Sy stemIn stallation GUIDELINES - SIG · PDF fileMetaldeck Concretedeck Plywooddeck. 10. 11 NB:Thisisaguideonly–pleaserefertoArmourplanApplicationManualforContractornotes InstallationGuidelines-ArmourplanSM/P

System InstallationGUIDELINES

Issue 3 - October 2013

1 Introduction

About the IKO Group 2 - 3

IKO Single Ply UK Manufacture 4

Armourplan PVC Membranes 5

2 General Information

Tools and Equipment 6 - 7

Storage Guidelines 8

Cleaning Regime 8

Day Joints 9

3 Armourplan System Overview

Mechanically Fastened Roofing System 11

Adhered Roofing System using Contact Adhesive 12

Adhered Roofing System using PU Adhesive 13

Inverted and Ballasted Roofing System 14

Warm Ballasted Roofing System 15

System Accessories 16 - 19

Contents

1

4 General Application Guidelines

Hand Welding 20 - 21

Cross Joints 22

Adhering Upstands 23 - 24

Armourplan System Construction 25

5 Standard Detail Procedure

Pipe Flashing 26 - 28

Rainwater Outlets & Parapet Outlets 29 - 31

Internal Corner (Horizontal and Vertical Folds) 32 - 35

External Corner 36 - 38

Rooflights 40 - 41

Peel Tests 42

Roof Trims 44 - 46

Armourplan Roof Trims Internal Corner 48 - 49

Armourplan Roof Trims External Corner 50 - 51

2

1 Introduction

About the IKO Group

IKO is a family owned company that has been committed to manufacturingquality residential and commercial roofing products since 1951. Our companymotto is "Setting the Standard" and that's what we do; set the standard forquality, durability and innovation.

3

The IKO Group is a global leader inthe manufacture and supply of roofingand waterproofing products. Groupheadquarters are in Alberta, Canada,with production carried out at plantsthroughout North America and Europe.

In the UK, IKO PLC embraced some ofthe most respected and long-establishedbrands in the marketplace, includingRuberoid Building Products, PermaniteEngineered Roofing Systems, PermaniteAsphalt, Marley Waterproofing,Hyload and SpectraROOF SinglePly Engineering.

IKO PLC’s product range includes:

• Polymeric Single Ply Systems

• Monolithic Hot Melt RoofingSystems

• Reinforced Bituminous MembraneSystems

• Mastic Asphalt Systems

• Green Roof Systems

• Insulation Materials and RoofingAccessories

• Pitched Roof Protection Systems

• High Performance DPC& Cavity Tray Systems

• Below Ground DPMs & TankingSystems

• Waterproofing Solutions &Compounds

4

1 Introduction

Key Benefits• Dedicated UK-basedmanufacturing unit• BS EN ISO 9001* accreditation• BS EN ISO 14001* accreditation• Extensive range of products• Complete system offer• Trained technical support staff• Stringent product testing procedures

As a global leader in themanufacture and supply ofwaterproofing, roofing and insulationmaterials, IKO is committed tominimising its environmental impact.IKO takes responsibility for theeffects its business has on the planet.From planning and paperwork, toour manufacturing processes andmaterials, distribution and use, weconsider the environmental impactsthroughout the product lifecycle.

IKO’s UK manufacturing plantis built using recycled buildingmaterials and is designed inaccordance with BREEAM**, theworld’s leading and most widelyused environmental assessmentmethod for buildings.

It also re-uses by-products frommanufacture, wraps products inminimal packaging and employs astreamlined transportation network.

All polymeric materials offered byIKO are resistant to weathering,chemical oxidation and UV radiationwhich ensures long term durability,a key factor in environmentalsustainability.

* ISO 9001 is the International Standards OrganisationStandard for Quality Management Systems.ISO 14001 is the International Standards OrganisationStandard for Environmental Management Systems.

**Building Research Establishment EnvironmentalAssessment Method.

IKO Single Ply UK ManufactureIKO manufactures the latest generation of polymeric single ply membranes,including PVC, TPO and TPE systems and associated ancillaries.

Armourplan membranes are manufactured in a purpose built, state-of-the-artmanufacturing facility based in Chesterfield, UK. Substantial investment in thelatest extrusion technology and computer controlled manufacture ensuresconsistently high quality membranes are produced while also saving on energyand wastage.

5

Armourplan PVC is produced in a range of differentmembrane ‘types’ designed for specific applications:

Armourplan PVC Membranes

• Armourplan SMPolyester scrim reinforced membrane for mechanically fastened roofing systems.The membrane is mechanically fastened in the overlap using IKOfix Stress Plates andIKOfix Screws, the fixing passes through the insulation and vapour control layer into thedeck. Overlaps are hot air welded. Armourplan SM can also be used for ballasted systemsor alternatively on adhered systems using contact adhesive. Armourplan SM is also usedas the upstand detailing membrane on all Armourplan SM systems. Available in either1.2mm or 1.5mm thicknesses and in three standard colours; light grey (RAL 7047), midgrey (RAL 7046) and slate grey (RAL 7015).

• Armourplan SGGlass tissue reinforced fleece backed membrane for bonded roofing systems. Themembrane is bonded to the substrate using Spectrabond low foaming PU Adhesive.Side laps are hot air welded. End laps are butt jointed and waterproofed with a coverstrip. Available in either 1.2mm or 1.5mm thicknesses and in one standard colour;mid grey (RAL 7046).

• Armourplan PSGGlass tissue reinforced fleece backed membrane for bonded roofing systems.Armourplan PSG offers enhanced mechanical properties over standard PVCmembranes and is completely UV stable throughout. The membrane is bonded tothe substrate using Spectrabond low foaming PU Adhesive. Side laps are hot airwelded. End laps are butt jointed and waterproofed with a cover strip. Available in1.2mm thicknesses.

• Armourplan P1.2mm thick polyester-reinforced membrane suitable for use in a wide range ofroofing applications on both flat and sloping roofs. Armourplan P offers enhancedmechanical properties over standard PVC membranes and is completely UV stablethroughout. Armourplan P can be mechanically fixed, adhered or ballasted and alloverlaps are heat welded using suitable hot-air welding equipment. Armourplan P isavailable in two standard colours; mid grey (RAL 7046) and slate grey (RAL 7015).

6


• Hot Air Hand Welders - Qualityhot air hand welding tools areavailable from Leister (Triac PID)and Sievert (TH1750). These toolsare lightweight and have a digitaltemperature display showing ‘set’and ‘actual’ air temperatures up tomaximum 700°C. The recommendedwelders have stepless electronictemperature control and areavailable in both 110v and 230v.

• Automatic Hot Air Welders -Suitable machines are availablefrom both Leister (Varimat) orSievert (TW5000), and weighapproximately 25kg. The digitaltemperature display shows ‘set’and ‘actual’ air temperatures upto a maximum 660°C. Maximumwelding speeds are between5-7metres per minute. Thesemachines have stepless electronictemperature and welding speedcontrol. The independentsuspension pressure roller ensuresconsistent distribution of pressureon uneven substrates.

Tools and Equipment

SAFETY NOTEAs with any light coloured surface membrane,it is advisable to take precautions to avoidany harmful effects caused by working indirect sunlight during installation.

7

• Nozzles - A 40mm wide nozzle shouldbe used where stresses occur on themembrane laps e.g. in the field zone.The 20mm wide nozzle is used forwelding laps located at intricatedetailing e.g. internal corners, and areinterchangeable with the hand weldersoutlined above.

• Seam Pressure Roller - 40mm widesilicone roller for providing pressure towelded laps.

• Penny Pressure Roller - 6mm brassroller for providing pressure towelded detailing.

• General Tools - Armourplan PVCmembranes are generally cut usingscissors although a flat bladed knifecan be advantageous at detailing.A wire brush is required to removepolymer deposits from weldingnozzles. Wide paintbrushes orcompatible application rollers aresuitable for application of ArmourplanPVC Contact Adhesive.A chalk line should be used to markthe membrane prior to cutting.Tape measures should be used toensure consistency of lap widths.Welded seams should be checkedusing a suitable seam check tool.

A chamfer tool is also used on1.5mm and 2.0mm Armourplanmembranes. This is an edgetrimming plane used for chamferingthe square edge of a seam.

8


Once delivered to site the membraneshould be protected against exposurefrom rain and site dirt.

When stored in clean & dryconditions the Armourplanmembrane needs no additionalcleaning during hot air welding.

Storage Guidelines

Clean - Unwrapped, installed andwelded immediately.

Soiled - Contamination frommoisture, building site dust & dirt.

Heavily Soiled - Extensive exposureto contamination from moisture,building site dust & dirt.

Clean Armourplan PVC -No action required

Soiled Armourplan PVC -actions 1, 2, 3 & 4

Heavily soiled Armourplan PVC -actions 1, 2, 5 & 4

Cleaning Regime

1.Wash/scrub membrane withwarm soapy water

2. Allow to dry

3. Clean with Armourplan PVC cleaner

4. Allow to fully dry (approx 1/2 hour)

5. Clean with Armourprep

If the membrane becomes wet orsoiled after preparation then thecleaning regime is to be repeated.Avoid all contact between theArmourprep and polystyrene insulation.

9

Day joints help to protect fromwater ingress under incompleteareas roof.

The day joints should be installedwhen work is either interrupted dueto adverse weather or at the end ofeach working day.

IKO would always recommend goodroofing practice and promote thatonly areas that can be completedthat day should be laid and thatdetail work is completed as theroof progresses.

The diagrams opposite show typicalmethods of sealing day joints.

Day Joints

Adhesive tape

Tape

Note: Remainder of plywood deckshould also be protected.

Adhesive Tapeon Torch-on layer.

Min 20 mm

Min 20 mm

Metal deck

Concrete deck

Plywood deck

10

11NB: This is a guide only – please refer to Armourplan Application Manual for Contractor notes

Installation Guidelines-Armourplan SM/P

1. Carefully unroll the ArmourplanSM/P out over the previouslyprepared substrate. If installing on aprofiled metal deck ensure that themembrane is perpendicular to thedirection of the deck sheet.

2. Install the IKOfix fasteners, usingan appropriate installation tool30mm from the rear edge.Fasteners must be installed at thefixing centre specified by IKO forthe specific project.

3. Unroll the next roll of ArmourplanSM/P ensuring the end laps arestaggered and the side overlaps thepreviously installed sheet by 110mm.

4. Hot air weld the side laps with anautomatic welder or hot air gun andallow to cool completely.

5.Mechanically check the integrity ofthe cooled weld by running a 4mmwide screwdriver (with roundededges) along the seam applyingpressure into the seam.

6. In corners and other areas whereadditional fastening is required installIKOfix fasteners through the roofsheet and cover with a 200mmwide strip of Armourplan SM/P. Hotair weld both sides and ends.

7. At upstands and at all roofpenetrations, secure the ArmourplanSM/P membrane with a toothed bar.

8. Cover 10mm gap in the toothedbars with a 50mm x 50mm piece ofArmourplan SM/P and weld to theroof sheet.

9.Waterproof the toothed bar withthe upstand flashing hot air weldedto the roof sheet.

Mechanically Fastened Roofing System

12


Installation Guidelines using PVCContact Adhesive - Armourplan SM/P

1. Before use, thoroughly stir thePVC Contact Adhesive. Replacethe container lid when workis interrupted.

2. Using a sheepskin roller apply aprimer coat of PVC ContactAdhesive to the prepared substratesurface, priming only the area ofsubstrate where the membranewill be laid the same day. Allowadhesive to dry. If the substrate isPIR insulation then all the boardjoints are to be taped usingself-adhesive foil faced tape prior tothe primer coat being applied.

3. Unroll the Armourplan SM/P overthe primed substrate and fold backapproximately half its length.

4. Apply PVC Contact Adhesive witha sheepskin or similar roller to theunderside of the Armourplan SM/Pmembrane ensuring the weld area iskept free of adhesive and allow tobecome tacky.

5. Carefully roll out the ArmourplanSM/P over the previously primedsurface and roll with water filled rolleror soft broom to ensure intimatecontact between the two surfaces.

6. Fold back other half of the rollof Armourplan SM/P and repeatthe procedure.

7. Unroll the next roll of ArmourplanSM/P, ensuring the end laps arestaggered and the side overlaps thepreviously installed sheet by 60mm.

8. Repeat the adhering process.

9. Fully hot air weld the 60mm sidelap, allow to cool completely.

10.Mechanically check the integrityof the cooled weld by running a4mm wide screwdriver (withrounded edges) along the seamapplying pressure into the seam.

11. At upstands and at all roofpenetrations, secure theArmourplan SM/P membranewith a Peel Stop Bar.

Adhered Roofing System using Contact Adhesive

NB: This is a guide only – please refer to Armourplan Application Manual for Contractor notes

Important: PVC Contact Adhesive must only beapplied to 100% dry substrates. Failure to do so couldresult in the membrane disbonding. Please note:Insulation boards will require their joints taped.

13

Installation Guidelines -Armourplan SG/PSG

1. Before use thoroughly stir theSpectrabond PU Adhesive. Replacethe container lid when work isinterrupted. If required warm theSpectrabond PU Adhesive inwarm water.

2. Unroll the Armourplan SG/PSGover the prepared substrate and foldback approximately half its length.

3. Using a sheepskin or similar rollerapply a primer coat of SpectrabondPU to the substrate surface, primingonly the area of roof where themembrane will be laid.

4. Carefully roll the ArmourplanSG/PSG into the primed surface.

5. Fold back other half of the roll ofArmourplan SG/PSG and repeatthe procedure.

6. Roll with water filled roller or softbristled broom to ensure intimatecontact between the two surfaces.

7. Unroll the next roll of ArmourplanSG/PSG, ensuring the end laps arestaggered and the side overlaps thepreviously installed sheet by 60mm.

8. Repeat the adhering process.

9. Fully hot air weld the 60mm side lapand allow to cool completely.

10.Mechanically check the integrityof the cooled weld by running a4mm wide screwdriver (withrounded edges) along the seamapplying pressure into the seam.

11. At upstands and at all roofpenetrations, secure theArmourplan SG/PSG membranewith a Peel Stop Bar.

The PU adhesive must be given timeto activate prior to applying themembrane. On activation i.e. the pointat which the adhesive will afford thehighest bond strength, the surface ofthe adhesive starts to change frompink to opaque.

Adhered Roofing System using PU Adhesive


14



Installation Guidelines usingArmourplan SM120or Armourplan P(Inverted Roof Option)

1. Carefully unroll the Armourplanlevelling layer over the previouslyprepared deck. All end and sidelaps to be a minimum of 100mm.

2. Carefully unroll the ArmourplanSM/P out over the levelling layer.

3. Unroll the next roll of ArmourplanSM/P ensuring the end laps arestaggered and the side overlaps thepreviously installed sheet by 80mm.

4. Hot air weld the side laps with anautomatic welder or hot air gunand allow to cool completely.


6. At upstands and at all roofpenetrations secure the ArmourplanSM/P membrane with a toothed bar.

7. Cover 10mm gap in the toothedbars with a 50mm x 50mm piece ofArmourplan SM/P and weld to theroof sheet.

8.Waterproof the toothed bar withthe upstand flashing hot air weldedto the roof sheet

9. Thoroughly check the roof area fordamage and weak welds payingclose attention to all cross-joints andT seams.

10. Install the approved thermalinsulation over the SM/P membraneensuring that all insulation boardsare laid with staggered joints andthe boards are clear from debris.

11. Unroll the filter/separation layerover the completed roof areaallowing 100mm overlap on all sideand end laps.

12. If using round washed pebbles asballast then the separation layermust be installed to a minimumheight of 50mm up all upstands.

13. Install approved ballast.

Inverted Roofing System

15NB: This is a guide only – please refer to Armourplan Application Manual for Contractor notes

Installation Guidelines usingArmourplan SM or Armourplan P

1. Carefully unroll the ArmourplanPVC membrane out over thepreviously prepared substrate.

2. Unroll the next roll of ArmourplanPVC membrane ensuring the endlaps are staggered and the sideoverlaps the previously installedsheet by 80mm.

3. Hot air weld the side laps with anautomatic welder or hot air gunand allow to cool completely.


5. At upstands and at all roofpenetrations secure theArmourplan PVC membranewith a toothed bar.

6. Cover 10mm gap in the toothedbars with a 50mm x 50mm pieceof Armourplan PVC and weld tothe roof sheet.

7.Waterproof the toothed bar withthe upstand flashing hot air weldedto the roof sheet.

8. Thoroughly check the roof area fordamage and weak welds payingclose attention to all cross-jointsand T seams.

9. Unroll the 300gsm separation layerover the completed roof areaallowing 100mm overlap on all sideand end laps.

10. If using round washed pebbles asballast then the separation layermust be installed a minimumheight of 50mm up all upstands.

11. Install approved ballast.

Warm Ballasted Roofing System

16


A range of ancillaries is available to complement the Armourplan PVC fieldsheet membranes:

PVC Coated Metal

PVC coated metal is a steel sheet pre-coated withhomogeneous PVC membrane. The coatedmetal can be fabricated off-site to form perimeterdetails such as drip edges and upstands. ThePVC membrane surfacing to the metal enablesArmourplan PVC Membranes to be heatwelded to preformed edge details to ensure theperimeters are fully sealed and waterproofed.

Spectrabond Low Foaming PU Adhesive

Spectrabond PU Adhesive is a ready to use, highperformance, single component, moisture curingpolyurethane adhesive for bonding fleece backedpolymeric single ply membranes to rigid insulationand other suitable substrates. The adhesive is coldapplied and has been specially developed to allowsafe and rapid bonding of suitable membranes.

System Accessories

• Armourplan DGlass tissue reinforced roofingmembrane for use on complex detailing.

• Armourplan WalkwayHeavy duty PVC membrane witha grid pattern for use on walkways.

Armourprep

Armourprep is a heavy duty cleaning solvent designed to be used to clean heavilysoiled PVC membranes. NOTE If in doubt when needed please contact IKOTechnical Services Department on +44 (0)1257 488012.

Avoid all contact between the Armourprep and polystyrene insulation.

17

PVC Contact Adhesive

PVC Contact Adhesive is a ready to use nitrile rubberbased, contact adhesive for adhering Armourplan PVCroofing membranes onto various substrates. It is easy toapply using a brush or a roller. Available in 5lt or 20lt tins.

PVC Membrane Seam Cleaner

PVC Membrane Seam Cleaner is a light cleaning solventdesigned to be used to clean PVC roofing membranesas required prior to welding. It can also be used as ageneral cleaner to remove wet adhesive and residualdirt from the surface of PVC roofing membranes.

Armourplan PVC Sealant

Specially formulated sealant for PVC membranes.Ideal for sealing detail terminations and availablein either white or grey.

Preformed Details

A range of preformed corner and outlet unitsdesigned to facilitate the installation of ArmourplanPVC Single Ply systems. Preformed PVC cornerunits are available in both internal and externalconfigurations and are flexible and easy to mouldand heat weld over the Armourplan PVC Membraneto detail and waterproof corner areas. PreformedOutlets are a range of PVC preformed straightand 90° roof drain outlets. The outlet units aremechanically fixed into position and waterproofedwith a cover flashing of Armourplan PVC Membranewhich is heat welded onto the outlet flange.

18


Pressure Plates

Metal pressure plates suitable for membrane andinsulation applications. Flat plates are used forrigid / flat surfaces and those with a deeperrecess are suitable for compressible substrates.

IKOfix Telescopic Fixing Plates and Fixing Screws

Polypropylene telescopic fixing tubes for fixingmembranes and insulation in warm roofbuild-ups, used in conjunction with the appropriatefixing screws. Using fixing tubes reduces thermalbridging and can offer cost savings when fixingthrough large insulation thicknesses. The telescopiceffect means they can also protect the fixing fromdamage caused by foot trafficking.

Flatbar Toothed, Peel Stop Bar & Clamping Strips

Metal clamping and termination bars formechanical fixing of Armourplan membranesat perimeters.

Armourplan Standing Seam Profile

Armourplan Standing Seam Profile is a preformedprofile used to simulate a metal standing seamjoint. The profile is manufactured fromhomogeneous PVC and is heat welded.

System Accessories (continued)

19

Spectratex Separation LayersSpectratex Separation Layers are a range of polyester geotextile isolation andprotection fleeces. They are used to protect the Armourplan waterproofingmembrane on ballasted roofs and as a separation layer over contaminated oruneven decks.

Vapour Control Layers (VCLs)A range of bituminous VCLs are available to complement Armourplansystems. These include metal lined membranes with an imperviousaluminium core, and a number of other high performance polyester-basedoptions suitable for either torch-on, pour and roll or self-adhesive application.

Spectravap - Polyethylene Vapour Control Layer (VCL)Spectravap is a 0.3mm thick polyethylene VCL, suitable for use on mostArmourplan mechanically fastened systems. It is loose laid over the surfacewith side and end laps overlapped by a minimum of 80mm and sealed witha suitable jointing tape.

PIR Thermal InsulationEnertherm PIR high performanceinsulation boards are totallyCFC/HCFC free, and are made fromrigid polyisocyanurate foam. They areavailable with a choice of facings -clay, or glass tissue, or aluminium.

20


1.When hot air welding Armourplan theoverlap should be clean and dry. Thefollowing minimum system overlaps arerequired. Adhered - 65mm, Loose laid- 80mm Mechanically fixed - 110mm.

TACK WELD The tack weld preventsmovement of the overlap.

2. Position the welding nozzle at the rear ofthe overlap allowing for a 30mm lap toremain once welded (see illustration).

PRE-WELD The pre-weld acts as acontinuous air trap, ensuring minimal heatloss during the final weld stage.

3. Always roll the pressure roller fully acrossthe seam. A distance of 20mm should bekept between the roller and nozzle.

FINAL WELD The final weld ensures that theoverlap is watertight.

Hand Welding

21

4. The seams are to be checked once theyhave completely cooled. Seams are checkedusing an approx 5mm wide probe withrounded edges.

SEAM CHECK A seam check is not a leak testbut will help to identify weak welds.

GENERAL INFORMATION ON WELDING ARMOURPLAN MEMBRANES

Armourplan SM, P and SG can be welded at temperatures ranging from400°C to 450°C.

The appropriate temperature should be selected depending on individualspeed preferences and ambient conditions.

Armourplan D should be welded at temperatures between 380°C and 420°C,allowing for greater control when dealing with intricate or difficult details.

Automatic machine welding guide rates:

SPEED: 1.8 - 2.0 linear metres per minuteTEMP: 420°C and 450°C

NOTEWelding should be carried out in adequately vented surroundings.

22


1. Mitre the lower layer of overlap seam asillustrated. Round off corner to top overlaplayer. Fully weld subsequent layers ofmembrane to fieldsheet.

NOTE Care should be taken at point ofpotential capillary (see illustration).

When installing 1.5mm & 2.0mm membranesit is recommended that the seam edge ischamfered in the areas of transverse jointsand cross joints. The chamfer must extend thewidth of the entire weld.

Cross Joints

23

1. The PVC Contact Adhesive is applied evenlywith a brush or compatible application roller.Absorbent substrates may require two ormore coats of adhesive.

NOTE If in doubt please contact IKO TechnicalServices Department on +44 (0)1257 488012.

The primed substrate must be allowed todry fully before further coats or membraneare applied.

NB. Normal conditions require one coat.

Please refer to the Armourplan ApplicationManual for advice on suitable substrates whenusing PVC Contact Adhesive.

Insulation boards will require their joints taped.

All substrates must be completely dry beforeapplying Contact Adhesive.

2. PVC Contact Adhesive is now applied to theback of the Armourplan membrane with abrush or compatible application roller.

Residual adhesive should be removed.

Care should be taken not to apply adhesivein areas of seam to be hot air welded.

NOTE If in doubt please contact IKOTechnical Services Department regardingcompatibility between the Contact Adhesiveand the substrate/insulation board.

Adhering Upstands

24


3.When the solvent has evaporated, positionthe Armourplan membrane onto theprimed substrate.

The evaporation time will depend on theweather conditions, amount of adhesiveapplied and type of substrate beingadhered to.

An indication of when sufficient solventhas evaporated is by the finger test(see diagram). Adhesive strands shouldbe approximately 10mm.

4. Once the membrane has been applied tothe substrate the surface must be rolled toensure all air pockets are removed andthat intimate contact is achieved betweenthe membrane and substrate.

Adhering Upstands (continued)

10mm

25

Armourplan System Construction

1. A 10mm clearance is needed between thebar ends due to expansion and contractionof the bar.

2. Cover the bar ends with a sacrificial pieceof Armourplan. This will help protect themembrane flashing from sharp edges.

10mm

26


Pipe Flashing

1. Cut a hole in the Armourplan fieldmembrane. This needs to be slightly largerthan the pipe diameter.

2a. Cut a hole in the Armourplan D base plateapron 10mm smaller than the pipe diameter.

NB. The outer diameter should be largeenough to cover any additional fasteners.

2b. Pull the base plate apron over the topof the pipe.

TIP Warming up the inner hole with a hotair gun will help this process.

27

3a.Once in position the base plate apron willcreate a 10mm upstand around the pipe.

3b. Hot air weld the outer edge of the baseplate apron to the field sheet.

TIP Welding temperature for Armourplan Dshould be approximately 380 °C - 420 °C.

4. Cut out a pipe collar flashing to suit thepipe dimensions. A 20mm (min) verticaloverlap and 15mm (min) horizontaloverlap should be allowed for.

It is advised to prepare the horizontaloverlap prior to installation (as illustrated).

Pre-stretch the horizontal overlap.

5. Once prepared, position the pipe collarflashing around the pipe and tack weldthe base into position.

10mm

28


6. Hot air weld the vertical pipe collar seam.

7. Hot air weld the horizontal seam to theapron base plate.

8. Completed detail

Once completed, the top of the pipe is tobe clamped with a mechanical restraintand sealed using Armourplan PVC sealant.

Pipe Flashing (continued)

29

Rainwater Outlets

1. Mechanically fixed systems requireadditional fasteners around the outlet.These can be positioned around thecompleted outlet and weatheredseparately or alternatively they can beinstalled under the outlet.(Not suitable for cold roof applications)

2. Connect and seal Armourplan outlet.Weld Armourplan outlet to field sheet.

OptionalCut and position the circular apron.

3.Weather outlet by welding apron tooutlet and membrane.

30


Parapet Outlets (Option A)

Two matching Armourplan D pieces should be cut as illustrated.One piece should be welded to the outlet first. Then the secondpiece can be positioned and welded to the outlet. Once thisoperation is completed the outer edge can be welded to thefieldsheet and upstand flashing.

31

Parapet Outlets (Option B)

Weld the two Armourplan D pieces to the outlet prior to installing it.Remember to leave the fixing points of the outlet free from weldand complete outer edge welding after the outlet has been installed.Once secured the Armourplan cloak can be welded to the fieldsheetand upstand membrane.

32


1. Adhere Armourplan SM membrane intocorner ensuring that the membrane is tightinto all angles.

TIP 20mm nozzle advised.

TIP For corners that are not 90 degrees,allow for an oversized membrane flashingthat can then be trimmed. Form internal foldas illustrated.

2. Form a 45 degree mitre and crease foldwith a silicon roller.

3. Cut out the lower layer of the gussetas indicated.

TIP Allow gusset to cool during procedure toreduce risk of fold splitting.

Internal Corner (Horizontal Fold)

33

4.Weld lower flap to fieldsheet.

5. Hot air weld the remainder of the gusset.

TIP The critical weld is at the internal fold.

6. Complete the weld from the corneroutwards, to achieve completedcorner detail.

34


1. Cut and adhere into position the ArmourplanSM membrane. Ensure that sufficient materialis allowed for on the vertical corner return.(see illustration). If the corner is not square,allow for an oversized membrane flashingand trim back. Ensure membrane is tight intoall angles.

2. Form a 45 degree mitre and crease fold witha silicone roller. Hot air weld the gusset.

TIP Allow the gusset to completely cool beforemoving onto next stage.

3. Hot air weld the Armourplan SM membraneflashing overlap to the adjacent flashingand fieldsheet.

TIP Work away from the internal angle.

Internal Corner (Vertical Fold)

A

A

35

4. Hot air weld the remainder of the gusset.

TIP The critical weld is at the internal fold.

5. Once tacked into position, pre-weldand final weld the corner to formcompleted corner.

Pre-formed internal corner

2. Tack pre-formedcorner into positionas illustrated, ensuringthat it fits all internaland external anglescorrectly. Pre-weld andfinal weld outer edge ofpre-formed corner tomembrane flashing.

1. ApplyArmourplanSM/Pmembraneas illustrated

36


1. Make a cut in the Armourplan SM/Pmembrane in line with the vertical corner.

2.Warm up the Armourplan SM/Pmembrane flashing along the vertical edgeand dress the membrane around thecorner, avoiding ripples.

3. Hot air weld the Armourplan SM/Pmembrane flashing overlap to thefield sheet.

External Corner

37

4. Prepare a corner patch from Armourplan Dapprox 20mm larger than the requireddimensions. Round off the corner beforetack welding into position.

5.Warm up rounded corner sufficiently andstretch so that it fits contour of theextended corner. Tack weld the roundedcorner into position. Allow for a minimumof 20mm on the vertical surface.

6. Hot air weld the top of the raised sectionof the corner patch to the upstandflashing. Allow Armourplan D to coolfully before proceeding to next stage.Now weld either side of the raised cornerto the adjacent angle.

NOTE Hot air weld Armourplan D atapprox 380°C - 420°C.

38


7. Trim thecorner patchin line withouter edge ofthe upstandflashing.

8. Hot air weldthe remainderof the cornerdetail.

External Corner (continued)

9. Completed detail.

TIP Care should betaken on the capillaries(see illustration)

Pre-formed external corner

2. Tack pre-formedcorner into positionas illustrated, ensuringthat it fits all internaland external anglescorrectly. Pre-weld andfinal weld outer edgeof pre-formed cornerto membrane flashing.

1. ApplyArmourplanSM/Pmembrane asillustrated

39

40


1. Adhere Armourplan D to the rooflight kerbusing Armourplan Contact Adhesive. Ensurethat there is sufficient membrane overlapeither side of the rooflight (see illustration).Cut out the corner as illustrated. Oncetrimmed allow for min 30mm extramembrane to return around rooflight corner.

2.Warm up the Armourplan D and adhere tothe adjacent surface. Ensure that areas to behot air welded are free from adhesive.

3. Ensure that there is sufficient membraneeither side of the rooflight. Trim excessmembrane and allow for a thumb sizedtab of material in the base of the corner(as illustrated).

Rooflights

41

4. The corner is now ready for welding.

TIP It is advised that all four cornersare prepared as outlined previously priorto welding.

5.a. Pre-weld the vertical and horizontalseam starting from the internal angleeach time. The protruding thumb tabshould be welded first.

5.b. The final weld can now be carried out.Start the vertical and horizontal weldfrom the thumb tab, to achieve thecompleted detail.

6. Completed detail.

42


1.Optimum welding quality can be ensured by

• Test weld prior to actual welding.• Seam check during welding.• Seam check after welding.

Before welding the membrane a peel test must be carried out to determinethe optimum welding parameters for that day. Subsequent test welds should becarried out if outside temperature dramatically changes. Peel tests shouldbe performed for each piece of hot air welding equipment used.

2. Peel test across the seam

The fully cooled welded seam must notseparate within the final weld zone. 20mmwide strips are cut across the welded seam andcare is to be taken to only cut the top layer.

When machine welding the test weld must notseparate within the whole width of the weld.

3. Peel test along the seam

The fully cooled welded seam is tested bypulling the top layer of the seam. This willalso establish if a continuous weld hasbeen achieved in the final weld zone.

Peel Tests

43

44


2. Apply a 30mm strip of self adhesivealuminium tape over expansion gap.

This will help to provide a clean line onthe pre-weld.

30mm

1. Insert butt strap between joint ofArmourplan trims.

Leave a 10mm expansion gap betweentrims as illustrated.

Trim Fixing Guidea. General trims on adhered upstands- fix at 250mm centres.

b. Trims used as mechanical restraint- fix at 150mm centres.

c. Trim used as part of a mechanically fixedupstand - fix at 150mm centres.

d. Fixings should be staggered on widehorizontal surfaces.

Roof Trims

10mm

45

3. An Armourplan D strip should be weldedto the face of the trim.

NOTEWelding temperature for Armourplan Dshould be approx 380°C - 400°C.

Face Fixing Guidea. 50mm - 90mm deep trims - 0.6mm thick butt strap plate needed.b. 90mm - 120mm deep trims - 0.6mm thick butt strap plate neededand face fixed at each end.

c. 120mm - 150mm deep trims - 0.6mm thick butt strap plate neededand face fixed at each end and in the centre.

In the event that Face Fixing is not possiblea. If a suitable face fixing cannot be achieved then face fixings can besubstituted for additional 0.6mm galvanised butt straps.

b. 50mm - 90mm deep trims - each end and in the centre of the trim.c. 90mm - 150mm deep trims - at 500mm spacings including each end.

Trims protected from wind damage by guttering may not need additionalface fixing. If in doubt please consult IKO Technical Services Departmenton +44 (0)1257 488012.

Min 80mm

46


4a. Carry out the remaining weld of theArmourplan D strap.

4b. Complete butt strap detail.

Roof Trims (continued)

5mm

5.Hot air weld the Armourplan field sheetor upstand flashing directly to the trim.

Ensure membrane is positioned a minimumof 5mm from the outer edge of the trim.

TIP Care should be taken to ensure acapillary is not created when passing overthe butt strap (See circles to left).

47

48


1. Mark a mitre on the Armourplan coatedmetal and cut out excess to fit internal corner.

TIP: Ensure drip return is cut directly belowfold point so that a straight corner canbe formed.

To ensure accuracy, transfer cutting pointwith a right angled straight edge.

2. Internal corner once cut.

3. Fold the Armourplan roof trim to forma corner and fix to substrate.

Armourplan Roof Trims Internal Corner

49

4. Cut and adhere Armourplan SM/Pmembrane to substrate. Ensure membraneis free from adhesive in the section to bewelded to Armourplan trim. Once inposition weld Armourplan SM/P membraneto the trim and fieldsheet.

TIP: Before folding the membrane onto thehorizontal surface of the parapet, heat up theArmourplan membrane at the point of thefold with the hot air welder.

This will help to create a clean, neat edge.

5. Cut and position patch as illustrated usingArmourplan D membrane only.

6. Hot air weld down the Armourplan Dcorner patch.

50


1. Mark a line on Armourplan coated metaland cut to fit external corner.

TIP: Ensure drip return is cut directly belowfold point so that a straight corner canbe formed.

To ensure accuracy, transfer cutting pointwith a right angled straight edge.

2. Fold the Armourplan roof trim to formexternal corner and fix to substrate.

Cover the remainder of the corner byinserting a section of Armourplan coatedmetal as illustrated.

3. Cut and adhere Armourplan SM/Pmembrane to the substrate.

Ensure membrane is free from adhesive insection to be welded to Armourplan trim.

Armourplan Roof Trims External Corner

51

6 Hot air weld the remaining side ofArmourplan SM/P membrane to theArmourplan trim.

Ensure mitered pocket is fully welded.

4. Cut Armourplan D patch and weld intoposition as illustrated. To ensure coverage,cover cut edge of trim.

5.Weld one side of the Armourplan SM/Pmembrane to the Armourplan coated metal.

Create a 45 degree fold in the ArmourplanSM/P membrane. Hot air weld the pockettogether and allow to fully cool beforecontinuing.

IKO Single Ply is a trading division of IKO PLC.VAT Registration No. GB 643 0358 57 Company Registered in UK No. 2678296.Registered Office: Coney Green Business Park, Coney Green Road, Clay Cross, Chesterfield S45 9HZ.

Whilst every care is taken to see that the information given in this literature is correct and up to date it is notintended to form part of any contract or give rise to any collateral liability, which is hereby specifically excluded.Intending purchasers of our materials should therefore verify with the company whether any changes in ourspecification or application details or otherwise have taken place since this literature was issued.

Member of the IKO Group

Coney Green Business ParkConey Green RoadClay CrossChesterfield S45 9HZ

Sales SupportT: 01257 488005F: 01246 868035E: [email protected]

www.ikogroup.co.uk

Technical ServicesT: 01257 488012F: 01246 868035E: [email protected]

Documents

Sy stemIn stallation GUIDELINES - SIG · PDF fileMetaldeck Concretedeck Plywooddeck. 10. 11 NB:Thisisaguideonly–pleaserefertoArmourplanApplicationManualforContractornotes InstallationGuidelines-ArmourplanSM/P