Spec 072200 - Roof And Deck Insulation.doc

03-10

SECTION 07 22 00

ROOF AND DECK INSULATION

PART 1 ‑ GENERAL

1.1 DESCRIPTION

A.

Installation of roof and deck insulation, on new construction ready to receive roofing or waterproof membrane.

B.

Repairs and alteration work to existing roof insulation.

1.2 RELATED WORK

A.

Insulating concrete systems: Section 03 52 00, LIGHTWEIGHT CONCRETE ROOF INSULATION; combination polystyrene and insulating concrete systems

B.

Wood blocking and edge strips: Section 06 10 00, ROUGH CARPENTRY.

C.

Perimeter, rigid, and batt or blanket insulation: Section 07 21 13, THERMAL INSULATION.

D.

Sprayed urethane insulation: Section 07 56 00, FLUID-APPLIED ROOFING.

E.

Sheet metal components: Section 07 60 00, FLASHING AND SHEET METAL.

1.3 QUALITY CONTROL

A.

Supervision of work by persons that are knowledgeable and experienced in roofing. See submittals for documentation of supervisor’s qualification.

B.

Unless specified otherwise, comply with the recommendations of the NRCA "Roofing and Waterproofing Manual" applicable to insulation for storage, handling, and application.

1.4 SUBMITTALS

A.

Submit in accordance with Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, AND SAMPLES.

B.

Manufacturer's Literature and Data:

1.

Asphalt materials, each type

2.

Roofing cement, each type

3.

Roof insulation, each type

4.

Fastening requirements

5.

Insulation span data for flutes of metal decks

C.

Samples:

1.

Roof insulation, each type

2.

Nails and fasteners, each type

D.

Certificates:

1.

Indicating type, thickness and thermal conductance of insulation.

2.

Indicating materials and method of application of insulation system on metal decks meet the requirements of Factory Mutual Research Corporation for Class 1 Insulated Steel Deck Roofs.

E.

Layout of tapered roof system showing units required.

G.

Documentation of supervisors training and experience showing knowledge of roofing procedures.

1.5 DELIVERY, STORAGE AND MARKING

A.

Deliver materials to the site in original sealed packages or containers marked with the name and brand, or trademark of the manufacturer or seller.

B.

Keep materials dry, and store in dry, weathertight facilities or under canvas tarps. Use of polyethylene or plastic tarps to cover materials is not permitted. Store above ground or deck level on wood pallets. Cover ground under stored materials with plastic tarp.

1.

Store rolled materials (felts, base sheets, paper) on end. Do not store materials on top of rolled material.

2.

Store foam insulation away from areas where welding is being performed and where contact with open flames is possible.

C.

Protect from damage from handling, weather and construction operations before, during, and after installation.

1.6 APPLICABLE PUBLICATIONS

A.

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

B.

Federal Specifications (Fed. Spec.):

UU‑B‑790A

Building Paper, Vegetable Fiber: (Kraft, Waterproofed, Water Repellent and Fire Resistant)

C.

American Society for Testing and Materials (ASTM):

C208‑08 Cellulosic Fiber Insulating Board

C209‑07 Test Methods for Cellulosic Fiber Insulating Board

C552‑07 Cellular Glass Thermal Insulation

C726‑05 Mineral Fiber Roof Insulation Board

C728‑05 Perlite Thermal Insulation Board

C1289-07 Faced Rigid Cellular Polyisocynurate Thermal Insulation Board

D41‑05 Asphalt Primer Used in Roofing, Dampproofing, and Waterproofing

D312‑00(R2006) Asphalt Used in Roofing

D2178‑04 Asphalt Glass Felt Used in Roofing and Waterproofing

D2822‑05 Asphalt Roof Cement

F1667-05 Driven Fasteners: Nails, Spikes, and Staples

D.

Factory Mutual Global (FM):

1‑28 Winds Loads to Roof Systems and Roof Deck Securement

P7825-05 Approval Guide

E.

National Roofing Contractors Association (NRCA):

The NRCA Roofing Manual 2009 F.

Underwriters Laboratories, Inc. (UL):

Fire Resistance Directory (2009)

G.

U.S. Department of Commerce (NBS):

PS 1-07

Structural Plywood

H.

National Particleboard Association (NPA):

A208.1-93 Mat-Formed Wood Particleboard

1.7 quality Assurance:

Roof insulation on combustible or steel decks shall have a flame spread rating not greater than 75 and a smoke developed rating not greater than 150, exclusive of covering, when tested in accordance with ASTM E 84. Insulation bearing the UL label and listed in the UL Building Materials Directory as meeting the flame spread and smoke developed ratings will be accepted in-lieu-of copies of test reports. Compliance with flame spread and smoke developed ratings will not be required when insulation has been tested as part of a roof construction assembly of the type used for this project and the construction is listed as fire-classified in the UL Building Materials Directory or listed as Class I roof deck construction in the FM P7825. Insulation tested as part of a roof construction assembly shall bear UL or FM labels attesting to the ratings specified herein.

PART 2 ‑ PRODUCTS

2.1 ASPHALT MATERIALS

A.

Primer: ASTM D41.

B.

Asphalt: ASTM D312, Type III or IV for vapor retarders and insulation.

C.

Glass (Felt): ASTM D2178, Type IV, heavy duty ply sheet.

D.

Venting Asphalt Base Sheet: ASTM D3672, Type I or Type II.

E.

Roof Cement: ASTM D2822, Type I or Type II, asbestos free; or, D4586, Type I or Type II.

2.2 INSULATION

A.

Cellular Glass: ASTM C552, Type IV, roof board.

B.

Mineral Fiberboard: ASTM C726.

C.

Perlite Board: ASTM C728.

D.

Isocyanurate Board: ASTM C1289, Type I, Class 2 or Type III.

E.

Cellulosic Fiberboard: ASTM C208, Type II, Grade 1 for built-up roofs; Grade 2 for single-ply roofing.

F.

Nail base insulating board:

1.

Top surface not less than 10 mm (3/8 inch) thick plywood, waferboard or wood particleboard nail base surface.

a.

Plywood: NBS PS 1, Exposure 1.

b.

Particleboard: ANSI A208.1, Type 1 Grade 1-M-2 or Type 2, Grade 2-M-2.

2.

Insulation: Isocyanurate or urethane conforming to material specifications.

3.

Bottom surface faced with felt facers.

G.

Tapered Roof Insulation System Segments:

1.

Fabricate of mineral fiberboard, isocyanurate, perlite board, or cellular glass. Use only one insulation material for tapered sections.

2.

Cut to provide high and low points with crickets and slopes as shown.

3.

Minimum thickness of tapered sections; 13 mm (1/2 inch), unless manufacturers allow taper to zero mm (inch).

2.3 MISCELLANEOUS

A.

Building Paper (Sheathing Paper):

1.

Fed. Spec. UU‑B‑790, Type I, Barrier paper, Grade D, Water ‑ Vapor permeable, Style 1a, Uncreped, not reinforced; or, Style 1b, Uncreped, not reinforced, red rosin sized.

2.

Weighing approximately 3 kg/10 m2 (six pounds per 100 square feet).

B.

Tapered Edge Strips:

1.

Tapered 1:12 (one inch per foot), from 0 mm (0 inches), 300 mm to 450 mm (12 inches to 18 inches) wide.

2.

Cellulosic Fiberboard: ASTM C208.

3.

Mineral Fiberboard: ASTM C726.

4.

Perlite Board: ASTM C728.

2.4 FASTENERS

A.

Staples and Nails: ASTM F1667. Type as designated for item anchored and for substrate.

B.

Nails for securing base sheets, and first ply of vapor retarder, to wood nailers and deck:

1.

Type I, Style 20, zinc coated steel roofing nails with minimum head diameter of 10 mm (3/8 inch) through metal discs at least 25 mm (one inch) across; or, 2.

One piece nails with an integral flat cap at least 24 mm (15/16 inch) across.

C.

Nails for securing building paper and dry felt edge strips to wood nailer and decks:

1.

Type I, Style 20, zinc coated steel roofing nails, 16 mm (5/8 inch) minimum head diameter.

2.

Type IV, staples, Style 3, flat top crown, zinc coated may be used.

D.

Nails into plywood: Annular thread type of length to provide at least 19 mm (3/4 inch) penetration.

E.

Nails for securing venting base sheet to insulating concrete:

1.

Self‑clinching type of galvanized steel having an integral flat cap at least 25 mm (one inch) across.

2.

Nails shall have a holding power of not less than 27 kg (60 pounds) when pulled from 11.7 kg (25.8 pounds) density insulating concrete.

F.

Nails for securing base sheet, building paper, or first ply of vapor retarder to structural wood fiber decks:

1.

Self‑clinching type having an integral flat cap not less than 25 mm (one inch) across.

2.

Nails shall have a holding power of not less than 18 kg (40 pounds) per fastener.

G.

Nails for securing insulation venting base sheet to poured gypsum roof deck:

1.

Special shaped nail providing diverging or hooking point.

2.

Nail shall have flat cap not less than 30 mm (1‑1/4 inch) across and shall have a withdrawal resistance of not less than 18 kg (40 pounds) per fastener.

H.

Fasteners for securing insulation to steel decks:

1.

Conform to requirements of Factory Mutual Research Corporation for wind uplift.

2.

Self‑drilling galvanized screws with 50 mm (two inch) diameter disk.

3.

Antibackout thread design.

4.

Have a pullout resistance of 14 kg (30 pounds) minimum.

2.5 RECOVERED MATERIALS

A.

Comply with following minimum content standards for recovered materials:

Plastic rigid foams: Polyisocyanurate/polyurethane

B.

The minimum-content standards are based on the weight (not the volume) of the material in the insulating core only.

PART 3 ‑ EXECUTION

3.1 GENERAL

A.

Do not apply roof insulation if deck will be used for subsequent work platform, storage of materials, or staging or scaffolding will be erected thereon.

B.

Entire roof deck construction of any section of the building shall be completed before insulation system work is begun. Curbs, blocking, edge strips, and other components which insulation, roofing and base flashing is attached to shall be in place ready to receive insulation and roofing. Coordinate roof insulation operations with roofing and sheet metal work so that insulation is installed to permit continuous roofing operations.

C.

Insulation system materials shall be dry and damage free when applied. Do not use broken insulation or insulation with damaged facings. Remove damaged insulation from the site immediately.

D.

Dry out surfaces, including the flutes of metal deck, that become wet from any cause during progress of the work before roofing work is resumed. Apply materials only to dry substrates.

E.

Except for temporary protection specified, do not apply materials during damp or rainy weather, during excessive wind conditions, nor while moisture (dew, fog, snow, ice) or frost is present in any amount in or on the materials when temperature is below 10 C (50 F). Do not apply materials to substrate having temperature of 10 C (50 F) or less.

F.

Phased construction is not permitted. The complete installation of all flashing, insulation, and roofing shall be completed in the same day except for the area where temporary protection is required when work is stopped.

G.

Temporary Protection for Built-Up Roofing:

1.

Install temporary protection consisting of glaze coats and water cutoffs at the end of each day's work and when work is halted for an indefinite period or work is stopped when precipitation is imminent.

2.

Glaze coat all exposed surfaces of insulation and felts to seal within the bitumen coating. No insulation or felt surfaces or edges shall be left exposed.

3.

Provide water cutoffs at exposed edges of insulation. Cutoffs shall consist of two plies of felt. The first ply extending 150 mm (six inches) beyond edge of roof insulation, the roof deck and the built‑up roofing. The second ply covering the first ply and extending 75 mm (three inches) beyond the first. Install as specified for vapor retarder. When the work resumes, cut the protective felts along the vertical face of insulation and remove, exposing the edges of the insulation.

4.

Securely anchor insulation in place to prevent blow off and damage by construction activities.

5.

Provide for removal of water or drainage of water away from work.

6.

For roof areas that are to remain intact and that are subject to foot traffic and damage, provide wood walkways with notches in sleepers to permit free drainage.

H.

Heating Bitumen:

1.

Heat the asphalt to the equiviscous temperature plus or minus 14 C (25 F), at the time of application.

a.

Asphalt shall not be heated more than 38 C (100 F) above the equiviscous temperature.

b.

When the equiviscous temperature is not furnished by the asphalt manufacturer, asphalt shall not be heated above 274 C (525 F) for Type III and IV and shall be not less than 246 C (475 F) at time of application.

2.

At no time shall bitumen be heated above the flash point temperature.

3.

Provide heating kettles with a thermometer kept in operating condition. Kettlemen shall be in attendance at all times during heating to insure that the bitumens are heated within the temperatures specified.

I.

Use Type III or Type IV asphalt between plies of felt and for installing insulation and vapor retarders.

J.

Application of Materials with Hot Bitumen:

1.

Apply bitumen in quantities required, immediately followed by materials to be embedded therein, before bitumen cools below the application temperature limit.

a.

Do not apply more material than can be covered at one time, except for glaze coats.

b.

Recoat cooled bitumen areas.

K.

Primer: Use four liters (one gallon) of primer per 10 m2 (100 square feet).

L.

Quantities of Asphalt:

1.

Per square unless otherwise specified.

2.

Between insulation layers and deck or vapor retarder: 9 to 14 kg (20 to 30 pounds).

3.

Glaze coats: 7 to 11 kg (15 to 25 pounds).

M.

Building Paper (Red rosin):

1.

Lay paper smoothly without buckles or wrinkles at right angles to the roof slope, starting at the low point.

2.

Lap each sheet of paper at least 50 mm (two inches) over preceding sheet, and at ends.

3.

Staple or nail sufficiently to hold in place until the insulation is installed.

3.2 SURFACE PREPARATION

A.

Sweep decks to broom clean condition. Remove all dust, dirt or debris.

B.

Remove projections that might damage materials.

C.

Concrete Decks, Except Insulating Concrete:

1.

Test concrete decks for moisture prior to application of materials. Heat bitumen as specified and pour approximately 0.5 liters (one pint) of bitumen on surface to which roofing materials are to be applied. If bitumen foams upon contact with the deck or after bitumen has cooled and bitumen is stripped clean from deck leaving no residue, the deck is not dry enough for application of prime coat and subsequent work.

2.

Prime concrete decks, including precast unit, with primer and allow to dry before application of bitumen. Keep primer back 100 mm (four inches) from joints in precast unit.

D.

Insulating Concrete:

1.

Allow to dry out for at least five days after installation before the placement of subsequent materials or insulation.

2.

If rain occurs during or at end of drying period or during installation, allow additional drying time before continuing the placement of the subsequent materials or insulation.

E.

Poured gypsum shall be dried out in accordance with manufacturer's printed instructions prior to application of subsequent materials.

F.

Cover wood sheathing, poured gypsum, gypsum plank, and cement wood fiber plank with a layer of building paper (red rosin).

G.

Existing Roofs:

1.

At areas to be altered or repaired, remove loose insulation and wet insulation.

2.

Cut and remove existing insulation and vapor retarder for new work to be installed. Clean cut edges and install a temporary seal to cut surfaces. Use roof cement and one layer of 7 kg (15 pound) felt strip cut to extend 150 mm (6 inches) on each side of cut surface. Bed strip in roof cement and cover strip with roof cement to completely embed the felt.

3.3 SELECTION OF RIGID INSULATION

A.

Insulation Type:

1.

Use either cellular glass, mineral fiberboard, perlite board, phenolic board, isocyanurate board, or urethane board or a combination thereof.

2.

Use not less than two layers of insulation unless specified otherwise.

3.

Use either 25 mm (one inch) thick mineral fiberboard, cellular glass, or perlite board as first layer over steel decks. Do not use phenolic, isocyanurate, or urethane board type insulation directly on steel roof decks.

4.

Use either 13 mm (1/2 inch) thick perlite board or mineral fiber board as a top layer over urethane board or isocyanurate board. Composite board is acceptable.

5.

Use only cellular glass block for plaza or promenade decks.

6.

Where tapered insulation is used, all insulation shall be factory tapered, except perlite board may be field tapered.

7.

Use same insulation as existing for roof repair and alterations unless specified otherwise.

B.

Insulation Thickness:

1.

Thickness of roof insulation shown on drawings is nominal. Actual thickness shall provide the thermal resistance "R" value of not less than 13 for uniform thickness (average thickness where tapered insulation is used).

2.

The minimum thickness of insulation for metal decks shall not be less than recommended by the insulation manufacturer to span the rib opening (flute size) of the metal deck used.

3.

When thickness of insulation to be used is more or less than that shown on the drawings, make adjustments in the alignment and location of roof drains, flashing, gravel stops, fascias and similar items at no additional cost to the Government.

4.

Where tapered insulation is used, the thickness of the insulation at high points and roof edges shall be as shown on the drawings; the thickness at the low point (drains) shall be not less than 38 mm (1‑1/2 inches).

5.

Use not less than two layers of insulation when insulation is 25 mm (one inch) or more in thickness unless specified otherwise.

3.4 INSTALLATION OF INSULATION

A.

Lay insulating units with close joints, in regular courses and with cross joints broken. When laid in more than one layer, break joints of succeeding layers of roof insulation with those in preceding layer. Bed insulation layers in Type III or IV asphalt firmly pressed into the hot bitumen. Keep bitumen below surface of insulation to receive single ply rubber roofing.

B.

Lay units with long dimension perpendicular to the rolled (longitudinal) direction of the roofing felt.

C.

Cover all insulation installed on the same day by either:

1.

The roofing membrane as specified.

2.

Temporary protection as specified.

D.

Seal all cut edges at penetrations and at edges against blocking with bitumen or roof cement.

E.

Cut to fit tight against blocking or penetrations.

F.

Over Concrete Deck: Lay insulation in hot bitumen as specified.

G.

Over Precast Concrete Unit Decks: Lay insulation in hot bitumen keeping bitumen back 100 mm (four inches) from joints in precast concrete units.

H.

Over Nailable Decks:

1.

Over poured gypsum, precast gypsum plank, cement‑wood fiber plank, wood plank, or plywood deck, install one ply of base sheet or venting base sheet as specified; or, apply two plies of felt.

2.

Lay first ply of felt down dry and mop second ply to first ply at laps. Nail both plies to deck as specified.

3.

Lay base sheet down dry with mineral surface down; lap and nail down as specified.

4.

Lay insulation in hot bitumen over membrane or base sheet as specified.

I.

Steel Deck:

1.

Material and method of application of insulation systems used on metal decks shall meet the requirements of Underwriters laboratories for Class A or Factory Mutual Research Corporation for Class I Insulated Steel Roof Deck.

2.

Mechanically anchor first layer of insulation to steel deck to conform to FM Class // 1‑60 // 1‑90 //, Insulated Steel Roof Deck.

3.

Locate the long dimension edge joints to have solid bearing on top of deck ribs; do not cantilever over deck rib openings or flutes.

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