FA3047-10-R-0012 Atch 2AA-Division 7

802 CONS/LGCA-3 FA3047-10-R-0012

Lackland AFB TX Roofing IDIQ

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Section J – Attachment 2AA Page 1 of 13 8 Feb 2010

SECTION 07 32 14

CLAY TILE ROOFING REPLACEMENT OR REPAIR

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced.

The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM B 370(2009) Standard Specification for Copper Sheet and Strip for Building

Construction

ASTM C 1167(2003; R 2009) Standard Specification for Clay Roof Tiles

ASTM C 1184(2005) Standard Specification for Structural Silicone Sealants

ASTM D 146(2004) Sampling and Testing Bitumen-Saturated Felts and Woven Fabrics for Roofing and Waterproofing

ASTM D 226(2006) Standard Specification for Asphalt-Saturated Organic Felt Used in

Roofing and Waterproofing

ASTM D 412(2006ae1e2) Standard Test Methods for Vulcanized Rubber and

Thermoplastic Elastomers - Tension

ASTM D 4586(2007) Asphalt Roof Cement, Asbestos-Free

SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL

ASSOCIATION (SMACNA)

SMACNA 1793(2006) Architectural Sheet Metal Manual, Sixth Edition, Second Printing

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

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Clay Tile Roofing Systems; G

Drawings showing clay tile installation and appearance details, flashing details, and fastening details for the tiles.

SD-03 Product Data

Clay Tile Roofing Systems; G

Manufacturer's catalog data and installation instructions.

Qualifications

Documentation showing qualifications of personnel proposed to perform the roofing work, and a listing identifying prior installations completed by the Contractor.

SD-04 Samples

Clay Roofing Tile; G

Five representative tiles of each type, to indicate full range of color.

Sealant

8 ounces of each type.

Underlayment Membrane; G

1 by 1 foot section of each type.

Fasteners; G

Representative samples of each fastener with identifying tags.

SD-07 Certificates

Materials

Certificates of compliance attesting that the materials meet specification requirements.

Warranty; G

Labor and material warranty from the Contractor as described in paragraph 1.6

WARRANTY. 75 years warranty that the tiles will pass applicable moisture absorption and flexural strength test established by the International Conference of Building

Officials (ICBO) effective at date of manufacture.

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1.3 QUALIFICATIONS

The Contractor shall provide qualified workers, trained and experienced in installing clay tile roofing systems of this configuration, and shall submit documentation of 5 consecutive years of work of this type. The Contractor shall be familiar with and shall perform work in accordance with SMACNA 1793. A list of installations shall be provided which identifies when, where, and for whom the installations were made.

1.4 DELIVERY, STORAGE AND HANDLING

Materials shall be delivered in manufacturer's unopened bundles and containers with the manufacturer's brand and name marked clearly thereon. Tiles shall be stored in accordance with manufacturer's printed instructions. Roll goods shall be stored on end in an upright position. Immediately before laying, roofing felt shall be stored for 24 hours in an area maintained at a temperature not lower than 50 degrees F.

1.5 PROJECT/SITE CONDITIONS

1.5.1 Environmental Requirements

Clay tile roofing work shall proceed when existing and forecasted weather conditions permit work to be performed in accordance with manufacturer's recommendations and warranty requirements.

1.5.2 Material Storage

Materials shall not be stored on roof decks in such a manner as to overstress and/or damage the deck and supporting structure. Placing of loads at midspans of framing shall be avoided. Superimposed loads shall be well distributed.

1.5.3 Units of Work

Units of work shall be established, including removal of existing materials, preparation of existing surfaces and application of underlayment and nailers, and related temporary and/or permanent flashing so that it can be completed prior to the end of each working day.

1.5.4 Temporary Protection Materials

Materials shall be provided and maintained on the site at all times for temporary roofing, flashing, and other protection when delays and/or changed weather conditions do not permit completion of each unit of work prior to the end of each working day. Materials which have been used for temporary roofing, flashing and other protection shall be removed and discarded.

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1.6 WARRANTY

A material and labor warranty shall be furnished against defects in material and workmanship that affect the appearance, leak resistance, underlayment and attachment of clay tile roof assembly, including related metal flashing for a period of 10 years from date of final acceptance of the work. Warranty shall also cover the blow-off at wind gusts up to, and including, 90 mph.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Existing Clay Tile

Intact and serviceable existing clay tiles shall be salvaged and reused whenever possible.

New clay tiles being incorporated into existing clay tile roofs shall match existing as closely as possible. Clay tiles from the same manufacturer as the original shall be used if possible.

2.1.2 Clay Roofing Tile

Clay roofing tile shall be minimum Grade 1 tile conforming to ASTM C 1167. Tile shall be two-piece barrel type (minimum roof pitch 5:12), unless indicated otherwise. Tile shall be unglazed. One piece, interlocking tile (S-Tile) is also acceptable for non-historic buildings (minimum roof pitch 4:12) when approved by Contracting Officer. Roof slopes less than listed above or extremely steep, see 3.7.2 High or Low Slope Pitches.

2.1.2.1 Colors

Clay tile color shall be red, to match existing.

2.1.2.2 Fittings

Clay tile fittings shall be of the following types as required by manufacturer's instructions: eave - eave closure; gable - gable rake; ridge - closed ridge end and ridge/hip terminal; hip - hip roll, hip starter and ridge/hip terminal; valley - cut valley and miscellaneous clay tile fittings required to provide complete clay tile roof, provide weatherproof installation and prevent bats/birds from nesting in tile roof voids.

2.1.3 Underlayment Membrane

An underlayment membrane shall be provided on surfaces to be covered with clay tile roofing. Membrane shall consist of high strength composite self-adhering membrane.

2.1.3.1 Roofing Felt

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Roofing felt shall be asphalt-saturated rag felt, Type II, No. 30 asphalt felt in accordance with ASTM D 226.

2.1.3.2 Elastomeric Membrane Underlayment

Elastomeric membrane shall be a cold applied composite self-adhering membrane, minimum 60 mils thick, high strength polyethylene film with slip resistant embossing, coated on one side with a thick layer of adhesive-consistency rubberized asphalt, interwound with a disposable silicone coated release sheet. The tensile strength and elongation values shall be not less than 250 psi when tested in accordance with ASTM D

412 and pliability shall be unaffected when tested in accordance with ASTM D 146.

2.1.3.3 Elastomeric Membrane Accessories

Two component urethane, mastic and primer shall be as approved by the membrane manufacturer. Flashing, expansion joint covers, temporary UV protection and corner fillets shall be as recommended by the membrane manufacturer.

2.1.4 Fasteners

2.1.4.1 Nails

Nails shall be solid copper, Number 11 gauge nails, minimum 5/16 inch head. Nails shall be of sufficient length to adequately penetrate into the roof sheathing, a minimum of

3/4 inch.

2.1.4.2 Miscellaneous Fasteners

Miscellaneous fasteners may include but are not limited to: wind locks, hurricane clips, tile attachment brackets, tile nails, twisted wire (tile-tie), deck anchor systems, and flashing cleats. Fasteners shall be made of solid copper (wind locks and hurricane clips can be made of stainless steel).

2.1.5 Flashing

Flashing shall be 20 ounce, light cold-rolled temper (H00) copper conforming to ASTM

B 370. Like metals shall be used on all components of fastening systems and flashing in order to avoid galvanic action. Flashing shall be in accordance with the requirements as specified in Section 07 60 00 FLASHING AND SHEET METAL.

2.1.6 Plastic Cement

Plastic cement for gable rakes, hip rolls, ridges, stringers and other conditions shall be non-running, heavy body plastic cement composed of ingredients complying with ASTM

D 4586.

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2.1.7 Sealant

Sealant, when used in lieu of plastic cement, shall be silicone in accordance with ASTM

C 1184.

2.1.8 Mortar

Mortar for filling the openings of cut valley tiles shall consist of 1 part Portland cement to

3 parts damp plaster sand, and shall be colored to the nearest possible match with the color of the tile.

2.1.9 Wood Strips

Wood strips for nailers, battens, cant strips, and eave strips shall be of foundation grade redwood or preservative treated Douglas fir. Sizes and lengths shall be provided per tile manufacturer's installation details.

2.1.10 Decking

Continuous decking shall be provided in accordance with Section 05 30 00 Steel Decks or with Section 06 10 00 Rough Carpentry.

2.1.11 Patch/Repair/Replacement Materials

Provide clay roofing tile materials to patch, repair and/or replace broken, cracked, missing roof tile materials of existing clay tile roofs. Replacement shall include all materials for a complete and proper installation to make clay tile roofs "whole."

Contracting Officer will identify areas that require patching/repairing/replacement.

PART 3 EXECUTION

3.1 PROTECTION OF ROOF SURFACES

Equipment (such as padded ridge ladders) and techniques shall be used which prevent damage to roof as a result of foot or material traffic. Contractor shall be responsible for controlling breakage of new or existing tile. The progression of work shall be laid out and presented to the Contracting Officer to prevent other trades from working on or above completed roofing. Personnel who are working on the roof shall have proper shoes which will not further damage tiles and shoe soles shall be made of a material which will aid in preventing falls.

3.2 TILE REMOVAL

Where work involves partial replacement or repair of roof, Contractor shall verify each tile for tightness and continued use. Tiles which have been identified for replacement or re-installation shall be marked for approval within 30 days of Notice to Proceed. Tiles

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Section J – Attachment 2AA Page 7 of 13 8 Feb 2010 identified for removal shall be marked with a non-destructive color mark which can be easily removed. Tiles fastened with non-copper fasteners shall be re-fastened with proper copper fasteners. Contractor shall remove existing clay tile elements where required to facilitate the patching/repair/replacement work.

3.3 PREPARATION OF SURFACES

Roof deck surfaces shall be smooth, clean, firm, dry, and free from loose boards, large cracks, and projecting ends that might damage the roofing. Foreign particles shall be cleaned from all interlocking areas to ensure proper seating and to prevent water damming. Prior to installation of tile, vents and other projections through roofs shall be properly flashed and secured in position, and projecting nails shall be driven firmly home.

3.4 ELASTOMERIC MEMBRANE UNDERLAYMENT

3.4.1 Surface Preparation

Dust, dirt, loose nails or other protrusions shall be removed. Priming is not required for wood or metal surfaces but is necessary on concrete or masonry surfaces.

3.4.2 Primer

Primer shall be applied at a coverage rate of 250-350 sq. ft./gal. Primer shall be applied by spray or paint roller.

3.4.3 Temperature

Membrane shall be applied only in fair weather when air and surface temperatures are above 40 degrees F.

3.4.4 Membrane Application

Membrane shall be applied according to manufacturer's instructions. Membrane shall be adhered directly to roof deck. Wood decks shall be covered with minimum 1/4 inch plywood prior to receiving membrane coverage. Membrane shall be cut into 10 to 15 foot lengths and shall be re-rolled. The release paper shall be peeled back 1 to 2 feet and the membrane shall be aligned on the lower edge of the roof and the first 1 to 2 feet shall be placed. The release paper under the membrane shall be pulled and peeled from the membrane. The membrane shall be pressed in place. Lower edges shall be rolled firmly with a wallpaper or hand roller. For ice dam protection, membrane shall be applied to reach a point above the highest expected level of ice dams. Ends and edges shall be overlapped a minimum of 6 inches. Membrane shall not be folded onto an exposed face of the roof edge. If the membrane becomes misaligned, the roll shall be cut and restarted.

The lower edges shall be rolled firmly with a wallpaper roller or other hand roller.

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After application, "Fish mouths" shall be split, pressed flat and covered with a patch of membrane of sufficient width and length to overlap each side and end of the slit a minimum of 3 inches. Flashing shall be installed in manner to prevent water backup.

3.4.5 Felt Application

One layer of No. 30 felt shall be laid in horizontal layers on deck areas on top of the elastomeric membrane underlayment to be covered with tile. One layer of No. 30 felt shall be applied. Applications shall be doubled on rough surfaces and overlapped 12 inches on hips, valleys, and ridges. Joints shall be lapped 6 inches horizontally and 6 inches vertically. Felt shall be carried 6 inches up vertical surfaces and 4 inches over gutter and valley metal. Edges shall be fastened with corrosion-resistant, 12 gauge, 1 inch head standard roofing nails on 6 inch centers. Felt shall be provided unbroken, tight and whole.

3.4.6 Valley and Ridge Application

The membrane shall be cut into 4 to 6 foot lengths. The release paper shall be peeled and the sheet centered over the valley or ridge, draped and pressed in place working from the center of the valley or ridge outward in each direction. For valleys, membrane shall be applied starting at the low point and working upwards. Sheets shall overlap a minimum of 6 inches.

3.4.7 Vertical Membrane Flashings

Vertical wall installations shall receive primer prior to the application of membrane.

Primer shall be applied at a coverage rate of 250-350 sq. ft./gal. Membrane shall be turned up walls and dormers as indicated on the drawings. Vertical membrane terminations shall be mechanically fastened. Vertical terminations shall receive a troweling of mastic as approved by the membrane manufacturer. Membrane may be folded onto the fascia, provided it will be covered by a gutter metal edge or other material.

3.4.8 Protection

Elastomeric membrane underlayment shall not be left permanently exposed to sunlight.

Membrane shall be covered with exposed roofing materials as soon as possible.

Membrane damaged due to exposure to sunlight shall be patched prior to the application of final roof covering.

3.4.9 Assembly

All roofs to receive Clay Tile Roofing shall have elastomeric underlayment covered with one ply of No. 30 felt as specified herein.

3.5 METAL FLASHING

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Metal flashing shall be as shown at intersections of vertical or projecting surfaces through the roof or against which the roof abuts, such as walls, parapets, dormers, and sides of chimneys. Flashing installation shall be in accordance with Section 07 60 00

FLASHING AND SHEET METAL.

3.5.1 Copper Flashing

Copper flashing shall be, as shown on Fig. 1, at end of section, at intersections of vertical or projecting surfaces through the roof or against which the roof abuts, such as walls, parapets, dormers, and sides of chimneys. Flashing installation shall be in accordance with Section 07 60 00 FLASHING AND SHEET METAL.

3.5.2 Valleys

Copper flashing shall be provided at all valleys as shown on Fig. 2, at end of section.

3.6 CLAY ROOFING TILE (GENERAL)

3.6.1 Repair and Replacement

Existing reusable clay tiles removed from the repair area shall be intermingled with new clay tiles to provide a smooth visual transition between new and existing areas.

3.6.2 High or Low Slope Pitches

Tiles on roof slopes of less than 3:12 shall be applied over indicated underlayment on solid decking. Tiles on extremely steep or vertical applications, shall have the butt of each tile set with mastic or sealant, and placed where it will not be seen. The mastic or sealant shall not stain the surface of the tile. Copper "hurricane clips" may be installed instead of using mastic or sealant.

3.6.3 Roof Decks and Fasteners

Tile shall be fastened to roof deck materials as follows:

DECK FASTENER

Plywood Slater's ring shank nail. Point shall just penetrate through underside of deck.

Plank board, Slater's plain shank nail, at least

1 inch or more in 1-1/2 inch thickness shall not penetrate deck.

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Gypsum plank or

Nailable Concrete Stainless steel or silicone bronze nails with spiral threads, 1-1/2 or 2 inch long. Nail shall penetrate deck at least 1/2 thickness but no more than 3/4. Underside of deck shall not be penetrated.

If deck material is old and excessively hard, smooth shank shall be used.

Metal Sheet metal screw and mastic

Fibrous cement Tile-tie system

Note: All fastening and flashing metals shall be of like material in order to avoid galvanic action.

3.6.4 Chalk Lines

Horizontal and vertical guide lines shall be chalked on the membrane to assure proper appearance. The chalk lines shall be spaced by measuring the delivered tiles for average length and width exposures. An exposure length of 1/4 inch beyond the average shall not be exceeded.

3.7 ONE-PIECE (INTERLOCKING S-TILE) BARREL TILE APPLICATION

3.7.1 Wood Strips

Wood stringers, 1 inch wide and of proper height, shall be applied on hips and ridges to carry hip roll and ridge. A 1 by 2 inch strip shall be applied for end bands. A 1 by 2 inch cant strip shall be applied at eaves if eave closures are not specified.

3.7.2 Tile Application

a. Eave closures shall be installed first.

b. Tiles shall be laid to straight lines parallel to ground level and shall be lapped 3 inches vertically.

c. Each tile shall be fastened with the quantity of nails, wind locks and/or hurricane clips recommended by the manufacturer for the specified roof slope, building height, and wind velocity.

d. Nails on tiles overlapping sheet metalwork shall not puncture the sheet metal. Tiles overlapping sheet metal shall be fastened with copper wire and plastic cement.

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e. Gable rakes shall be cemented to field tiles and fastened with nails.

f. Hip rolls shall be cemented in laps and fastened with 2 inch copper nails.

g. Ridges shall be cemented and fastened with 2-1/2 inch copper nails in laps and where they rest on roof tiles.

h. Where tiles join hip stringers they shall be made waterproof with flashing cement.

i. When hip starter and closed ridge end fittings are not used, the voids at ends of hips and ridges shall be filled with mortar colored to nearest match of tile color.

j. Tile in contact with cement mortar shall be immersed in water for at least 2 minutes before laying.

k. When ridge angles are not used, they shall be mitered on job, nailed or wired, and set in plastic cement.

l. When short course tiles are not otherwise specified for rafters which do not accommodate full courses, they shall be cut and drilled on job by roofer unless a plus or minus 1 inch adjustment of regular tile overhang at eave is sufficient.

3.8 TWO-PIECE BARREL TILE APPLICATION

3.8.1 Wood Strips

Wood stringers, 1 inch wide and of proper height, shall be applied on hips and ridges to carry hip roll and ridge. A 1 by 3-1/2 inch strip shall be applied and spaced appropriately for covers. When covers are laid at random exposure, strips shall be 1 by 4 inches. At first row of cover tile after gable roll, a regular nailing strip shall be applied with an adjacent 2 by 2 inch nailing strip along rake side. A 1 by 2 inch cant strip shall be applied at eaves if eave closures are not specified.

3.8.2 Tile Application

a. Eave closures shall be installed first.

b. Tiles shall be laid to straight lines parallel to ground level, and shall be lapped 3 inches vertically.

c. Each tile shall be fastened with the quantity of nails, wind locks and/or hurricane clips recommended by the manufacturer for the specified roof slope, building height, and wind velocity.

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d. Tiles overlapping sheet metalwork shall have the nails so placed as to avoid puncturing the sheet metal. Tiles overlapping sheet metal shall be fastened with copper wire and plastic cement.

e. When tile is applied tight method, short course covers shall be installed over regular pans at eave and regular covers over short course pans at ridge. Top edge of covers shall abut bottom edge of pans in the succeeding course throughout the roof.

f. When covers are laid at random exposure, 10 percent extra covers in the first three courses at eave shall be used to avoid horizontal and diagonal lines and maintain this effect throughout roof.

g. Gable rakes shall be cemented to field tiles and fastened with nails.

h. Hip rolls shall be cemented in laps and fastened with 2 inch copper nails.

i. Ridges shall be cemented and fastened with 2-1/2 inchcopper nails in laps and where they rest on roof tiles.

j. Where tiles join hip stringers they shall be made waterproof with flashing cement.

k. When hip starter and closed ridge end fittings are not used, the voids at ends of hips and ridges shall be filled with mortar colored to nearest match of tile color.

l. Tile in contact with cement mortar shall be immersed in water for at least 2 minutes before laying.

m. When ridge angles and hip/ridge terminals are not used, they shall be mitered on job, nailed or wired, and set in plastic cement.

n. When short course tiles are not otherwise specified for rafters which do not accommodate full courses, they shall be cut and drilled on job by roofer unless a plus or minus 1 inch adjustment of regular tile overhang at eave is sufficient.

3.9 INSTALLATION

3.9.1 Installation Not Covered

Installation not covered by definite specifications or details shall be as per practice for obtaining waterproof work, as recommended by manufacturer of roofing materials and necessary to provide guarantee.

3.9.2 Cleaning

Prior to acceptance of the Work of this Section, thoroughly clean all exposed portions removing all labels and traces of foreign substances, using only a cleaning solution

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