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WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES

WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES

Product catalog summary

Overview: This document provides a comprehensive guide on waterproofing operations using synthetic membranes for flat roofs. It includes specifications, procedures, and best practices for various waterproofing systems, such as those ballasted with gravel, cement slabs, bonded tiles, concrete screed, soil, and exposed systems.

1. Preparation of the Substrate:

Flat Roofs: Ensure the substrate is smooth, clean, and dry. Reinforced cement and concrete-masonry roofs must withstand design loads and have a cement levelling layer. Corrugated steel and wooden decking roofs require specific preparation for continuity and smoothness.
Minimum Requirements: For mechanical fixing, substrates must meet specific compressive strength and thickness criteria.

2. Waterproofing Systems for Flat Roofs Ballasted with Gravel:

Cold-Roof System: Involves substrate preparation, application of a compensation and levelling layer using non-woven fabric, and installation of a synthetic waterproof membrane. Membranes are heat-welded for a weathertight seal.
Vertical Turn-Ups: Use specific membranes for edges and protrusions, bonded with contact adhesive and heat-welded.
Perimeter Fixing System: Prevents membrane movement due to environmental factors.
Ballast Layer: Applied to counteract wind suction, using washed gravel.

3. Specifications for Materials:

Non-Woven Fabric: Must meet tensile strength, elongation, and puncture resistance standards.
Synthetic Membranes: PVC-P and TPO/FPO membranes must be UV-resistant, weather-resistant, and meet various EN standards for impermeability, fire reaction, and mechanical properties.

4. Additional Systems: The document outlines procedures for systems ballasted with cement slabs, bonded tiles, concrete screed, and soil, as well as adhered and mechanically-fixed systems for exposed roofs.

5. Standard Accessory Parts and Details: Includes procedures for roof edging, wall fillets, and drainage outlets.

Conclusion: The guide emphasizes the importance of proper substrate preparation and adherence to material specifications to ensure effective waterproofing of flat roofs using synthetic membranes.

Specifications:

Membrane Types: The document specifies the use of synthetic waterproof membranes in PVC-P and TPO/FPO, with thicknesses of 1.5 mm and 1.8 mm.
Production Process: Membranes are produced by a "multi-extrusion coating" process, ensuring internal reinforcement without pre-lamination.
Standards Compliance: All membranes must comply with EN 13956 standards and be CE marked.
Characteristics: Key characteristics include UV and weather resistance, impermeability to water, fire reaction class Euroclass E, and various mechanical strengths (e.g., tensile strength, tear strength).

Procedures:

Installation: Membranes are loose-laid with overlaps of approximately 8 cm, followed by heat-welding of overlaps using manual and automatic hot-air welders.
Welding Process: Manual heat-welding involves spot-welding, internal pre-welding, and final external welding to ensure a weathertight seal.
Cleaning: Overlaps must be cleaned with specific cleaning products before welding.

Vertical Turn-Ups:

Vertical turn-ups are applied around roof edges and other structures using membranes in PVC-P and TPO/FPO, bonded with specific adhesives and heat-welded for sealing.

Perimeter Fixing System:

A mechanical fixing system using zinc-plated carbon steel profiled bars is applied around the perimeter to prevent membrane movement due to environmental factors.

Environmental Considerations:

Membranes are formulated to resist macrobiological attack and are eco-compatible, with no plasticisers or volatile organic compounds.

1. Perimeter Mechanical Fixing System: A linear perimeter fixing system is used to secure waterproof membranes, preventing movement due to temperature changes or substrate deformation. It involves Mapeplan Metalbar fastening bars and suitable fasteners, with anti-tear seaming cords welded to the membrane.

2. Protection and Ballast Layers: A Polydren 500 PP protection layer is applied, followed by a ballast layer of cement slabs to counteract wind suction. The slabs are laid on plastic supports, ensuring no damage to the waterproofing layer.

3. Waterproofing Systems for Flat Roofs: The document outlines systems for roofs ballasted with cement slabs and bonded tiles, suitable for foot traffic. It includes procedures for warm-roof and cold-roof systems.

4. Warm-Roof System: This involves substrate preparation, application of a vapour barrier, insulating layer, separation layer, and waterproof membrane. Membranes can be PVC-P or TPO/FPO, with specific installation and welding instructions.

5. Cold-Roof System: Similar to the warm-roof system but includes additional layers like an anti-imbibition flow layer to prevent cement laitance issues. The ballast layer consists of frost-proof tiled flooring, bonded with specific adhesives.

6. Vertical Turn-Ups: Instructions for creating vertical turn-ups for waterproof membranes around roof edges and other structures, using PVC-P or TPO/FPO membranes, with detailed bonding and welding procedures.

7. Application of Layers: Detailed steps for applying various layers, including protection, separation, and ballast layers, ensuring proper overlaps and sealing to maintain waterproof integrity.

Conclusion: The document provides comprehensive guidelines for installing waterproofing systems on flat roofs, emphasizing the importance of each layer and the correct application techniques to ensure durability and effectiveness.

1. Specifications for Bonded Tiles:

Substrate Preparation: Ensure substrates are smooth, clean, and dry with a suitable cement levelling layer to form a slope.
Vapour Barrier Application: Use a self-adhesive bituminous membrane with overlaps sealed using a metal roller.
Insulating Layer: Apply rigid, self-extinguishing EPS panels to avoid thermal bridges.
Waterproof Membrane: Options include PVC-P and TPO/FPO membranes, both requiring heat-welded overlaps for a weathertight seal.
Vertical Turn-Ups: Fully bond and heat-weld turn-ups using specific adhesives and cleaners.
Perimeter Fixing System: Use Aluzinc-plated steel plates and fasteners to secure membranes.
Protection and Anti-Imbibition Layers: Apply non-woven fabrics and micro-perforated polyethylene sheets to protect underlying layers.
Ballast Layer: Install frost-proof tiles with expansion joints and cushioning layers to prevent damage.

2. Specifications for Concrete Screeds:

Substrate Preparation: Similar to bonded tiles, ensuring smooth and dry surfaces.
Compensation and Levelling Layer: Use polypropylene non-woven fabric for even distribution.
Waterproof Membrane: Options for light and heavy vehicles, with specific thicknesses and reinforcement.
Vertical Turn-Ups: Similar bonding and welding procedures as for bonded tiles.
Perimeter Fixing System: Prevents membrane movement due to environmental factors.
Protection and Anti-Imbibition Layers: Similar application as for bonded tiles, ensuring protection and drainage.

Key Considerations:

Ensure all overlaps are properly sealed to maintain waterproof integrity.
Use appropriate adhesives and cleaners for bonding and welding processes.
Consider environmental factors such as UV resistance and thermal expansion in material selection.

Specifications:

Waterproof Membranes: The document specifies the use of 2.0 mm-thick synthetic waterproof membranes in PVC-P and TPO/FPO, reinforced with dimensionally-stable glass mat. These membranes are UV and weather-resistant, designed to withstand macrobiological attack and bacteria, and comply with EN 13956 standards.
Membrane Characteristics: Key characteristics include impermeability to water, reaction to fire (Euroclass E), tensile strength, elongation at failure, impact resistance, and resistance to UV rays and root penetration. The membranes are produced by a multi-extrusion coating process and are certified according to ISO 9001 and ISO 14001 standards.

Procedures:

Application of Membranes: Membranes are loose-laid with overlaps of approximately 8 cm and heat-welded using manual and automatic hot-air welders. Cleaning with specific products is required before welding.
Vertical Turn-Ups: Vertical turn-ups are applied around roof edges and other structures using specific contact adhesives and are heat-welded to ensure a weathertight seal.
Ballast Layer Application: A cementitious screed is applied as a ballast layer, designed to resist static loads and dynamic stress. Reinforcement may be embedded if required, and a cushioning layer is applied to prevent thermal expansion damage.

Recommendations:

Ensure substrates are smooth, clean, and dry before application.
Verify the compressive strength of insulating panels used in warm-roof systems.
Follow specified overlap and welding procedures to maintain membrane integrity.

Key Considerations:

Membranes must be eco-compatible and have a low environmental impact.
Proper installation and welding techniques are crucial for ensuring the longevity and effectiveness of the waterproofing system.

Vertical Turn-Ups: The document specifies the use of Mapeplan T B 15 and T B 18 membranes, which are UV and weather-resistant, reinforced with glass mat, and have a high-reflectance Smart White surface. These membranes are bonded to substrates using Mapeplan ADS 300 adhesive and heat-welded for a weathertight seal.

Mechanical Fixing System: The system involves mechanical spot-fixing under membrane overlaps on concrete substrates using Aluzinc-plated carbon steel anchoring plates and suitable fasteners. A linear fixing system is applied around the perimeter using zinc-plated carbon steel profiled fastening bars and anti-tear seaming cords.

Application of Synthetic Waterproof Membranes: The document details the application of 1.5 mm and 1.8 mm thick synthetic waterproof membranes in PVC-P and TPO/FPO. These membranes are UV and weather-resistant, reinforced with high-strength polyester mat, and produced by multi-extrusion coating. They must comply with EN 13956 standards and have specific physical properties such as impermeability, tensile strength, and resistance to UV rays.

Key Specifications: The membranes must meet various EN standards for characteristics like thickness, mass per unit area, water impermeability, fire reaction, hail resistance, weld strength, and more. The document also emphasizes the importance of substrate requirements for effective mechanical fixing, including compressive strength and thickness.

Installation Procedures: Membranes are to be loose-laid, overlapped, and mechanically fastened to counteract wind suction. Heat-welding is performed on overlaps to ensure a weathertight seal, with specific cleaning products recommended for preparation.

Recommendations: The document advises conducting preliminary pull-out tests on-site to ensure substrate suitability and emphasizes the need for manufacturer approval of the mechanical fixing system design and dimensions.

Preparation of the Substrate: The substrate must be smooth, clean, and dry with all corners and edges smoothed. A suitable cement leveling layer is used to form a slope.

Application of the Vapour Barrier: A coat of Polyprimer HP 45 Professional primer is applied, followed by a vapour barrier using a DOUBLE-ADHESIVE bituminous membrane with 10 cm overlaps. The membrane is reinforced with aluminium foil and protected by a polyethylene film.

Application of the Insulating Layer: Insulating panels made from 150 kPa sintered expanded polystyrene (EPS) are used. Panels are either bonded or loose-laid and fixed with metal plates and fasteners.

Application of the Separation Layer: A Polydren PES 200 polyester non-woven fabric is used, with 10 cm overlaps. This layer is not required with TPO/FPO membranes.

Application of the Waterproof Membrane: Options include PVC-P membranes (Mapeplan M 15 or M 18) and TPO/FPO membranes (Mapeplan T M 15 or M 18). Membranes are spot-fixed with mechanical fasteners and heat-welded for a weathertight seal.

Vertical Turn-Ups: For PVC-P membranes, Mapeplan B 15 or B 18 is used, and for TPO/FPO membranes, Mapeplan T B 15 or B 18 is used. Turn-ups are fully bonded and heat-welded to the membrane.

Mechanical Fixing System: Spot-fixing systems use Aluzinc-plated carbon steel anchoring plates and fasteners. A linear fixing system is applied around the perimeter using zinc-plated steel bars.

Warm-Roof System on Corrugated Steel Sheet: Similar procedures are followed with specific adaptations for corrugated steel sheets, including the use of a vapour control layer made from LDPE polyethylene and specific mechanical fixing systems.

Specifications:
The document outlines the use of Aluzinc-plated, carbon steel anchoring plates and zinc-plated, carbon steel profiled fastening bars for waterproofing systems. These components are treated with anti-corrosion products and are designed to be compatible with waterproof membranes. The anchoring plates measure 82x40x1 mm, while the fastening bars have specific dimensions and pre-punched holes for ease of installation.

Procedures:
The installation process involves several steps, including substrate preparation, application of a vapor control layer, insulating layer, separation layer, and the waterproof membrane. The document details the use of specific materials such as Mapeplan products for each layer, emphasizing the importance of proper overlap and heat-welding techniques to ensure a watertight seal.

Standards and Recommendations:
The mechanical fixing system must be supplied by a reputable manufacturer and approved by the membrane manufacturer. The substrate must meet minimum thickness requirements, and preliminary pull-out tests are recommended to ensure adequate anchorage.

Roof Edging and Wall Fillets:
The document describes the use of specific "L" shaped profiles for roof edging and wall fillets, coated with either PVC-P or TPO/FPO membranes. These profiles are applied using mechanical fasteners and require proper alignment and sealing to ensure effectiveness.

Key Requirements:
- Minimum substrate thickness for various materials.
- Use of anti-corrosion treated fasteners.
- Approval and qualification by membrane manufacturers.
- Preliminary on-site tests for anchorage strength.

Best Practices:
- Ensure all substrates are smooth, clean, and dry before installation.
- Properly align and seal profiles and membranes.
- Conduct manual and automatic heat-welding for secure seals.

Standard Accessory Parts and Details

Wall Fillets Using Specific Profiles

Wall fillets are made from zinc-plated steel sheets coated with TPO/FPO membrane. The material specifications include a thickness of 0.6 mm for the steel sheet and 1.2 mm for the membrane, with a total flat length of 70 mm. The upper part is specially shaped for a bead of sealant. Installation involves mechanical fasteners and sealing with a suitable sealant, possibly after applying a primer. The cost is calculated per metre.

Drainage Outlets

Drainage outlets are available in two types: PVC-P and TPO/FPO, both suitable for use with waterproof membranes. They feature a double-seal anti-backflow elbow for guttering. The outlets are heat-welded to the waterproof membrane and covered with a round, gravel/leaf guard with locking fins. The cost is calculated per outlet.

PVC-P Drainage Outlet

The PVC-P drainage outlet has a height of 240 mm and is heat-welded to the waterproof membrane. It includes a gravel/leaf guard.

TPO/FPO Drainage Outlet

The TPO/FPO drainage outlet also has a height of 240 mm and is heat-welded to the waterproof membrane. It includes a gravel/leaf guard.

Catalog excerpts

WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES-1

DESIGN GUIDE ARCHITECTURAL SOLUTIONS WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES ADHESIVES • SEALANTS • CHEMICAL PRODUCTS FOR BUILDIN

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WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES-2

specifications of WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES N.1 PREPARATION OF THE SUBSTRATE N.1.1 INSTALLATION AND PREPARATION OF FLAT ROOFS Procedure N.2 WATERPROOFING SYSTEMS FOR FLAT ROOFS BALLASTED WITH GRAVEL N.2.1 FLAT ROOFS BALLASTED WITH GRAVEL - COLD-ROOF SYSTEM Procedure N.2.2 WATERPROOFING SYSTEMS FOR FLAT ROOFS BALLASTED WITH GRAVEL Procedure N.3 WATERPROOFING SYSTEMS FOR FLAT ROOFS BALLASTED WITH CEMENT SLABS ON SUPPORTS (SUITABLE FOR FOOT TRAFFIC) N.3.1 WATERPROOFING SYSTEM FOR FLAT ROOFS BALLASTED WITH CEMENT SLABS ON SUPPORTS - COLD-ROOF SYSTEM Procedure N.3.2 WATERPROOFING...

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WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES-3

N.6.2 WATERPROOFING SYSTEMS FOR FLAT ROOFS BALLASTED WITH SOIL -WARM-ROOF SYSTEM Procedure N.7 ADHERED WATERPROOFING SYSTEMS FOR EXPOSED FLAT ROOFS N.7.1 ADHERED WATERPROOFING SYSTEMS FOR EXPOSED FLAT ROOFS - COLD-ROOF SYSTEM Procedure N.7.2 ADHERED WATERPROOFING SYSTEMS FOR EXPOSED FLAT ROOFS - WARM-ROOF SYSTEM Procedure N.8 MECHANICALLY-FIXED WATERPROOFING SYSTEMS FOR EXPOSED FLAT ROOFS N.8.1 MECHANICALLY-FIXED WATERPROOFING SYSTEMS FOR EXPOSED FLAT ROOFS -COLD-ROOF SYSTEM Procedure N.8.2 MECHANICALLY-FIXED WATERPROOFING SYSTEMS FOR EXPOSED FLAT ROOFS -WARM-ROOF SYSTEM ON A REINFORCED CEMENT...

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WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES-4

N.1 PREPARATION OF THE SUBSTRATEN.1.1 INSTALLATION AND PREPARATION OF FLAT ROOFS Procedure Before installing a waterproofing system made from a synthetic membrane, the roof must be installed and/or checked to make sure it is suitable for use and that it has been prepared correctly. Reinforced cement and concrete-masonry flat roofs Reinforced cement and concrete-masonry flat roofs must be dimensioned to withstand the design loads and overloads, and a cement levelling layer must be applied to form a slope. To make the substrate suitable for applying the system, the following must be carried out:...

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WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES-5

Wooden decking flat roofs Wooden decking flat roofs must be dimensioned to withstand the design loads and overloads. The wooden decking may be made from planks of deal perfectly butted together, beaded birch planks, plywood panels or oriented strand board (OSB). To fix the planks and/or panels for the decking in place to the load-bearing structure and prevent them warping, use special wood screws or deformed shank nails. Fixing the planks or panels in place with traditional nails is not recommended. To make the substrate suitable for applying the waterproofing system, the following must be carried...

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WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES-6

WATERPROOFING SYSTEMS FOR FLAT ROOFS BALLASTED WITH GRAVEL FLAT ROOFS BALLASTED WITH GRAVEL - COLD-ROOF SYSTEM Procedure Preparation of the substrate Installation and/or checking of reinforced concrete or concrete-masonry substrates with a suitable cement levelling layer to form a slope (see section N.1.1). When handed over, substrates must be smooth, clean and dry and all corners and edges must be smooth. Application of the compensation and levelling layer Loose-laid Polydren 500 PP 100% polypropylene non-woven, needle-punched fabric with a weight of 500 g/m², with overlaps approximately 10...

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WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES-7

Vertical turn-ups PVC-P membranes Vertical turn-ups for waterproof membranes around the edges of roofs, wall fillets, mass fillets, skylights, etc. using: - Mapeplan B 15 1.5 mm-thick, UV-resistant and weather-resistant membrane in PVC-P reinforced with dimensionally-stable glass mat (see section N.2.1.6) for 1.5 mm thick waterproof membranes; - Mapeplan B 18 1.8 mm-thick, UV-resistant and weather-resistant membrane in PVC-P reinforced with dimensionally-stable glass mat (see section N.2.1.7) for 1.8 mm thick waterproof membranes. Fully-bond the turn-ups to the substrate using Mapeplan ADS 200,...

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WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES-8

Application of the protection layer Loose-laid Polydren 500 PP protection layer in 100% polypropylene non-woven, needle-punched fabric with a weight of 500 g/m², with overlaps approximately 10 cm wide between adjacent sheets (see section N.2.1.11). Application of the ballast layer Application of a layer of ballast to counteract the suction effect of wind, made from washed, round gravel with a grain size of 16 to 32 mm (see section N.2.1.12). Apply an even layer at least 50 mm thick. Apply the layer of ballast carefully to avoid damaging the underlying waterproofing layer.

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WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES-9

N.2 WATERPROOFING SYSTEMS FOR FLAT ROOFS BALLASTED WITH GRAVEL N.2.1.1 Application of non-woven fabric to form the compensation and levelling layer Supply and application of a compensation and levelling layer made from 100% polypropylene non-woven, needle-punched fabric with a weight of 500 g/m2 (such as Polydren 500 PP produced by POLYGLASS S.p.A.). The product must have the following characteristics: average tensile strength according to EN ISO 10319: 12 (-13%) kN/m average elongation at maximum load according to EN ISO 10319: > 50% static puncture resistance CBR according to EN ISO 12236:...

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WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES-10

none < 30 mm < 10 mm 1.8 kg/m2 (-5/+10%) > 400 kPa/72h Euroclass E > 300 N/50 mm > 500 N/50 mm μ 19,000 > 9 N/mm2 > 200% method A > 600 mm method B > 850 mm > 20 kg > 100 N < 0.2% < -25 °C compliant: class 0 compliant N.2 WATERPROOFING SYSTEMS FOR FLAT ROOFS BALLASTED WITH GRAVEL N.2.1.2 Application of 1.5 mm-thick synthetic waterproof membrane in PVC-P Supply and application of UV-resistant and weather-resistant synthetic waterproof membrane in PVC-P reinforced with dimensionaMy-stable glass mat (such as Mapeplan B 15 produced by POLYGLASS S.p.A.), specifically formulated to resist macrobiological...

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WATERPROOFING OPERATIONS USING SYNTHETIC MEMBRANES-11

none < 30 mm < 10 mm 2.2 kg/m2 (-5/+10%) > 400 kPa/72h Euroclass E > 300 N/50 mm > 500 N/50 mm μ 19,000 > 9 N/mm2 > 200% method A > 800 mm method B > 950 mm > 20 kg > 100 N < 0.2% < -25 °C compliant: class 0 compliant N.2 WATERPROOFING SYSTEMS FOR FLAT ROOFS BALLASTED WITH GRAVEL N.2.1.3 Application of 1.8 mm-thick synthetic waterproof membrane in PVC-P Supply and application of UV-resistant and weather-resistant synthetic waterproof membrane in PVC-P reinforced with dimensionaMy-stable glass mat (such as Mapeplan B 18 produced by POLYGLASS S.p.A.), specifically formulated to resist macrobiological...

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