07510 Built-up Bituminous Roofing.doc

Built-up Roofs, Indefinite Delivery Indefinite Quantity (IDIQ) Contract Hill AFB, Utah

DIVISION 7 SECTION 07510 – BUILT-UP BITUMINOUS ROOFING

PART 1 - GENERAL

1.1 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 and insulation 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 manufacturers 20-year warranted system. The BUR Manufacturer Certification, (Submittal #1), is a qualification to bid this contract. The contractor shall have the BURS manufacturer of the proposed roofing system execute Submittal #1 prior to submitting bid proposal. The submittal shall be included in the bid proposal submitted to the Air Force. QC procedures, tolerances and testing are specified in these contract documents. Nonconforming work will be rejected as a violation to these specifications.

1.2 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.

1.3 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.

1.4 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.

1.5 SUBMITTALS:

Submittals 1 through 3 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 #1:

Built-up Roofing System Manufacturer's Certification (Submittal #1). Submittal #1 is a qualification to bid this contract and must be submitted as part of the bid, and be accepted by the contracting officer.

B. Designation of Roofing Quality Control Controller (Air Force contact person) (Submittal #1):

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 that meets these requirements. This person may have other responsibilities in addition to roofing quality control such as job foreman. 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 2 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.

C. 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.

D. 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.

E. Contractor Reporting:

The following shall be submitted:

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

2. Supplier's certification: For bitumen in hot bulk and truckloads of aggregate. (As required.)

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

F.

Plan view drawing.

1. 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, (i.e., 4" x 36" or 12" x 12").

2.

As-built Roof Summary. (Submittal #3).

1.6 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.

1.7 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.

1.8 FIRE PROTECTION:

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

1.9 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.

1.10 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.

1.11 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

2.1 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 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.

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

B. Over steel decks:

1. Underlayment: None

2. Underlayment attachment: None

3. Insulation: Two layers (minimum).

4. 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 of additional layers: Asphalt Type III or as recommended by manufacturer.

5. Membrane: 4 plies asphalt-coated fibrous glass felts, Type VI.

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 plies asphalt-coated fibrous glass felts, Type VI.

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 plies asphalt-coated fibrous glass felt, Type VI.

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 1-90.

b. Second layer or additional layers: Asphalt Type III or as recommended by manufacturer.

5. Membrane: 4 plies asphalt-coated fibrous glass felt, Type VI.

2.2 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.

2.3 FELTS, FABRICS, AND MATS:

A. ASTM D1668 Treated Glass Fabric:

1. Type I, for asphalt systems.

B. Asphalt Glass Felt: ASTM D2178 Type VI used in roofing and waterproofing only.

C. Base Sheet: ASTM D4601-95, Type II asphalt coated glass fiber.

D. Roll Roofing: ASTM D5147 Asphalt (Glass Felts) surfaced with mineral granules, non-woven polyester reinforced mat (250 g/m2), SBS minimum.

2.4 CEMENTS:

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

B. Non-asbestos, fibered adhesive, meeting ASTM D3019.

C. Flashing Cement: BURS manufacturer's standard.

2.5 INSULATION:

A. Perlite/Tapered Perlite Thermal Insulation Board, ASTM C-728, 3/4" minimum.

B. Federal Specification (FS) HH-I-1972/GEN Insulation/Tapered Insulation Board, thermal, faced, polyisocyanurate:

1. FS HH-1-1972/2 Insulation Board, thermal, polyisocyanurate, faced with asphalt/organic felt or asphalt/glass mat on both sides of the foam, class 3 or class 4, R-19 minimum. ASTM D2126

2.6 AGGREGATE:

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

2.7 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.

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

2.8 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 or supplements. 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

2.9 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, with a 70% KYNAR 500 Factory Coated Finish, 24 gauge minimum.

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.

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 WWPA, NELMA, or 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: 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 1.

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: AWPB specification LP 22 standard for lumber, timber, and plywood pressure treated with waterborne preservatives for ground contact use, 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 13 percent. For exterior trim, soffits, and wood exposed to view, the moisture content applies at the time it is painted. For wood enc1osed 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 (COM-NBS) (Feb 2, 1970) including Amendment 2 (Oct 19, 1970) 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 install on a wood curb extending 8 inches minimum above the roof, as per the NRCA Roofing and Water proofing Manual – Fifth Edition.

2.13 FELT ENVELOPES:

ASTM D226 Asphalt-Saturated Organic Felt, Type II.

PART 3 - EXECUTION

3.1 GENERAL:

A. Application of roofing: The entire roofing system, including aggregate surfacing, shall be finished in one operation up to the line of termination at end of day's work. Daily graveling-in may be delayed for designated roof areas where specified. Application of roofing shall immediately follow application of insulation as a continuous operation. Phased construction will not be permitted. BURS 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. Asphalt shall not be heated higher than 50 degrees (F) below the flash point. 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 l 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:

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. Existing roof-top equipment: Remove as indicated on the drawings; all equipment remains government property unless otherwise designated.

3. Metal and Metal Accessories: Lift or remove as indicated to aid the installation of new materials.

4. Conditions that 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.

3.2 UNDERLAYMENT INSTALLATION:

A. Concrete decks: Prime the deck with a uniform coating of asphalt primer at the rate to 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.

3.3 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.

Cant and tapered edge strips secure: 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 1-90, 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.

3.4 MEMBRANE INSTALLATION:

A. General requirements: Except as modified and supplemented herein, apply membrane to meet requirements and recommendations of the BURS manufacturer. On slopes over l 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 (1-inch minimum' no maximum). Maintain a straight run of felts so that kinks or fish mouths do not result, and the felts are completely flat.

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 G1ass Fiber Roofing Felts, shall be used as a recommended procedure.

3.5 FLASHING INSTALLATION:

A. General requirements:

1. All surfaces to be flashed: Prime 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). Use fasteners, adhesives, and other components as provided and as required by the cover manufacturer.

3.6 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.

3.7 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.

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 may be used where they can be securely anchored to prevent warping.

3.8 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.

3.9 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. Graveling-in may be delayed for designated roof areas if approved in writing by the contracting officer and job conditions dictate this procedure. Graveling-in for any area within the designated area must be completed within 10 days. The entire designated area must be complete before starting the next designated area unless otherwise directed by the contracting officer. Graveling-in procedures will be as recommended by the manufacturer.

B. Buildings 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:

A.

A minimum of one test cut 4 inches X 36 inches in dimension taken perpendicular to the long dimension of the felts is required each day of construction until a level of confidence is established between the quality controller and the inspector. 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). 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 completed 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.

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, and report work conditions daily on AF Form 1063, Quality Control Record. Instructions on how to use it are included in PART 4 of this specification. 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. Upon discovery of variance, the contractor shall immediately institute corrective action to eliminate the variance and to ensure 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. However, the quality controller can be the job foreman.

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 presentation relating to job site membrane sampling and analysis.

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 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.

C. 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. Understand AF Form 1063, Quality Control Record, and reporting Procedures. (See PART 4 of this specification).

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

e. Attend the preconstruction 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. Nonconductive 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 36 inches and 12 inches X 12 inches) for BUR samples.

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 l inch, no maximum. (Work Item #9).

b. Endlap: Minimum 6 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 above flash point (Fp).

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. Do not heat coal tars above 410 degrees (F) for ASTM D450 Type 1 and 425 degrees (F) for ASTM D 450 Type III.

e. Interply moppings: As required 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: Quantity, as required for complete coverage, embedment by weight, 50 percent minimum of specified amount. (Work Item #14).

h. Foaming hot bitumen at point of application: Not acceptable for ply mopping construction. (Work Items #1 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 13 pct; insulation as per manufacturer requirements. (Work Item #1).

n. Felt laying: Wrinkles, buckles, kinks, and fish mouths: Not acceptable. (Work Item #9).

o. Interply voids for individual sample: (Work Item #10).

1) Maximum area of all voids: 5 percent of interply area for individual sample.

2) Dry voids (felt on felt): Not acceptable.

3) Overlapping voids between 2 or more plies: Not acceptable.

4. Quality Control Record: The quality controller shall complete AF Form 1063 daily. (See PART 4 of this specification).

D. 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 storage period, or contaminated bitumens. Permanently remove such bitumens from the site.

E. Daily Work Production:

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 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.

2. Temporary water cutoffs and tie-ins: Install each workday. Remove temporary cutoffs and tie-ins so that all vertical faces of insulation are exposed at the beginning of the next day's work.

3. Staggered insulation: Do not cut the 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.

F. 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.

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

1. Check items mentioned in preparatory and initial inspections.

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.

3.12 WARRANTY SIGN:

Provide 10inch X 12 inch minimum size painted signs made of aluminum with a dark color background and letters of contrasting color. Use paint compatible with the aluminum. Sign shall read as indicated. Permanently post signs at all access points leading to the roofs and prominent points on the roofs. Provide at least one sign on each roof with at least four signs on each building.

DO NOT MAKE

REPAIRS OR ALTERATIONS

TO THIS ROOF

WITHOUT APPROVAL

FROM THE CHIEF OF

OPERATIONS & MAINTENANCE OFFICE

THIS ROOF IS UNDER WARRANTY UNTIL ____(1)______

MANUFACTURER _________(2)_________________

ADDRESS ____________(3)__________________

PHONE _____(4)_____

SIGNS TO BE POSTED AS SPECIFIED

(1) INSERT MONTH AND YEAR (20 YEARS AFTER FINAL ACCEPTANCE DATE).

(2) INSERT THE MANUFACTURER'S NAME.

(3) INSERT THE MANUFACTURER'S ADDRESS.

(4) INSERT THE MANUFATURER'S PHONE NUMBER WITH AREA CODE.

3.13 NONDESTRUCTIVE TESTING:

The Air Force reserves the right to perform nondestructive 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

4.1 SECTION A - QUALITY CONTROL RECORDS:

INSTRUCTIONS FOR COMPLETING AF FORM 1063, QUALITY CONTROL RECORD

A. GENERAL. An example of a completed AF Form 1063 is included hereinafter. Contractor quality control personnel must follow instructions 1 through 5 below when completing the daily record. Pages following discuss and identify Work Items l through 14. 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.

B. INSTRUCTIONS

1. Top Section:

a. Insert date and record number.

b. Insert weather description and temperature.

c. Indicate crew start and stop times.

d. Indicate your start and stop times.

e. Indicate total roof area.

f. Indicate roof area previously completed.

2. Products Section: This section is divided into major categories. Each category may include several materials:

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

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

c. 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.

3. Execution Section:

a. The work item numbers in this section of the record correspond 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.

b. 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.

4. Variance Section:

a. 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.

b.

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.

5. Closing Section. Sign the record at the end of the workday and submit it to the Air Force inspector.

CABLE

UNDERLAYMENT

INSULATION

MEMBRANE

COMPO-FLASHING

SHEET METAL

FASTENERS

WOOD

SEALANTS

EXPANSION JOINTS

ALL OTHER MATERIALS

EXPLAIN VARIANCE (If none write NONE)

UNRESOLVED VARIANCES ON RECORDS NOS.

ACTION TAKEN TO RESOLVE VARIANCE

I CERTIFY THAT I HAVE PERSONALLY PERFORMED THE REQUIRED TESTS AND MEASUREMENTS AND ATTEST THAT THIS Q.C.

RECORD IS AN ACCURATE RECORD OF ALL WORK ACCOMPLISHED TODAY.

QUALITY CONTROLLER (Signature)

AF Form 1063

4.2 SECTION B - WORK ITEMS:

A. WORK ITEM NUMBER AND DESCRIPTION

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MATERIAL…