board 20 mm min. Fesco loose-laid, or bonded with hot bitumen or cold adhesive to the vapour barrier 2c. service roof concrete or stone paving slabs Advantages of fully-bonded system: - faster waterproofing installation - the protective can be installed later Fesco loose-laid, or bonded with hot bitumen or cold adhesive to the vapour barrier 3

4 3 Pedestrian access roofs protects the waterproofing from perforation no separation with loose-laid waterproofing 3a. pavers on paving supports suitable for all types of traffic increases the service life of the waterproofing concrete (or wood) pavers max. load on the base of supports: 0,6 dan/cm 2 on Fesco Fesco loose-laid, or bonded with hot bitumen or cold adhesive to the vapour barrier 3b. tiling or paving slabs tiling finish reinforced concrete self-blocking paving stones on bed of sand Fesco loose-laid, or bonded with hot bitumen or cold adhesive to the vapour barrier 4 Roof gardens no separation with loose-laid waterproofing high weight of soil permitted increases the service life of the waterproofing soil polyester filter membrane drainage Advantages of fully-bonded system: - faster waterproofing installation - the protective can be installed later root-resistant waterproofing without separation Fesco in 1 or 2 s, loose-laid or bonded (hot bitumen or cold adhesive) to the vapour barrier 4

5 5 Car park roofs and window cleaning equipment support the "benchmark" for insulated car parks for light and heavy vehicles optimisation of the reinforced concrete slab due to the excellent compression resistance protects the waterproofing from perforation no separation with loose-laid waterproofing 5a. light-weight vehicles reinforced concrete slab (*) Fesco in 1 or 2 s, loose-laid or bonded (hot bitumen or cold adhesive) to the vapour barrier 5b. heavy vehicles or window cleaning equipment support Advantages of fully-bonded system: - faster waterproofing installation - the protective can be installed later reinforced concrete slab (*) Fesco in 1 or 2 s, loose-laid or bonded (hot bitumen or cold adhesive) to the vapour barrier (*) For the calculation of the reinforced concrete the specialised Engineering office should take into account the recommendations of the Building regulations and the following design considerations for use under reinforced concrete: compressive stress for Fesco R cs = 0,13 MPa (130 kpa) corresponding deformations d smin = 0,7 % d smax = 1,2% construction elements such as expansion joints, safety factor for speed, etc Some examples of loadings (other examples are to be found in Eurocode 1, DIN 1055 and DIN 1072): Twin wheels Weight per wheel kn Surface area of one wheel cm 2 Distance between centres cm Fire engine 22,5 (~ 2,25 t) Heavy goods vehicle 32,5 (~ 3,25 t) Very heavy goods vehicle 60 (~ 6 t) Thermal insulation: to protect the supporting concrete deck against cracking etc... it is recommended, even if there is no specific requirement for energy conservation, to insulate with a minimum thermal resistance of R = 1,00 m 2 K/W, i.e. minimum 50 mm thick for Fesco. 5

6 6 Mastic asphalt roofing inaccessible, pedestrian access, roof garden and lightweight vehicles unaffected by the heat of the asphalt conservation of thermal insulation properties 6a. new build (except car parks) protects lower of organic insulation (PF, PUR or EPS) quick application with bulk asphalt trucks protective mastic asphalt s separation sheet 20 mm min. Fesco on PF, PUR or EPS (*) loose-laid lower of PF, PUR or EPS (*) on EPS: 30 mm minimum Fesco when mastic asphalt applied in bulk 6b. total refurbishment or car park decks protective mastic asphalt s separation sheet Fesco loose-laid or bonded, in one or several s 7 Refurbishment over existing built-up roofing simplifies preparatory work on the existing waterproofing fits into available height of existing upstands flat, even surface for the new waterproofing compensates for the thermal inertia of the previous protective new, fully-bonded waterproofing Retrofit or Retrofit S fully-bonded existing waterproofing (fully or partially bonded, or asphalt) (*) existing insulation (*) vapour barrier (*) (*) an initial evaluation of the existing built-up roofing system should be carried out to ensure its suitability as a base for the new waterproofing. Alternative: for improved insulation value - Fesco or Fesco S 6

7 Design considerations Codes of Practice The design considerations indicated in this brochure are applicable for the United Kingdom and Northern Ireland and should be assessed in accordance with BS 8217: 1994, Code of Practice for Built-up felt Roofing, BS 6339: Part 2: 1997: loading for buildings: Code of Practice for wind loads, BRE Digests N os. 119 of July 1970 and 346 parts 1 to 8 July 1989 to December Typical U-values The minimum thickness of insulation - either Fesco by itself or as a protection to a lower of organic insulation (PF, PUR or EPS) will depend on the insulation requirements and the available height at the roof upstands. The figures below show the overall insulation thickness required for a given U-value, under the following conditions: concrete deck 12 cm thick with a two self-protected waterproofing system (or under ballast). These figures are for guidance only. U-value W/m 2.K 0,38 0,33 0,29 0,25 Fesco mm 120 2x70 2x80 2x95 PF + Fesco 20 mm mm PUR + Fesco 20 mm mm In new building work reference should be made to the Building Regulations revised after 2001, which stipulate the minimum recommended U-values for roofs, i.e. 0,25 W/m 2.K. Thickness requirements for U-values beyond those shown above are available on request. Roof build-up Concrete roof deck Decks should be designed in accordance with current and relevant standards. Flat roofs should have a minimum finished fall to ensure adequate drainage. Tapered insulation boards can be used to achieve certain falls (see the specific brochure - FescoDrain). Water vapour control A suitable vapour control must be installed as described in BS 8218: 1998 or BS 8217: Care should be taken to ensure continuity at joints, upstands and roof penetrations. Application of the insulation boards Boards can be applied to the vapour barrier as follows: Bonded with a cold bituminous adhesive under ballasted waterproofing systems, or according to the recommendations of the waterproofing manufacturer, EPS + Fesco 20 mm mm Mechanically fastened in accordance with the technical documentation of the fastener manufacturer and approved specifications for the mechanically fastened waterproofing, Loose-laid under ballasted waterproofing systems. On site, insulation boards should be stored clear of the ground on a clean level surface, under cover, to protect them from moisture or mechanical damage. Boards should be installed dry and any boards that have been allowed to get wet should be put to one side to dry out before use. Boards should be laid break-bonded and all joints lightly butted.the waterproofing should be applied to the boards as soon as possible after fixing. At the end of each day's work, or whenever work is interrupted, a night joint must be made to avoid water penetration. Waterproofing Boards are for use with waterproofing specifications of: built-up bitumen felt to BS 747: 1994 in accordance with BS 8217: 1994 mastic asphalt in accordance with BS 8218: other waterproofing systems should be applied in accordance with the manufacturer's recommendations and relevant Agrément Certificate. Depending on the use of the roof, Fesco insulation boards are suitable for use with waterproofing that is either: fully-bonded mineral surface finish bonded or loose-laid under ballasted systems (without the need for a separation ) or mechanically fastened. When installing torch-receivable Fesco S insulation boards, the roofing felts are torched directly on to the specially coated upper surface of the insulation board, by melting the sacrificial polypropylene facing with the gas-torch. When using Retrofit S, it is recommended to melt the polypropylene first and then direct the flame on to the waterproofing roll to effect the welding of the two elements. Roof Protection Fesco insulation boards are suitable for use under all types of ballasted waterproofing systems: Gravel, pavers on paving supports, paving stones on a bed of sand, concrete or stone paving slabs on a protection, Roof garden build-up with its specific requirements for filter and drainage s, etc..., Poured concrete for reinforced concrete - pedestrian, technical or light vehicle access - or calculated specifically for use with heavy goods vehicles and window cleaning equipment support. For applications under asphalt concrete for roof decks with pedestrian access and roof gardens, consult the brochure E-a3 (solutions with Fesco LT and SP). 7

8 Product information Fire Safety The fire rating of a roof containing Fesco insulation boards will depend on the type of deck and the nature of the waterproofing and/or the surface finish used. Reference should be made to national Building Regulations: England & Wales: Approved Document B, Section 14 Scotland: Technical standards D3.5 and D6.7, and Appendix to part D "Provisions deemed to satisfy the Technical standards". N. Ireland: Technical Booklet E, Regulation E8. Standards and Approvals Fesco and Retrofit insulation boards are manufactured under a quality control system approved to ISO 9001: 2000.The high quality of all products is continuously monitored, not only internally, but also by external audits by the different European Agrément Boards that certify the production process.these boards also meet the requirements of EN and are CE marked. All products in the Fesco range of insulating boards are certified under Acermi thermal conductivity procedures, and the principal applications are covered by current Agrément Certificates. Resistance to roof traffic Expanded perlite insulation boards, with D classification to UEAtc test methods, are highly resistant to compression and point loading. Flat roofs incorporating expanded perlite boards are better able to resist the constraints of frequent roof traffic, thus limiting the risks of damage to the roofing felts during and after installation. Rigid roof insulation boards contribute to the service life of the built-up roofing system by limiting the risk of perforation, and the possibility of the felts splitting or tearing at the joints in the insulation. Health and Safety No special precautions need to be taken when using the range of Sitek's insulation boards. A leaflet satisfying the requirements of the Control of Substances Hazardous to Health Regulations 1988 (COSHH) is available. Product description A technical data sheet is available, on request, for each product in the range. Environment Expanded perlite insulation boards are manufactured from both natural and recycled products, have zero ODP (Ozone Depletion Potential) and are chemically neutral. For further information consult the brochure "Respecting the Environment". Other applications Built-up roofing solutions over rigid insulation boards on profiled-metal decks for new-build and refurbishment High performance roof insulation boards for waterproofing systems on profiled-metal roof decks Fire protection under expanded polystyrene insulation boards on profiled-metal roof decks Transformation of standing seam cold roofs into waterproofed warm roofs Tapered insulation roofing systems Insulated car park decks for light and heavy vehicular traffic Thermal insulation under asphalt concrete for roof decks with pedestrian access, car parks for light vehicles, and roof gardens Sales office: Sitek - Thermal Ceramics UK Ltd. Commercial Road, Bromborough,Wirral CH62 3NL Tel: / Fax: Sitek - Thermal Ceramics reserves the right to amend specifications without prior notice. Whilst information contained in this publication is true and accurate to the best of our knowledge and belief, all liability for errors and omissions, damage or loss resulting herefrom, is hereby excluded. Recommendations for use should be verified as to suitability and compliance to actual requirements, specifications and any applicable laws and regulations. This publication is a guide and when the products and methods included herein are considered for purposes other than those described please contact Sitek-Thermal Ceramics. ALYZÉA - 12/04

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