01 11 02 30 Contractor Quality Control-1111(Nov).pdf

IDIQ ROOF MAINTENANCE/REPAIR/REPLACEMENT VNVP 111080

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November 2011

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CONTRACTOR’S QUALITY CONTROL

(For Use With Section 07 51 13)

PART 1: GENERAL:

1.1. APPLICABLE PUBLICATIONS: See Section 07 51 13 for reference publications.

Publications listed in this section form a part of this specification to the extent referenced.

The publications are referred to in the text by the basic designations only.

1.2. DESCRIPTION OF WORK: This section covers the quality control inspection, sampling, and testing of all supplies, services, and/or workmanship required to be performed by the contract drawings, specifications, and requirements when a Built Up Roof is re-roofed. The contractor shall perform all quality control inspection and/or testing required by this contract (unless specifically designated in this section to be performed by the

Government) and shall be responsible for reviewing the contract drawings and specifications and ensuring that all materials and/or procedures used comply with the approved AF Form

3000's.

1.3. BASIS FOR PAYMENT: No separate payment will be made for the contractor's quality control inspection performed under this contract

PART 2: PRODUCTS: See Section 07 51 13: PRODUCTS

PART 3: EXECUTION:

3.1. CONTRACTOR QUALITY CONTROL:

3.1.1. It is the responsibility of the contractor to ensure that the designated roofing quality control person complies with all requirement relating to the roofing work. To accomplish this, the quality controller must observe work in progress, including observation of testing and measuring conducted by the Air Force inspector, and report work conditions daily of AF Form 1063, Quality Control Record. Instructions on how to use this form are included in Part 4. Work accomplished on a daily basis will be considered satisfactory only when the daily record form show that all “variances” have been corrected and that the work is in conformance with the contract.

3.1.2. Quality Control (QC).

3.1.2.1. As specified herein, provide the evidence needed to establish confidence that quality control (QC) is being performed adequately.

3.1.2.2. Except as modified and supplemented herein, follow the published requirements and written recommendations of the BURS and other materials manufacturers. Concerning methods of installation, industry practices apply only when this contract does not address the matter.

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3.1.2.3. The specified QC requirements are minimums. Provide additional QC, if in the opinion of the Contracting Officer, the QC is not effective enough to provide conforming work. This additional QC does not constitute a change to the contract.

3.1.2.4. The QC is subject to audit by an Air Force inspector. Provide the inspector all information necessary for this audit.

3.1.2.4.1. The Air Force is not obligated to inspect a contractor’s work or to protect a contractor from the consequences of such work. Air Force inspection is a general examination of the contractor’s conduct and work, and is solely for the purposes of the Air Force. Air Force inspectors do not have the authority to accept any work, whether or not it is conforming. Air Force inspection is not to be construed as conclusive. Information that may be offered to the contractor does not change the contract.

3.1.2.4.2. Air Force agents, including inspectors, engineers and quality assurance evaluators, are not authorized to change the contract without the written authorization of the Contracting Officer. This lack of authority extends to all situations in which the actions of these agents could be construed as constituting a change.

3.1.3. Provide Quality control defined as follows:

3.1.3.1. Quality control is the regulatory process by which the contractor measures actual performance quality, compares it with standards, and acts on the difference.

The quality function is the entire collection of activities through which fitness for use is achieved.

3.1.3.2. Contractor inspection is a careful and critical investigation of all work to assure that it conforms to the contract, and to detect variances and act to correct them in time to prevent reworking and delay. This includes detailed, skillful examination and testing with immediate comparison to the requirements of the contract. On discovery of variance the contractor shall immediately institute corrective action to eliminate the variance and to insure that all future work conforms to the requirements of the contract.

3.1.3.3. The quality controller shall have at least 5 years experience in the supervision and inspection of BUR construction. The quality controller shall not be a principal or officer of the roofing contractor’s company. However, the quality controller can be the job foreman. The quality controller shall be on the jobsite at all times Built-Up Roof construction is underway.

3.1.3.4. The contractor shall attend each preconstruction conference. The quality controller and the foreman or superintendent must attend each conference. The technical representatives from both the membrane and insulation manufacturers typically do not attend this conference, but shall be present if requested. These representatives shall be knowledgeable in the installation peculiarities and compatibility of their product. The contractor shall give an oral presentation of proposed construction method. The manufacturers’ representatives shall provide

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November 2011 input where necessary to describe the proper installation of their materials. The conference may include a visit to the work site.

3.1.3.5. Basic quality control requirements are contained in Part 4 of this specification. As a minimum, the quality controller shall perform each of the actions listed in Part 4, this section, on a daily basis. Failure to perform these actions is a failure to prosecute the work with such diligence that will ensure its compliance with clearances specified in this contract and is grounds for the

Contracting Officer to stop the work.

3.1.4. Preparatory Inspection (To be conducted prior to commencing work)

3.1.4.1. Before actual work begins, the quality controller must:

3.1.4.1.1. Read the specifications and study the drawings.

3.1.4.1.2. Understand the required tests and measurements.

3.1.4.1.3. Understand AF Form 1063, Quality Control Record, and reporting procedures. (See Part 4, this section).

3.1.4.1.4. Visit the roof and become familiar with its layout.

3.1.4.1.5. Attend the preconstruction conference.

3.1.4.2. The quality controller shall supply the following equipment for tests and measurements required to be performed under this contract:

3.1.4.2.1. Provide accurate chart making temperature recorders on kettles to measure and record the bitumen temperature during times the kettle is in operation.

3.1.4.2.2. Calibrated portable thermometer to measure the bitumen temperature at the point of application.

3.1.4.2.3. Nonconductive measuring tape, 50 to 100 feet.

3.1.4.2.4. Hand held Delmhorst Model BD-y Moisture Meter or approved equal for determining moisture content of materials at time of installation.

3.1.4.2.5. Sheet metal template (4 inches x 36 inches) for BUR samples.

3.1.4.2.6. Tools required for cutting samples.

3.1.4.2.7. MIL gauge for measuring flood coat thickness.

3.1.4.3. Allowable Tolerances. The following tolerances establish the range of acceptable variances. The quality controller shall review these tolerances and ensure that work is in compliance. Follow manufacturer recommendations as they apply to their 5, 10, and 20-year No Dollar Limit warranted system. If Air Force requirements are more stringent, follow them. The work item listed after each tolerance should be used to assure compliance with this specification.

3.1.4.3.1. Headlap: Minimum 1 3/4 inch, no maximum (Reference Section 4, Work Item #9).

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3.1.4.3.2. Endlap: Minimum 6 inches, no maximum (No Work Item)

3.1.4.3.3. Insulation board joint gaps: 3/16-inch maximum between boards and 1/4-inch maximum between boards and abutting surfaces (Reference

Section 4, Work Item #8)

3.1.4.3.4. Temperatures:

3.1.4.3.4.1. Maximum at kettle: Do not heat ASTM D 312, Type I asphalt above 500 degrees F. Do not heat all other ASTM 312 type asphalts above 525 degrees F.

3.1.4.3.4.2. Temperature at point of application: Equiviscous

Temperature (EVT) plus or minus 25 degrees (F).

3.1.4.3.4.3. Holding Temperature: Do not heat and hold asphalt between

500 - 525 degrees (F) for more than 4 hours. Overnight Holding temperature for asphalt shall not exceed 325 degrees F.

3.1.4.3.5. Interply moppings: 23 pounds per square of roof, or as established by the BURS manufacturer, plus or minus 15 percent

(Reference Section 4, Work Item #10).

3.1.4.3.6. Flood Coat: Asphalt, 60 pounds per square of roof, or as established by the BURS manufacturer, plus or minus 15 percent

(Reference Section 4, Work Item #14).

3.1.4.3.7. Surfacing: Quantity, 400 pounds per square of roof, or as established by the BURS manufacturer, plus or minus 15 percent.

Aggregate embedment by weight shall be 50 percent minimum of specified amount unless the facility is in the vicinity of aircraft operations whereupon the embedment shall be 100%. (Reference Section 4, Work

Item #14)

3.1.4.3.8. Foaming hot bitumen at point of application: Not acceptable for ply mopping construction (Reference Section 4, Work Items #1 and

#10).

3.1.4.3.9. Foreign Materials between plies: None acceptable (Reference

Section 4, Work Item #9)

3.1.4.3.10. Material variance from specified: None acceptable (Reference

Section 4, Work Item #3)

3.1.4.3.11. Variance from number of plies specified: None acceptable.

(Reference Section 4, Work Item #9)

3.1.4.3.12. Phased construction of membrane felts: Not acceptable.

(Reference Section 4, Work Items #4 and #9)

3.1.4.3.13. Material moisture content: Maximum percent by dry weight as follows: Organic felts 2.5 pct; fiberglass felts 1 pct; lumber 13 pct;

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November 2011 insulation as per manufacturer requirements. (Reference Section 4, Work item #1)

3.1.4.3.14. Felt laying: Wrinkles, buckles, kinks, and fishmouths: Not acceptable (Reference Section 4, Work Item #9)

3.1.4.3.15. Interply voids for individual sample: (Reference Section 4, Work Item #10)

3.1.4.3.15.1. Maximum area of all glazed voids: 5 percent of interply area for individual samples.

3.1.4.3.15.2. Unsealed or dry voids (felt on felt): Not acceptable

3.1.4.3.15.3. Overlapping voids between 2 or more plies: Not

acceptable

3.1.4.4. Quality Control Record: The quality controller shall complete AF Form

1063 daily. (See Part 4, this section).

3.1.5. Initial Inspection: (To be conducted after a representative sample of the work is complete.)

3.1.5.1. Review each significant feature and segment of the work each day.

3.1.5.2. Deliver all materials to the site, except those in quantity (bitumen in hot bulk and truckloads of aggregate) with packaging intact and with readable labels.

Use those materials have labels that:

3.1.5.2.1. Identify the material.

3.1.5.2.2. Indicate conformance with the reference standard applicable to the material.

3.1.5.3. For bitumens in hot bulk and truckloads of aggregate delivered to the site in quantity, obtain a certification for each shipment.

3.1.5.4. Store and handle all materials, except bitumen, metal components, and material in sealed cans, as follows:

3.1.5.4.1. Aggregate shall comply with moisture and dust content requirements of ASTM D 1863.

3.1.5.4.2. Other materials:

3.1.5.4.2.1. Do not expose materials to water (rain, snow, and so forth) before, during, or after delivery to the site.

3.1.5.4.2.2. Completely cover materials with waterproof canvas tarpaulins to protect from weather and moisture. Arrange covers to prevent condensation from occurring beneath them; do not allow covers to extend onto the ground.

3.1.5.4.2.3. Conspicuously mark unprotected materials and permanently remove these materials from the site.

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3.1.5.5. Equip kettles and tankers with automatic thermostatic controls and keep them in working order.

3.1.5.6. Use separate kettle and materials application and transporting equipment for asphalt and coal tar products.

3.1.5.7. Do not use bitumen which has been overheated, heated and held beyond specified storage period, or contaminated bitumen. Permanently remove such bitumen from the site.

3.1.6. Daily Work Production:

3.1.6.1. Roofing operations shall be coordinated with sheet metal work so that flashings are installed to permit continuous roof surfacing operations the same day felts are installed where practical. If gravel stops or perimeter flashings are not installed on the same day as roof completion, the roof membrane at perimeters shall be nailed with large-headed nails 8 inches on-center to perimeter wood nailers and sealed against water entry with glass fabric (ASTM D 1668) set in roofing cement.

Roofing operations shall be coordinated with roof insulation work so that all insulation applied each day is waterproofed the same day with complete roofing system. Graveling-in may be delayed for designated roof areas where permitted.

3.1.6.2. Install temporary water cutoffs and tie-ins each work day. Remove temporary cutoffs and tie-ins so that vertical faces of insulation are exposed at the beginning of the next day’s work.

3.1.6.3. Do not cut the staggered insulation pieces that are already installed.

Straighten the staggered insulation side of the day’s work with unattached cut pieces of insulation, do not permanently include such cut pieces into the roof system.

3.1.7. Weather Considerations: Except for expedient temporary work, do not proceed with roofing work during inclement weather. Remove all temporary work before installing permanent components and materials.

3.1.8. Follow-up Inspection: (To be conducted daily to assure compliance with results of initial inspection).

3.1.8.1. Check items mentioned in preparatory and initial inspections.

3.1.8.2. A copy of these records and contractor tests, as well as the corrective action taken, shall be furnished to the Air Force as directed by the Contracting

Officer.

3.2. NON-DESTRUCTIVE TESTING: The Air Force reserves the right to perform non-destructive evaluation (NDE) of the in-place roofing assembly to determine whether or not the newly installed roofing assembly has been affected by moisture infiltration. Testing shall be at Air Force expense. The contractor is encouraged to be present during the time of

NDE.

PART 4: QUALITY CONTROL PROCEDURES: Instruction for Completing AF

Form 1063, Quality Control Record:

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4.1. An example of a completed AF Form 1063 is included with this specification

(Reference Attachment B to Section 01 11 02-10, Forms). A blank copy of an AF Form

1063 follows the completed example of an AF 1063. The Contractor shall reproduce copies of this blank AF Form 1063, as needed. Contractor shall be required to complete one set of the AF Form 1063 per day of work; one set includes three copies with carbon paper between each copy. The original and first carbon copy goes to the Contracting Officer. The second carbon copy is retained by contactor. Contractor quality control personnel must follow instructions 1 through 5 below when completing the daily record. Work Items 1 through 14 are identified and discussed. Contractor quality control personnel shall review the work items daily and designate on the Daily Record Form Compliance or Noncompliance with them. All variances must be explained to the satisfaction of the contracting officer. The following are instruction for filling out AF Form 1063.

4.1.1. TOP SECTION:

a. Insert date and record number

b. Insert weather description and temperature

c. Indicate crew start and stop times.

d. Indicate you start and stop times.

e. Indicate total roof area.

f. Indicate roof area previously completed.

4.1.2. PRODUCTS SECTION: This section is divided into major categories. Each category may include several materials:

4.1.2.1. Examine each material within the category and check the proper box.

4.1.2.2. Check the "Not Applicable" box for materials not included in today's work.

4.1.2.3. Assure that all materials in a category comply with the contract to result in a check in the "Complies" Box. To determine compliance, compare the material with the project specifications and drawings, and also with the approved manufacturer's literature submitted. Since materials other than those covered by the components listed may be used, enter their compliance in the "All Other

Materials" category.

4.1.3. EXECUTION SECTION:

4.1.3.1. The work item number is this section of the record corresponds to the work items in these basic QC requirements. The work items are specification items considered to be of major concern. These items are in the basic QC requirements for convenience and tabulation.

4.1.3.2. Performance of the "actions" below the work item will result in an entry in the proper box on the QC record. Specification items not in the basic QC requirements must also be considered, and their acceptability grouped and documented in the "Other" box.

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4.1.4. VARIANCE SECTION:

4.1.4.1. An entry in any "Varies" box under the "Products" or "Execution" sections requires an explanation of the variance in this section. The explanation should be limited to a description of the variance only. Reasons for variance are not necessary.

4.1.4.2. Indicate action taken to resolve each variance to result in complying work.

Certain actions resulting from variances from some of the specification requirements are included with the specified requirement. If a variance is not resolved on the same day it occurs, the number of that day's record must be entered in the space provided on records for all succeeding days, until the variance is resolved.

4.1.5. CLOSING SECTION: Sign the record at the end of the workday and submit it to the Air Force inspector.

4.2. Work Items: Work items numbers correspond to Work Items under Execution on AF

Form 1063.

4.2.1. Work Item 1, Material Moisture Content.

4.2.1.1. Requirements:

4.2.1.1.1. Do not expose materials to moisture before, during, or after delivery to the site.

4.2.1.1.2. Do not apply BURS components if moisture in any form can be seen or felt on the substrate to which the components will be applied.

4.2.1.2. Actions:

4.2.1.2.1. Inspect materials upon delivery for intact manufacturer's shipping containers.

4.2.1.2.2. Verify that the vehicle delivering materials has provided protection of the materials. The vehicle must be enclosed or materials must be completely covered with tarps.

4.2.1.2.3. Inspect materials before acceptance for evidence of contact with moisture (such as felt wrappers that are wet or stained, insulation with torn or missing transit covers, or other evidence of moisture by feel or sight).

4.2.1.2.4. Inspect storage at job site. Be sure enclosed storage or other storage completely protects material from moisture in any form.

4.2.1.2.5. Observe material handling from storage area to roof. Total protection is required and must be immediately available in case of inclement weather. Delivery to the job site require the same attention as delivery to the storage area.

4.2.1.2.6. Mark conspicuously all materials exposed to any form of moisture and have them permanently removed from the project site.

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4.2.1.2.7. Make sure components are not applied if the hot bitumen steams, foams or bubbles.

4.2.1.2.8. Inspect application of bitumen to felts for similar evidence that shows moisture in felts.

4.2.1.2.9. Inspect application of aggregate into flood coat for similar evidence that would indicate wet aggregate.

4.2.1.3. Air Force Audit Procedures:

4.2.1.3.1. Observe the mopping procedure. If the bitumen is frothing

(foaming) at point of application, further investigate for wet materials.

4.2.1.3.2. Use a Delmhorst Model BD-7 moisture meter with 2E and 21E probes or approved equal to check moisture content of materials on the roof, insulation and felts. Assure that the moisture meter is set properly for the material being checked. For the Delmhorst moisture meter, see Table I for settings and readings that apply:

TABLE I

Material Setting Reading

Insulation: 20 Less than 15 acceptable

Felts: 30 Any reading unacceptable

4.2.1.3.3. Check the edges and middle of the material. The edges and first 4 to

6 feet of a felt roll may be wet if improperly stored. Edges of insulation may also be wet if improperly stored.

4.2.1.3.4. Materials that have been stored in the sun may give erroneously high moisture readings. When moisture content is questionable, have the contractor hot mop to a sample piece of material. If the material does not foam or froth, use it.

4.2.1.3.5. If moisture content of materials is questionable, send a sample in sealed plastic bag to a government approved laboratory for analysis. Do not use questionable materials until laboratory results are final. Do not use the moisture meter to measure the moisture content of a complete membrane. If use of wet materials is suspect in a particular area of construction, cut a sample and inspect for moisture on the job site.

4.2.1.3.6. If materials looks wet, smell wet and moisture tests wet, do not use them.

4.2.2. Work Item 2, Bitumen Temperature:

4.2.2.1. Requirements: Equip kettle and tankers for bitumen with automatic thermostatic controls. Post the EVT and flashpoint temperature conspicuously on

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November 2011 each piece of equipment that will hold hot bitumen during roofing operations.

Make sure the contractor has an EVT measuring device on the job site in working order and checks and records the EVT temperature at the point of application hourly.

4.2.2.2. Action: Periodically check the accuracy of the thermostatic controls by using a portable thermometer. Periodically check bitumen temperature within tanker or kettle and at the point of application (EVT).

4.2.2.3. Air Force Audit Procedures: Using a portable thermometer check the bitumen temperature in the tanker or kettle and at the point of application. Kettle temperature should be no higher than 50 degrees (F) less than the flash point of the bitumen. The temperature at point of application should be within 25 degrees (F) of the EVT of the bitumen.

4.2.3. Work Item 3, Material Identification/Handling:

4.2.3.1. Requirements:

4.2.3.1.1. Use separate kettle, materials, application and transporting equipment for coal tar and asphalt products.

4.2.3.1.2. Apply membrane to meet requirements and recommendations of the

BURS manufacturer.

4.2.3.2. Actions:

4.2.3.3.1. Inspect equipment upon arrival at job site for conditions and identification of previous use. Maintain identification of use throughout the project.

4.2.3.3.2. Observe the bitumen handling at the kettles and on the roof to make sure that asphalt felts are being placed in asphalt bitumen and that coal tar compatible felts are being placed in coal tar bitumen.

4.2.3.3.3. Make sure the proper type bitumen is being used for roof slope by checking the slope of the roof in the field as well as on the drawings. Review manufacturer and contract specifications for material and installation requirements and compare then with those being used.

4.2.3.4. Air Force Audit Procedures: (At the Option of the Government)

4.2.3.4.1. Obtain equipment identification information from the Quality

Controller. If material variation is expected take a sample of the bitumen in each piece of equipment and send them to a government approved laboratory for analysis of the following: ASTM D 312 - Asphalt type, ASTM D 5-penetration, ASTM D 92 - Flash point. Laboratory results will verify that the proper type of bitumen is being used and that materials are not contaminated.

4.2.3.4.2. If material variation is expected after the membrane system is assembled, take a 12-inch x 12-inch roof sample from the completed

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November 2011 membrane assembly, prior to surfacing or material samples as required. Send to a government approved laboratory for generic identification of materials.

4.2.4. Work Item 4, Weathering-In of Days Work:

4.2.4.1. Requirements:

4.2.4.1.1. Where practical execute the work so that each area of the BURS installation is completed on the same day it is begun. All bituminous and metal flashings and all related parts necessary to complete the assembly should be completed with exception of the surfacing. If gravel stops or perimeter flashings are not installed on the same days as roof completion, the roof membrane at perimeters shall be nailed with large head nails, approximately 12 inches on-center to perimeter wood nailers and sealed against water entry with glass fabric set in roofing cement; or with 20 mil vinyl nailed through membrane to perimeter wood nailers.

4.2.4.1.2. Install temporary water cutoffs and tie-ins at the end of each workday. Remove temporary cutoffs and tie-ins on resuming work so that all vertical faces of insulation are exposed.

4.2.4.2. Action:

4.2.4.2.1. Determine area of work planned and make sure that enough materials are on hand to complete that area.

4.2.4.2.2. Inspect work completed at day's end.

4.2.4.2.3. Confirm completion to include final roof surfacing, where practical, on all material installed except the area required for tie-in of future work. The tie-in area is glaze-coated with bitumen.

4.2.4.2.4. Observe tie-in to verify that insulation joints are staggered and ply structure in continued.

4.2.4.2.5. Confirm removal of temporary work and check previously installed system for moisture.

4.2.4.3. Air Force Audit Procedures:

4.2.4.3.1. Compute the number of square of unused insulation on the job.

Compare with contractor's previous days work performance. Question shortage or excess materials required for a day's work.

4.2.4.3.2. Periodically perform daily audit at the close or beginning of the work day to visually inspect watertightness of temporary water cutoffs.

4.2.5. Work Item 5, Inclement Weather:

4.2.5.1. Requirements: Except for expedient temporary work, do not proceed with roofing work during inclement weather.

4.2.5.2. Action:

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4.2.5.2.1. During bad weather, make sure that work being performed is only temporary and protects the facility and previously completed roofing system.

4.2.5.2.2. Make sure all temporary work is removed before installation of permanent components when work is resumed.

4.2.5.3. Air Force Audit Procedures: Check job site to ensure that roofing is not being installed during inclement weather. Make sure all previously constructed work is weathered-in properly. Conspicuously mark any insulation or felts left on the job site and not properly protected from the elements. When the weather breaks, be sure these materials are removed from the job site and not used in future roof construction.

4.2.6. Work Item 6, Protecting Completed Work:

4.2.6.1. Requirements:

4.2.6.1.1. Do not load or permit any part of a structure to be loaded with a weight that will adversely affect it safety.

4.2.6.1.2. If wheeled or other traffic over the partially or fully completed roofing is unavoidable, provide and use adequate plank or plywood protection for the roofing.

4.2.6.2. Action:

4.2.6.2.1. Inspect activities and methods used to transport materials over the completed or partially completed roofing system.

4.2.6.2.2. Check adequacy of plank or plywood to protect system.

4.2.6.2.3. Make sure runways (such as wood planks or plywood) are used to distribute the load of materials and equipment hauling over the deck so as not to cause deflection of the deck. Check for broken welds or bends in metal decking due to materials or equipment handling.

4.2.6.3. Air Force Audit Procedures:

4.2.6.3.1. Periodically lift the plank or plywood used to protect the roofing system. Check the membrane at this location for puncture or other surface damage.

4.2.6.3.2. After the weight is removed from a suspect overloaded area, walk the area and check for soft or depressed areas. Check soft areas from under side of deck for structural damage. Lay straight edge across suspected depressed areas to verify presence of a depression and possible future ponded area.

4.2.7. Work Item 7, Substrate Preparation:

4.2.7.1. Requirements: Removal of existing materials must result in a clean and dry substrate, except for residual stains, providing a surface suitable to apply new materials.

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4.2.7.2. Action:

4.2.7.2.1. Inspect substrate for excessive roughness, cracks, holes, or deteriorated material.

4.2.7.2.2. Make sure decking or other substrate determined to be defective is repaired, replaced, or brought to the attention of the contracting Officer.

4.2.7.2.3. Make sure deck joints are treated to prevent bitumen drippage through the joints.

4.2.7.3. Air Force Audit Procedures: Periodically check the substrate before the roof system is installed to be sure it is clean and dry.

4.2.8. Work Item 8, Insulation Installation:

4.2.8.1. Requirements:

4.2.8.1.1. Make sure insulation boards, cant strips and tapered edge strips are adequately secured and spaced.

4.2.8.1.2. For insulation boards on steel deck, first (bottom) layer; position insulation so that side joints between boards do not occur over deck rib opening. Stagger end joints. Secure insulation boards to the metal deck with approved mechanical fasteners according to insulation manufacturer, FM and

UL requirements.

4.2.8.1.3. Second or additional layers, cant strips and tapered edge strips;

secure in full and uniform moppings of hot fluid bitumen, stagger end joints, bring boards into moderate, uniform contact at sides and ends and press insulation boards firmly into the bitumen while the bitumen is hot and fluid.

Offset all joints between layers in both directions.

4.2.8.2. Action:

4.2.8.2.1. Make sure the first layer of insulation is fully secured to the substrate in the specified manner according to FM I-90.

4.2.8.2.2. Measure the distance from the inner row of fasteners to the perimeter. Count and locate fasteners with respect to insulation board.

4.2.8.2.3. Test bond on insulation boards, cant strips, and tapered edge strips by trying to lift them after installation. Materials that are readily lifted without breaking the board or strip are not securely fastened.

4.2.8.2.4. Observe application of asphalt by machine; be sure jets are flowing evenly and consistently. Application rate must be controlled to the rate specified by the manufacturer.

4.2.8.2.5. Make sure long edges of insulation are parallel to and supported by the flanges and that joints do not occur over a rib opening.

4.2.8.2.6. Make sure staggered pattern of insulation joints is begun at start of placement and develop a pattern to establish the joints at one-half the length of

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November 2011 a full piece of insulation board. Measure joints that are not in contact to assure that the gap is less than the 3/16-inch requirement.

4.2.8.2.7. Make sure contact at sides and ends of board is obtained when insulation boards are placed in hot and fluid bitumen.

4.2.8.2.8. Make sure insulation covers entire area of deck to within 1/4-inch of vertical surfaces and wood insulation stops. Test bond on insulation boards, cant strips and tapered edge strips by trying to lift them after installation.

Materials that are readily lifted with breading are not securely fastened.

4.2.8.3. Air Force Audit Procedures:

4.2.8.3.1. Spot check the gap between insulation boards. Maximum allowable is 3/16-inch.

4.2.8.3.2. When mechanical fasteners are used, check all installed board that have not been covered with the second layer of insulation for the proper number of fasteners and spacing.

4.2.8.3.3. Spot check bond of mopped in place insulation boards, cant strips and tapered edge strips by trying to lift them.

4.2.8.3.4. Check the end of the first layer insulation run to make sure boards are not butted over and are parallel to the steel deck ribs where applicable and end laps are staggered by a minimum of 6 inches. Check the end of the second layer of insulation of ensure that end joints are offset by maximum dimensions.

4.2.8.3.5. Fasteners. Look for overdriven or underdriven fasteners, overdrilled holes, fasteners driven at angles, and fasteners driven too close to the edge of the insulation board (minimum 6 inches from board edge). Check underside of deck to ensure that fasteners are penetrating the deck, when required. On steel decks, examine underside to make sure fasteners are engaging a point at or near the middle of the top flange. (It may be necessary to snap a chalkline on the insulation over the flange centers).

4.2.9. Work Item 9, Ply Construction:

4.2.9.1. Requirements:

4.2.9.1.1. Apply felts shingle fashion and keep proper lap distance to result in a 1-inch minimum. Maintain a straight run of felts so that kinks or fishmouths do not result, and the felts are completely flat.

4.2.9.1.2. Once established, do not change the direction of felt application.

4.2.9.2. Action:

4.2.9.2.1. Make sure felts are rolled true to premarked lines on felts or chalklines.

4.2.9.2.2. Immediately upon deviating from the felt line, make sure the roll of felt is cut and restarted with specified endlap. Do not allow roll to be forced back on line without cutting.

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4.2.9.2.3. Make sure fishmouths or kinks do not appear at the felt edges due to a run of felts other than in a straight line. Cut and patch these discrepancies as they occur or by the end of each days work.

4.2.9.2.4. Make sure no foreign particles (aggregate, etc.) are sealed between plies.

4.2.9.2.5. Measure lap exposure (the distance between two exposed adjacent edges) and compare this to the required felt line distances. These distances must be equal.

4.2.9.2.6. Make sure the ply lines are parallel for the entire roof area and that the direction of felt application is not changed.

4.2.9.3. Air Force Audit Procedures:

4.2.9.3.1. Spot check the distance between adjacent plies for accuracy.

4.2.9.3.2. Spot check the distance across four plies for accuracy. Keep in mind that the minimum acceptable head lap is 1 inch.

4.2.9.3.3. Walk completed ply construction that has not been surface coated.

Check for fishmouths and kinks.

4.2.9.3.4. Check felt application versus roof slope to assure that felt edges do not oppose the flow of water.

4.2.10. Work Item 10, Interply Bitumen Integrity:

4.2.10.1. Requirements:

4.2.10.1.1. Broom or squeegee each ply of roll goods into place, full width, while the bitumen is hot and fluid, so that felt does not touch and bitumen layer does not have voids or skips. Do not walk on felts until bitumen is "set".

4.2.10.1.2. Description of Voids:

4.2.10.1.2.1. Glazed Void: A bubble within the interply layer that is completely encapsulation in bitumen. A maximum of 5 percent (7.2 sq.

inches) surface measure is permitted in any one interply layer.

4.2.10.1.2.2. Uncoated Void: A bubble within the interply layer that is not completely encapsulated, but exposed to the roofing felt on one surface.

Uncoated voids are not acceptable.

4.2.10.1.2.3. Dry Void: A bubble within the interply layer that is not encapsulation, but is exposed to the roofing felt on both surfaces. Any dry voids are unacceptable.

4.2.10.1.2.4. Voids that overlay in two or more adjacent interply layers are not acceptable.

4.2.10.2. Action:

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4.2.10.2.1. Periodically during the day, check the temperature of the bitumen at the point of application.

4.2.10.2.2. Each ply of the rolled felts must be pressed in place with a broom or squeegee the full width of the roll. Confirm that brooming or squeegeeing is adequate to embed the felts into the bitumen and to make sure that bitumen is between all surface areas of the felts, including the edges. Asphalt must be continuously visible along each edge of the sheet.

4.2.10.2.3. Do not permit walking over felts until bitumen is cooled to set temperature. Refer to NRCA Publication, Application Techniques for Glass

Fiber Roofing Felts, as a recommended application procedure.

4.2.10.3. Air Force Audit Procedures: (At Option of the Government)

4.2.10.3.1. At the beginning of a job, cut a 12-inch x 12-inch sample daily from each crew's work. Cut samples accurately using a template. Continue this daily sampling process until each work crew consistently meets stated tolerances on interply bitumen weight, head laps, and void content. Samples to be analyzed IAW ASTM D 3617. Thereafter, cut samples only when one of the following occurs:

4.2.10.3.1.1. Climate conditions such as wind, temperature, humidity, changes significantly from when the last sample was taken.

4.2.10.3.1.2. Crew members change, or their job on the crew changes.

4.2.10.3.1.3. Visual observations indicate non-standard construction techniques such as walking on freshly laid felts, not brooming full width of felts, and so forth.

4.2.10.3.1.4. EVT out of tolerance.

4.2.10.3.1.5. Continuous bitumen film not present at edge of felts.

4.2.10.3.1.6. Equipment malfunction.

4.2.10.3.2. At the beginning of the job, weigh 5 to 10 rolls of felt. Calculate the average weight per roll in pounds per square. This information is needed to calculate average mopping weights on the Sample Analysis Worksheet.

4.2.10.3.3. Cut the sample perpendicular to the plies starting at a ply lap edge.

Cut the sample from the completed membrane assembly before any surfacing is applied.

4.2.10.3.4. Weigh the sample in grams. Measure the head laps and overall size of the sample. Freeze the sample. Split the plies apart. (Note: If the plies do not split apart easily, you may have to fracture the interply bitumen by tapping the sample with a wood mall or similar blunt object. This will not disturb the void patter. Using a clear grid template, lay the sample out and measure the air voids, and areas where no bitumen exist (felt on felt). Record all information on an appropriate form. Examine the sample with the Quality

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Controller and the Job Foreman. Compare the sample against acceptable tolerances. Discuss any variances, determine probable cause and make immediate adjustments in the construction process to preclude recurrence. The intent of the membrane sampling and on-the-job analysis and feed back is to:

4.2.10.3.4.1. Improve the overall quality of the BUR construction. A single occurrence of variance does not necessarily mean that the construction is unacceptable. But, do not proceed with further construction unless the cause of the out-of-tolerance condition can be adjusted to provide acceptable construction thereafter.

4.2.10.3.5. If samples are unacceptable, some recommend adjustments are as follows: Improve brooming of the felts to minimize air voids; a series of small pin holes indicates moisture in the felts - check materials; on windy days follow closely behind felt layer with brooming to minimize premature bitumen cooling and voids; closely monitor EVT and tanker bitumen temperature.

4.2.11. Work Item 11, Sample Removal and Repair:

4.2.11.1. Requirements: The Contractor must remove samples and repair the area of sample removal. Samples to be cut and analyzed IAW ASTM D 3617.

4.2.11.2. Action:

4.2.11.2.1. Witness removal of test samples required by the project specification.

4.2.11.2.2. Visually examine sample components for adhesion to each other, edge voids and presence of moisture. Record observations of defects on AF

Form 1063.

4.2.11.2.3. Direct and observe repair of sample area.

4.2.11.2.4. Do not leave sample on the roof or in the sun. Remove the sample from the roof immediately and evaluate for compliance with the Air Force

Inspector.

4.2.11.3. Air Force Audit Procedures:

4.2.11.3.1. Select the location and size of all samples to be cut from the membrane and evaluate the sample for compliance.

4.2.11.3.2. Inspect all sample repair areas for water tightness.

4.2.12. Work Item 12, Envelopes and Bitumen Dams:

4.2.12.1. Requirements: Provide organic felt envelopes, or other approved methods, at gravel stop roof edges, and at deck penetrations to stop bitumen drippage.

4.2.12.2. Action:

4.2.12.2.1. Before the start of felt application, assure that a organic felt strip, at least 18 inches wide, is set in steep asphalt or flashing cement and is applied so

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November 2011 that half width is set on the nailer around perimeter of building and half width is lapped over the edge of the building.

4.2.12.2.2. After felt application is complete, make sure the overlapped section of felt is folded back over the BUR and mopped down to form an envelope around the edge of the roof membrane.

4.2.12.2.3. Make sure at all penetrations, have a felt envelope or other positive means of preventing bitumen drippage is installed.

4.2.12.2.4. Make sure flanges of metal are primed before installation into system.

4.2.12.3. Air Force Audit Procedures: At the beginning of the job, verify that an organic felt envelope has been installed at all roof edges and that a positive means of preventing bitumen drippage is installed at all roof penetrations.

4.2.13. Work Item 13, Flashing Installation:

4.2.13.1. Requirement: Flashing system according to BURS manufacturer's requirements.

4.2.13.2. Action:

4.2.13.2.1. Make sure proper materials are being applied and that materials are the products of the BURS manufacturer as recommended for 5, 10, and 20-year warranted system over the substrate involved.

4.2.13.2.2. Before start of flashing application, assure that roofing felts extend to top of cant strips.

4.2.13.2.3. Make sure all vertical surfaces are primed before receiving flashing. The primer must be dry before applying the flashing.

4.2.13.2.4. Check for flashing bond to all areas of contact and for overlap of all end joints.

4.2.13.2.5. Make sure end joints between layers of flashing do not coincide during application.

4.2.13.3. Air Force Audit Procedures:

4.2.13.3.1. Obtain a copy of the BURS manufacturer's requirements from the

Quality Controller. Periodically check for compliance of materials and installation procedure.

4.2.13.3.2. Check all installed flashings for compliance with drawings.

4.2.14. Work Item 14, Surfacing:

4.2.14.1. Requirement: The surface shall be flood-coated uniformly and aggregate surfacing applied according to BURS manufacturer requirements and specifications.

4.2.14.2. Action:

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4.2.14.2.1. The surface shall be broom cleaned and free from moisture.

4.2.14.2.2. Aggregate surfacing shall be clean and dry, and meet specifications requirements.

4.2.14.3. Air Force Audit Procedures:

4.2.14.3.1. Use MIL gauge to check flood coat film thickness. Note: Two mil film thickness is approximately equal to one pound of bitumen per square.

Check film thickness while flood coat is hot.

4.2.14.3.2. Send a sample of the aggregate to a government approved laboratory for gradation analysis.

4.2.14.3.3. Broom away loose aggregate from a one-foot-square area.

Estimate amount of embedded aggregate coverage.

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