CI/SfB (47) Ln2 FLAT ROOF SOLUTIONS

Transcription

1 CI/SfB (47) Ln2 FLAT ROOF SOLUTIONS

2 HOT MELT STRUCTURAL WATERPROOFING ENVIRONMENTAL & TECHNICAL The rubberised asphalt is formulated with a percentage of post-consumer recycled materials. With no need to replace the product during the buildings expected life, the life cycle costing of the system is excellent. Insulation The XPS insulation for inverted roofs is thermally efficient and is CFC and HCFC free with a zero ozone depletion potential (ODP) It is resistant to the passage of water and will not degrade. British and European Standards Bauder Bakor has been tested by the British Board of Agrément (BBA) and carries certificate number 06/4350. Fire Rating EXT.F.AA rating awarded to the Bauder Bakor with a ballast, paved or green roof finish for zero spread of flame and no fire penetration. Tested to BS 476 Part 3 External Fire Exposure to Roofs as covered by European Standard DD ENV 1187:2002. bauder.ie 62

3 Bauder Bakor Structural Waterproofing is an extremely robust and very flexible self healing monolithic membrane system for podiums and plazas, protected roofs and green roof installations. The system is designed to give a 100% bond to the concrete substrate and is formulated with SBS rubberised bitumen, with a percentage of post consumer recycled content, combined with reinforcement and an uppermost protection layer the system delivers reliable waterproofing in a harsh environment. Hot Melt Structural Waterproofing The Bauder Bakor Hot Melt Structural Waterproofing System provides a monolithic, fully bonded waterproofing membrane that is tough, flexible and self healing to minor punctures for use on most protected roofs such as inverted, paved, ballasted, terraces, car parks, podiums and plazas or green roof applications. Bakor is one of the world s market leaders in the manufacture and installation of hot melt monolithic membrane systems, with a track record of research and development and a portfolio of successfully completed projects spanning over 40 years. KEY FEATURES Seamless application provides monolithic waterproofing. Can be installed on zero falls. Bridges minor cracks. Infills minor irregularities. Full adhesion to deck restricts lateral water movement. Durability to match the expected life of the building. BBA Certificate 06/4350 Guaranteed for 20 years. STRUCTURAL WATERPROOFING SPECIFICATION SUPPORT CAD DRAWINGS & NBS SPECIFICATIONS TECHNICAL HELPLINE T: +44 (0) E: [email protected] The Vibe Lower Broughton, Manchester 63 bauder.co.uk

4 BAUDER BAKOR HOT MELT Bauder Bakor is applied in two 3mm layers sandwiching a reinforcement layer to create one monolithic layer with no laps. It will infill minor cracks and deviation in the deck to form a 100% bond, eliminating the possibility of water being able to track beneath in the event of damage. BAKOR HOT MELT INVERTED SYSTEM WITH PAVING SUITABLE FOR PLAZAS AND TERRACES Paving on Supports, suitable for a roof terrace. Bauder U-Max or BauderJFRI vapour permeable membrane, designed to increase the thermal capacity of the insulation. Bauder XPS or BauderJFRI Insulation, thickness to suit U-value required. Bauder API Access Protection Sheet to suit the proposed landscaping, fully bonded into the Bakor 790-II. Bakor 790-II, second 3mm layer bleeds through the reinforcement to create a 6mm monolithic waterproofing membrane. Bauder Polyester Reinforcement strengthens the system, providing a uniform surface to apply the second layer of hot melt. Bakor 790-II, first 3mm layer infills and fully bonds to all minor deviations and the deck. Bauder Polymer Primer dries in minutes, promoting nearly a 50% increase in bond strength compared to a normal primer. BAKOR HOT MELT INTENSIVE GREEN ROOF SYSTEM Bauder Intensive Substrate (with turf). Lightweight growing medium Bauder Filter Fleece is a filtration layer that prevents substrate fines from washing into the drainage or water storage layer. DSE60 is a 60mm thick water storage and drainage layer infilled with Bauder mineral drain which provides multi-directional drainage. Bauder Root Barrier AP2 to suit the proposed landscaping, fully bonded into the Bakor 790-II. This protection layer is root resistant and complies with FFL guidelines. Bakor 790-II, second 3mm layer bleeds through the reinforcement to create a 6mm monolithic waterproofing membrane. Bauder Polyester Reinforcement strengthens the system, providing a uniform surface to apply the second layer of hot melt. Bakor 790-II, first 3mm layer infills and fully bonds to all minor deviations and the deck. Bauder Polymer Primer dries in minutes, promoting nearly a 50% increase in bond strength compared to a normal primer. BAKOR TARMAC ROAD OR CAR PARK Hot Rolled Tarmacadam asphalt road or pathway surface Bauder AP3 Protection Sheet is loose-laid to deliver a robust surface onto which the tarmacadam is installed. Bauder API Access Protection Sheet to suit the proposed landscaping, fully bonded into the Bakor 790-II. Bakor 790-II, second 3mm layer bleeds through the reinforcement to create a 6mm monolithic waterproofing membrane. Bauder Polyester Reinforcement strengthens the system, providing a uniform surface to apply the second layer of hot melt. Bakor 790-II, first 3mm layer infills and fully bonds to all minor deviations and the deck. Bauder Polymer Primer dries in minutes, promoting nearly a 50% increase in bond strength compared to a normal primer. bauder.ie 64

5 PROJECT FOCUS The Vibe Lower Broughton, Manchester STRUCTURAL WATERPROOFING The Vibe Lower Broughton, Manchester Leaky pipe irrigation system hot melt being installed Quick drying polymer primer AP2 - FLL root resistant protection layer Bauder DSE60 and Mineral Drain Substrate prior to turf 65 bauder.co.uk

6 Sharrow School Sheffield bauder.ie 66

7 HOT MELT STRUCTURAL WATERPROOFING TECHNICAL GUIDE TECHNICAL GUIDE Suitable Substrates 68 Concrete Curing and Drying 68 Surface Preparation 69 Priming 69 Method of Application 70 Access and Protection Layers 71 Equipment 71 Testing and Inspections bauder.co.uk

8 SUITABLE SUBSTRATES Not every form of deck substrate construction is suitable to receive the Bauder Bakor System. ACCEPTABLE SUBSTRATES Structural Concrete Deck - The concrete deck should be properly cured. The recommended curing time is 28 days. Depending on site conditions and weather, it can be possible to install Bauder Bakor monolithic membrane onto a concrete deck after only 14 days curing - provided the membrane has successfully passed a bond strength test. CONCRETE CURING AND DRYING CURING COMPOUNDS These additives are a popular method of speeding the curing time of concrete, due to their ease of application, and low material cost. Typically, the liquid type curing compounds tend to form a film on the concrete surface that significantly slows the evaporation rate of retained moisture. Below is an indicative listing of types suitable for use in conjunction with Bauder Bakor and also those considered unsuitable. ACCEPTABLE COMPOUNDS Sodium Silicate Based Compounds - These compounds when properly applied do not leave a film or residue on the concrete surface which would otherwise affect the bond strength of the membrane to the concrete surface. Resin Based Compounds - These form a residue that can take between days to oxidize and flake off, when exposed to the elements. The residue can be removed by brushing down the surface with a wire brush, or washing the concrete with a light solution of muriatic acid or trisodium phosphate (TSP) resin based curing compounds therefore may be acceptable as a curing method, but only on the proviso that they must be completely removed prior to the application of the membrane. Lightweight Structural Concrete Deck - The lightweight concrete should have a wood float finish. The recommended curing time is 28 days. A bond test is carried out to confirm proper adhesion to the deck. Concrete Deck Installed into Vented Profiled Metal Deck - A wood float finish will be required, and may have to cure for up to 60 days before proper adhesion is achieved. A bond check must be carried out to check for the correct adhesion. Plywood, OSB or Dens-Deck (gypsum) - providing the correct preparation has been carried out i.e. fixings counter-sunk, joints properly taped, and the deck correctly supported to withstand the inverted build-up loading weight. UNACCEPTABLE SUBSTRATES Lightweight Insulating Concretes Concrete made with aggregates such as Perlite, Pumice, Vermiculite will have a very low density and by their very porous make up, will retain a high degree of moisture. This high moisture content can create a problem in achieving a good bond with the deck surface. However, this type of lightweight concrete can be modified with a suitable latex, resin, or polymer treatment to provide an appropriate surface onto which membrane will adhere satisfactorily. UNACCEPTABLE COMPOUNDS Wax Based Curing Compounds - These cease to be an effective curing compound after about 28 days, but take days to fully dissipate when exposed to the elements. The wax residue will weaken the bond of the monolithic membrane, and is also difficult to remove. Therefore wax based compounds are not acceptable. Acrylic Silicate Based Curing Compounds - These form a permanent film on the surface of the concrete, and could prevent the monolithic membrane from forming an acceptable bond with the concrete. These compounds are therefore not acceptable. The use of any liquid curing compound in conjunction with Bauder Bakor monolithic membrane must be approved by Bauder Ltd. Please contact our technical department on +44 (0) It is imperative that the concrete substrate is allowed to cure sufficiently to ensure that it forms the required adhesion with the membrane. British Codes of Practice consider that it takes approximately 28 days for concrete to cure properly using the standard methods of curing. Concrete decks constructed using profiled metal as formwork will take longer to cure and dry and this process can take up to 60 days. Screeds Please note that Bauder Ltd discourages the specification of screeded surfaces, because although a good adhesion can be obtained once prepared, they will permit water to track and become absorbed beneath the system in the event that the waterproofing is damaged. DRAINAGE FALLS Although the Bauder Bakor is suitable for use at zero falls, in applications where inverted insulation is to be installed above, it is imperative that ponding water is eliminated. If ponding water is present there will be no recognised method to follow when undertaking U-value calculations. For this reason, falls should always be designed into the structure. bauder.ie 68

9 SURFACE PREPARATION PRIMING Cleaning and preparing of a concrete deck generally consists of thoroughly removing dirt, debris and dust by means of sweeping and blow/suction cleaning, the deck prior to applying the surface primer. However, the deck can be affected by surface contaminants that are not easily removed by sweeping such as oil or diesel spills, laitance, liquid curing compounds or form release agents. When any of these substances have been spilled, applied or have transferred to a concrete surface; or when laitance occurs, it must be removed prior to the application of the Bakor monolithic membrane. Below are listed some methods of preparation: The deck surface must be thoroughly primed with Bakor Polymer primer This greatly enhances the adhesion between the Bakor membrane and the substrate. Bauder Polymer Primer can be either spray or roller applied, and has a coverage rate of 4 6 m² per litre. Chemical Cleaning: This may be necessary as a first step to employing blast methods to remove oil, grease, and dirt. Scrubbing vigorously with solutions of Caustic Soda, Trisodium Phosphate or detergents formulated for use on concrete, then flushing thoroughly with water to remove all traces of the cleaning agent. Solvents must not be used, as flushing will tend to dissolve and spread the contaminant. Scarification: This is a mechanical means of effectively removing dirt build up, and laitance. Water blasting after scarification will help to remove any aggregate that was loosened during the process. Blast Cleaning: Sand blasting or by high pressure water jet is the most effective way to remove laitance or weakened material. Acid Etching: This method is not generally used, unless there is no alternative. Proper precautions and personal protective equipment must be used. The manufacturer of the chemical being used should be consulted as to their recommended procedures. Surface Defects: Hollows, holes, in the concrete surface should be cleaned out and infilled with a suitable mortar. Latex modified mortar is an acceptable product to use. Back falls should be remedied before waterproofing. This can be best done by applying a latex screed to the affected area to bring the back fall level. Fins, snots and irregular projections from the surface must be removed, possibly by chipping, scrapping or wire brushing. Bauder Polymer Primer has two significant advantages over ordinary bituminous primers. It dries within 30 minutes this can help in changeable weather conditions, and speed the application process. It also provides excellent adhesion qualities, which could be critical where the bond test has indicated possible adhesion problems. All surfaces to which the Bakor are to be applied to MUST be primed, this includes timber and metal used for forming details and outlets. Peel Testing The Bauder approved contractor will undertake a peel test prior to the installation of the to ensure the suitability of the surface to receive the first layer. TECHNICAL GUIDE Density The density of the concrete is critical. Below 1850 kg/m³ and it is possible that the surface of the concrete will tend to dust, making it difficult to achieve any sort of satisfactory bond. Recommended Surface Finishing A wood float finish is the recommended finish to concrete substrates receiving the Bauder Bakor waterproofing. This type of finish is rough enough to provide the hot melt membrane with a strong key to the surface and yet smooth enough to be able to achieve an even depth of membrane over its entire surface. Treatment of Minor Cracks Prior to the installation of the all minor cracks or board joints should be pre-covered with either a strip of polyester reinforcement, in the case of cracks from 1.5mm - 3mm in width or with either a butyl or neoprene reinforcement on cracks from 3mm - 12mm in width. The reinforcement should be bedded into place by applying a coat of material either side of the crack and embedding the reinforcement into this material whilst still hot, ensuring no wrinkles or creases. 69 bauder.co.uk

10 METHOD OF APPLICATION Typically, hot melt monolithic rubberised bitumen systems are installed, by first waterproofing the details of the deck such as upstands and outlets, before applying the membrane to the main field area of the deck. Standard method of detailing using Hot Melt The Bauder Bakor is first poured carefully into the nick of the upstand, and then drawn up the upstand in a series of passes with the trowel or plywood spreader. With each pass, the membrane is built up to 3mm in thickness. The relevant reinforcement is then bedded into the membrane whilst it is still hot. Where the upstand is monolithic concrete, block or brickwork, the reinforcement will be polyester fleece. Where the upstand is formed in metal, timber, plywood or any other material, the reinforcement will be part-cured neoprene. First Layer of Bauder Bakor The application of the Bauder Bakor system to the main deck area is carried out in a planned and organised manner to achieve an even monolithic application of the system across the deck. The hot melt membrane is applied in two 3mm thick layers at the combined nominal rate of 6.5kg/m² for the two layers. The system is installed using a grid method to accurately control the consistent application rate of the membrane across the whole area of the deck. Working methodically within a 900mm wide grid line, the first 3mm layer of membrane is installed by pouring the Bauder Bakor hot melt onto the deck and spreading it with a rubber bladed squeegee, to achieve an even coverage over the whole width area within each grid line. The second 3mm layer of membrane is then applied using the same method as previously described. The specified Bauder access/protection sheet is then fully bedded into membrane while it is still hot. Waterproofing to items of complex detailing The application of the waterproofing system to these details will vary depending on a number of factors, including the construction sequencing, design of the protrusion such as a balustrade base, size & shape etc. Other considerations include surface levels, expansion joint widths, and initial construction movement or anticipated postinstallation movement. CAD drawings for standard detailing are available for download on our website, Additionally we can advise, design, and provide CAD drawings to illustrate the waterproofing detailing to any structure on receipt of drawings, for guidance. Complex detailing may include: Balustrades Vent pipes Expansion joints I beams Metal upstand brackets Concrete stairways Smoke vents Glazing cills Reinforcement Sheet When the first section of hot melt membrane has been spread and is still hot, the relevant reinforcement layer, usually the Bauder Polyester Fleece is carefully placed into the first layer of hot melt, and rolled out, fully bedding the fleece into the hot melt membrane. A wide headed clean brush can be used to brush down the fleece into the hot melt to ensure it is fully bedded into the membrane with no air pockets and no bare areas of deck beneath. The fleece, which is white in colour, will turn grey as the bitumen starts to partially bleed through. The installer only lays enough of this first layer that can be safely covered by the second coating layer and its relevant access/protection layer by the end of each day or according to the prevailing weather conditions. Second Layer of Bauder Bakor The second layer of membrane is always installed on the same day as the first and is applied in the same manner; pouring, and evenly spreading the membrane to a 3mm depth within each grid line formed by the polyester reinforcement. As the installation of the second layer progresses, the appropriate access/ protection sheet is bedded into the membrane while it is still hot. An example of how a very complex detail features can be undertaken using the Bakor waterproofing. bauder.ie 70

11 ACCESS AND PROTECTION LAYERS For all applications, whether it is roofing or tanking, the membrane requires an access/protection layer bedded into it to protect it from trafficking and likely damage from following trades. The protection layer also allows for access for the safe installation of the landscape finish. The type of protection layer will depend on the proposed build-up and the expected period of time that the system is going to be exposed to following trades. Bauder AP1 This is a 2.2mm reinforced modified bitumen membrane for use on horizontal and vertical surfaces to provide access and solar protection. Bauder AP2 A 4mm reinforced modified mineral surfaced bitumen membrane root barrier for horizontal and vertical surfaces, and solar protection to exposed areas. Bauder AP3 This is a rigid 3mm composite board for horizontal and vertical surfaces. It is used for heavy landscaping, tarmac and areas requiring substantial protection. EQUIPMENT The Bakor material must first be heated to the correct temperature until it is molten, during which time it is constantly mixed to ensure its full physical properties develop. The rubber content of the membrane, which is integral to this form of waterproofing material, makes it necessary to use indirect heat, as achieved by using a double-jacketed hot melt mixing machine (unlike a standard single-shell asphalt mixer). The outer jacket holds a heat transfer oil that when heated by one or two propane burners, gently warms the Bauder Bakor compound in the inner jacket. This type of mixer ensures uniform heating of the material. Air jacketed machines are also a popular alternative, which can offer additional benefits of economy and versatility. A mechanical sweep agitator within the machine keeps the melted compound stirred. This is usually at the bottom of the inner shell and takes the form of a reciprocating blade, driven via external cranks and powered by a small engine mounted on the machines chassis. TESTING AND INSPECTIONS As part of their own quality control procedures, the installing Bauder approved contractor will mechanically test the membrane as it is installed to ensure that the membrane is at least 6mm thick beneath the protection sheet. Additionally, our site technicians will randomly inspect the work during installation. To meet the criteria of the Bauder System Guarantee, we will carry out the final inspection with the approved contractor in attendance to ensure the integrity of the finished roof and that it meets the required standards of installation. Any issues identified will be reported to the Bauder approved contractor for immediate rectification. Any remedial work will then be re-tested. As the Bauder Bakor monolithic membrane system is described as a protected roof membrane it should always be covered by some form of build up. This will generally entail following trades accessing the roof and using it as a platform to install the additional finish. Bauder recommends that integrity testing be carried out and the results notified to the client and Bauder prior to any other trades works starting. There are a variety of testing options available: Leak Testing Immediately prior to installing any landscaping, the integrity of the waterproofing system must be independently checked for leaks. The method of testing should be agreed with the client s representative. Electronic Test This method is considered the quickest and most accurate method of testing, as this accurately locates very small penetrations on main deck areas. Independent certification is a warranty requirement and a copy of this test certificate must be submitted to Bauder Ltd prior to the issue of the Guarantee. Additional Localised Testing It has been known that the electronic method can be inaccurate when conducted in close proximity to metal objects, such as outlets, & metal upstands. In these cases a localised flood test against the areas/details to be checked is more accurate and may be done in conjunction with the electronic test method. Once all additional trades have completed their works, it may be necessary to re-test any affected areas and remedial repairs made. TECHNICAL GUIDE The oil-jacketed melting machine is typically equipped with two temperature gauges, so that the mixer operator can continually monitor both the temperature of the heat transfer oil and the compound. The safe operating temperature ranges from 162 C to 215 C (320 F to 419 F) with the most common operating temperature range from 180 C to 200 C (356 F to 392 F). Image courtesy of IRT Surveys 71 bauder.co.uk

12 UNITED KINGDOM Bauder Limited 70 Landseer Road, Ipswich, Suffolk IP3 0DH, England T: +44 (0) E: bauder.co.uk IRELAND Bauder Limited O Duffy Centre, Cross Lane, Carrickmacross, Co. Monaghan, Ireland T: +353 (0) E: [email protected] bauder.ie