SOW CHA ATCT Roof.pdf

Reroof of the Air Traffic Control Tower

Chattanooga, TN 5921 Pinehurst Ave, Chattanooga, TN

37421

DIVISION 1 – GENERAL REQUIREMENTS

01000 GENERAL REQUIREMENTS

This specification covers the requirements to replace the roof on Chattanooga ATCT, located at Chattanooga Regional Airport, Chattanooga, TN.

01013 SUMMARY OF WORK

Scope of Work

The contractor shall furnish all labor, equipment, transportation, and materials needed to complete the work required under this contract. The work consists of, but is not limited to the following:

1.) Remove existing cab roof including insulation board and flashing material around the parapet wall, curb, and hatch. For estimating purposes CAB roof is approximately 600 SQFT and the height of the CAB is at approximately 90’ AGL.

2.) Install two layers of 1.5” polyiso insulation.

3.) Install one mechanically attached layer of ¼” densdeck or approved equal.

4.) Temporarily remove the lightning protection bases while maintaining system operability during roof replacement. The existing lightning protection system should be temporarily secured during roof work. After the new roof system is installed, reinstall new lightning protection system after the parapet wall flashing has been restored. See companion SOW for extents of the LPGBS scope of work.

5.) Install 60 mil, mechanically fastened single ply membrane roofing system. Electromagnetic induction bonding/welding (ie Rhinobond) is not to be used due to interference with FAA radio systems.

6.) Install cross grip walkway pad between the roof access hatch and the roof perimeter.

7.) Clean out all debris from the existing roof drain grate and cleanout caps. Ensure that the drains flow freely and that no water stands at drain level. After drain inspection and testing, replace all drains, caps and flashing as necessary.

8.) 30 days prior to work start, contractor must coordinate sampling of the existing roof assembly with the COR and provide a report from certified asbestos testing agency verifying no asbestos containing materials were identified in the sample. If asbestos materials are discovered, notify COR immediately for further direction.

01043 COORDINATION

All coordination between the contractor and FAA shall be through the Contracting Officer’s Representative, hereafter referred to as COR.

All construction and working permits required by local and state agencies shall be procured by the contractor at no expense to the FAA.

01140 WORK RESTRICTIONS

Ingress and egress to the work areas shall be as directed by the resident engineer. Security precautions against unauthorized site entrance shall be maintained. The contractor shall keep all vehicles, working equipment and materials within the area designated by the resident engineer.

Working around and above the cab window frame, and on the catwalk surrounding the cab, requires coordination with Air Traffic personnel so as to cause no disruptions to air traffic. Prior to commencing work, the contractor shall coordinate with the COR to make all of the contractor’s personnel aware of these requirements and their importance.

Even when sufficient advance notice is received from the contractor and agreed to at that time, the FAA can make no guarantees for opportunities to proceed with the work. Every effort will be given the contractor to accommodate the work schedule, but some delay could be anticipated.

Hours of work

It is anticipated that this work will take place during both operational and non-operational hours (Hours of Operation for CHA ATCT are 0600 – 2350) in order to minimize interference with air traffic operations. The following areas shall have work planned and scheduled for non-operational hours only:

1) The ATCT CAB roof

2) The Terminal Radar Approach Control Facility (interior to the CHA base building)

Any work affecting areas that are outside of the building and / or at a distance from the operational areas, can be scheduled for daytime hours of 0700 – 1530.

01303 SUBMITTALS

A. Related Documents

Drawings and general provisions of the Contract including General Requirements and all Division 1-16 specification sections, apply to this section. If conflicts occur between FAA specification and any other publications, FAA requirements shall govern.

B. Scope

This section covers the procedure and requirements for all submittals. Additional detailed submittal requirements may be specified in other sections of these specifications.

C. Definition

Where the word "Submittal" is used it refers to the submitting of shop drawings, samples, manufacturer's catalog cuts, technical data, specifications, installation instructions, material lists, test reports, certificates, guaranties, operation and maintenance manuals, and as-built drawings.

D. Submittals

Samples, certificates, test reports, and shop drawings shall be submitted in advance for a determination of specification compliance within 42 calendar days after award of contract. The time necessary for approval or disapproval of samples, certificates, test reports, and shop drawings is at least fourteen (14) calendar days after receipt of the items. All materials installed in the work shall exactly match the approved submittal. After a submission by the contractor has been approved, no substitution will be permitted without written approval by the Contracting Officer or his authorized representative. Any disapproved submittal must be re-submitted within five (5) calendar days. Unless otherwise specified, number of copies of submittals shall be as follows:

1. Product data and Samples PVC metal and membrane, fasteners, and other items specified in individual sections.

2. Certificates, Test Reports, Warranties, etc.: 2 copies

3. Safety Data Sheets (SDS): pdf copies provided to COR.

4. Shop Drawings: one reproducible and 2 copies

5. Manufacturer's Brochures: 2 copies

6. Installation Instructions: 2 copies

7. Maintenance Manuals: 2 copies

8. Certification of installers affiliation with manufacturer of roofing system

9. As Built Drawings: As specified herein after Shop Drawings

10. Manufacturer’s 15-year material and 1 year workmanship warranty

11. Contractor’s Health and Safety Plan

12. Contractor schedule and workplan

13. Contractor’s list of key personnel with role and contact information

The term "Shop Drawings" includes drawings, diagrams, layouts, schematics, descriptive literature, illustrations, schedules, performance and test data, and similar materials furnished by the contractor to explain in detail specific portions of the work required by the contract which differs from the plan. Scale of shop drawings: minimum 1/4" = 1'-0" for plans and elevations; minimum 3/4" = 1'-0" for details. Electronic copies only are required.

A. The contractor shall coordinate all such drawings and review them for accuracy, completeness, and compliance with subcontract requirements and shall indicate his approval thereon as evidence of such coordination and review. Shop drawings submitted to the Contracting Officer without evidence of the contractor's approval may be returned for resubmission. The Contracting Officer will indicate his approval or disapproval of the shop drawings and if not approved as submitted, shall indicate his reason therefore. Any work done prior to such approval shall be at the contractor's risk. Approval by the Contracting Officer shall not relieve the contractor from responsibility for any error or omissions in such drawings, nor from responsibility for complying with the requirements of this contract, except with respect to variations described and approved in accordance with paragraph B. below.

B. The contractor shall submit to the Contracting Officer for approval one reproducible and two copies (unless otherwise indicated herein) of all shop drawings as called for under various headings of these specifications and two sets of all samples. The reproducible copies of all shop drawings will be retained by the Contracting Officer, and two sets will be returned to the contractor.

01500 TEMPORARY FACILITIES AND CONTROLS

Sanitary facilities are available at the site. The contractor shall keep the bathroom facilities clean at the end of each day. Prior to the start of construction, the contractor must install temporary floor coverings over the floors that connect the areas of work both inside and outside of the building with the restroom facilities. Any damages incurred to existing building facilities or infrastructure must be repaired / restored by the contractor at no cost to the government.

For work at the ATCT CAB roof, building electrical services can be made available. The contractor shall coordinate electricity needs for temporary spot lighting and hand tools with on-site COR before plugging in to any receptacles. No circuits used for ATC equipment can be used. Advance coordination with facility POCs is required.

The contractor is responsible for supplying temporary electricity, air, light and water as needed throughout the construction of the project for all work exterior to the ATCT. There are no exterior receptacles available for contractor use.

01600 PRODUCT REQUIREMENTS

General

The contractor shall furnish all materials, equipment, and labor to complete the job unless otherwise specified. The use of brand names or the identification of specific product source in this specification does not constitute a requirement that they are the only materials that meet the specifications of this project. They are used as an illustration of known acceptable sources or products. Each product required for use in the contract drawings and specifications must meet the actual minimum needs of the FAA as demonstrated in the salient characteristics for that product. For use of a product that is not listed as an acceptable source, a test report or product data sheet must be submitted prior to the pre-construction meeting for each product, indicating the product meets the requirements set forth in this document.

Contractor’s Warranty

The contractor shall supply the FAA with a one-year workmanship warranty. In the event that any work relating to the roofing, flashing, or metal work, is found defective or otherwise not in accordance with the contract documents within one years of completion, the contractor shall remove and replace at no cost to the FAA.

Manufacturer’s Warranty

Roof Membrane: The single-ply roofing membrane material shall be guaranteed against defects by the manufacturer and be leak-free for a period of fifteen (15) years after completion. This warranty will identify the FAA as owner of the facility. The location of the facility and the effective starting date of the warranty shall be indicated.

The contractor shall not be responsible for damage to the roof from extreme weather conditions such as tornadoes, lightning strikes, large hail, or damage caused by maintenance people working on the roof surface.

In the event water penetrates the roof system for reasons of either workmanship or material, the contracting officer will notify the contractor in writing within the 1-year workmanship warranty or 15-year manufacturer warranty period. If the contractor fails to remedy any failure, defect, or damage within a reasonable time, the FAA has the right to replace, repair, or remedy the failure at the contractor’s expense. All labor, materials, and travel expenses incurred during warranty repairs are considered incidental to the warranty and will not be allocated to the FAA.

01613 DELIVERY, STORAGE, AND HANDLING

The contractor shall store all materials in a manner to protect them from all elements of the weather. Materials will be stored as directed by the Resident Engineer.

01700 EXECUTION REQUIREMENTS

A. General

Bidders are strongly encouraged to visit the site as part of the pre-bid site walk and carefully examine the areas in question as to conditions that may affect proper execution of the work. All dimensions and quantities shall be determined or verified by the contractor. No claims for extra costs will be allowed because of lack of full knowledge of the existing conditions.

To arrange for a site visit, contact Andrew Milhollin at (404) 984-8872 or Brett Charap at 917-447-7211. There will likely be one day scheduled for all prospective bidders to visit the site listed as part of this SIR.

The contractor shall attend a pre-construction conference prior to starting work at a location agreed upon between the contractor and the contracting officer. Working hours will be scheduled with the COR and agreed upon at the pre-construction conference. The contractor shall submit a work schedule for approval prior to beginning work. The contractor shall keep the COR updated daily of any change.

Damage to existing facilities and equipment caused by the contractor shall be reported to the COR immediately. The contractor will be responsible for repairing, or having damages repaired. Any damage to the building or equipment will be repaired at the contractor's expense. All repairs shall be accomplished to the satisfaction of the Resident Engineer.

All work shall be accomplished by experienced workers in accordance with the highest standards of the various work trades involved.

Working Hours

THE WORK IN AND AROUND OPERATIONAL AREAS (i.e., the CAB or TRACON) IS EXPECTED TO BE COMPLETED BETWEEN 2350-0600 SO AS TO NOT INTERFERE WITH ACTIVE AIR TRAFFIC OPERATIONS.

PLEASE BID AND PLAN ACCORDINGLY. Additionally, all bidders should plan for temporary power and lighting requirements when working exterior to the building. No exterior receptacles are available for contractor use. Work inside of the building can support light electrical demand incurred by hand tool use.

Cleaning

1. Working Area: The contractor shall keep the working area in a clean and proper condition. All rubbish and waste resulting from the execution of the work shall be removed at the end of each day or as directed by the Resident Engineer.

2. Waste Packing Material: Immediately after unpacking, all packing material, case lumber, excelsior, or other rubbish, flammable or otherwise, shall be removed from the building and the premises.

3. Final Clean Up: Upon completion of work, and before final inspection, the contractor shall remove his working tools, equipment, debris, rubbish, and unused materials from the building site.

Disposal

Disposal of rubbish, debris, and removed materials will be off the site at the contractor's expense or as directed by the resident engineer.

Some existing materials that are to be removed and discarded are believed to contain asbestos. It is the contractor’s responsibility to dispose of those materials in strict accordance with federal, state, and local requirements.

Safety

The contractor shall be responsible for safety on the work site. It is the responsibility of the contractor to eliminate hazards, which may result in tripping, electrical shock, fire, falling objects, environmental hazards, vehicular accidents, etc. The contractor shall comply with all safety precautions required by OSHA.

01781 PROJECT RECORD DOCUMENTS

See Attachment 3 – Design Drawings List. The drawings of the issue date specified form a part to this specification and are applicable to the extent specified herein. If any conflict exists between drawings and the specifications, the specifications shall govern.

PART 1 - GENERAL CONDITIONS

1.01 DESCRIPTION

A. Scope

The contractor shall furnish all labor, equipment, transportation, and materials needed to complete the work required under this contract. The work consists of, but is not limited to the work detailed in section 1013 above.

B. Related Work

The roof work includes but is not limited to the installation of:

1. Substrate Preparation

2. Roof Drains

3. Vapor Barrier

4. Wood Blocking

5. Insulation

6. Separation Layers

7. Roof Membrane

8. Fasteners

9. Adhesive for Flashings

10. Roof Membrane Flashings

11. Walkways

12. Metal Flashings

13. Sealants

C. Upon successful completion of work the following warranties must be obtained and provided to the government:

1. Manufacturer roofing Warranty (15 years)

2. Roofing Contractor Warranty (1 year)

D. Qualified roofing Manufacturers:

1. Sika Sarnafill

2. Johns Manville

3. Soprema

4. Others will be evaluated via submittal process

1.02 QUALITY ASSURANCE

A. This roofing system shall be applied only by a Roofing Contractor authorized by Roofing manufacturer prior to bid (Roofing manufacturer "Applicator").

B. Upon completion of the installation and the delivery to Roofing manufacturer by the Applicator of a certification that all work has been done in strict accordance with the contract specifications and Roofing manufacturer's requirements, an inspection shall be made by a Technical Representative of Roofing manufacturer to review the installed roof system.

C. There shall be no deviation made from the Project Specification or the approved shop drawings without prior written approval by the Owner, the Owner's Representative and Roofing manufacturer.

D. All work pertaining to the installation of PVC membrane and flashings shall only be completed by applicator personnel trained and authorized by Roofing manufacturer in those procedures.

1.03 SUBMITTALS

At the time of bidding, the Applicator shall submit to the Owner (or Representative) the following:

A. Copies of Specification.

B. Samples of each primary component to be used in the roof system and the manufacturer's current literature for each component.

C. Written approval by the insulation manufacturer (as applicable) for use and performance of the product in the proposed system.

D. Sample copy of Roofing manufacturer's warranty.

E. Sample copy of Applicator's warranty.

F. Dimensioned shop drawings which shall include:

1. Outline of roof with roof size and elevations shown.

2. Profile details of flashing methods for penetrations.

3. Technical acceptance from Roofing manufacturer.

G. Certifications by manufacturers of roofing and insulating materials that all materials supplied comply with all requirements of the identified ASTM and other industry standards or practices.

H. Certification from the Applicator that the system specified meets all identified code and insurance requirements as required by the Specification.

I. Material Safety Data Sheets (MSDS)

1.04 CODE REQUIREMENTS

The applicator shall submit evidence that the proposed roof system meets the requirements of the local building code and has been tested and approved or listed by the following test organizations. These requirements are minimum standards, and no roofing work shall commence without written documentation of the system's compliance, as required in the "Submittals" section of this specification.

A. Factory Mutual Research Corporation (FM) - Norwood, MA

1. Class 1-90 (for high wind exposure)

B. Underwriters Laboratories, Inc. - Northbrook, IL

1. Class A assembly

1.05 PRODUCT DELIVERY, STORAGE AND HANDLING

A. All products delivered to the job site shall be in the original unopened containers or wrappings bearing all seals and approvals. On-site material storage and lay down areas shall be coordinated in advance of mobilization with facility POCs and the COR.

B. Handle all materials to prevent damage. Place all materials on pallets and fully protect from moisture.

C. Membrane rolls shall be stored lying down on pallets and fully protected from the weather with clean canvas tarpaulins. Unvented polyethylene tarpaulins are not accepted due to the accumulation of moisture beneath the tarpaulin in certain weather conditions that may affect the ease of membrane weldability.

D. As a general rule all adhesives shall be stored at temperatures between 40º F (5º C) and 80º F (27º C). Read instructions contained on adhesive canister for specific storage instructions.

E. All flammable materials shall be stored in a cool, dry area away from sparks and open flames.

Follow precautions outlined on containers or supplied by material manufacturer/supplier.

F. Any materials which the owner’s representative and/or Roofing manufacturer determine to be damaged are to be removed from the job site and replaced at no cost to the owner.

1.06 JOB CONDITIONS

A. PVC materials may be installed under certain adverse weather conditions but only after consultation with Roofing manufacturer, as installation time and system integrity may be affected.

B. Only as much of the new roofing as can be made weathertight each day, including all flashing and detail work, shall be installed. All seams shall be cleaned, and heat welded before leaving the job site that day.

C. All work shall be scheduled and executed without exposing the interior building areas to the effects of inclement weather. The existing building and its contents shall be protected against all risks. This is an operational facility and will remain so during the construction effort. Therefore, all measures must be taken to ensure the uninterrupted access and use of this facility for air traffic control operations.

D. All surfaces to receive new insulation, membrane or flashings shall be dry. Should surface moisture occur, the Applicator shall provide the necessary equipment to dry the surface prior to application.

E. All new and temporary construction, including equipment and accessories, shall be secured in such a manner as to preclude wind blow-off and subsequent roof or equipment damage.

F. Uninterrupted waterstops shall be installed at the end of each day's work and shall be completely removed before proceeding with the next day's work. Waterstops shall not emit dangerous or unsafe fumes and shall not remain in contact with the finished roof as the installation progresses.

Contaminated membrane shall be replaced at no cost to the Owner.

G. The Applicator is cautioned that certain PVC membranes are incompatible with asphalt, coal tar, heavy oils, roofing cements, creosote and some preservative materials. Such materials shall not remain in contact with PVC membranes. The Applicator shall consult Roofing manufacturer regarding compatibility, precautions and recommendations.

H. Arrange work sequence to avoid use of newly constructed roofing as a walking surface or for equipment movement and storage. Where such access is absolutely required, the Applicator shall provide all necessary protection and barriers to segregate the work area and to prevent damage to adjacent areas. A substantial protection layer consisting of plywood over pvc felt or plywood over insulation board shall be provided for all new and existing roof areas that receive rooftop traffic during construction.

I. Prior to and during application, all dirt, debris, and dust shall be removed from surfaces either by vacuuming, sweeping, blowing with compressed air and/or similar methods.

J. The Applicator shall follow all safety regulations as required by OSHA and any other applicable authority having jurisdiction.

K. All roofing, insulation, flashings, and metal work removed during construction shall be immediately taken off site to a legal dumping area authorized to receive such materials. Hazardous materials, such as materials containing asbestos, are to be removed and disposed of in strict accordance with applicable City, State and Federal requirements.

L. All new roofing waste material (i.e., scrap roof membrane, empty cans of adhesive) shall be immediately removed from the site by the Applicator and properly transported to a legal dumping area authorized to receive such material.

M. The Applicator shall take precautions that storage and/or application of materials and/or equipment does not overload the roof deck or building structure.

N. Flammable adhesives and deck primers shall not be stored and not be used in the vicinity of open flames, sparks, and excessive heat.

O. All rooftop contamination that is anticipated or that is occurring shall be reported to Roofing manufacturer to determine the corrective steps to be taken. The Applicator shall verify that all roof drain lines are functioning correctly (not clogged or blocked) before starting work. Applicator shall report any such blockages in writing (letter copy to Roofing manufacturer) to the Owner's Representative for corrective action prior to the installation of the Roofing manufacturer roof system.

P. Applicator shall immediately stop work if any unusual or concealed condition is discovered and shall immediately notify Owner of such condition in writing for correction at the Owner's expense (letter copy to Roofing manufacturer).

Q. Daily Site cleanup, including both interior and exterior building areas that have been affected by construction, shall be completed to the Owner's satisfaction.

R. All landscaped areas or facilities damaged by construction activities shall be repaired at no cost to the government.

S. The Applicator shall conduct fastener pullout tests in accordance with the latest version of the SPRI/ANSI

Fastener Pullout Standard to help verify condition of the deck/substrate and to confirm expected pullout values.

T. The PVC membrane shall not be installed under the following conditions without consulting Roofing manufacturer’s Technical Dept. for precautionary steps:

1. The roof assembly permits interior air to pressurize the membrane underside.

2. Any exterior wall has 10% or more of the surface area comprised of opening doors or windows.

3. The wall/deck intersection permits air entry into the wall flashing area.

U. Precautions shall be taken when using Sarnacol adhesives at or near rooftop vents or air intakes. Adhesive odors could enter the building. Coordinate the operation of vents and air intakes in such a manner as to avoid the intake of adhesive odor while ventilating the building. Keep lids on unused cans at all times.

V. Protective wear shall be worn when using solvents or adhesives or as required by job conditions.

W. PVC membranes are slippery when wet or covered with snow, frost, or ice. Working on surfaces under these conditions is hazardous. Appropriate safety measures must be implemented prior to working on such surfaces. Always follow OSHA and other relevant fall protection standards when working on roofs.

X. Fire stopping must be provided for all through-penetrations of fire-resistance rated assemblies by a licensed UL certified applicator / installer.

1.07 WARRANTIES

Roofing manufacturer Membrane Warranty

Upon successful completion of the work to Roofing manufacturer's satisfaction and receipt of final payment, the Roofing manufacturer Membrane Warranty shall be issued.

Roofing manufacturer System Warranty for 15 years.

Upon successful completion of the work to Roofing manufacturer's satisfaction and receipt of final payment, the Roofing manufacturer System Warranty shall be issued.

A. Applicator/Roofing Contractor Warranty

The Applicator shall supply the owner with a separate (1) one-year workmanship warranty. In the event any work related to roofing, flashing, or metal is found to be within the Applicator warranty term, defective or otherwise not in accordance with the Contract Documents, the Applicator shall repair that defect at no cost to the Owner. The Applicator's warranty obligation shall run directly to the Owner, and a copy shall be sent to Roofing manufacturer.

B. Owner Responsibility

Owner shall notify both Roofing manufacturer and the Applicator of any leaks as they occur during the time period when both warranties are in effect.

PART 2 - PRODUCTS

2.01 GENERAL

A. The components of the roof system are to be products of Roofing manufacturer as indicated on the Detail

Drawings and specified in the Contract Documents.

B. Components to be used that are other than those supplied or manufactured by Roofing manufacturer may be submitted for review and acceptance by Roofing manufacturer. Roofing manufacturer’s acceptance of any other product is only for a determination of compatibility with Roofing manufacturer products and not for inclusion in the Roofing manufacturer warranty. The specifications, installation instructions, limitations, and/or restrictions of the respective manufacturers must be reviewed by the Owner’s Representative for acceptability for the intended use with Roofing manufacturer products.

C. Manufacturer to have a minimum of two years’ experience recycling their membranes at the end of their service life back into new membrane products.

2.02 MEMBRANE

A. PVC polyester reinforced membrane with a lacquer coating.

B. Membrane shall conform to ASTM D4434 (latest version), “Standard for Polyvinyl Chloride Sheet

Roofing,” Classification: Type III.

1. PVC POLYESTER REINFORCED MEMBRANE-20, 60 mil thermoplastic membrane with polyester reinforcement.

C. Certified Polymer Thickness

1. Membrane manufacturer is to certify that the polymer thickness is of the polymer thickness specified.

Certification is to be signed by the membrane manufacturer’s quality control manager. ASTM +/-tolerance for membrane thickness is not accepted.

D. Color of Membrane

1. Energy Smart (white), initial reflectivity of 0.83, initial emissivity 0.90, solar reflective index (SRI) of

>104.

2. Other

E. Typical Physical Properties

Parameters

ASTM

Test Method

Minimum ASTM Requirement

PVC Typical Physical Properties

Reinforcing Material - Polyester Overall Thickness, min., inches (mm) D751 0.045 (1.14) [0.080inches] Breaking Strength, min., lbf/in. (KN/m) D751 200 (35.0) 230 (40.0) Elongation at Break, min. D751 15% 20% Seam strength*, min. (% of breaking strength) D751 75 85 Retention of Properties After Heat Aging D3045 - -

Breaking Strength, min., (% of original) D751 90 95 Elongation, min., (% of original) D751 90 90

Tearing Strength, min., lbf (N) D1004 45.0 (200) 50 (220) Low Temperature Bend, -40°F (-40°C) D2136 Pass Pass Accelerated Weathering Test (Florescent Light, UV exposure) G154 5,000 Hours Pass

Cracking (7x magnification) - None None Discoloration (by observation) - Negligible Negligible Crazing (7 x magnification) - None None

Linear Dimensional Change D1204 0.5% max. 0.1% Weight Change After Immersion in Water D570 + 3.0% max. 2.5% Static Puncture Resistance, 33 lbf (15 kg) D5602 Pass Pass Dynamic Puncture Resistance, 14.7 ft-lbf (20 J) D5635 Pass Pass

* Failure occurs through membrane rupture not seam failure. Physical Properties shown are prior to applying felt backing, if specified.

2.03 FLASHING MATERIALS

A. Wall/Curb Flashing

1. PVC G410 Membrane

A fiberglass reinforced membrane adhered to approved substrate using adhesive. Consult Product Data Sheets for adhesive options and additional information.

2. PVC G459 Membrane

An asphalt-resistant, fiberglass reinforced membrane adhered to approved substrate using adhesive.

Consult Product Data Sheet for adhesive rates and additional information.

3. PVC polyester reinforced membrane

A polyester reinforced membrane used for mechanically attached flashings to approved substrate. Consult Product Data Sheet for additional information.

4. PVC clad

A PVC-coated, heat-weldable sheet metal capable of being formed into a variety of shapes and profiles. PVC clad is a 24 gauge, G90 galvanized metal sheet with a 20 mil (0.5 mm) unsupported PVC membrane laminated on one side. Consult Product Data Sheet for additional information.

B. Perimeter Edge Flashing

1. PVC METAL

A PVC-coated, heat-weldable sheet metal capable of being formed into a variety of shapes and profiles.

Consult Product Data Sheet for additional information.

2. Non-Typical Edge

Project-specific perimeter edge detail reviewed and accepted for one-time use by Roofing manufacturer's Technical Department. Consult Regional Technical Manager prior to job start for review and consideration for acceptance.

C. Miscellaneous Flashing- These are example products from one manufacturer. Other manufacturer’s products will be reviewed as submitted.

1. Sarnaflash

A prefabricated expansion joint cover made from PVC membrane. Sarna flash is designed for securement to vertical or horizontal surfaces to span and accommodate the movement of expansion gaps from 1 inch to 4½ inches (25 mm to 114 mm) across. Available in 40-foot (12 m) rolls. Consult Product Data Sheet for additional information.

2. Sarna Reglet (Surface Mount Reglet)

A heavy-duty, extruded aluminum flashing termination Reglet used at walls and large curbs. Sarna Reglet is produced from 6063-T5, 0.10 inch - 0.12 inch (2.5 mm - 3.0 mm) thick extruded aluminum. Sarna Reglet has a 2¼ inch (57 mm) deep profile and is provided in 10 foot (3 m) lengths. Use prefabricated Sarna Reglet mitered inside and outside corners where walls intersect.

Consult Product Data Sheet for additional information.

3. Sarnastack

A prefabricated vent pipe flashing made from 0.048 inch (48 mil/1.2 mm) thick PVC G410 membrane.

Available in five different sizes. Consult Product Data Sheet for sizes and additional information.

4. Multi-Purpose Sealant

A proprietary sealant used at flashing terminations. Consult Product Data Sheet for additional information.

5. Sarnacol 2165 Adhesive

A two-component urethane adhesive used for pitch pocket filler. Cures with excellent elasticity and adhesion to various surfaces. Consult Product Data Sheet for additional information.

6. Sarnacol 2170 Adhesive

A solvent-based reactivating-type adhesive used to attach membrane to flashing substrate. Consult Product Data Sheets for additional information.

7. PVC POLYESTER REINFORCED MEMBRANE Cover strip

8 inch (0.20 m) wide precut flashing made from PVC POLYESTER REINFORCED MEMBRANE polyester reinforced membrane. Used to cover strip Sarnabar and Sarnadisc.

2.04 INSULATION/OVERLAYMENT/RECOVER BOARD

1. DensDeck®

A siliconized gypsum, fire-tested hardboard with glass-mat facers. DensDeck is provided in 4 ft. x 4 ft. (1.2 m x 1.2 m) and 4 ft x 8 ft (1.2 m x 2.4 m) board size and in thicknesses of 1/2 ". Consult Product Data Sheet for size, thickness and additional information.

2. Insulation A. Rigid Insulation Board: Polyisocyanurate foam core bonded to a glass fiber mat facers and approved by the membrane manufacturer for a fully adhered membrane system meeting the Factory Mutual I- 130 uplift requirement. The rigid insulation sheets shall be 4 feet by 4 feet (non-tapered) and 4 feet by 4 feet (tapered), and have an average R value of 7 per inch, using the ASTM C518 test at 75 F. The insulation meet the following typical physical properties:

Property Test Method Typical Results

Dens., Overall ASTM C209 2.0 pcf (nom.)

Comp. Strength ASTM D 1621 20 psi Flame Spread ASTM E 84 25 or less Moisture Vapor ASTM E 96 Less than 1 Transmission perm.

Dim. Stability ASTM D2126 Less than 2% linear change Service Temp. ---- -100 F to +200 F

Two manufacturers and insulation materials that are acceptable to the FAA and meet the typical physical properties are as follows:

Johns-Manville:

Non-tapered sections: ISO 3 Tapered sections: Tapered ISO 3

Rmax, Inc.

Non-tapered sections: MULTIMAX FA-3 Tapered sections: Tapered Thermaproof-3

7A.3 INSTALLATION:

General:

A. Insulation: Insulation shall be installed according to the manufacturer’s requirements and recommendations. Install insulation using the Fastener pattern as indicated on the mechanical roof system. Built as shown on the drawings.

Installation shall meet the uplift and wind 100 mph loading requirements.

The insulation shall be two 1.5” layers of insulation board with staggered joints and shall not be wider than 1/8". Do not install more insulation board than can be covered with roofing membrane by the end of the day or the onset of inclement weather.

Stagger end joints of adjacent lengths. Butt ends and edges. Installation shall be as recommended by the roof system manufacturer and shall meet the uplift and wind loading requirements.

Install tapered insulation around drains creating a drain sump.

Use at least 2 layers of insulation when the total insulation thickness exceeds 2-1/2 inches (64 mm).

Stagger joints at least 12 inches (0.3 m) between layers.

2.06 WALKWAY PROTECTION EXAMPLE

A. Sarna tread (walkway tread)

A polyester reinforced, 0.096 inch (96 mil/2.4 mm), weldable membrane with surface embossment. Used as a protection layer from rooftop traffic. Sarnatred is supplied in rolls of 39.3 inches (1.0 m) wide and

32.8 feet (10 m) long. Consult Product Data Sheet for additional information.

2.07 MISCELLANEOUS ACCESSORIES

A. Aluminum Tape

A 2 inch (50 mm) wide pressure-sensitive aluminum tape used as a separation layer between small areas of asphalt contamination and the membrane and as a bond-breaker under the covers trip at Sarnaclad joints.

B. Sealing Tape Strip

Compressible foam with pressure-sensitive adhesive on one side. Used with metal flashings as a preventive measure against air and windblown moisture entry.

C. Multi-Purpose Tape

A high-performance sealant tape used with metal flashings as a preventive measure against air and windblown moisture entry.

2.08 SEALANTS AND PITCH POCKET FILLERS

A. PVC Multi-Purpose Sealant (for termination details).

B. Sarnacol 2165 Adhesive (two-component urethane adhesive for pitch pocket toppings).

C. Depending on substrates, the following sealants are options for temporary overnight tie-ins:

1. Type III hot asphalt conforming to ASTM D312 (latest version).

2. Sarnacol 2165 Adhesive.

3. Multiple layers of roofing cement and felt.

4. Spray-applied, water-resistant urethane foam.

5. Mechanical attachment with rigid bars and compressed sealant.

2.09 MISCELLANEOUS FASTENERS AND ANCHORS

A. All fasteners, anchors, nails, straps, bars, etc. shall be post-galvanized steel, aluminum or stainless steel.

Mixing metal types and methods of contact shall be assembled in such a manner as to avoid galvanic corrosion. Fasteners for attachment of metal to masonry shall be expansion type fasteners with stainless steel pins. All concrete fasteners and anchors shall have a minimum embedment of 1¼ inch (32 mm) and shall be approved for such use by the fastener manufacturer. All miscellaneous wood fasteners and anchors used for flashings shall have a minimum embedment of 1 inch (25 mm) and shall be approved for such use by the fastener manufacturer.

2.10 RELATED MATERIALS

A. Wood Nailer

Treated wood nailers shall be installed into the structural purlins at the perimeter of the entire roof and around such other roof projections and penetrations as specified on Project Drawings. Thickness of nailers must match the insulation thickness to achieve a smooth transition. Wood nailers shall be treated for fire and rot resistance (wolmanized or osmose treated) and be #2 quality or better lumber. Creosote or asphalt-treated wood is not acceptable. Wood nailers shall conform to Factory Mutual Loss Prevention Data Sheet 1-49. All wood shall have a maximum moisture content of 19% by weight on a dry-weight basis.

B. Plywood

When bonding directly to plywood, a minimum 1/2 inch (12 mm) CDX (C side out), smooth-surfaced exterior grade plywood with exterior grade glue shall be used. Rough-surfaced plywood or high fastener heads will require the use of Sarnafelt behind the flashing membrane. Plywood shall have a maximum moisture content of 19% by weight on a dry weight basis.

PART 3 - EXECUTION

3.01 PRE-CONSTRUCTION CONFERENCE

A. The Applicator, Owner's Representative/Designer and Manufacturer(s) shall attend a pre-construction conference.

B. The meeting shall discuss all aspects of the project including but not limited to:

1. Safety

2. Set up

3. Construction schedule

4. Contract conditions

5. Coordination of the work

3.02 SUBSTRATE CONDITION

A. Applicator shall be responsible for acceptance or provision of proper substrate to receive new roofing materials.

B. Applicator shall verify that the work done under related sections meets the following conditions:

1. Roof drains, gutters and/or scuppers have been reconditioned and/or replaced and installed properly.

2. Roof curbs, nailers, equipment supports, vents and other roof penetrations are properly secured and prepared to receive new roofing materials.

3. All surfaces are smooth and free of dirt, debris, and incompatible materials.

4. All roof surfaces shall be free of water, ice and snow.

3.03 SUBSTRATE PREPARATION

The roof deck and existing roof construction must be structurally sound to provide support for the new roof system. The Owner's Representative and Applicator shall determine the condition of the roof deck.

Deteriorated decking or wet or deteriorated materials are to be removed and replaced. The Applicator shall load materials on the rooftop in such a manner as to eliminate risk of deck overload due to concentrated weight.

The Owner's Representative shall ensure that the roof deck is secured to the structural framing according to local building code and in such a manner as to resist all anticipated wind loads in that location. A structural evaluation by a licensed structural engineer should be performed to determine that the combined weight of the roofs, other collateral, and live loads do not exceed the load capacity of the structure.

3.04 SUBSTRATE INSPECTION

A. A dry, clean and smooth substrate shall be prepared to receive the mechanically attached roof system.

B. The Applicator shall inspect the substrate for defects such as excessive surface roughness, contamination, structural inadequacy, or any other condition that will adversely affect the quality of work.

C. The substrate shall be clean, smooth, dry, free of flaws, sharp edges, loose and foreign material, oil and grease. Roofing shall not start until all defects have been corrected.

D. All roof surfaces shall be free of water, ice and snow.

E. Compressible fill material or spray, expanding urethane foam shall be used to minimize air infiltration under wood nailers for corrugated metal roof panels.

Roofing materials shall be applied over compatible or acceptable substrates only.

3.05 INSULATION INSTALLATION

General Criteria:

A. Insulation shall be installed according to insulation manufacturer's instructions.

B. Areas between standing seams shall be filled with polyisocyanurate, expanded or extruded polystyrene insulation, with a minimum compressive strength of 20 psi. (137.8 kPa). The fill layer shall be cut to fit snug and flush with the top of the standing seam and secured to hold in place.

C. Top layer of insulation shall be the membrane underlayment, with edges butted together having no gaps greater than ¼ inch (6mm).

D. Insulation shall be neatly cut to fit around penetrations and projections with gaps not exceeding ¼ inch.

F. If applicable, install tapered insulation around drains creating a drain sump.

G. Do not install more insulation board than can be covered with PVC membrane by the end of the day or the onset of inclement weather.

H. Use at least 2 layers of insulation when the total insulation thickness for the overlayment exceeds 2-1/2 inches (64 mm). Stagger joints at least 12 inches (0.3 m) between layers.

I. Mechanical Attachment - General

Insulation shall be mechanically fastened to the purlins with or the structural deck with approved fasteners and PVC coated according to the insulation manufacturer's, Roofing manufacturer's and FM (if insured by FM) recommendations for fastening rates and patterns, but not less than 1 fastener per 5.33 square feet (4,952 square cm). The quantity and locations of the fasteners and plates shall also cause the insulation boards to rest evenly on the roof deck/substrate.

Each insulation board shall be installed tightly against the adjacent boards on all sides. With Purlin attached system use the manufacturer’s suggested standard to ensure each board of insulation has at least 6 fasteners, one in each corner at one on either long side at the midpoint. The grid attached systems are adequate as is for the insulation attachment. No additional insulation fastening is required.

a) Fasteners are to be installed consistently in accordance with fastener manufacturer's recommendations. Fasteners are to have minimum penetration of 1 inch (25 mm) through the structural deck.

b) Use fastener tools with a depth locator and torque-limiting attachment as recommended or supplied by fastener manufacturer to ensure proper installation.

J. Membrane Attachment to Metal Panel (Documented Pullout Tests Required)

General

a) Fastener pullout tests shall be conducted on the metal roofing deck with approved fasteners by the manufacturer of the fasteners, or the specifier/designer for the project. A minimum of 15 pullouts for up to 50,000 square feet (4,650 square meters) of which 8 are to be in perimeter and corner zones. Seven additional pullouts for each additional 50,000 square feet (4,650 square meters) or portion thereof. A report indicating each pullout value with a roof plan noting location of the pullouts shall be submitted to the Roofing manufacturer Technical Department for review.

b) Perimeter and Corner Areas

The perimeter and corner area will be determined by building height and width and other conditions according to ASCE 7 guidelines, Roofing manufacturer Technical or FM LPDS 1-29 if insured by Factory Mutual. To meet the perimeter and corner uplift requirements, increased fastener density by decreasing the spacing between fastener points in one or both directions.

The total tributary area to each fastener is no more than 60% for the perimeter and 40% for corners, based on the field of roof fastening density.

Notes:

a) Perimeter area is defined as the outer boundary of the roof. If the roof is broken into different levels, each roof area shall be treated as an individual roof with its outer boundary being treated as a perimeter. Typically, internal expansion joints and firewalls are not considered to be full perimeters. Refer to Factory Mutual’s Data Sheet 1-28 for more information.

b) The ridge area is defined as the high point in the roof area formed by two intersecting planes.

When the sum of the slopes is a minimum of 4 inches in 12 inches (30°), each side of the ridge shall be treated as a perimeter area.

3.06 INSTALLATION OF PVC MEMBRANE

The surface of the insulation or substrate shall be inspected prior to installation of the PVC roof membrane.

The substrate shall be clean, dry, free from debris and smooth with no surface roughness or contamination.

Broken, delaminated, wet or damaged insulation boards shall be removed and replaced.

A. Attachment to Metal Panel (Documented Pullout Tests Required)

1. General

a) PVC 10 ft. (3.0 m), 5 ft. (1.5 m) or 6.5 ft. (2 m) full width rolls shall be placed over the installed boards. Membrane overlaps shall be shingled with the flow of water where possible.

b) Tack welding of the membrane for purposes of temporary restraint during installation is not permitted. Consult Roofing manufacturer’s Technical Department for further information.

2. Field, Perimeter and Corner Areas

Over the properly prepared, installed and attached substrate surface following either the 2’ by 2’ (0.6 by

0.6 m) or 2’ by 3’ (0.6 by 0.9 m) grid pattern, PVC POLYESTER REINFORCED MEMBRANE full- width rolls are to be installed so as to properly shed water.

3. Securement around Rooftop Penetrations

a) Around all perimeters, at the base of walls, drains, curbs, vent pipes, or any other roof penetrations, fasteners, flashing, and bracing shall be installed according to perimeter rate of attachment. shall be installed using the fastener manufacturer’s recommended torque-sensitive fastening tools with depth locators. Fasteners shall clamp the PVC membrane tightly to the substrate.

b) PVC membrane flashings shall extend 2-1/2 inches (63 mm) past the Sarnadisc or Sarnadisc- XPN, and 2-1/4 inches (57.2 mm) past the Sarnadisc-MAXLoad and be hot-air welded to the PVC deck membrane.

3.10 HOT-AIR WELDING OF SEAM OVERLAPS

A. General

1. All seams shall be hot-air welded. Seam overlaps should be 3 inches (75 mm) wide for the Inductive

System, 5-1/2 inches (140 mm) wide for Sarnadisc and Sarnadisc-XPN, and 7 inches (177.8 mm) wide for Sarnadisc-MAXLoad when automatic machine-welding and 4 inches (100 mm) wide when hand-welding, except for certain details.

2. Welding equipment shall be provided by or approved by Roofing manufacturer. All mechanics intending to use the equipment shall have successfully completed a training course provided by a Roofing manufacturer Technical Representative prior to welding.

3. All membrane to be welded shall be clean and dry.

B. Hand-Welding

Hand-welded seams shall be completed in two stages. Hot-air welding equipment shall be allowed to warm up for at least one minute prior to welding.

1. The back edge of the seam shall be welded with a narrow but continuous weld to prevent loss of hot air during the final welding.

2. The nozzle shall be inserted into the seam at a 45° angle to the edge of the membrane. Once the proper welding temperature has been reached and the membrane begins to "flow," the hand roller is positioned perpendicular to the nozzle and rolled lightly. For straight seams, the 1-1/2 inch (40 mm) wide nozzle is recommended for use. For corners and compound connections, the 3/4 inch (20 mm) wide nozzle shall be used.

C. Machine Welding

1. Machine welded seams are achieved by the use of Roofing manufacturer's automatic welding equipment. When using this equipment, Roofing manufacturer's instructions shall be followed and local codes for electric supply, grounding and over current protection observed. Dedicated circuit house power or a dedicated portable generator is recommended. No other equipment shall be operated simultaneously off the generator.

2. Metal tracks may be used over the deck membrane and under the machine welder to minimize or eliminate wrinkles.

D. Quality Control of Welded Seams

1. The Applicator shall check all welded seams for continuity using a rounded screwdriver. Visible evidence that welding is proceeding correctly is smoke during the welding operation, shiny membrane surfaces, and an uninterrupted flow of dark grey material from the underside of the top membrane. On-site evaluation of welded seams shall be made daily by the Applicator at locations as directed by the Owner's Representative or Roofing manufacturer's representative. One inch (25 mm) wide cross- section samples of welded seams shall be taken at least three times a day. Correct welds display failure from shearing of the membrane prior to separation of the weld. Each test cut shall be patched by the Applicator at no extra cost to the Owner.

3.11 MEMBRANE FLASHINGS

All flashings shall be installed…