Roofing Systems TPO MEMBRANE INSTALLATION HANDBOOK Tool and Supply Checklist Step-by-Step Instructions Photo Illustrations Detail Drawings Product List
CONTENTS PAGE 3 4 6 7 10 12 27 35 38 40 66 Equipment Listing Perimeter Sheet Requirements Plate and Fastener Spacing Requirements Substrate Preparation Mechanically Attached Membrane Placement & Securement Flashing Hot Air Welding Guidelines Roof Repair Guide Flex RhinoBond™ Attachment System Detail Drawings Product List ABOUT FLEX ROOFING SYSTEMS Flex manufactures Elvaloy® KEE-, PVC- and TPO-based materials for the commercial roofing industry.
EQUIPMENT AND ACCESSORIES LISTING Clean, asphalt-free extension cord sufficient to handle power requirements One (1) pair of scissors per man Tape measures, varying up to 100 feet in length Chalk boxes, chalk Four inch (4”) wide paint brushes Clean cotton rags Caulking guns Push brooms Non-permanent ink or crayon writing element for marking seams Several Flex Seam Probes for probing of seams Clean, asphalt free waterproof canvas or tarp for covering of materials S
FLEX TPO PLUS MECHANICALLY ATTACHED ROOF SYSTEMS PERIMETER SHEET REQUIREMENTS AND FASTENER GUIDE Perimeter Sheets Flex TPO mechanically attached roof systems require the installation of ½ (half) sheets (a sheet 4’ or 5’ wide) along the roof perimeter. The roof perimeter is defined as the edges of each roof section.
Notes: 1) Fastener assembly spacing for perimeter sheets is the same as required for the fastener spacing of the roof field area sheets. *Installation of 12’ wide membrane requires 2 rows of perimeter sheets fastened 12” o.c. **Gypsum or Cementitious Wood Fiber Decks in the 100 to 129 mph wind zone require installing 3 rows of perimeter sheets.
GUIDE TO FLEX FASTENER AND FLEX PLATE PLACEMENTS This guide is based on current FM Approvals for the field sheet securement criteria. Steel Deck or Structural Concrete Membrane Type Row Spacing Fastener Type Fastener Spacing Uplift Rating (psf) TPO Plus 42.5” 42.5” 91” 91” 91” 115” 115” 115” 115” 115” 138.
FLEX TPO PLUS MECHANICALLY ATTACHED ROOF MEMBRANE INSTALLATION GUIDE This guide is intended to be a point of reference in assisting the Flex Authorized Applicator. The installer should always refer to the project specifications for details and application requirements for each unique roof system installation. Loading the roof. Follow all OSHA procedures for safety. SUBSTRATE PREPARATION Defects in the substrate surface must be reported and documented to the Building Owner’s Representative for assessment.
Existing Single Ply Roof Membranes: If the existing membrane is to be left in place it must be cut into sections no larger than 100 square feet per each section. All flashing must be removed at the perimeter edge, roof drains and roof penetrations. Gravel-Surfaced Built Up Roofing: The loose gravel must be removed either by vacuuming or power brooming. The surface must be leveled to prevent the insulation or recover board from bridging.
is installed so the top of wood is flush with the top surface of the roof insulation or recover board. The wood blocking width is to exceed the width of flange to be attached to the blocking. The securement of the blocking shall be in a manner to meet or exceed the local building code requirements and the wind uplift pressure resistance required in the project specifications.
MECHANICALLY ATTACHED MEMBRANE PLACEMENT AND SECUREMENT The substrate must be clean and dry prior to installing the Flex Roof Membrane. The type of Flex fastener is dependent upon the deck type. The specific type of approved fastener is found in the components section of Flex’s Technical Manual if the proper fastener cannot be determined contact the Flex Technical Service Department.
Mechanically fastened Flex TPO membrane Flex fasteners and screws help make installation easier and faster.
FLASHING General Flashing Conditions Flex Reinforced Flashing Membrane is to be installed for the flashing of parapet walls, roof equipment curbs, expansion joints and roof dividers, and for most other roof detail flashing areas. Flex non-reinforced flashing membrane may be used for those areas where the use of pre-formed accessories cannot be installed such as certain pipe penetrations, corners, and scuppers details.
Hanging the wall flashing Rolling wall flashing into place 13
Flashing on an open top curb Flashing existing mechanical unit 14
Hand welding a field-fabricated flashing Hand welding a pre-formed outside corner flashing 15
Pre-formed inside corner flashing Wall flashing with Flex Lip-T bar, with approved caulking 16
Wall flashing with metal counter-flashing FlexClad™ metal drip edge, properly secured 17
Flex Trim Strip welded to FlexClad™ metal and field membrane Applying water block to a drain flange under the field membrane 18
Installing a Flex TPO Flashing target sheet over the field sheet drain opening Tightening the clamping ring on a drain flashing 19
Welding a Flex pre-formed pipe boot to the field membrane Clamp and caulking is required at the top of the pipe boot 20
Field-fabricated method with Flex TPO Flashing Membrane Flex Split Pipe Boot, a pre-fabricated flashing 21
Post support flashing, available pre-formed from Flex FlexClad™ metal pitch pan, fabricated by the contractor 22
Pitch pan topped off with Flex Pourable Sealer Pitch pans solve difficult flashing details 23
Through-wall scupper made of FlexClad™ Metal Expansion joint cover, with Flex TPO Reinforced Flashing Membrane 24
ACCESSORIES Walkway Pads Install walkway pads in those locations as designated in the specifications. Thoroughly clean and prepare the area of the roof membrane that is to be hot air welded to the walkway pad. The Flex Walkway Pad is installed in maximum lengths of 10’. Position sections of the walkway pad to leave a space between adjacent sheets approximately 2” wide. Do not cover field seams with the Walkway Pad. Position the pads to leave minimum 4” wide area exposed at the field seams.
Pavers Either a protection sheet of Flex TPO Flashing Membrane or Flex 180N Geotextile Separation Layer must be installed under all concrete paver blocks. Pavers installed over properly flashed drain detail Night Seal The new roof membrane must be sealed at the end of each work day to prevent water infiltration. The membrane may be temporarily sealed by securing the down slope edge with roof cement, hot asphalt, spray urethane foam or similar water blocking materials.
HOT AIR WELDING GUIDELINES Hot Air Welding Equipment A. The Flex Automatic Welding Machine is an electrically powered, self propelled device that utilizes an electric heating element and forced air to weld the seams in Flex Thermoplastic Single Ply Membranes. Flex Automatic Hot Air Welding Machine B. Hand Held Welder is an electrically powered hand held device that utilizes an electric heating element and forced air to weld the seams in Flex Thermoplastic Single Ply Membranes.
C. The Flex Pressure Roller is a silicon hand roller used for rolling the hot air welded seams. Silicon hand roller D. Seam probe is a hand held instrument used for probing the hot air welded seams to insure the integrity of the welds.
E. When using a portable generator for providing electrical power to the automatic or hand held welders, a 9500 watt minimum output generator is recommended to run one automatic and one held welder.
Welding Preparation The surfaces to be welded must be clean and dry. Check the membrane overlaps to determine whether they have been contaminated with field dirt. If the seam is contaminated, thoroughly clean the membrane with the recommended cleaner. It is required that all installed membrane seams be hot air welded the same day the membrane is installed.
Cut a test sample across the width of the seam at least 1” wide and longer than the width of the seam. Pull the welded seam sample apart and examine the width of the delamination from the reinforcing fabric. The width of the weld should be no less than 1.5” indicating a proper hot air welded seam. Automatic hot air welder allows workers to operate upright, which is more comfortable and much faster.
Hand Welder Operation The hand welder is generally utilized for flashing details and field seams less than 10’ in length. Consult the welding machine manufacturer’s recommendations for proper temperature setting for the equipment. The temperature setting will vary with ambient temperature, type of substrate and membrane thickness. As a general guide for welding the Flex TPO Plus Membrane the Leister Triac Hand Welder suggested starting setting is # 6.
Using a hand held hot air welder to install wall flashing 33
Seam Probing All welded seams must be probed with the Flex Seam Probe to determine the quality and integrity of the weld. Allow the hot air welded seam to cool to ambient temperature before beginning the probing process. Apply pressure and pull the point of the seam probe along the edge of the seam. The tool will not penetrate the edge of a properly welded seam. Repair any voids discovered by cleaning and re-welding the seam. After the repair cools, probe the area to confirm the proper weld.
ROOF REPAIR GUIDE Temporary or Emergency Repair In the event that the Flex Roofing System becomes damaged the building owner may be required to make temporary repairs to the roof system, which will not affect the warranty coverage. Materials Flex one component gun grade moisture curing polyurethane sealant. Flex Thermoplastic Reinforced TPO Plus® 45 mil, 60 mil, or 80 mil Flashing Membrane. A detergent cleaner such as Flex orange power cleaner or trisodium phosphate is applied to remove residual dirt.
Permanent Repair Flex requires that this repair be performed by a Flex Approved Applicator. This repair is required to be completed in accordance with current Flex Details and Specifications. Materials Flex Thermoplastic Reinforced TPO Plus® 45 mil, 60 mil, or 80 mil Flashing Membrane. A detergent cleaner such as Flex orange power cleaner or trisodium phosphate is applied to remove residual dirt.
Procedure to Repair Voids in Hot Air Welded Seams Prepare the surface by removing debris, contaminants and ballast from the area of the membrane or flashing to be repaired. The area should extend beyond the perimeter of the void to provide an ample-sized clean work area. Check all hot air welded seams for voids with a Flex seam probe. When a void is found open the seam until a fully welded seam area is determined.
Flex RhinoBond™ System - An Optional Installation Technique As an alternative to manual mechanically attached systems, the Flex RhinoBond™ System allows faster and more secure installation of single ply thermoplastic membranes.
Q Q Q Q Flex RhinoBond Insulation Plates™ are installed beneath the membrane. The Flex RhinoBond Tool™ heats the plate, welding it to the membrane. The magnet holds the membrane to the plate to complete the weld. The Flex RhinoBond Tool™ welds the RhinoBond Plate™ and Flex Roof Membrane™ in approximately 5 to 7 seconds. How Does It Work? The Flex RhinoBond Tool™ creates heat by induction, heating the specially treated Flex RhinoBond Plate™ that attaches the insulation to the roof deck.
DETAIL INDEX Drawing Content Page Flex Ref # TPO Insulation Attachment 41 1.04 Membrane Sheet Layout 42 2.01 Lap Cross Section 43 2.03 Plate & Fastener Placement 44 2.05 60 Mil & 80 Mil T-Joint 45 2.06 Ridge Membrane Attachment 46 2.07 Low Profile Expansion Joint 47 3.01 Expansion Joint Wall 48 3.02 Curb Flashing 49 3.03 Coated Metal Curb Flashing 50 3.04 Parapet Flashing 51 3.06 Flashing Terminations 52 3.08 Roof Drain 53 4.01 Roof Drain II 54 4.
DETAILS 41
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Flex Membrane International, Inc. 2670 Leiscz’s Bridge Road, Suite 400, Leesport, PA 19533 Phone: 1-800-969-0108 Fax: 610-916-9501 FLEX TPO MEMBRANES .045 Thickness .045 Thickness FLEX WHITE Reinforced TPO Membrane Item Code 8300 8425 8405 8301 8303 8426 8302 8340 Roll Size 4’ X 100’ 5’ X 50’ 5’ X 100’ 6’ X 100’ 8’ X 100’ 10’ X 50’ 10’ X 100’ 12’ X 100’ Gross Coverage 400 sq. ft. 250 sq. ft. 500 sq. ft. 600 sq. ft. 800 sq. ft. 500 sq. ft. 1,000 sq. ft. 1,200 sq. ft. Weight 95 lbs. 58 lbs. 115 lbs.
Flex Membrane International, Inc. 2670 Leiscz’s Bridge Road, Suite 400, Leesport, PA 19533 Phone: 1-800-969-0108 Fax: 610-916-9501 FLEX TPO MEMBRANES .060 Thickness .060 Thickness FLEX WHITE Reinforced TPO Membrane Item Code 8343 8447 8437 8307 8308 8350 8353 Roll Size 4’ X 100’ 5’ X 50’ 5’ X 100’ 6’ X 100’ 8’ X 100’ 10’ X 100’ 12’ X 100’ Gross Coverage 400 sq. ft. 250 sq. ft. 500 sq. ft. 600 sq. ft. 800 sq. ft. 1,000 sq. ft. 1,200 sq. ft. Weight 128 lbs. 58 lbs. 155 lbs. 190 lbs. 251 lbs. 318 lbs.
Flex Membrane International, Inc. 2670 Leiscz’s Bridge Road, Suite 400, Leesport, PA 19533 Phone: 1-800-969-0108 Fax: 610-916-9501 FLEX TPO MEMBRANES .072 Thickness .072 Thickness FLEX WHITE Reinforced TPO Membrane Item Code 8360 8452 8453 8362 8356 8358 8364 Roll Size 4’ X 100’ 5’ X 50’ 5’ X 100’ 6’ X 100’ 8’ X 100’ 10’ X 100’ 12’ X 100’ Gross Coverage 400 sq. ft. 250 sq. ft. 500 sq. ft. 600 sq. ft. 800 sq. ft. 1,000 sq. ft. 1,200 sq. ft. Weight 153 lbs 58 lbs. 115 lbs. 228 lbs. 305 lbs. 388 lbs.
Flex Membrane International, Inc. 2670 Leiscz’s Bridge Road, Suite 400, Leesport, PA 19533 Phone: 1-800-969-0108 Fax: 610-916-9501 FLEX TPO MEMBRANES .080 Thickness .080 Thickness FLEX WHITE Reinforced TPO Membrane Item Code 8365 8456 8439 8367 8369 8371 8374 Roll Size 4’ X 100’ 5’ X 50’ 5’ X 100’ 6’ X 100’ 8’ X 100’ 10’ X 100’ 12’ X 100’ Gross Coverage 400 sq. ft. 250 sq. ft. 500 sq. ft. 600 sq. ft. 800 sq. ft. 1,000 sq. ft. 1,200 sq. ft. Weight 171 lbs. 58 lbs. 205 lbs. 256 lbs. 342 lbs. 442 lbs.
Flex Membrane International, Inc. 2670 Leiscz’s Bridge Road, Suite 400, Leesport, PA 19533 Phone: 1-800-969-0108 Fax: 610-916-9501 FLEX TPO SELF ADHERED MEMBRANES .045 Thickness FLEX WHITE SELF-ADHERED REINFORCED TPO Membrane Item Code 8417 8413 8415 Roll Size 5’ X 50’ 5’ X 100’ 10’ X 100’ Gross Coverage 250 sq. ft. 500 sq. ft. 1,000 sq.ft. Weight 91 lbs. 182 lbs. 363 lbs. .
Flex Membrane International, Inc. 2670 Leiscz’s Bridge Road, Suite 400, Leesport, PA 19533 Phone: 1-800-969-0108 Fax: 610-916-9501 FLEX TPO ACCESSORIES Item Code Description Packaging 8328 .045 Reinforced White 6” x 100’ 3 / Ctn 8388 .045 Reinforced Gray 6” x 100’ 3 / Ctn 8389 .
Flex Membrane International, Inc. 2670 Leiscz’s Bridge Road, Suite 400, Leesport, PA 19533 Phone: 1-800-969-0108 Fax: 610-916-9501 FLEX TPO ACCESSORIES Item Code 8010 8011 5007 6014 6025 Name BAK Rion Hand Welder BAK Laron Auto Welder with Tool Box Pressure Roller Seam Probe Flex Stand Up Seam Probe Description Hot Air Hand Welder Auto Hot Air Welder Silicon Hand Roller Hand Held Seam Probe Stand Up Seam Probe Green Guard PB6W Fan Fold 4’ X 5’ - 3/8” (200 sq.ft.
Flex Membrane International, Inc.
Flex Membrane International, Inc.
Flex Membrane International, Inc.
Flex Membrane International, Inc.
Flex Membrane International, Inc.
Flex Membrane International, Inc.
® Roofing Systems For additional information: Call Flex Roofing Systems 1-800-969-0108 or visit our website www.FlexRoofingSystems.com There you can search “Technical Documents” for CSI Formatted Specifications, additional Detail Drawings and other important information. Flex Membrane International, Inc.
Roofing Systems Flex Membrane International, Inc. 2670 Leiscz’s Bridge Road, Suite 400 Leesport, PA 19533 Phone: 1-800-969-0108 Fax: 610-916-9501 FlexRoofingSystems.
