1-3 SPECS 07600.doc

IDC Base Roof Repair

DIVISION 7 – THERMAL & MOISTURE PROTECTION

SECTION 07510 - BUILT-UP ROOFING

PART 1 - GENERAL

1.01 APPLICABLE PUBLICATIONS: The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.

A. American Society for Testing and Materials (ASTM) Publications:

D 1863

Mineral aggregate used on built-up roofs

D 41

Asphalt primer used in roofing

D 3909

Asphalt roll roofing (glass felts) surfaced with mineral granules

D 312

Asphalt used in roofing

D 4022

Coal tar roof cement

D 2178

Asphalt glass felt used in roofing and waterproofing

D 1668

Treated glass fabric

D 2822

Asphalt roof cement

D 450

Coal tar bitumen

1.02 DESCRIPTION OF WORK: Furnish the administration, facilities, materials, labor, equipment, and quality control (QC) necessary to integrate the work into the total building system so that leakage into the Built-Up Roof System (BURS) or the building does not occur. The BURS is an assembly of components including the underlayment as applicable, and roofing membrane, final surfacing, bituminous and metal flashings, and all related parts necessary to complete the assembly. The BURS manufacturer is the roofing membrane manufacturer, who may or may not manufacture and market the other components of the BURS. Complete the work to assure that the BURS satisfies the quality control standards of the BURS manufacturer's

20-year warranted system. The BUR Manufacturer Contractor's Certification, (Submittal #11), is a qualification for this contract. The contractor will have the BURS manufacturer of the proposed roofing system execute Submittal #11 at the time of bid opening. QC procedures, tolerances and testing are specified in these contract documents. Nonconforming work will be rejected as a violation to these specifications.

1.03 STORAGE OF MATERIALS: Roofing materials such as insulation, felts, roll roofing, and so forth, shall be stored under cover (building, van trailers or water proof canvas tarpaulin) to protect them from rain or snow. Materials must be stored on raised platforms or pallets. Vinyl or polyethylene sheets or insulation shipping wrappers are not suitable covering and material so stored will be marked, rejected and removed from the site. Materials shall remain on the original shipping pallets or placed on raised platforms to keep them off the ground or storage surface. All rolled goods shall be stored on pallets or raised platforms ON END and not laid flat on the storage surface. Damaged or "flattened" rolls will be rejected and removed from the job site. All cants and tapered edge strips shall be protected from the weather at all times. Packaged asphalt shall be stored in a protected area to prevent contamination during storage. Wet materials shall not be used. Surfacing aggregate shall be maintained as defined by ASTM D 1863. Make sure materials are covered by the night of delivery.

1.04 COORDINATION REQUIREMENTS: 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 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 the complete roofing system. Graveling-in may be delayed for designated roof areas where specified.

1.05 MATERIALS: Materials to be installed shall conform to applicable ASTM standards as specified. Certificates of compliance may be required from each respective material manufacturer at the discretion of the contracting officer. Certification shall be provided for all bitumen, bulk or packaged, delivered to the construction site. All materials to be installed shall be delivered to the job site bearing product labels of their manufacturer.

1.06 SUBMITTALS: Submittals 1 through 4 are included at the end of this specification. Additional submittal forms shall be obtained from the contracting officer if required. Submit requests for all changes (including resolution for variances) in writing. Do not proceed with any changes without written authorization of the contracting officer. Approvals of submittals which do not conform to the contract shall not be construed as a change unless such nonconformance is a change specifically so indicated on the submittal and approved by the Contracting Officer.

A. Submittal #11: Built-Up Roofing System Manufacturer's Certification (Submittal #11). Submittal #11 is a qualification for award of this contract. It must be submitted as part of the bid, or executed prior to contract award, and be accepted by the Contracting Officer.

B. Submittal #19: System Summary Sheet. It must be signed by both the perspective contractor and BUR manufacturer, and submitted to the contracting officer prior to contract award. This document is tailored to present BUR project requirements to the system manufacturer who can then ascertain the technical aspects of the project and the acceptability of the design to their 20-year warranty system.

C. Submittal #12: Designation of Roofing Quality Control Controller. The most effective means to evaluate quality installation is by thorough, continuous visual examination at the time of installation, conducted by a person who is knowledgeable in roofing technology and good workmanship practices. The contractor shall designate a person to be in charge of roofing quality control. The quality controller shall have at least 5 years experience in the supervision and inspection of BUR construction and shall not be a principal or officer of the roofing contractor's company. The Air Force inspector will audit the quality control process on a daily basis. (See paragraph 3.11, CONTRACTOR QUALITY CONTROL), for specific quality control requirements. The contractor must furnish Submittal 3 as required herein, modified as necessary, to identify the person in charge of roofing quality control. This submittal must be approved by the Contracting Officer before the Notice To Proceed (NTP) is issued.

D. Submittal #13: Built-Up Roof System 20-Year Labor and Material Garranty/Guaranty. The manufacturer shall provide an executed copy of the 20-Year Warranty/Guaranty (Submittal #13) upon satisfactory completion of the roofing system. The warranty is to be provided to the Contracting Officer prior to final acceptance of the project.

E. Materials Approval: Within 10 days after award of contract, the contractor shall submit to the Contracting Officer, certifications from the insulation and fastener manufacturers/suppliers that the materials to be used conform to specified standards as applicable to produce the BURS manufacturer's 20-year warranted system.

F. Manufacturer Publications: Four (4) copies of the following must be submitted before start of roofing work:

1. Latest edition of each BURS manufacturer's published general requirements and applicable literature for each roofing system to be used on the buildings included in this contract.

2. Latest editions of all other applicable materials, manufacturer's products and installation literature.

G. Contractor Reporting. The following shall be submitted:

1. Quality Control Record (AF Form 1063). See paragraph 3.11. and Part Four. (Daily)

2. Suppliers certification for bitumen in hot bulk and truckloads of aggregate. (As required)

H. End of Job Submittals. Before final acceptance the contractor shall submit:

1. A plan view drawing of each roof showing location, size and date of each day's work; Location where each membrane sample was cut to include sample identification number, date sample was taken, and size of sample.

2. Submittals #2 and #4: The manufacturer shall provide the executed 20-year BUR system warranty prior to final acceptance, along with an as-built system summary sheet.

1.07 APPLICATION REQUIREMENTS: Surfaces will be inspected and approved by the Contracting Officer or representative immediately prior to application of roofing and flashings; said inspection to be coordinated by the Contractor. The roofing or flashing shall be applied to a smooth and firm surface free of ice, frost, moisture, dirt, projections, and foreign materials.

Application of roofing shall not be performed under damp or wet conditions or excessive wind conditions as determined by the Contracting Officer.

1.08 ROOF PROTECTION: When wheeled or other traffic over the partially or fully completed roofing is unavoidable, use adequate plank or plywood protection for the roofing.

Mechanical application devices shall be mounted on pneumatic-tired wheels, and shall be designed and maintained to operate without damaging the insulation or the roofing membrane.

1.09 FIRE PROTECTION: Provide 15-pound minimum size fire extinguishers, using ammonium phosphate firefighting agent. Locate two at each kettle, tanker, and site of hot bitumen application on the roof.

1.10 DAILY CLEANUP: Remove all debris daily from the roof. Use enclosed chute, crane and bucket or construction hoist to reduce amount of dust, dirt, and noise.

1.11 ACCEPTANCE OF COMPLETED WORK: Acceptance of completed work will be based on its conformance to the contract. Nonconforming work will be rejected. The Air Force is not obligated to accept nonconforming work at a reduced price. The contractor shall start replacement or correction of rejected work within 10 calendar days after receipt of the rejection notice. A QC program not in compliance with Part Four is considered nonconforming work. Contractor receipt of a final acceptance certificate, signed and dated by the contracting officer, will constitute Air Force acceptance of roofing work.

1.12 OPERATIONAL PROCEDURES: Confine operations, movement of workmen and equipment, storage, materials and debris within limits as directed by the contracting officer. Do not load the deck or any part of the building structure or permit to be loaded with a weight which will cause excessive deflection or endanger safety or cause damage. Do not put kettles on the roof deck or roofing systems. Protect the building and surrounding area from damage or injury. The contractor must determine the nature of these operations and provide proper protection. Repair all damage caused by lack of such protection to the Contracting Officer's satisfaction. If repairs are not made, or if the Contracting Officer determines that repairs are beyond the contractor's ability, the Air Force will have the work done by others, and will charge the cost to the contractor.

PART 2 – PRODUCTS

2.01 MATERIALS: Materials shall conform to the following requirements or equivalent 20-year warranted system:

A. Applicable for the Indicated Slopes Over All Decks:

1. Slopes 1/8-inch per foot and less: Aggregate-surfaced, with 4 plies of coal tar compatible fibrous glass felt and coal tar ASTM D450 Type I or III.

2. Slopes 1/8 inch to 1/2 inch per foot:

a. Aggregate-surfaced, with 4 plies of asphalt-coated fibrous glass felts and asphalt, ASTM D312 Type II or Type III.

b. Mineral-surfaced, with 4 plies of asphalt-coated fibrous glass felts and an additional glass fiber cap sheet and asphalt, ASTM D312 Type II or Type III.

3. Slopes 1/2-inch to 3 inches per foot: Same as 2.01 A.2, except use Type III or IV asphalt.

4. Slopes over 3 inches per foot:

a. Smooth (emulsion) surfaced, with 4 plies of asphalt impregnated glass felts and asphalt.

b. Mineral-surfaced with 3 plies of asphalt impregnated glass felts and a glass fiber base cap sheet and asphalt.

B. Over Steel Decks:

1. Underlayment: None.

2. Insulation: Two Layers (Minimum)

3. Insulation Attachment:

a. First Layer: Full mechanical fasteners as required by Factory Mutual Loss Prevention Data Bulletin 1-28, current edition, Windstorm Rating Class I-90.

b. Second Layer or Additional Layers: Asphalt Type III or as recommended by manufacturer.

4. Membrane: 4-ply roofing system.

C. Over Concrete Decks:

1. Underlayment: One ply of asphalt-coated fibrous glass felt or heavy duty base sheet as recommended by the manufacturer.

2. Underlayment Attachment: Asphalt or coal tar as recommended by manufacturer.

3. Insulation: Two Layers (Minimum)

4. Insulation Attachment: Asphalt Type III or as recommended by manufacturer.

5. Membrane: 4-ply roofing system.

D. Over Gypsum Decks:

1. Underlayment: One ply asphalt-coated fibrous glass felt or heavy duty base sheet as recommended by manufacturer.

2. Underlayment Attachment: Mechanical fasteners.

3. Insulation: Two Layers (Minimum)

4. Insulation Attachment: Asphalt Type III or as recommended by manufacturer.

5. Membrane: 4-ply roofing system.

E. Over Wood Decks:

1. Underlayment: Five-pound rosin-sized sheathing paper overlaid with one ply of asphalt glass fiber felt or heavy duty fibrous glass base sheet as recommended by the manufacturer.

2. Underlayment Attachment: Nails.

3. Insulation: Two Layers (Minimum)

4. Insulation Attachment:

a. First Layer: Full mechanical fasteners as required by FM I-90.

b. Second Layer or Additional Layers: Asphalt Type III or as recommended by manufacturer.

5. Membrane: 4-ply roofing system.

2.02

BITUMEN:

A. Primer: ASTM D41 Asphalt Primer.

B. Asphalt: ASTM D312 type as specified herein or as determined by the slope requirements of the BURS manufacturer.

C. Coal Tar: ASTM D450, Type I or Type III or as recommended by the BURS manufacturer.

2.03

FELTS, FABRICS, MATS AND WALKWAYS:

A. ASTM D1668 Treated Glass Fabric:

1. Type I, for asphalt systems.

2. Type II, for coal tar systems.

B. ASTM D2178 Type IV or Type VI Asphalt Glass Felt used in roofing and waterproofing as recommended by the manufacturer.

C. ASTM D4601 Type II Asphalt Coated Glass Fiber Base Sheet.

D. ASTM D3909 Asphalt Roll Roofing (Glass Felts) surfaced with mineral granules.

E. Organic Felts for Envelopes and Water Cutoffs:

1. ASTM D226 Asphalt-Saturated Organic Felt Type 2 (30-16).

2. ASTM D227 Coal Tar-Saturated Organic Felt.

F. ASTM 517 Asphalt Plank for Walkways.

G. Flashing: Base flashings to be standard product of the BUR manufacturer. Modified Bitument Flashing (APP or SBS modified) membranes may be used IAW manufacturers' instructions.

2.04

CEMENTS:

A. Asphalt Base Roofing Cement: ASTM D2822 Asphalt Roof Cement, Type II.

B. Coal Tar Base Roofing Cement: ASTM D4022 Coal Tar Roof Cement.

C. Flashing Cement: BURS manufacturer's standard.

D. Plastic Cement: Shall conform to FS SS-C-153 Type I Class A.

2.05 INSULATION:

A. Mineral Fiber, and Mineral Fiber Rigid Cellular Polyurethane Composite Roof Insulation Board, ASTM C 726.

B. Perlite Thermal Insulation Board, ASTM C 728. Perlite board shall be treated to reduce asphalt absorption.

C. Insulating Board (Cellulosic Fiber) Structural and Decorative, ASTM C 208.

D. Federal Specification (FS) HH-I-1972/GEN Insulation Board, Thermal Faced, Polyurethane or Polyisocyanurate.

E. FS HH-I-1972/2 Insulation Board, Thermal, Polyurethane or Polyisocyanurate Faced with Asphalt/Organic Felt, Polymer/Organic mat, Asphalt/Glass mat, or Polymer/Glass mat on both sides of the foam, Class I.

F. FS HH-I-1972/3 Insulation Board, Thermal, Polyurethane or Polyisocyanurate Faced with Perlite Insulation Board on one side of the foam and Asphalt/Organic Felt Style 1 or Asphalt/Glass Fiber Felt on the other side of the foam, Style 2.

G. FS HH-I-1972/5 Insulation Board, Thermal, Polyurethane or Polyisocyanurate Faced with Perlite Board on both sides of the foam.

H. Phenolic Insulation. Phenolic insulation shall be closed cell phenolic foam board with a density in excess of 2.5 pounds (minimum) per cubic foot. The top and bottom surfaces of the board shall be covered with an uncoated glass facer bonded to the phenolic foam during manufacture. Phenolic insulation shall conform to physical requirements of FS HH-I-1972/2, Class 1. Test data shall be submitted to demonstrate compliance.

2.06 AGGREGATE: ASTM D 1863 Mineral Aggregate used on built-up roofs, graduation size 6, 7, or 67.

2.07

CANT AND TAPERED EDGE STRIPS:

A. ASTM C 208 Insulating Board (Cellulosic Fiber), Structural and Decorative, ASTM C 726 Mineral Fiber and Mineral Fiber, Rigid Cellular Polyurethane Composite Roof Insulation

Board, or as recommended by the BURS manufacturer.

B. Size:

1. Cants: 4 inch X 4 inch or as required by conditions. In high wind areas, install cants in compliance with FM I-90.

2. Tapered Edge Strips: 1-1/2 inch X 18 inches or as required by conditions.

2.08

FASTENERS:

A. Nails: Nonferrous or galvanized steel.

B. Bolts and Nuts: ASTM A307 Carbon Steel Externally and Internally Threaded Standard Fasteners, hot-dip galvanized.

C. Roofing Fasteners: Fasteners used to fasten to steel, wood and gypsum decks must be approved by FM as evidenced by being listed in the FM Approval Guide for I-90 windstorm rating when used with the specified insulation. Fasteners shall be the threaded type that will fill the penetration through the deck. Fasteners shall be treated to prevent corrosion according to FM

Std 4470.

D. Underlayment, Roof Membrane, and Base Flashing Fasteners: Types as recommended by the BURS manufacturer.

E. Sheet Metal Fasteners:

Metal Type

Fastener Material Galvanized Steel

Galvanized or Cadmium Plated Steel

Copper

Copper or Bronze

Lead

Galvanized or Cadmium-plated Steel

Lead-Coated Copper

Copper or Bronze

2.09

SHEET METAL:

A. Galvanized Steel: ASTM A526 hot-dipped zinc-coated sheet steel, commercial quality. Coating designation G 90, not chemically treated, not oiled, phosphatized.

B. Copper: ASTM B370 copper sheet and strip for building construction, cold-rolled temper.

C. Lead: Manufactured from a base metal conforming to FS QQ-L-171E Lead Pig, Grades A or C or ASTM B29 Pig Lead, chemical lead type modified as follows: Hard lead containing 4 to 6 percent antimony, and the remainder lead or hard lead containing

3.75 to 4.25 percent antimony, 0.07 to 0.10 percent arsenic.

D. Lead Coated Copper: ASTM B101 lead coated copper sheets, Type I, Class A, 16 ounce per square foot minimum weight copper exclusive of coating, cornice temper for cornices and roofing temper for all other metal work.

E. Solder, Flux, and Accessories: As necessary and compatible with the material being installed.

F. Pre-Finished Galvanized Steel: ASTM A 526, Steel Sheet, Zinc-Coated (Galvanized) by the Hot-dip Process, Commercial Quality, coating designation G 90, not chemically treated, not oiled, phosphatized. Factory pre-finished galvanized steel shall be primed and coated with a full strength fluoropolymer (containing a minimum of 70% Kynar 500 resin). Color shall be selected by the contracting officer but shall be a standard factory color to match or complement the existing color scheme. Provide the manufacturer's 20-year warranty.

2.10

WOOD PRODUCTS:

A. Lumber Species: Choose from the following: Douglas fir, northern white pine, ponderosa pine, southern pine, jack pine and red pine.

B. Grades: Choose either Western Wood Products Association (WWPA), Northeastern Lumber Manufacturers Association (NELMA), or Southern Pine Inspection Bureau (SPIB) grading rules for the specified grades for lumber provided. Plywood panels shall meet the requirements of the latest edition of U.S. Product Standard PS 1.

1. Exterior trim, soffits, and wood exposed to view.

a. Lumber:

(1) WWPA and NELMA: Selects and finish class, "D"

Select Grade or:

(2) SPIB: "C" Finish Grade.

b. Plywood: American Plywood Association (APA), veneer grade A-C, plywood, exterior.

2. Enclosed and incorporated into the roof system (for example, nailers, sleepers, blocking, and decking).

a. Lumber:

(1) Thickness less than 2 inches, and all widths: WWPA and NELMA; Board Class No. 2 common grade or SPIB No. 1 boards.

(2) 2 to 4 inches thick, and 2 to 4 inches wide: SPIB, WWPA, and NELMA: Structural light framing class, No. 2 grade.

(3) 2 to 4 inches thick, and 4 inches and over in width: SPIB, WWPA, and NELMA: Structural joists and planks Class, No. 2 grade.

b. Plywood for all uses except decking, choose from the following:

(1) APA, veneer grade C-C plugged, plywood, exterior.

(2) APA, veneer grade C-D plywood, Exposure 1.

(3) APA, Structural I or II Rated Sheathing, Exterior.

(4) APA, Structural I or II Rated Sheathing, Exposure

c. Plywood for Decking:

(1) APA, veneer grade C-C, plywood, Exterior.

(2) Minimum 1/2-inch thickness required.

C. Preservative Treatment:

1. Exterior trim, soffits, and wood exposed to view: Do not treat with preservatives.

2. Enclosed and incorporated into the roof system: American Wood Preservers Bureau (AWPB) specification LP 22 standard for lumber, timber, and plywood pressure treated with water-borne preservatives for ground contact use. (July 1975), except, do not use acid copper chromate (ACC) preservative. Dry preservative-treated wood products after treatment to values specified in LP 22.

D. Moisture: The allowable moisture content for lumber and plywood is to be 12 percent. For exterior trim, soffits, and wood exposed to view, the moisture content applies at the time it is painted. For wood enclosed and incorporated into the roof system, the moisture content specified in LP 22 applies at the time of enclosure.

E. Marking:

1. Each piece of lumber must bear a grade stamp or grade mark showing the association under whose rules it was graded, the grade, the species, and either "S-DRY," "KD," or "MC 15."

2. Each panel of plywood must bear the appropriate trademark of the American Plywood Association (APA).

3. Each piece of preservative-treated lumber and plywood must bear the AWPB quality mark.

2.11

SEALANT:

A. Sealant Primer. As manufactured and recommended by the sealant manufacturer in writing. All sealants must be used with a primer. If a manufacturer does not routinely require a primer, obtain a recommendation to fill this requirement.

B. Sealant Backup Material. As manufactured or recommended by the sealant manufacturer for the substrate type and joint design on this project. Unless indicated or specified otherwise, all joints must have a backup material sized to be slightly compressed in the joint when installed.

C. Color. As specified herein or, if unspecified, to match the adjacent substrate as closely as possible with standard stock colors.

D. Sealant Type for General Use. FS TT-S-230C including amendment 2 single component sealing compound, Type II, Class A. Sealant material must be urethane or acrylic polymer.

E. Use sealants whose date of manufacture shows they have not exceeded their shelf life. Do not use sealants with a date of manufacture more than 12 months old.

2.12 EXPANSION JOINT: Metal cap type roof expansion joints are to be installed on wood curbs extending 8 inches minimum above the roof. Metal cap-type shall be manufactured in accordance with the recommendations of the NRCA. Elastomeric-type shall have a non-reinforced EPDM or neoprene bellows with a foam backing, and it shall be mechanically interlocked to the metal mounting flanges with a continuous bifurcated metal edge crimp. All intersections shall be prefabricated by the manufacturer.

2.13 FELT ENVELOPES: ASTM D226 Asphalt-Saturated Organic Felt, Type II or ASTM D227 coal-tar saturated organic felt.

PART 3 - EXECUTION

3.01

GENERAL:

A. APPLICATION OF ROOFING: The entire roofing system, excluding aggregate surfacing, shall be finished in one operation up to the line of termination at end of day's work.

Application of roofing shall immediately follow application of insulation as a continuous operation. Phased construction will not be permitted. BURS and graveling-in shall be installed according to BURS manufacturer's requirements and specifications. To ensure a waterproof membrane, care shall be taken to preclude bare spots (voids) between plies. To prevent slippage, care shall be taken to preclude use of excessive amounts of bitumen. Kettle attendants shall be present at the kettle at all times during the heating. Application temperatures shall be measured at the mop bucket or mechanical applicator. Asphalt shall be applied at or no less than 25 degrees (F) below the manufacturer's stated EVT. Asphalt at a temperature below this shall be returned to the kettle. Coal tar shall not be heated above 410 degrees (F) for ASTM D 450, Type I and 425 degrees (F) for ASTM D 450, Type III. Coal tars shall be applied at the roofing felt manufacturer's recommended temperature range. Coal tar at a temperature below this range shall be returned to the kettle. The surface of the felts shall be broomed-in full width to obtain complete adhesion between plies and to eliminate air pockets. The method of mopping a half sheet width and turning the sheet back to mop under the other half will not be used. Workers shall avoid walking on mopped surfaces when the bitumen is sticky. Each layer of roofing felt shall be carried up abutting vertical surfaces at least 4 inches, or the top of the cant strip.

B. Preparation for Roofing (Work Item #7):

1. Removals must result in a clean and dry substrate, except for residual stains, providing a surface suitable to apply new materials. A substrate surface is suitable when application of new materials results in a uniform positive, and maximum bond between such materials and the substrate.

2. Remove existing roof-top equipment as indicated on the drawings; all equipment remains Government property unless otherwise designated.

3. Lift or remove metal and metal accessories indicated to remain, to aid the installation of new materials.

4. If conditions are uncovered or created that would be detrimental to the application of specified work, immediately notify the Contracting Officer of such conditions for determination of treatment.

5. Roof drains are to be removed, replaced and/or adjusted as indicated to accomodate the new roofing system. Existing drainage system shall be protected during construction. Tapered insulation around the roof drains shall be provided as shown in the standard NRCA roof drain details.

3.02

UNDERLAYMENT INSTALLATION:

A. Concrete Decks: Prime the deck with a uniform coating of asphalt primer at the rate of one gallon per square and allow to dry. Apply one ply of the specified felt underlayment in a strip or spot mopping of hot and fluid asphalt with 2-inch side laps and 6-inch end laps minimum per manufacturer's specifications. NOTE: On precast concrete decks, joints shall be treated as recommended by BURS manufacturer, and primer and asphalt moppings shall be held back 4 inches minimum from panel joints.

B. Gypsum Decks: Apply one ply of the specified felt underlayment with 4-inch side laps and 6-inch end laps minimum. Attach with specified mechanical fasteners through side laps on 6 to 9-inch centers. Also, stagger nail center of sheets at approximately 18 inches on-center, in two parallel rows, 10 to 12 inches from the edges of the base ply. Do not drive fasteners into or between the metal edges of the gypsum planks.

C. Wood Decks:

1. Completely cover the deck with one ply of sheathing paper. Lap each sheet a minimum of 2 inches and nail sufficiently to hold in place.

2. Over the sheathing paper, apply one ply of the specified felt underlayment with 2-inch side laps and 6-inch end laps minimum. Nail through side laps on 6 to 9-inch centers and stagger-nail center of sheets at approximately 18 inches on center in two parallel rows, 10 to 12 inches from the edges of the base ply.

3.03

INSULATION INSTALLATION:

A. General Requirements:

1. On slopes of 1 inch per foot or more, provide pressure treated wood insulation stops according to the roof insulation manufacturer's requirements.

2. Secure cant and tapered edge strips in place with asphalt; cut and neatly fit all joints and miters. Cant strip may be tacked in-place for ease of installation (approximately 3 nails every 4 feet).

3. Insulation board, cant strips and tapered edge strips that can be readily lifted or displaced by hand are not adequately secured. Reinstall all lifted and displaced items that are not damaged. Replace damaged items with new material.

4. Follow additional applicable requirements of the roof insulation manufacturer and BURS manufacturer.

B. Over Steel, Wood and Gypsum Decks:

1. First (bottom) Layer:

a. Place insulation so that side joints between boards are fully supported at all times.

b. Stagger end joints by a minimum of 6 inches; bring boards into moderate, uniform contact.

c. Also, secure all insulation boards in the first layer with mechanical fasteners over the entire roof deck according to FM Loss Prevention Data Sheet 1-28. Filler pieces must have at least two fasteners. Locate all fasteners such that there is at least 1 fastener every 2 square feet, or comply with FM Windstorm Class FM I-90, whichever is more stringent.

d. Use those driving methods prescribed by the fastener manufacturer.

2. Second or Additional Layers: Secure in full and uniform moppings of hot, fluid bitumen; stagger end joints by minimum 6 inches; bring boards into moderate, uniform contact at sides and ends while the bitumen is hot and fluid. Offset all joints between layers by maximum dimensions in both directions.

C. Over Non-Nailable Decks With Underlayments:

1. Secure all insulation boards in full and continuous moppings of hot fluid bitumen.

2. Stagger end joints by minimum 6 inches. Bring boards into moderate, uniform contact at sides and ends while the bitumen is hot and fluid. Offset all joints between layers by maximum dimensions in both directions.

3.04

MEMBRANE INSTALLATION:

A. General Requirements: Except as modified and supplemented herein, apply membrane (4-ply) to meet the quality standards of the BURS manufacturer's 20-year warranted system. On slopes over 1 inch per foot, provide nailers and backnail felts, and if required by the BURS manufacturer on lower slopes.

B. Felts and Roll Goods:

1. Apply felts shingle fashion and maintain proper lap distance to result in a 2-inch nominal headlap (l-inch minimum, no maximum). Maintain a straight run of felts so that kinks or fishmouths do not result, and the felts are completely flat.

a. Bitumen Dams: Felt envelopes shall be provided at the eaves and rakes and sheet metal dams at deck penetrations to prevent bitumen drippage. Felt envelopes are required for membranes using coal-tar pitch, Type I and Type II asphalt bitumen. Sheet metal bitumen dams shall be installed with the flange set in plastic cement on top of the insulation. Roofing felts shall be applied over the flanges with the sleeve of the dam set to prevent drippage of bitumen.

b. Edge envelopes shall be organic felt strips at least 18 inches wide. The strip shall be set in plastic cement or Type IV asphalt and positioned to extend 9 inches onto the nailer around the perimeter of the building with 9 inches lapped over the edge of the building. After roofing felt application is complete, the 9-inch overlapped section shall be folded back over the plies and mopped down to form an envelope around the perimeter of the membrane.

2. Once established, do not change the direction of felt application. Provide organic felt envelopes at gravel stop roof edges and sheet metal pitch dams at deck penetrations to prevent bitumen drippage.

3. Broom or squeegee each ply of roll goods into place, full width, while the bitumen is hot and fluid, such that felt does not touch felt and interply voids or skips in the bitumen do not occur. Broom or squeegee and do not walk on the freshly laid felt until bitumen has reached set temperature. Bitumen shall be visible continuously along both edges of the felt.

NRCA Publication, Application Techniques for Glass Fiber Roofing Felts, shall be used as a recommended procedure.

3.05

FLASHING INSTALLATION:

A. General Requirements (Work Item #13): Install flashings as detailed on the drawings and/or as recommended by the manufacturer. Modified Bitumen (MB) type membranes may be used if approved and installed per BUR manufacturer's instructions (torched, hot, cold applied, etc).

1. Prime all surfaces to be flashed with asphalt primer and allow to dry.

2. Completely bond all flashings to the substrate, and the flashing plies to each other without voids. Coat all flashing substrate and ply interfaces to achieve a full and uniformly bonded laminate. Flashing cement shall be applied in a continuous layer. Brushing application is not acceptable.

3. Follow additional applicable published requirements of the BURS manufacturer.

4. Tops of all membrane base flashings must be mechanically attached to the vertical substrate with large-headed nails 6 to 9 inches on-center.

5. All side laps of membrane flashing surfacing sheets must be sealed with roofing cement reinforced with woven glass fiber 4 inches wide centered over the lap.

6. Tops of all membrane base flashings must be sealed with roofing cement reinforced with 4-inch wide woven glass fiber fabric.

B. Roof Drain Flashing: Follow applicable published requirements of BURS manufacturer or NRCA published details and procedures.

C. Expansion Joint Covers: Install expansion joint covers as detailed and recommended by NRCA, or Sheet Metal and Air Conditioning Contractors National Association, Inc., (SMACNA). Install and splice in accordance with the manufacturer's installation instructions. Use only fasteners and splicing materials, including adhesives, supplied for this purpose by the manufacturer.

3.06

METAL INSTALLATION:

A. Fabricate and install metal as shown on drawings. Meet the requirements of the components of materials manufacturers, NRCA, SMACNA, and Copper Development Association, as they apply to this project.

B. The contractor is responsible for all the work required to make any displaced mechanical units operational. Included are repair, testing, and balancing to conform to the original level of performance as determined by the Contracting Officer.

C. Prime all sheet metal that will come in contact with bituminous materials with asphalt primer and allow to dry before applying bitumen.

D. Isolate dissimilar metals in contact by painting with a compatible bituminous coating, or by using an uncured neoprene gasket.

E. Sheet Metal with Flanges: Follow applicable published requirements of BURS manufacturer.

F. Do not overlap edge metal. Allow 1/4-inch minimum spacing between edge metal pieces. Cover gap between adjacent edge metal with a joint cover 4 to 6 inches wide set in mastic.

3.07

WOOD INSTALLATION:

A. Provide wood members as indicated on drawings.

B. Provide fasteners at not more than 2 feet 8 inches on-center, and also within approximately 6 inches of each end to secure nailers to the building construction. Anchors shall be not less than 3/8-inch in diameter and shall be countersunk and flush with top of nailer.

C. Where nailers are stacked, secure the top nailer to the lower with spikes or nails of proper length, spaced maximum 18 inches on-center, staggered and within approximately 6 inches of all nailer ends. Ends of stacked nailers shall be offset approximately 12 inches in long runs and staggered (alternated) at corners.

D. Brush apply one coat of copper naphthenate solution onto all cut surfaces of preservative-treated lumber.

E. Wood cants are to be used in critical wind areas and securely anchored to prevent warping.

3.08

SEALANT INSTALLATION:

A. Follow sealant manufacturer's installation requirements except as specified herein.

B. Clean the substrate so no contaminants such as bitumen, concrete curing compound, paint, dirt, or moisture will prevent bonding of the primer or sealant directly to the substrate.

C. Prime with sealant primer, all substrates to which sealant will be applied and allow the primer to cure. This must be done regardless of whether the sealant manufacturer requires priming.

D. Except for sheet metal joints, install sealant backup material.

3.09

SURFACING:

A. After roofing felts have been laid and flashings installed, the roof surface shall be flood-coated uniformly and appropriate aggregate surfacing applied according to BURS manufacturer requirements and specification.

B. Walkways: Where shown, mineral-surfaced asphalt plank treads, meeting the requirements of ASTM D517, shall be embedded in the flood coat prior to gravel surfacing. Treads shall be spaced 6 inches apart. If pavers, grating or any other walkway system is specified, install in accordance with the BUR manufacturer recommendations.

C. Building No. ________ is in the vicinity of aircraft operations. Apply aggregate surfacing as follows:

1. Over the entire surface of the roofing membrane apply a continuous coating of bitumen and sufficient aggregate to completely cover the surface. Remove loose gravel.

2. Apply a second continuous coating of bitumen and sufficient aggregate to completely cover the area. Loose aggregate must be removed from the final surface resulting in complete aggregate embedment.

3.10 ROOF MEMBRANE SAMPLING (Work Items #10 and #11):

A. A minimum of one test cut 12 inches X 12 inches in dimension is required each day of construction until a level of confidence is established between the quality controller and the government inspector. The contractor will take the required test at the direction of the contracting officer or his/her designated representative. A test cut of same dimensions is also required when job conditions change significantly thereafter, such as, ambient temperature, crew members, or when visual observations indicate that membrane integrity may be compromised, such as, bitumen too cool, workers walking on freshly laid felts, or continuous bitumen film not present at edge of felts. Remove the test samples before application of the surface coating at locations selected by the inspector. Immediately take the sample off the roof and cool it to about 0 degrees (F), using dry ice. Comply with stated tolerances on interply bitumen weight, head laps and void content. If results show out-of-tolerance conditions, the construction process will be adjusted and an additional sample taken to verify that construction is back within tolerance.

B. Sample removal and repair of the roof shall be done by the contractor. Do not cut a sample from a completed membrane until it has cured for at least two hours. Using a template and utility knife, cut the membrane a little at a time. Ensure that you cut through the entire membrane. Any bitumen that sticks to the insulation after the sample is removed shall be carefully removed and included with the sample for weighing and analysis. Remove the cut sample slowly taking care not to bend the sample.

C. Repair the sampled area immediately after taking the sample. Install a new piece of insulation, if necessary. Fill remaining void level with layers of cut felts of the same type as the roofing system, set in plastic cement. Cover repaired area with four layers of felt.

(1) Solid mop each layer into place in hot bitumen. (2) Overlap test cut area 3 inches on all sides with first layer. (3) Lap each succeeding layer 3 inches on all sides over layer below.

D. Testing and analyses shall be done in accordance with ASTM D3617, Standard Practice for Sampling and Analysis of Built-Up Roof Membranes. Samples shall be tested in the field by an approved commercial testing laboratory at the contractor's expense.

E. Nonconforming work. If insufficient headlap, deficient asphalt quantities , unacceptable voids or other defects are present, the roofing system manufacturer shall be requested to furnish written recommendations for remedial action.

3.11

CONTRACTOR QUALITY CONTROL:

A. It is the responsibility of the contractor to ensure that the designated roofing quality control person complies with all requirements 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 (e.g., audit procedures), and report work conditions daily on AF Form 1063, Quality Control Record. Instructions on how to use it are included in Part Four. Work accomplished on a daily basis will be considered satisfactory only when the daily record form shows that all "variances" have been corrected and that the work is in conformance with the contract.

B. Quality Assurance (QA):

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

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.

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.

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

a. 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.

b. 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.

C. Provide quality control defined as follows:

1. Quality control is the regulatory process by which the contractor measures actual quality performance, 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.

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. 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. The designated QC shall always be on the job site during BUR construction.

4. Within 10 days after the issuance of the Notice to Proceed and before the start of roofing work, the contractor shall attend a preconstruction conference at the air base to review the contract. The quality controller and foreman or superintendent must attend the conference. A technical representative from both the membrane and insulation manufacturers shall also be present at this conference, 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 input where necessary to describe the proper installation of their materials. The conference may include a visit to the work site, and a slide or video presentation relating to job site membrane sampling and analysis.

5. Basic quality control requirements are contained in Part Four of this specification. As a minimum, the quality controller shall perform each of the actions listed in Part Four 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 tolerances specified in this contract and is grounds for the Contracting Officer to stop the work.

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

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

a. Read the specifications and study the drawings.

b. Understand the required tests and measurements.

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

d. Attend the pre-construction conference.

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

a. Calibrated portable thermometer to measure the bitumen temperature at the kettle and at the point of application.

b. Triple beam scale or postal-type platform scale for weighing roof membrane samples.

c. Non-conductive measuring tape, 50 or 100 feet.

d. Hand held Delmhorst Model BD-7 Moisture Meter or approved equal for determining moisture content of materials at time of installation.

e. Sheet metal template (4 inches X 40 inches and 12 inches X 12 inches) for BUR samples. (Reference ASTM D3617.)

f. A capability for cooling BUR samples to a temperature of at least 0 degrees (F) in 30 minutes.

g. Tools required for cutting samples and splitting felt plies apart (cutting knife and blades).

h. Clear template with 1/2-inch grid for analyzing sample void area.

i. MIL gauge for measuring flood coat thickness.

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 20-year 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.

a. Headlap: Minimum 1 inch, no maximum. (Work Item #9).

b. Endlap: Minimum 4 inches, no maximum. (No Work Item).

c. Insulation Board Joint Gaps: 3/16-inch maximum between boards and 1/4-inch maximum between boards and abutting surfaces. (Work Item #8).

d. Bitumen Temperatures: (Work Item #2).

(1) Maximum At Kettle: Do not heat ASTM D312, Type I asphalt above 500 degrees (F) and all other ASTM D312 type asphalt above 525 degrees (F). Do not heat coal-tars above 410 degrees (F) for ASTM D450, Type I and 425 degrees (F) for ASTM, Type III.

(2) Temperature At Point of Application: Equiviscous

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

(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). If heating of coal-tar is desired during a non-use period, temperature shall not exceed 325 degrees (F). If storage exceeds 4 hours, kettle shall be shut off. Large quantities of coal-tar, 1000 gallons or more, can be held at a maximum of 300 degrees (F) for no more than 96 hours.

e. Interply Moppings: As required by the BUR manufacturer plus or minus 20 percent. (Work Item #10).

f. Flood Coat: Asphalt, 60 pounds per square average and at no location less than 50 pounds; coal tar, 70 pounds per square average and at no location less than 60 pounds. (Work Item #14).

g. Surfacing: Uniformly cover roof area with the quantity of aggregate specified by the BUR manufacturer. Embedded by weight, a minimum of 50 percent of the specified amount. (Work Item #14).

h. Foaming Hot Bitumen at Point of Application: Not acceptable for ply mopping construction. (Work Items #l and #10).

i. Foreign Materials Between Plies: None acceptable. (Work Item #9).

j. Material Variance From Specified: None acceptable. (Work Item #3).

k. Variance From Number of Plies Specified: None acceptable. (Work Item #9).

l. Phased Construction of Membrane Felts: Not acceptable. (Work Items #4 and #9).

m. Material Moisture Content: Maximum percent by dry weight as follows: Organic felts 2.5 pct; fiberglass felts 1 pct; lumber and plywood 12 pct; insulation as per manufacturer requirements. (Work Item #1).

n. Felt Laying: Wrinkles, Buckles, Kinks and Fishmouths: Not acceptable. (Work Item #9).

o. Interply Voids for Individual Sample: (See Work Item #10 for description of voids).

(1) Maximum Area of All Glazed Voids: 5 percent of interply area for individual sample.

(2) Unsealed and Dry Voids (felt on felt): Not acceptable.

(3) Overlapping Voids Between 2 or More Plies: Not acceptable.

4. Quality Control Record: (Not Used)

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

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

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 having labels that:

a. Identify the material.

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

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

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

a. Aggregate shall comply with moisture and dust content requirements of ASTM D1863.

b. Other materials:

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

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

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

6. Use separate kettles and materials application and transporting equipment for asphalts and coal tar products.

7. Do not use bitumens which have been overheated, heated and held beyond specified…