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CONTENTS

Polyroof Corporate Overview 3 - 6

Polyroof Product Selector Guide 7 - 11

Polyroof 185

Product Information & Design Guide 13 - 24

Guideline Specification - Standard Warm Roof Timber Joists 25 - 35

Balcony Warm Roof Timber Joists 36 - 47

Standard Cold Roof Timber Joists 48 - 58

Polyroof Elastex


Guideline Specification - Asphalt 69 - 79

Felt 80 - 91

Galvanised Steel Gutters (Weathered) 92 - 102

Polyroof Protec


Guideline Specification - Asphalt 113 - 124

Felt 125 - 136

Concrete Deck 137 - 148

Polyroof Case Files

Polyroof improves the home improvements market 149 - 150

Refurbishment Systems 151 - 152

Polyroof: Cold appied for lower fire risk and lower insurance cost 153 - 155

Lead and Copper Reproduction 155 - 156

Regeneration and New Build 157 - 160

A D V A N C E D L I Q U I D R O O F I N G S Y S T E M S

Contents Section Start Next Section Page Page

P O L Y R O O F A D V A N C E D L I Q U I D R O O F I N G S Y S T E M S

Cold applied liquid roofing

solutions

INTRODUCTIONContents Section Start Next Section Page �� Page

INTRODUCTION Contents Section Start Next Section Page �� Page

APPROVALS AND GUARANTEES

Polyroof 185 was the first membrane system to

receive (in 1988) the British Board of Agrément

(BBA) certificate. Polyroof 185 is also fire tested

to BS476 (Part 3) and designated external FAA,

the highest roof rating. Elastex is BBA approved

and Protec has attained the internationally

recognised Factory Mutual (FM) and Underwriters

Laboratories (UL) approvals.

Polyroof overlay systems come with flexible

guarantees from 10-25 years, dependent on the

substrate condition. The Polyroof 185 20 year

guarantee is supported by an insured and

independently administered trust-fund.

APPROVED CONTRACTORS

The quality systems of Polyroof Products are

approved to ISO 9001:2000. Our network of

approved contractors maintain these high

standards and receive training at our in-house

facilities as well as on-site. On-going technical

assistance and monitoring ensure that Polyroof's

criteria for the application of their membranes is

kept to the highest standards.

POLYROOF TECHNICAL SUPPORT

Polyroof offers its clients a high level of on-going

technical support. Our technical team will, when

required, carry out surveys and produce detailed

roof specifications, drawings and proposals.

COLD LIQUID APPLIED ROOFING SOLUTIONS

Polyroof Products Ltd. is one of the

country’s leading producers of cold,

liquid applied seamless membrane

systems for the waterproofing of flat and

inclined roofs. A range of quality

approved systems is available for new

roofs and for roof refurbishment. R&D

programmes are focused on continually

improving and extending our product

range. Over five million square metres of

Polyroof have been laid since the company

was first established in 1984. Most local

authorities now specify Polyroof systems

- together with major housing associations,

construction companies, banks, airports,

breweries and other industrial and

commercial organisations throughout the

country. Likewise in the domestic market,

Polyroof has brought peace of mind to

many thousands of homes by providing a

permanent solution to persistently

leaking roofs.

The Polyroof Group is also

active in North America

operating through a wholly

owned subsidiary, Applied

Liquid Technologies (ALT)

ALT has already won large

and prestigious contracts

such as the Empire State

Building and New York

State University

T H E P O L Y R O O F G R O U P



L I Q U I D - A P P L I E D R O O F I N G S Y S T E M S

ElastexA fully reinforced, elastomeric polyurethane overlay available in

10 - 25 year guarantee versions. Suitable for overlaying a wide

range of existing roof surfaces such as felt, concrete, plastic

coated metals, stone, brick and most single ply membranes.

Elastex provides an extremely durable and long lasting

waterproofing solution.

■ For waterproofing existing roofs and gutters

■ Ideal for large refurbishment projects

■ Seamless, cold liquid applied membrane

■ Up to 25 year guarantees available

■ BBA approved

■ Minimal disruption

■ Minimal surface preparation

■ Highly flexible and resilient

■ Available in a range of colours and finishes including anti-slip

■ High levels of UV protection

Elastexprotection coat

Elastexembedmentcoat

Reinforcement

Elastexembedmentcoat

Existing prepared substrate

ELASTEX

Mineral finish(Optional)

Protec resin

Reinforcement

Protec resin

Primed existing substrate or new timber

PROTEC

Flexi-Resin 185C

Flexi-Resin 185B

Polymat

Flexi-Resin 185B

New plywood decking

POLYROOF 185Polyroof 185Complete glassfibre reinforced polyester (GRP) composite

roofing system applied to an exterior grade plywood deck.

Specially developed flexi-resins fuse together to form a seamless,

highly durable, impervious membrane that accommodates

normal structural variations and regular foot traffic. Polyroof

185 was the first GRP roofing system to receive BBA approval:

■ For all flat roofs and box / valley gutters

■ New build or refurbishment


■ BBA approved and 30 year durability rated

■ 20 year insurance backed guarantee

■ Withstands regular foot traffic

■ Highly suitable for balconies and walkways

■ Impact resistant and vandal resistant

■ Warm or cold roof specifications

■ Available in a range of colours and finishes

Polyroof 185 was used forwaterproofing the balcony

and barrel roof of this awardwinning project in Plymouth.

Protec was used to waterproofthis concrete roof in Greenwich

Village, New York.

A protective membraneof Elastex was applied to the

roofs of these refurbishedflats in Norwich.

ProtecFast curing overlay based on a highly flexible polyester resin with

glassfibre reinforcement. Adheres to a variety of substrates and

can be extremely cost effective. Suitable for large or small

projects. Since no stripping of the old roof is required, Protec is

ideal for contracts requiring minimal disruption.

■ For all flat roofs



■ UL and FM approved

■ 10 year guarantees available

■ Withstands occasional foot traffic


■ Minimal surface preparation

■ Available in a range of colours and finishes

Nothing in this specification brochure or any other marketing literature produced by or on behalf of Polyroof Products Limitedis to be regarded as constituting a contract binding in law between Polyroof Products Limited and any customer.

The only contract which Polyroof will enter into with the customer is that contained in the Guarantees, the details of whichare available on request. This Guarantee is in the form of a written guarantee which takes effect only when issued in writingby Polyroof to the customer at the request of the Contractor.

PLUS OVER ONE HUNDRED LOCAL AUTHORITIES AND HOUSING ASSOCIATIONS

O U R C L I E N T S I N C L U D E :

POLYROOF PRODUCTS LTD

FURNESS HOUSE

CASTLE PARK INDUSTRIAL ESTATE

FL INT FL INTSHIRE

CH6 5XA

Tel : 01352 735 135

Fax: 01352 735 182

Emai l : technica l@polyroof .co.uk

www.polyroof .co.uk

FREEPHONEH E L P L I N E

0800 801 890

E S T. 1984


POLYROOF 185ELASTEX

PROTEC

PROTEC

THE NATIONAL FEDERATION OFROOFING CONTRACTORS LIMITED

Associate Member

■ Anglian Windows

■ Ansells Breweries

■ Asda Stores

■ ATS

■ BAE Systems

■ Barclays Bank

■ Barratt Homes

■ Batesman Brewery

■ Bath Breweries

■ Berkeley Homes

■ Bluesky Developments

■ BNFL

■ BP

■ Bradford & Bingley

■ British Alcan

■ British Gas

■ British Telecom

■ Buccleugh Estates

■ Burtonwood Brewery

■ Cable & Wireless

■ Cheltenham &

Gloucestershire

■ Clydesdale Bank

■ Cognies Chemicals

■ CO-OP ■ Corus ■ Dandara■ DSM Resins UK ■ Dublin Airport■ Eli Lilly■ English Partnerships ■ Gateway Building Society■ Gatwick Airport■ GlaxoSmithKline■ Greenhall Brewery ■ Heathrow Airport■ HSBC■ IBM ■ J W Lees Brewery■ Kimberly Clark■ King Sturge■ Laura Ashley ■ Lloyds Supersave

Drug Stores ■ Lloyds TSB■ Manchester Airport■ Marks & Spencer■ Marsden Brewery■ Marsdens Thomas

& Evershed

■ M O D

■ Nat West

■ National Trust ■ Nationwide

Building Society

■ NationwideEstate Agents

■ Nestlé

■ New York Port Authority

■ New York State University

■ Next

■ Northern Gas Board

■ Northern Ireland

Electricity Board

■ Northern IrelandHousing Executive

■ Oxford Brookes University

■ Raytheon

■ Remploy

■ Rentokil Property Care

■ Robinsons Brewery

■ Royal Bank Buildings

■ Royal Bank of Scotland

■ Royal MailProperty Holdings

■ Schering Plough

■ Scottish Hydro Electric

■ Scottish Landowners

■ Scottish & NewcastleBreweries

■ Severn Trent Water

■ Slough Estates

■ Southern Electric

■ South West Water

■ Spar Grocery Chains

■ Spillers Pet Food

■ Stead & Simpson

■ The Post Office

■ Thwaites Brewery

■ Tinsley Food

■ United Grain& Malt Distillery

■ United Utilities

■ Waitrose

■ Walkers Shortbread

■ Woolworths

■ Wrexham Lager Brewery

■ Zurich Financial Services

PRODUCT SELECTOR


P R O D U C T S E L E C T O R G U I D E

Contents Section Start Next Section Page �� Page

PRODUCT SELECTOR

L I Q U I D - A P P L I E D R O O F I N G S Y S T E M S

Polyroof Products is a market leader in cold–applied,

liquid roofing solutions. Reinforced flexible resin

systems are available for new roofs, roof replacement,

over-decking and overlaying: everything from

complete roof strip and re-boarding to overlay

protection. They are completely seamless systems

that do not crack or blister and substantially outlast

and outperform traditional roofing materials. This

Product Selector Guide is designed to help you select

the right system for the job in question, but our

Technical Department are always on hand for advice

and assistance.

COMPLETE COMPOSITE ROOFING SYSTEM

For long life protection in new build or roof refurbishment

(strip and re-boarding or over-decking) we recommend a

consolidated GRP composite that is applied in-situ.

Polyroof 185

A reinforced, seamless, cold applied flexible polyester

resin system comprising base coat and topcoat. The

system is designed to be used with high-grade plywood

and glassfibre reinforcement to produce a totally

waterproof and weatherproof flat roof deck. Specially

developed flexi-resins fuse together to form an extremely

durable, impervious skin, which accommodates normal

structural variations and regular foot traffic, and is highly

resistant to vandalism. Polyroof 185 is 30-year durability

rated by the BBA (British Board of Agrément) and comes

with an insurance backed 20-year guarantee.

OVERLAY SYSTEMS

Our flexible overlay resin range is ideal for refurbishment

projects as they can overcoat virtually every existing

substrate with minimal preparation and disruption.

Overlay systems can be applied equally well to pitched or

flat roofs, and since no stripping of the old roof is

required, Polyroof overlay systems offer a quick and neat

solution with competitive price / performance. They

rapidly become weather resistant and provide high levels

of UV protection.

Protec

A seamless, cold applied, flexible reinforced polyester

resin for flat or inclined roofs. Single resin application

makes Protec very cost effective, especially for

commercial projects. The system is available with 10,

15 or 20 year guarantees

Elastex

A reinforced, seamless, cold applied, highly flexible

polyurethane overlay system available with 10, 15, 20

or 25 year guarantees. Ideal for larger commercial

contracts and for weatherproofing a wide range of flat

or inclined roof surfaces.

Roofcoat Plus

A reinforced, seamless, cold applied, flexible acrylic/PU

hybrid overlay system guaranteed 10 years. Ideal for

coating pitched asbestos sheeted roofs, Plastisol and

metal sheeting.

EBS (Elastex balcony system)

A reinforced, seamless, cold applied balcony

refurbishment system. EBS is a moisture-activated ultra-

high solids polyurethane overlay that is easy to clean and

has excellent UV resistance. Aluminium oxide grits are

incorporated into the system to provide an attractive

finish, slip resistance and surface wear protection.

Roofcoat (Repair system)

A reinforced, acrylic roof repair system, easily applied by

brush with minimum surface preparation. Roofcoat is the

ideal material for localised repair or for weather proofing

most roofs regardless of the substrate.


PRODUCT SELECTOR

GRP COMPOSITETO PLYWOODDECKING

POLYURETHANEOVERLAY SYSTEM

PU/ACRYLICHYBRID OVERLAY SYSTEM

POLYESTEROVERLAY SYSTEM

Polymat

Flexi-Resin 185B

New plywood decking

Flexi-Resin 185B

Roofcoat PlusHB Smooth

Elastex treatment to laps and bolts

Roofcoat PlusFibretex

Existing primedsubstrate

Mineral finish(Optional)

Protec resin

Reinforcement

Protec resin

Existing substrate or timber

ElastexProtection Coat

ElastexEmbedment Coat

Reinforcement

ElastexEmbedment Coat

Existing substrate

POLYROOF 185

ROOFCOAT PLUSPROTEC

ELASTEX

Flexi-Resin 185C


PRODUCT SELECTOR

Polyester(GRP)

New deck /overdeck

Flat / Inclined

✔ GRP Trims ✔ ✔ ✔

P R O D U C T S E L E C T O R

RESI

N B

ASE

TYPE

PITC

H

INSU

RAN

CEBA

CKIN

G

DET

AIL

ING

OCC

ASI

ON

AL

LIG

HT

TRA

FFIC

MED

IUM

TRA

FFIC

BALC

ON

Y/W

ALK

WAY

SH

EAVY

TRA

FFIC

✔

PON

DED

ARE

AS

There are many considerations to take into account in the specification of a new roof or roof

renovation system. They can include factors such as the type and condition of the substrate;

whether or not an upgrade to a warm roof is necessary; length of required guarantee; and the level

of anticipated foot traffic.

We’ve devised this selector guide to help you choose the most appropriate Polyroof system for the

job in question. If you are in any doubt which is the most suitable, or if you would like any further

information, then please call our freephone technical helpline on 0800 801 890.

SPECIFIER HELPLINE: 0800 801 890email: [email protected] or visit: www.polyroof.co.uk

There's no substitute for personal contact, so if you can't find what you're

looking for, or if you're not sure which is the best system for the job in

hand, then don't hesitate to call, fax or email our Technical Department.

C O N T A C T U S F O R F U R T H E R I N F O R M A T I O N

Polyurethane Overlay Flat / Inclined Opt

Refurbish existing detail

or use new GRP trims

✗ ✗

Polyester(Flexible GRP) Overlay Flat /

Inclined Opt



✔ ✗ ✗

Polyurethane Overlay Flat Opt



✔ ✔ ✗

PU/Acrylichybrid Overlay Pitched Opt N/A N/A N/A N/A

✔

✔

✔

✗

✔

S Y S T E M S G U I D E

185GUARANTEE 20 YEARS

NEW BUILD /OVERDECK

OVERLAYSYSTEMS

ELASTEXGUARANTEE 10, 15, 20, 25 YEARS

PROTECGUARANTEE 10-20 YEARS(Single resin application)

EBSGUARANTEE 10 YEARS(Balconies only)

ROOFCOAT PLUSGUARANTEE 10 YEARS

† Polyroof 185 must alwaysbe laid to a new plywooddeck. Defective substratesmust be replaced.

Detailed technical information and health and safety data on each of the products

mentioned in this Selector Guide are available on request from our Technical Department.

For green roof applications please contact Polyroof Technical Department.


PRODUCT SELECTOR

ASP

HA

LT

FELT

CO

NC

RET

E

PLY

WO

OD

PITC

HED

ASB

ESTO

SC

EMEN

T SH

EETI

NG

LEA

D &

C

OPP

ER

PRO

FILE

MET

AL

SHEE

TIN

G /

PLA

STIS

OL

BR

ICK

& S

TON

E

SLA

TES

/ TI

LES

GR

P

ASB

ESTO

SG

UTT

ERS

MET

AL

GU

TTER

S

SIN

GLE

PLY

MEM

BR

AN

E *1

† Polyroof 185 must alwaysbe laid to a new plywooddeck. Defective substratesmust be replaced.

Detailed technical information and health and safety data on each of the products

mentioned in this Selector Guide are available on request from our Technical Department.

For green roof applications please contact Polyroof Technical Department.

✔ ✔ ✔ ✔ ✗ ✔ ✔ ✗ ✔ ✗ ✔ ✔† † †

✔† † † † † †

✔ ✔ ✔ ✔ ✗ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✗ ✗ ✗ ✔ ✗ ✔ ✗ ✗ ✗

✔ ✗ ✔ ✗ ✗ ✗ ✗ ✔ ✗ ✔ ✗ ✗ ✗

✗ ✗ ✗ ✗ ✔ ✗ ✔ ✔ ✔ ✗ ✗ ✗ ✗

S U B S T R A T E C O M P A T I B I L I T Y

For advice on other substrates, including woodwool slabs, strammit, chipboard etc contact 0800 801 890

185GUARANTEE 20 YEARS

NEW BUILD /OVERDECK

OVERLAYSYSTEMS

ELASTEXGUARANTEE 10, 15, 20, 25 YEARS

PROTECGUARANTEE 10-20 YEARS(Single resin application)

EBSGUARANTEE 10 YEARS(Balconies only)

ROOFCOAT PLUSGUARANTEE 10 YEARS


PRODUCT SELECTOR

A NATIONWIDE NETWORK OF COMPANY TRAINED TECHNICIANS

Polyroof guaranteed systems are only supplied to and installed by contractors fully application

trained and licensed by the company, to ensure consistent quality of installation. Contractors’

performance is regularly monitored. Failure to comply with the company’s stringent standards

leads to withdrawal of certification.

QUALITY CONTROL

Polyroof Products Ltd operates comprehensive and rigorous quality control procedures in

accordance with ISO 9001:2000. The scope of this approval includes the design and

installation of roofing systems, the provision of technical support, as well as the appointment

and monitoring of installers. Not only is the manufacture of Polyroof liquid applied roofing

systems and accessories quality approved, but so too is the procurement, storage and supply

of all related materials and consumables.

GUARANTEES

Flexible guarantees are available for most Polyroof systems, when applied by approved

contractors. Polyroof 185 carries a 20-year insurance backed guarantee supported by an

insured and independently administered Trust Fund. Different term guarantees are available

for overlay systems, the period of the guarantee being largely dependent on the soundness

of the substrate.



POLYROOF 185


FURNESS HOUSE


FL INT FL INTSHIRE

CH6 5XA

Tel : 01352 735 135

Fax: 01352 735 182


www.polyroof .co.uk


0800 801 890

E S T. 1984


Associate Member


POLYROOF 185


P R O D U C T I N F O R M A T I O N & D E S I G N G U I D E

185

POLYROOF 185


POLYROOF 185

FLEXI-RESIN 185CAn unique combination of flexibility, toughness

and weather-resistance, exclusive to Polyroof.

FLEXI-RESIN 185BAnother exclusive resin,

which is also flexible and so highly impact-resistant

that it withstands a hammer blow without penetration.

POLYMATA reinforcing glass fibre mat,

which gives the system itsstrength to withstand expansion

and contraction forces.

FLEXI-RESIN 185BApplied either side of

the matting, it penetrates down into the decking

and up to chemically bond with Flexi-Resin

185C to form a single, homogeneous membrane.

DECKING18mm Polyroof approved

plywood such as Finnforest Spruce l l / l l l

A D V A N C E D S E A M L E S S R O O F I N G S Y S T E M S

■ COLD APPLIED ■ 20 YEAR GUARANTEE ■ SEAMLESS ■ MAINTENANCE-FREE ■ 30 YEAR DURABILITY ■ SUITABLE FOR FREQUENT FOOT TRAFFIC

F O R S P E C I F I C AT I O N A D V I C E

C A L L T H E T E C H N I C A L H E L P L I N E O N

0 8 0 0 8 0 1 8 9 0185

NOT THE SYSTEM YOU’RE LOOKING FOR?

Polyroof 185 is part ofour range of liquidapplied roofing systems.

If you’re not sure which isthe best system to use, referto our Product Selector or phone 0800 801 890.

RELATED BROCHURESPROTEC (Overlay)ELASTEX (Overlay)EBS (Balconies)ROOFCOAT PLUS (Overlay)ROOFCOAT (Repairs)PRODUCT SELECTOR

C O N T E N T S

POLYROOF 185

PRODUCT DATA

DESIGN CONSIDERATIONS

WARM ROOF DESIGNS

TYPICAL NBS WARM ROOF SPECIFICATION

COLD ROOF DESIGNS

TYPICAL NBS COLD ROOF SPECIFICATION

PRE-FORMED COMPONENTS

DESIGN DETAILING


POLYROOF 185


Polyroof 185 is the UK’s market leading in-situ fibreglass

roofing system. Some ten million square metres have

been laid in domestic, commercial and industrial

applications since the product was first launched back in

1984. It is widely acknowledged by professional specifiers

as a quality benchmark and is specified for refurbishment

and new build by Housing Associations, Architectural

Practices and Local Authorities throughout the country.

■ Complete composite roofing solution

for flat roofs and box/valley gutters



■ 30 year durability rated by the BBA

■ 20 year insurance backed guarantee

■ Withstands regular foot traffic

■ Impact resistant & vandal resistant

■ Warm or cold roof specifications

POLYROOF 185 IS NOT A COATING BUT A COMPLETE

COMPOSITE ROOF DECK SYSTEM

Developed exclusively with Europe’s largest polyester resin

producer and technology leader, Polyroof 185 is based on

specially developed flexi-resins that fuse together with the

reinforcement to form a tough, impervious skin, which is

applied to a substrate of high-grade plywood. The roof

deck accommodates normal structural variations and

regular foot traffic, while the durability of the product

makes it ideal for walkways and balconies. Individual

contracts of over 15,000m 2 have been laid as a single

membrane, and a range of BS4800 colours are available

to blend with natural stone, brick, slate and wood.

POLYROOF 185 IS COLD APPLIED FOR SPEED

AND SAFETY

Like all Polyroof systems, Polyroof 185 is cold applied so

there is minimum disruption, without the fire and safety

risks associated with conventional roofing systems that

rely on boilers and exposed flames. Polyroof 185 achieves

external FAA rating to BS 476 Part 3, the most stringent

test for roofing membranes in the UK.

POLYROOF 185 HAS CLASS LEADING 30 YEAR

DURABILITY RATING AND A 20 YEAR INSURANCE-

BACKED GUARANTEE

Polyroof 185 has been proven to be technically superior

to other fibreglass roofing systems. This is why Polyroof

185 is durability rated by the BBA for a full 30 years.

It was also the first such system to receive BBA approval

in 1988. All Polyroof 185 installations come with a

watertight, insurance backed, 20 year guarantee and

work is carried out by a national network of fully

accredited Polyroof contractors. Polyroof Products Ltd

is a ISO 9001:2000 approved company.

P O L Y R O O F 1 8 5



0 8 0 0 8 0 1 8 9 0


POLYROOF 185


PROPERTIES IN RELATION TO FIRE

A system comprising Polyroof 185 applied to a 19mm thick

plywood substrate, when tested to BS.476 : Part 3 : 1958,

was designated EXT.F.A.A.

The designation of other specifications (e.g. on

combustible substrates) should be confirmed by:

England and Wales

Test or assessment in accordance with Document B,

Appendix A, Clause A1.

Scotland

Test to conform with Standards D2.5 and D3.6.

WEATHERTIGHTNESS

Test data confirms that the systems will adequately resist

the passage of moisture to the inside of the building and

so meet the requirements of the National Building

Regulations:

England and Wales

Approved Document C4, Section 5.1.

Scotland

Standard G3.1, Regulation 17.

Northern Ireland

Regulation C5.

The system is impervious to water when used as described,

and will give a weathertight roofing capable of accepting

minor structural movements without damage.

RESISTANCE TO WIND UPLIFT

Resistance to wind uplift is adequate to meet the effects of

wind suction likely to occur in practice.

DURABILITY

The British Board of Agrément has confirmed that a GRP

laminate constructed in accordance with the installation

guide and formed in satisfactory weather conditions,

can be expected to maintain its integrity and show no

measurable loss of physical properties for a period of 30

years. The system will have a life expectancy of at least 20

years provided there is no abnormal movement of the roof

structure and the roof is subject to the normal regular

inspections and maintenance.

STANDARDS COMPLIANCE

B.B.A Certificate No: 91/2604. Certificate held since 1988.

Fire tested to BS.476 (Part 3), designed Ext. F.A.A.

Resins manufactured to BS.3532 and BS.2872, matting to

BS.3496 and colours to BS.4800.

Tested for impact resistance and strength by Natlas

certified laboratories.

Produced to quality management ISO 9001:2000.

COLOUR RANGE

Polyroof is supplied in a range of five standard BS.4800

colours to blend with natural stone, brick, slate, wood etc.

Non-standard colours are available on request.

P R O D U C T D A T A

Dark Grey

Dark Battleship Grey

Light Battleship Grey

Lead Green

Havana Brown

For technical reasons connected with the colour printing process

these colours may not precisely match the topcoat colour.



0 8 0 0 8 0 1 8 9 0


SUITABLE SUBSTRATES

Polyroof 185 is always applied to a quality Polyroof approved

plywood such as Finnforest II/III, in accordance with BS 5268

Part 2. Roof design to which the Polyroof system is to be

applied, should be in accordance with the relevant regulations,

codes and good practice existing at the time of construction.

For a list of Polyroof approved plywood, please contact Polyroof

Technical Services.

PREPARATION

Refurbishment

Strip to a sound structure of good order to take a positive

mechanical fixing i.e. to the joist, concrete, or metal deck.

Covering existing felt and chipboard decking must be avoided.

New Build

The deck should be a solid structure to which a positive

mechanical fixing can be made.

■ Timber satisfying the relevant British Standards preservativetreatment requirements.

■ Metal decking complying with the Metal Deck AssociationDesign Code.

■ Concrete in-situ or pre-cast.

FIXINGS

Substrate should be mechanically fixed to a sound substrateusing appropriate timber, masonry or metal deck fixings. Fixingheads should be countersunk into the decking to avoidunsightly finish. Advice and pull-out tests can be arranged bythe Polyroof Technical Services Dept.

FALLS

Minimum fall recommended by the relevant British StandardCode of Practice is 1:80. However, a design fall of 1:40 is oftenadopted to provide a construction tolerance. In refurbishment,falls may be increased by the use of firrings or cut-to-fall insulation.

DRAINAGE

Advice on roof drainage is given in Code of Practice BS.6367.The majority of standard rainwater outlets can be incorporatedinto Polyroof installations and care should be taken to ensurethat they are always recessed into the plywood substrate.

PENETRATIONS

The system can be moulded tosuit penetrations such as soilpipes, stanchions or machineryfixing positions.

EXPANSION AND CONTRACTION

Polyroof 185 laid in accordance with specifications will

withstand normal building movement without the need for

special expansion joints on contracts up to 100m2. Expansion

joints may be required on warm roof designs over 100m2 and

the advice of the Polyroof Technical services should be sought.

PRE-CONTRACT APPROVAL

Specifications of roofs over 100m2 must be approved by

Technical Services prior to commencement of works.

WALKWAYS/TRAFFIC

Polyroof is available with non-slip finish with BBA approval,

Certificate No. 91/2604. Polyroof 185 Non-Slip should be

specified for traffic areas and will provide adequate protection

for normal use on verandas, terraces and walkways on flat

roofs, without further covering. The surface finish is anti-slip

but cannot possibly eliminate all risk of slipping, this is

particularly relevant in the event of ice forming on the roof

surface.

BOX AND VALLEY GUTTERS

Polyroof 185 is BBA approved for use in internal gutterapplications under Certificate No. BBA 91/2604. Box and valleygutters and special trims, in strong GRP can be either suppliedpre-formed or constructed on site.Generally pre-formedversions will offer economy on larger, new-build projects, whileon-site construction is used for refurbishment and canaccommodate “lead steps”. Compared to lead, Polyroof iseasily and economically laid, is highly damage resistant and,since it has no resale value, it is not prone to theft.

ABUTMENTS

A minimum girth of a 150mm should be achieved under anycover flashing in accordance with building regulations. Thecover flashing would typically be created using traditional lead.GRP alternatives do exist, but please note the Cover flashing isnot covered under the guarantee. The adhesion of the PolyroofSystem directly to a door or windowsill should not be relied onand a cover flashing or tray should be installed. If this is notpossible, consult Polyroof Technical Services for further advice.

REPRODUCTION LEAD AND COPPER

Polyroof 185 can be used to reproduce the appearance of leadand copper rolls or standing seams. The roll is formed using apreformed fibre glass trim. Various levels of reproductionquality exist and it is recommended that a sample is producedand agreed as the standard to which the reproduction will beproduced before the contract begins.

POLYROOF 185


F O R S P E C I F I C AT I O N A D V I C E C A L L T H E

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Warm Roofs are the preferred method for

constructing a flat roof, giving the best

thermal performance and vapour control,

whilst maximising flexibility of design by

reducing the need for natural ventilation.

In general, any high risk condensation areas

should have a Warm Roof construction.

General advice for Warm Roof constructions

can be found in BS 5250 : 2002.

Care should be taken to ensure the chosen

insulation can withstand the loads likely to be

applied to the roof, particularly in balcony

and walkway applications. We recommend

when fixing to joist or metal deck, that a

layer of plywood is incorporated prior to

fixing the insulation, to act as a spreadsheet

and avoid point loading.

Standard Calculations based on British

Standard BS.6229, exist for checking the

thermal characteristics and condensation risk

for a roof construction. It is recommended

that whenever a warm roof is specified, and

particularly over a humid environment, that

these calculations are carried out.

The majority of insulation manufacturers such

as Kingspan provide a calculation service and

our own technical department can provide

standard calculations, if supplied with full

construction and environmental details.

W A R M R O O F D E S I G N S

TIMBER DECK

CONCRETE DECK

METAL DECK

1 Polyroof pre-formed edge detail

2 Polyroof 185 membrane

3 18mm Polyroof approved plywood such as Finnforest Spruce l l / l l l

4 Kingspan Thermaroof TR26 Insulation

5 1000 Gauge visqueen vapour barrier

6 12mm shuttering grade plywood

7 Structure (Joist/Concrete/Metal Deck)

1

The examples above show typical warm roof constructions

2 3 4 5 6 7

1 2 3 4 5 6 7

1 2 3 4 5 7




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POLYROOF 185


T Y P I C A L W A R M R O O F (Based on Timber Construction)

T Y P I C A L N B S S P E C I F I C A T I O N F O R T I M B E R J O I S T S

GENERAL:

Application can only be carried out by Polyroof Products Ltd trained and

approved applicators. Consult Polyroof Products Ltd for details. Polyroof

Products can also provide a design and specification advisory service and

it is recommended that they are consulted early in the design process.

BASE (support layer for warm roof construction):

12mm Sheathing Plywood laid on timber joists and S.W. Firrings (min 1 :

80 fall), at 400mm C/S. Lay boards staggered with long edges 90º to

joists, with 3mm gaps between boards and 20mm at wall abutments.

End Joints to be centred over joists. Ensure fixings do not protrude above

surface of board. Fixings to be of a type recommended for the purpose

by the manufacturer. Minimum fixings per board 24Nr.

VAPOUR CONTROL LAYER:

1000 Gauge Visqueen, Monarflex Monofilament 250VB or similar. Lay sheets

loose, flat and without wrinkles. Seal Joints using materials and method

recommended by the sheet manufacturer. Dress sheets up all upstands,

kerbs and other penetrations around the edge of the insulation and lap over.

INSULATION:

Kingspan Thermaroof TR26FM zero ODP, approved by factory mutual

research USA, comprising a CFC/HCFC -free rigid urethane insulation core

with bonded low emissivity composite foil facings on both sides

manufactured to BS EN ISO 9002 : 1994 / IS EN 9001 : 2000 by Kingspan

Insulations Limited and shall be applied in accordance with the instructions

issued by them.

BASE (substrate for coating):

18mm Polyroof approved plywood such as Finnforest Spruce l l / l l l .

Lay boards staggered with long edges 90º to joists, with 3mm gaps

between boards and 20mm at wall abutments. End Joints to be centred

over joists. Ensure fixings do not protrude above surface of board. Fixings

to be SFS STADLER IR2-C range or similar. Minimum fixings per board 24Nr.

PREPARATION:

■ Plywood decking to be dry, sound and free from loose material

or contamination.

■ Tape joints to plywood decking with 75mm Polyroof glass fibre tape.

■ Fix in place all roof trims.

■ Consult with Polyroof Products to receive a site inspection report

and for recommendations and details.

WATERPROOF COATING:

Polyester based system with glass fibre reinforcement.

MANUFACTURER:

Polyroof Products Ltd. Furness House,

Castle Park Industrial Estate, Flint, Flintshire CH6 5XA

Tel: 01352 735 135

Fax: 01352 735 182

Email: [email protected]

Web: www.polyroof.co.uk

MEMBRANE SYSTEM REFERENCE:

Polyroof 185 System.

APPLICATION:

1 coat comprising Flexi-Resin 185B applied at a rate of 1.2 litres/m2 using a

synthetic lambswool roller, with Polymat glass fibre reinforcement. 1 coat

Flexi-Resin 185C applied at a rate of 0.6 litres/m2 using a synthetic

lambswool roller.

COLOUR:

Dark Grey / Dark Battleship Grey / Light Battleship Grey / Lead Green /

Havana Brown. Consult with Polyroof Products Ltd for the availability of

alternative colours and to obtain samples.

REINFORCEMENT:

Polymat glass fibre matting.

MINIMUM DRY FILM THICKNESS:

2mm.

SURFACE PROTECTION:

For Anti slip finish, add grit at rate of 250 g/litre to Flexi-Resin 185C topcoat

mix. Polyroof 185 is BBA Approved as a balcony / walkway surface.

ACCESSORIES :

Polyroof GRP Trims.

Note: This is a typical application. For more specific details visit our website or contact our Technical Helpline.




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POLYROOF 185


Cold Roofs are the traditional method for

constructing a flat roof. They rely on ventilation

to the roof space to reduce condensation.

The thermal performance achievable is also

restricted, based on the size of the roof

members. This type of construction is generally

adequate for low risk condensation areas only.

General advice for Cold Roof constructions

can be found in BS 5250 : 2002.

There are a number of instances where cold

roof designs are commonly used. For example

in refurbishment projects if constraints such

as existing window heights do not permit

conversion to a warm roof: or in new build

situations where adequate insulation and

ventilation can be achieved, such as a

mansard roof, insulated at ceiling level.

A minimum of 50mm ventilation space is

required between the insulation and the

underside of the roof deck. As a minimum

this should be ventilated at both ends of the

roof structure. It is recommended that advice

is sought from a specialist manufacturer to

ensure adequate ventilation is achieved to

required standards to comply with building

regulations approved document F2 and

BS 5250 : 2002.

C O L D R O O F D E S I G N S

TIMBER DECK

1 Polyroof pre-formed edge detail

2 Polyroof 185 membrane

3 18mm Polyroof approved plywood such as Finnforest Spruce l l / l l l

4 Existing joist/firrings

5 Rockwool insulation or similar

6 Plaster board ceiling or similar

Installation at flat roof abutment

Installation at flat roof edge

2 3 4 5 61




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POLYROOF 185


T Y P I C A L C O L D R O O F (Based on Timber Construction)

T Y P I C A L N B S S P E C I F I C A T I O N F O R T I M B E R J O I S T S

GENERAL:

Application can only be carried out by Polyroof Products Ltd trained and

approved applicators. Consult with Polyroof Products Ltd for details.

Consult Polyroof Products technical literature for details. Polyroof Products

can also provide a design and specification advisory service and it is

recommended that they are consulted early in the design process.

INSULATION:

Rockwool or similar insulation. Thickness dependant on material specified

and size of roof members. All insulation to comply with building

regulations Part L (England and Wales) and Part J (Scotland).

VENTILATION:

Glidevale FV250 ventilator at wall abutments and perimeter drip details to

provide continuous ventilation through joisted structure.

BASE (substrate for coating):

18mm Polyroof approved plywood such as Finnforest Spruce l l / l l l .

Lay boards staggered with long edges 90º to joists, with 3mm gaps

between boards and 20mm at wall abutments. End Joints to be centred

over joists. Ensure fixings do not protrude above surface of board. Fixings

to be Annular Ringshank Nails 75mm. Minimum fixings per board 24Nr.

PREPARATION:

■ Plywood decking to be dry, sound and free from loose material

or contamination.

■ Tape joints to plywood decking with 75mm Polyroof glass fibre tape.

■ Fix in place all roof trims.

■ Consult with Polyroof Products to receive a site

inspection report and for recommendations and details.

WATERPROOF COATING:

Polyester based system with glass fibre reinforcement.

MANUFACTURER:


Castle Park Industrial Estate, Flint,

Flintshire CH6 5XA

Tel: 01352 735135

Fax: 01352 735 182



MEMBRANE SYSTEM REFERENCE:

Polyroof 185 System.

APPLICATION:

1 coat comprising Flexi-Resin 185B applied at a rate of 1.2 litres/m2 using

a synthetic lambswool roller, with Polymat glass fibre reinforcement.

1 coat Flexi-Resin 185C applied at a rate of 0.6 litres/m2 using a synthetic

lambswool roller.

COLOUR:

Dark Grey / Dark Battleship Grey / Light Battleship Grey / Lead Green /

Havana Brown. Consult with Polyroof Products Ltd for the availability of

alternative colours and to obtain samples.

REINFORCEMENT:

Polymat glass fibre matting.


2mm.

SURFACE PROTECTION:

For anti slip finish, add grit at a rate of 250 g/litre to Flexi-Resin 185C

topcoat mix. Polyroof 185 is BBA approved as a balcony / walkway surface.

ACCESSORIES:

Polyroof GRP Trims.

Note: This is a typical application. For more specific details visit our website or contact our Technical Helpline.


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POLYROOF 185


P R E - F O R M E D C O M P O N E N T S

The polyroof range of rigid GRP trims offers a fast, reliable way of

installing finishing trims and ensuring perfect detailing.

A wide range of non standard profiles exists. Consult Polyroof with

your specific requirements.

Polyroof pre-formed GRP Trims have a nominal thickness of 2.15mm

and are supplied in 2.44m lengths. NB. Drawings are not to scale.

Thickness (mm) Dial gauge 2.15

Apparent density (kgm-3 ) ISO 1183 1360

Glass/resin ratio BS.2782: 1 : 4Part 10 : 1002

Barcol hardness BS.2782: 9 - 18Part 10 : 1001

Cross-breaking strength (MPa) BS.2782:unaged Part 10 : 1005 135heat aged (1) (test speed

0-5mm min-1) 173UV aged (2) 138

Tensile strength (Nmm-2) BS.2782unaged Part 10 : 1003 72.8heat aged (1) (test speed

2mm min-1) 53.5UV aged (2) 53.0water soak(3) 59.5

Water vapour permeability BS.3177 0.83(gm-2d-1)

Water vapour resistance BS.3177 247(MNsg-1)

Dimensional stability (%) MOAT 27: 5.1.6longitudinal direction -0.08transverse direction -0.88

(1) Heat aged 100 days at 80ºC

(2) UV aged 1500 light hours using UQUV 313 lamps and a cycle of 4 hour light at 50ºC and 4 hours condensation at 50ºC

(3) Water soak 60 days at 60ºC

TEST UNITS METHOD MEANRESULT

S E R V I C E P E R F O R M A N C E


Resistance to water pressure MOAT 27: 5.1.4 pass(6 metre head)

Static indentation MOAT 27: 5.1.9 L 4

Dynamic impact MOAT 27: 5.1.10 I 4

Fatigue cycling MOAT 27: 5.1.8unaged passheat aged (1) pass

Tensile strength (MPa) BS.5241unaged 0.254(3)

heat aged (2) 0.202

(1) Heat aged 28 days in an oven at 80± 2ºC

(2) Heat aged 56 days in an oven at 80± 2ºC

(3) All failures within the plywood

TEST ON POLYROOF 185 Non-s l ip


Apparent density (kgm-2) ISO 1183 1541

Barcol hardness BS.2782:Part 10 : 1001 25-35

Tensile strength (Nmm-2) BS.2782unaged 66.3UV aged (1) 71.1

(1) UV aged 1000 light hours using QUV 313 lamps and a cycle of 4 hours light at 45ºC and 4 hours condensation at 40ºC

110mm

Butt strap required

Available in lengths:100mm125mm175mm

Butt strap required


UPSTAND FASCIA TRIMS

Butt strap not required

Available in lengths:150mm250mm350mm400mm


Available in 300mm lengths:

Butt strap required

Available with internal angles:126º145º155ºNB. 155º has external length of 300mm.

Alternative detail available for exposed areas.

FILLET TRIM

100mm

DRIP TRIMS

FLAT TRIMS

75mm

MANSARD TRIMS

100mm

126º

300mm

250mm

P H Y S I C A L P R O P E R T I E S


POLYROOF 185


ABUTMENT DETAIL DRIP DETAIL

FIXING STANCHIONS

1. Pre-formed trim2. Plywood deck3. Polyroof basecoat4. Polyroof topcoat5. Cover flashing

Note: It should benoted that flashingdetails are notcovered by thePolyroof guarantee.

1. Drip detail2. Plywood deck3. Polyroof basecoat4. Polyroof topcoat5. Polyroof butt strap6. Guttering

PIPE DETAILROOF-LIGHT UPSTAND

MANSARD DETAIL

D E S I G N D E T A I L I N G

BOX GUTTER DETAIL7. Tile and felt8. Polyroof laid to

plywood kickboard or flat trim (300mm) mechanically fixed

9. Fillet trim

Note: It may be possible to create the detail using special ornon-standard trim profiles. This may prove to be moreeconomic, but will depend on the size and shape of the gutter.

1. Pre-formed trim2. Plywood deck

(mechanically fixed)3. Polyroof basecoat4. Polyroof topcoat5. Right angle trim

(lip removed from trim)6. Re-inforced with extra

layer of base and mat

1

2

3

4

56

1

23

4

5

1

23

41

23

4

5

6

5

12

3

3

4

5

1. Pre-formed drip trim

2. Plywood deck3. Polyroof basecoat4. Polyroof topcoat5. Lead ‘mansard

flashing’ detail6. Timber support

battens

1. Stanchion mechanically fixed to hardwood block

2. Hardwood block3. Polyroof basecoat4. Polyroof basecoat

to completely encapsulate hardwood block creating a double seal

5. Polyroof topcoat

Note: A popular alternativeinvolves the use of a socketinto which the stanchionupstand fits. The socket canbe completely enclosedwithin the Polyroof system.

1

2

3

45

1. Pre-formed trim2. Plywood deck3. Polyroof basecoat4. Polyroof topcoat5. Roof-light upstand

Note: It is preferable touse proprietary roof lightsincorporating a GRPupstand whereverpossible. GRP upstand tobe abraded prior tolaminating direct.

1. Polymat (Re-inforced usingtwo layers)

2. Plywood deck3. Polyroof basecoat4. Polyroof topcoat5. Weathering

flange/seal

Note: A flashing detailshould be created with aweathering flange/seal.

15

2

3

6

8

99

7

4




A NATIONWIDE NETWORK OF COMPANY TRAINED TECHNICIANSPolyroof is only supplied to and installed by contractors fully application trained and licensed by the company, to ensure consistent quality of installation. Contractors’ performance is regularly monitored and random inspection of installations carried out. Failure to comply with the Company’s stringent standards leads to withdrawal of certification.

QUALITY CONTROLPolyroof Products Ltd operates comprehensive and rigorous quality control procedures in accordance with ISO 9001:2000. The scope of this approval includes the design and installation of roofing systems, the provision of technical support, as well as the appointment and monitoring of installers.Not only is the manufacture of Polyroof liquid applied roofing systems and accessories quality approved, but so too is the procurement, storage and supply of all related materials and consumables.

20 YEAR INDEPENDENTLY BACKED GUARANTEEThe Polyroof 20-year Guarantee is supported by an insured and independently administered Trust Fund. For your total security and peace of mind Polyroof Products Limited will indemnify any customer against their liability in respect of the cost of labour and materials incurred in rectifying degeneration of glass fibre roof materials supplied by the Company and installed in accordance with their instructions by an approved contractor.An Independent Trust administers the Guarantee and therefore protection will continue irrespective of the existence of Polyroof Products Limited. The Trustees have arranged an annually renewable insurance to augment this valuable protection with leading UK insurers.

POLYROOF 185

POLYROOF 185


FURNESS HOUSE


FL INT FL INTSHIRE

CH6 5XA

Tel : 01352 735 135

Fax: 01352 735 182


www.polyroof .co.uk


0800 801 890

E S T. 1984


Associate Member


POLYROOF 185

Please note that this is an outline proposal only and will be subject tofurther site investigation by Polyroof Products Ltd Technical Department

Standard Warm RoofTimber Joists

GUIDELINE SPECIFICATION

1.1 Overview

1.2 Structural Preparation

Falls and Drainage

New Construction

Plywood and Fixing Schedule

1.3 Polyroof 185 Trims

1.4 Polyroof 185 Membrane

Taping

Base Coat

Top Coat

1.5 General

Thermal Performance

Guarantee Details

Other Notes

1.6 Appendices

Appendix A Polyroof 185 Features & Benefits

Appendix B Polyroof 185 General Material Requirements

Appendix C Polyroof 185 Material Requirements

Appendix D Expansion Trim Guidelines

Appendix E Approved Plywood List


POLYROOF 185

1.1 Overview

Proposed Construction

1. Polyroof 185 membrane

2. 18mm Finnforest Spruce II/III plywood

3. 110mm Kingspan Thermaroof TR26 insulation

4. 1000 gauge visqueen vapour barrier

5. 12mm shuttering ply

6. Timber firrings to create a minimum 1 in 80 design fall

7. Timber joists at 400mm centres

8. Pre-formed Polyroof edge details

9. Tanilised timber support batten


POLYROOF 185


Falls & Drainage

This proposal provides for a minimum recommended 1 in 80 design fall. You

may wish to note that standing water is not detrimental to the Polyroof 185

system. Please note however that additional consideration should be given to

the falls on walkways as standing water could be hazardous to foot traffic in

icy conditions. It has been assumed that the current/proposed drainage

capacity is adequate.

New Construction

Timber firrings are to be mechanically fixed to the timber joists to create a

minimum recommended 1 in 80 design fall.

A 12mm plywood spreadsheet is to be mechanically fixed to the timber joists

and a 1000 gauge visqueen vapour barrier laid.

110mm Kingspan Thermaroof TR26 insulation and 18mm Finnforest Spruce

II/III plywood decking, are then to be mechanically fixed to the timber joists,

creating a warm deck.


POLYROOF 185

Plywood / Fixing Schedule

A 12mm Shuttering Plywood to Timber Joists

Fixing Type Annular Ringshank Nails

Min Penetration into Timber Joists 45mm

Minimum Fixings per Board 24 Nr

B 18mm Finnforest II/III Plywood to Timber Joists

Fixing Type SFS Intec IR2-C Range



Lay Boards staggered (brick pattern) with long edges 90° to joists, with 3mm

gaps between boards and 20mm at wall abutments. End joints to be centred

over joists. Boards should be fixed at each corner and at a maximum of

400mm (16”) centres with a minimum of 24 fixings per 2400mm x 1200mm

(8’ x 4’) sheet. Fixing heads must always be countersunk into the decking.

For roof areas in excess of 100m2 or for any continuous run exceeding 15lm

further advice should be sought from Polyroof Products with regards

Expansion Trim Positions. At Expansion Trim positions a 20mm allowance in

plywood board joint must be made.

Where required, provide temporary covers as required to keep plywood

deck dry.

1.3 Polyroof 185 Trims (Pre-Formed)

Pre-formed Trims

Polyroof pre-formed GRP trims are to be mechanically fixed to the plywood

deck to form edge detailing. Trims to be fitted with butt straps (where relevant).


POLYROOF 185

1.4 Polyroof 185 Membrane (In-Situ)

Taping

Plywood Boards and GRP Trim Butt Joints are to be taped with 75mm wide

Polymat and Polyroof 185B Flexi-Resin.

Base Coat

Polyroof 185B Flexi-Resin and Polymat is then to be cold applied to the roof

area.

Top Coat

Polyroof 185C Flexi-resin is then to be cold applied in desired colour to the

whole roof including faces of all trims.

1.5 General

Thermal Performance

Approximate U value achieved by construction 0.20 W/m2K.

NB: This specification is for a new ‘Warm Roof construction’.

The above U-Value is for consideration by the architect. It is the architect’s

responsibility to confirm the required U-value based on performance

requirements and current building regulations standards.

Guarantee Details

20 Year Insurance Backed Guarantee.

30 Year BBA Durability Statement.

Other Notes

Please refer to Appendices for further information and general material

requirements.


POLYROOF 185

1.6 Appendices

Appendix A - Polyroof 185 Features & Benefits

Further to discussions regarding the Polyroof specification requirements, our

recommendation to utilise the Polyroof 185 System is supported by the following:

• A twenty year guarantee supported by Lloyd's of London insurance through

an independent trust fund is provided on completion of the project.

• The Polyroof 185 and Anti-Slip systems have been fully tested and approved

by the British Board of Agrement (Cert. No BBA 91/2604). The BBA can

confirm that Polyroof 185 constructed in accordance with the installation

guide and formed in satisfactory conditions can be expected to maintain its

integrity and show no measurable loss of physical properties for a period of

30 years.

• The ability to provide a waterproof structure capable of withstanding

regular foot traffic is unique to this system and avoids the hazards

associated with foot traffic which occurs up and down valley gutters.

BBA 91/2604 C1.9.2

• To achieve a totally waterproof solution it is possible to lay Polyroof along a

flat roof into a gutter, up underneath slates or encapsulate parapet walls in

one durable, completely seamless membrane.

• Polyroof flexi-resin system will provide a high degree of flexibility to accommodate

structural expansion/contraction without the requirement of special expansion

joints. BBA 91/2604 T.3

• The Polyroof 185 System is a maintenance free solution.

• The Polyroof 185 System is available in a variety of 5 standard colours, enabling

it to blend into local environments.

• The Polyroof 185 System is cold-applied and achieves F.A.A. external fire

certification.

• All Polyroof contractors are trained and approved to a CITB registered scheme

and their performance is monitored thereafter.


POLYROOF 185

Appendix B - Polyroof 185 General Material Requirements

Insulation

Boards should be laid staggered and should comply with the specification of

the manufacturer.

Vapour Barrier

Shall be continuous and encapsulate the insulation boards at abutments,

penetrations and at exposed edges.

Support

Timber supports should be fixed at all roof edges using proprietary fixings

applicable to the construction and environmental conditions.

Fixings

Should be capable of withstanding necessary wind uplift and environmental

conditions. Fixings should finish flush with the surface of the plywood and

should not be over fixed.

Hydro - Thermal Calculations

The roofing contractor is responsible to provide Hydrothermal calculations in

respect of insulation values and condensation/dew points of the roof coverings

and deposit a copy of the calculations with the architect on completion of the

contract. Calculations are available through Polyroof Products Ltd.

Note

Care should be taken to ensure accessories such as skylights and vents are

compatible with the Polyroof 185 System and adhesion will be sufficient.

Although good adhesion can be obtained on the majority of surfaces by simply

abrading the surface a mechanical joint under a collar or lip should be created.

If detailing to accessories is not covered in the Polyroof Manual advice should

be sought in writing from the Polyroof Technical department.


POLYROOF 185

Appendix C - Polyroof 185 Material Requirements

Approved Contractors

Polyroof 185 should only be applied by contractors in possession of a current

approval certificate. Confirmation of approval can be sought by calling

Polyroof Products Ltd Technical Services on 01352 735135. A final inspection

shall be carried out by a Polyroof technician prior to a guarantee being issued.

Approved Applicators

The contractor must provide an approved applicator to supervise the Polyroof

185 work and the approved applicator must remain on the site until the works

are complete. The contractor must obtain the consent of the client before

changing the approved applicator.

Immediate Plywood Decking

Plywood decking to be Finnforest Spruce II/III grade. Permission should be

sought from Polyroof Products Ltd before any variation is made to this

specification. Boards should be laid staggered and have a 3mm expansion gap

between all joints and a 15mm gap at abutments.

Preparation

All joints in the plywood should be reinforced with a 75mm wide strip of

Polyroof glassfibre tape. Any angles or details formed without pre-formed

trims should be double taped.

Pre-formed Trims

Shall be fixed to the plywood at 150mm maximum centres using treated clout

nails. All angles shall be mitred and all jobs reinforced with butt straps where

applicable and reinforced with a 75mm Polyroof tape.

Application

The Polyroof 185 Waterproof system consists of glassfibre reinforced polyester

resin, cold applied on site by hand lay and processed to a minimum thickness

of 1.5mm giving a seamless, joint-free construction. The System should be

applied in accordance with the Polyroof Application Manual issued August

1996 and the British Board of Agrement Certificate 91/2604.


POLYROOF 185

Appendix C - Polyroof 185 Material Requirements Continued

Note, The system should not be applied if the air or surface temperature is

outside the range of 5degC - 30degC; in damp or cold conditions which could

cause surface condensation; during frost or if there is a risk of rain.

Anti-Slip Grit

If anti-slip is specified it should be mixed into the top-coat and applied in

accordance with the Polyroof Application Manual issued August 1996. It

should be noted that this surface finish is anti-slip and cannot possibly

eliminate all risk of slipping.

Collars

Collars are to be formed at all protrusions.

Hoppers/Outlets

The Polyroof system should be dressed sufficiently into all outlets of this nature.

Box/Valley gutters

Box and valley gutters should be formed whenever possible with a Finnforest

II/III plywood base. Any right angles joints should be removed using timber

fillets or preferably pre-formed Polyroof trims.

Note

It is important that the full application of base and top coat is completed

within each working day. However in certain circumstances this is not possible

due to a sudden change in weather conditions. In such cases the correct Polyroof

application procedure of vacuum drying and solvent wiping must be followed

to re-juvenate the base coat prior to application of the top coat.


POLYROOF 185

Appendix D - Expansion Trim Guidelines

GUIDELINES FOR THE FITTING OF EXPANSION TRIMS

• A 20mm gap is to be left between the plywood board joints at the position

of the expansion trim.

• Expansion trims to be overlapped, NOT butted, by a minimum of 50mm.

• All overlaps to be double taped using normal Polyroof chopped strand matting

with Poly Patch.

• The curved section of the Expansion trim (the whole flat area in the case of

flat expansion trims) should be coated using Poly Patch resin only. Under no

circumstances must normal Polyroof Topcoat be used as cosmetic hairline

cracks will appear.

• Masking tape should be used to ensure that a clean line is created between

the Polyroof 185 finish and the Poly Patch resin.

Extra Note:

All decking must be staggered in at least one direction on all contracts over

50m2.

Apply Polypatch following same procedure as that used for applying Polyroof

Base coat. Catalyst addition is per Polyroof Base resin, scale coverage 10 litres

per 6m2.

GUIDELINES FOR WHERE EXPANSION TRIM MEETS EDGE DETAILS

• The expansion trim must be taken to the very edge of the roof. At this point

the standard Polyroof trim i.e. upstand, drip, fillet, mansard trim etc should

be jointed with a 10mm gap left.

• The trim is then to be double taped using Poly Patch resin and normal

chopped strand matting. Care should be taken to avoid any untidy overlaps

between the two systems.

• Expansion trims to be chamfered appropriately against mansard and fillet

details. Should you require clarification on any of the above points please

contact the Technical Department on 0800 801 890.


POLYROOF 185

Appendix E - Approved Plywood List

Name Grade 3rd Party CPD Compliance CommentsControl

Finnforest II/III Fin ply / BBA CE Marked Strong, lightweight, rarely warps.

Spruce Structural 2+ Will have very small knot holes on

good face but acceptable for Polyroof.

Wisa II/III BBA CE Marked Strong, lightweight, rarely warps.



Southern BCX American CE Marked Good quality veneer with few

Yellow Plywood Structural 2+ knotholes. Susceptible to slight

Pine Association deflection / warping during storage.

(SYP) Currently expensive.

Canadian Select Canply CE Marked Strong, lightweight, rarely warps.

Softwood Tight Structural 2+ Will have small knotholes on good

(CSP) Faced face but acceptable for Polyroof.


POLYROOF 185


1.1 Overview


Falls and Drainage

New Construction


1.3 Polyroof 185 Trims


Taping

Base Coat

Top Coat

1.5 General

Thermal Performance

Guarantee Details

Other Notes

1.6 Appendices







Balcony Warm RoofTimber Joists


POLYROOF 185

1.1 Overview


1. Polyroof 185 (Anti-Slip) membrane

2. 18mm Finnforest Spruce II/III plywood

3. 50mm Kingspan TR26 between battens at 400mm centres

4. 75mm Kingspan TR26 between battens at 400mm centres

5. 1000 gauge visqueen vapour barrier

6. 12mm shuttering ply

7. Timber firrings to create a minimum 1 in 80 design fall

8. Timber joists at 400mm centres

9. Pre-formed Polyroof edge details


POLYROOF 185


Falls & Drainage





icy conditions. It has been assumed that the current/proposed drainage

capacity is adequate.

New Construction

Timber firrings are to be mechanically fixed to the timber joists to create a

minimum recommended 1 in 80 design fall.

A 12mm plywood spreadsheet is to be mechanically fixed to the joists and a

1000 gauge visqueen vapour barrier laid.

75mm x 50mm timber battens are then to be mechanically fixed perpendicular

to the timber joists and at 400mm centres, with 75mm Kingspan Thermaroof

TR26 insulation laid in between.

A layer of 50mm x 50mm timber battens are then to be mechanically fixed to

the first layer of timber battens and at 400mm centres, with 50mm Kingspan

Thermaroof TR26 insulation laid in between.

18mm Finnforest Spruce II/III plywood decking is then to be mechanically fixed

to the timber battens, creating a warm deck.


POLYROOF 185


A Timber Battens to Timber Joists & Timber Battens to Timber Battens

Fixing Type SFS Intec IR2-C Range

Min Penetration into Joists/Battens 35mm


B 18mm Finnforest Spruce II/III Plywood to Timber Battens


Min Penetration into Battens 45mm


Lay Boards staggered (brick pattern) with long edges 900 to joists, with 3mm









Where required, provide temporary covers as required to keep plywood deck dry.


POLYROOF 185


Pre-formed Trims


deck to form edge detailing. Trims to be fitted with butt straps (where

relevant).


Taping



Base Coat

Polyroof 185B Flexi-Resin and Polymat is then to be cold applied to the roof

area.

Top Coat

Polyroof 185C Flexi-resin (Anti-Slip Version) is then to be cold applied in

desired colour to the whole roof including faces of all trims.


POLYROOF 185

1.5 General

Thermal Performance

Approximate U value achieved by construction 0.25 W/m2K.

NB: This specification is for a new ‘Warm Roof construction’.

The above U-Value is for consideration by the architect. It is the architect’s

responsibility to confirm the required U-value based on performance requirements

and current building regulations standards.

Guarantee Details



Other Notes


requirements.


POLYROOF 185

1.6 Appendices



recommendation to utilise the Polyroof 185 System is supported by the

following:

• A twenty year guarantee supported by Lloyd's of London insurance

through an independent trust fund is provided on completion of the

project.

• The Polyroof 185 and Anti-Slip systems have been fully tested and

approved by the British Board of Agrement (Cert. No BBA 91/2604). The

BBA can confirm that Polyroof 185 constructed in accordance with the

installation guide and formed in satisfactory conditions can be expected

to maintain its integrity and show no measurable loss of physical

properties for a period of 30 years.




BBA 91/2604 C1.9.2

• To achieve a totally waterproof solution it is possible to lay Polyroof along

a flat roof into a gutter, up underneath slates or encapsulate parapet

walls in one durable, completely seamless membrane.

• Polyroof flexi-resin system will provide a high degree of flexibility to

accommodate structural expansion/contraction without the requirement

of special expansion joints. BBA 91/2604 T.3


• The Polyroof 185 System is available in a variety of 5 standard colours,

enabling it to blend into local environments.


certification.

• All Polyroof contractors are trained and approved to a CITB registered

scheme and their performance is monitored thereafter.


POLYROOF 185


Insulation


the manufacturer.

Vapour Barrier



Support



Fixings









Note








POLYROOF 185




approval certificate. Confirmation of approval can be sought by calling

Polyroof Products Ltd Technical Services on 01352 735135. A final inspection

shall be carried out by a Polyroof technician prior to a guarantee being issued.











Preparation

All joints in the plywood should be reinforced with a 75mm wide strip of Polyroof

glassfibre tape. Any angles or details formed without pre-formed trims should

be double taped.

Pre-formed Trims





POLYROOF 185


Application









Anti-Slip Grit





Collars


Hoppers/Outlets

The Polyroof system should be dressed sufficiently into all outlets of this nature.

Box/Valley gutters




Note



due to a sudden change in weather conditions. In such cases the correct

Polyroof application procedure of vacuum drying and solvent wiping must be

followed to re-juvenate the base coat prior to application of the top coat.


POLYROOF 185



• A 20mm gap is to be left between the plywood board joints at the

position of the expansion trim.


• All overlaps to be double taped using normal Polyroof chopped strand

matting with Poly Patch.

• The curved section of the Expansion trim (the whole flat area in the case

of flat expansion trims) should be coated using Poly Patch resin only.

Under no circumstances must normal Polyroof Topcoat be used as

cosmetic hairline cracks will appear.

• Masking tape should be used to ensure that a clean line is created

between the Polyroof 185 finish and the Poly Patch resin.

Extra Note:

All decking must be staggered in at least one direction on all contracts over 50m2.

Apply Polypatch following same procedure as that used for applying Polyroof

Base coat. Catalyst addition is per Polyroof Base resin, scale coverage 10 litres

per 6m2.


• The expansion trim must be taken to the very edge of the roof. At this

point the standard Polyroof trim i.e. upstand, drip, fillet, mansard trim etc

should be jointed with a 10mm gap left.


chopped strand matting. Care should be taken to avoid any untidy

overlaps between the two systems.

• Expansion trims to be chamfered appropriately against mansard and fillet

details.

Should you require clarification on any of the above points please



POLYROOF 185

















POLYROOF 185


1.1 Overview


Falls and Drainage

New Construction


1.3 Polyroof 185 Trims (Pre-formed)


Taping

Base Coat

Top Coat

1.5 General

Thermal Performance

Guarantee Details

Other Notes

1.6 Appendices







Standard Cold RoofTimber Joists


POLYROOF 185

1.1 Overview


1. Polyroof 185 membrane

2. 18mm Finnforest Spruce II/III Plywood

3. Timber joists/firrings

4. Loosely laid insulation (Rockwool or similar)

5. Plaster board ceiling (or similar)

6. Polyroof pre-formed edge detail

NB: This construction relies on a minimum 50mm

unobstructed void and an adequate cross-flow of ventilation.


POLYROOF 185


Falls & Drainage





icy conditions.

It has been assumed that the current/proposed drainage capacity is adequate.

New Construction

18mm Finnforest Spruce II/III plywood decking is to be mechanically fixed to

the timber joists.


POLYROOF 185


A 18mm Finnforest II/III Plywood to Timber Joists




Lay Boards staggered (brick pattern) with long edges 900 to joists, with 3mm









Where required, provide temporary covers as required to keep plywood

deck dry.


Pre-formed Trims


deck to form edge detailing. Trims to be fitted with butt straps (where

relevant).


POLYROOF 185


Taping



Base Coat

Polyroof 185B Flexi-Resin and Polymat is then to be cold applied to the roof area.

Top Coat

Polyroof 185C Flexi-resin is then to be cold applied in desired colour to the

whole roof including faces of all trims.

1.5 General

Thermal Performance

This construction will not alter the existing thermal performance of the roof

and any existing condensation problems will remain. Options for improving the

thermal performance of the roof are available upon request from the Technical

Department.

Guarantee Details



Other Notes


requirements.


POLYROOF 185

1.6 Appendices



recommendation to utilise the Polyroof 185 System is supported by the

following:

• A twenty year guarantee supported by Lloyd's of London insurance

through an independent trus tfund is provided on completion of the project.

• The Polyroof 185 and Anti-Slip systems have been fully tested and

approved by the British Board of Agrement (Cert. No BBA 91/2604).

The BBA can confirm that Polyroof 185 constructed in accordance with

the installation guide and formed in satisfactory conditions can be

expected to maintain its integrity and show no measurable loss of

physical properties for a period of 30 years.




BBA 91/2604 C1.9.2

• To achieve a totally waterproof solution it is possible to lay Polyroof along

a flat roof into a gutter, up underneath slates or encapsulate parapet

walls in one durable, completely seamless membrane.

• Polyroof flexi-resin system will provide a high degree of flexibility to

accommodate structural expansion/contraction without the requirement

of special expansion joints. BBA 91/2604 T.3


• The Polyroof 185 System is available in a variety of 5 standard colours,

enabling it to blend into local environments.


certification.

• All Polyroof contractors are trained and approved to a CITB registered

scheme and their performance is monitored thereafter.


POLYROOF 185


Insulation


the manufacturer.

Vapour Barrier



Support



Fixings









Note








POLYROOF 185




approval certificate.

Confirmation of approval can be sought by calling Polyroof Products Ltd

Technical Services on 01352 735135. A final inspection shall be carried out by

a Polyroof technician prior to a guarantee being issued.











Preparation

All joints in the plywood should be reinforced with a 75mm wide strip of

Polyroof glassfibre tape. Any angles or details formed without pre-formed

trims should be double taped.

Pre-formed Trims





POLYROOF 185


Application









Anti-Slip Grit





Collars


Hoppers/Outlets

The Polyroof system should be dressed sufficiently into all outlets of this

nature.

Box/Valley gutters




Note



due to a sudden change in weather conditions. In such cases the correct

Polyroof application procedure of vacuum drying and solvent wiping must be

followed to re-juvenate the base coat prior to application of the top coat.


POLYROOF 185



• A 20mm gap is to be left between the plywood board joints at the

position of the expansion trim.


• All overlaps to be double taped using normal Polyroof chopped strand

matting with Poly Patch.

• The curved section of the Expansion trim (the whole flat area in the case

of flat expansion trims) should be coated using Poly Patch resin only.

Under no circumstances must normal Polyroof Topcoat be used as

cosmetic hairline cracks will appear.

• Masking tape should be used to ensure that a clean line is created

between the Polyroof 185 finish and the Poly Patch resin.

Extra Note:

All decking must be staggered in at least one direction on all contracts over 50m2.

Apply Polypatch following same procedure as that used for applying Polyroof Base

coat. Catalyst addition is per Polyroof Base resin, scale coverage 10 litres per 6m2.


• The expansion trim must be taken to the very edge of the roof. At this

point the standard Polyroof trim i.e. upstand, drip, fillet, mansard trim etc

should be jointed with a 10mm gap left.


chopped strand matting. Care should be taken to avoid any untidy

overlaps between the two systems.

• Expansion trims to be chamfered appropriately against mansard and

fillet details.

Should you require clarification on any of the above points please



POLYROOF 185

















ELASTEX

ELASTEXA D V A N C E D L I Q U I D R O O F I N G S Y S T E M S



ELASTEX

A D V A N C E D S E A M L E S S R O O F I N G S Y S T E M S

■ COLD APPL IED ■ 10 - 25 YEAR GUARANTEES ■ SEAMLESS ■ MINIMAL D ISRUPT ION ■ COST EFFECT IVE ■ S INGLE PACK



0 8 0 0 8 0 1 8 9 0

ELASTEXPROTECTION COAT

Highly durable & flexible finishing coat.

ELASTEX EMBEDMENT COAT

Reinforcement saturated with embedment coat.

ELASTEX EMBEDMENT COAT

REINFORCEMENTReinforcing mat offers

strength plus flexibility properties.

EXISTING PREPAREDSUBSTRATE

ELASTEX


Elastex is part of ourrange of liquid appliedroofing systems.


RELATED BROCHURESPOLYROOF 185 (GRP System)PROTEC (Overlay)EBS (Balconies)ROOFCOAT PLUS (Overlay)ROOFCOAT (Repairs)PRODUCT SELECTOR

C O N T E N T S

ELASTEX

APPLICATIONS

DESIGN CONSIDERATIONS & PRODUCT DATA

OVERLAY SYSTEMS

OPTIONAL PREFORMEDCOMPONENTS

PHYSICAL PROPERTIES


DESIGN DETAILING


ELASTEX


E L A S T E X

TECHNICALLY ADVANCED OVERLAY SYSTEM

Elastex is a cost-effective single pack reinforced

polyurethane overlay system that is ideal for extending

the life of existing roofs and gutters. This tough membrane

provides a resilient long lasting barrier to water penetration

and is resistant to UV degradation. The toughness and

flexibility of the system easily accommodates normal

surface movement and it is also resistant to occasional

foot traffic.

Elastex is the ideal refurbishment system as it can be applied

virtually all year round, to practically all roof surfaces,

including built-up felt, concrete, asphalt, asbestos cement,

plastic coated metals, stone, brick and some single plys.

It is effective on complex areas such as valley gutters,

extraction units, coping stones and parapet walls. Because

there is generally no stripping of the old roof, Elastex is

ideal for projects that require a fast solution with minimum

disruption. It is cold applied and rapidly becomes weather

resistant, providing high levels of UV protection.

Suitable for both warm and cold roofs, flexible Elastex can

also withstand maintenance foot traffic, and through the

addition of bauxite grits, provide an anti-slip surface.

� For waterproofing existing roofs and gutters

� Seamless cold liquid applied membrane

� 10 - 25 year guarantees available

� Suited to larger projects

� Minimal disruption

� Quickly becomes weather resistant

� Highly flexible and resilient

ELASTEX IS COLD APPLIED FOR SPEED AND SAFETY

Like all Polyroof systems, Elastex is cold applied so there

is minimum disruption, without the fire and safety risks

associated with conventional systems that rely on boilers

and exposed flames. Full tests also show that the system

achieves FAA rating (to BS476 : Part 3).

GUARANTEES

Elastex is fully backed by a manufacturer’s guarantee.

10 - 25 year systems are available. All Work is carried out

by a network of fully accredited Polyroof Contractors.

Polyroof Products Limited is an ISO 9001:2000

approved company.

Elastex protection coat

Elastex embedment coat


ELASTEX


A P P L I C A T I O N S

FLAT & LOW PITCHED ROOF APPLICATIONS

During refurbishment, care should be taken that existing

roofs have sufficient insulation and condensation control,

in accordance with correct Buildings Regulations Standards.

Advice on warm and cold roof designs can be found in

BS5250. The main types of substrates encountered in flat

& low-pitched roof refurbishment are:

Asphalt

For typical NBS specification please refer to page 8.

Built-up Felt (Existing)

Chippings should be stripped and removed from site.

All areas to be treated should be thoroughly cleaned

and a fungicide used if fungal growth or moss is present.

Areas of badly damaged or decayed felt should be

replaced to provide a sound substrate for the system.

Loose or de-bonded felt must be made good. Any blisters

should be made good by star cutting and re-bonding to

the substrate. Allow to dry out before re-fixing.

Primer may be required*, consult Polyroof Products

Technical Department for advice 0800 801890.

Single Ply PVC Membranes

Adhesion tests may be required due to the variation of single

ply systems on the market – please contact Polyroof Products

for advice. Standard preparation will include thorough

cleaning followed by wiping with Elastex solvent.

Lead Sheeting

Thoroughly clean down all areas to be treated and remove

all patination. Apply approved Elastex primer*.

COATED ROOFS

Solar reflective

Adhesion tests may be required for these areas,

especially in the case of aluminium pigmented coatings.

Consult Polyroof Products Technical Department for

Advice 0800 801890.

Liquid applied polyurethanes and GRP

Thoroughly clean down all areas to be treated.

Wipe surfaces using Elastex solvent.

GUTTER REFURBISHMENT APPLICATIONS

Elastex is the ideal seamless membrane to line existing

box and valley gutters due to its flexibility and resilience

to standing water. The main types of gutters encountered

are as follows:

Galvanised Metal Gutters (weathered)

Clean out and remove debris and dirt from the gutters

and water outlets to be treated, ensuring free drainage.

Wipe surfaces with Elastex solvent. Mechanically abrade

surfaces and remove debris. Apply approved Elastex

primer*.

Concrete Gutters (Finlock)

Clean out and remove debris and dirt from the gutters and

water outlets to be treated, and ensure free drainage.

Remove any existing, loose or poorly adhering materials

and repair where appropriate and then treat with a

fungicidal wash to kill off any moss or fungal spores left in

the gutters. Remove all residues and apply Elastex primer*.

Asbestos Gutters 1

Thoroughly clean down all areas to be treated to remove

all mould, moss, dirt, etc. Treat cleaned Asbestos with

fungicidal wash to ensure all moss and fungal spores are

destroyed. Remove all residues and inspect asbestos for

damage or cracks. Make good or replace broken or

defective profiles as required. Inspect all fixing bolts and

make good or replace as required. Apply Elastex primer*

to bolts and main gutter areas.

1Ensure compliance with the HSE guidelines regarding any material containing asbestos.

*Consult Overlays Manual. Tel: 0800 801 890 or visit www.polyroof.co.uk

Call or email for Inverted, Warm orGreen Roof specifications


ELASTEX


The design of the roof or gutter to which the Elastex system

is to be applied should be in accordance with the relevant

building regulations codes and good practice existing at the

time of construction. Since the Elastex system is also designed

as an overlay membrane for existing constructions, care should

be taken to ensure that the existing construction is structurally

sound and is unaffected by problems such as condensation.

PREPARATION

This varies depending on the substrate type and the condition.

In general all areas need to be thoroughly cleaned to remove all

dirt and debris, mould growth, moss, etc. A fungicidal wash

may also be required. Any loose or flaking material must be

removed and any defective areas made good or replaced.

Certain metals will require abrasion or pre-treatment,

before application of the required primer, and some aluminium

leaf based coatings may require special treatment.

Adhesion tests are usually recommended for such areas.

It is strongly recommended that Polyroof Products Technical

Services are consulted at an early stage in the design process

to determine exact preparation and priming required for any

particular contract.

FALLS

Elastex is normally applied to existing substrates and therefore

no changes to falls are usually necessary. Standing water is not

detrimental to the Elastex system, but where it is seen as a

problem - particularly if the area is to be accessed - then cut to

falls insulation or timber firrings and plywood can be used to

reduce the problem. The minimum fall recommended by the

relevant British Standard code of practice is 1 in 80, although

a design fall of 1 in 40 is commonly adopted to provide

a construction tolerance.

PROTRUSIONS

The system can be moulded to suit penetrations such as soil

pipes, stanchions or machinery fixing positions.


Elastex laid in accordance with specifications, will withstand

normal building movement without the need for special

expansion joints. Existing expansion joints in structures can

be accommodated by use of a de-bonding tape.


Roof specifications require approval from Polyroof Technical

Services before the contract begins.

WALKWAYS / TRAFFIC

Elastex is available with a slip resistant finish that is suitable for

light maintenance foot traffic.

Please note that, although the surface finish is slip resistant,

it cannot possibly eliminate all risk of slipping. This is particularly

relevant in the event of ice forming on the roof surface.

If regular foot traffic is a requirement, please consult Polyroof

Products for advice on additional surface protection or details

of our specialist balcony / walkway systems (See Polyroof 185

and EBS brochures).

DRAINAGE

Advice on roof drainage is given in code of practice BS.6367.

The Elastex system is compatible with the majority of standard

rainwater outlets.


Full tests show that the system achieves EXT FAA in

accordance with (BS476 Part 3)

WEATHERTIGHTNESS

Test data confirms that the system will adequately resist the

passage of moisture to the inside of the building and so meet

the requirements of the National Building Regulations.


Elastex is a fully bonded system. Resistance to wind uplift is

adequate to meet the effects of wind suction likely to occur

in practice.

DURABILITY

The Elastex Systems have minimum durability ratings of up to

25 years depending on the system specified.


Systems and components are produced to ISO 9001:2000

quality standards.

COLOUR

Elastex is supplied in standard Dove Grey and Slate Grey.

Other colours available subject to minimum quantities.




O V E R L A Y S Y S T E M S

Overlay systems offer an alternative to the complete

replacement of existing flat roofs. The principal advantage

of this is to minimise disruption and, in the majority of

cases, keep the building fully operational during the

refurbishment.

An overlay system is usually considered when the existing

roof covering is showing early signs of breakdown.

This, for example, could be a felt roof where bubbles or

blisters are starting to appear, or a single ply or gutter

installation where seams or joints are beginning to fail.

The condition of the existing roof largely determines the

level of preparation required.

In general, most common roof coverings can be overlaid

but care should be taken to ensure that the existing

underlying substrate is sound and of reasonable quality.

We recommend that a site survey is carried out by Polyroof

Technical Services if there is any doubt about the condition

of the substrate. Existing detailing is also usually retained,

but new detailing can also be integrated into the system

if required.

It is advisable that, where possible, the whole area is

overlaid rather than carrying out localised repairs. This

ensures that the system is completely seamless throughout

and offers a fully guaranteed solution. Localised repairs

are, of course, possible if a short-term solution is required.

Overlay systems should not be considered a ‘cure-all’ for

a badly designed roof. Care should always be taken to

ensure that any underlying problems are first addressed -

such as condensation or inadequate insulation (poor U-

Values) – before work begins. Advice on upgrading to a

warm roof design can be obtained from Polyroof Technical

Services.

1 2 3 4

TYPICAL BUILD-UP

61 542 3

INSULATED DECK

1 Existing substrate made goodto form VCL or new metal lined felt VCL

2 Rigid urethane insulation core

3 Felt prepared and primed

4 Elastex embedment coat

5 Elastex mat reinforcement

6 Elastex protection coat

1 Existing prepared substrate





ELASTEX Contents Section Start Next Section Page �� Page


ELASTEX

The Polyroof range of rigid GRP components offer a fast reliable way of

upgrading and finishing most flat roof detailing requirements. All trims

are optional as, in many cases, the existing detailing can be retained.

A wide range of non standard profiles exists. Consult Polyroof with

your specific requirements.


and are supplied in 2.44Im lengths. NB. Drawings are not to scale.

Tensile Strength (BS2782 : 320A)

Unreinforced System 7N/mm2

Reinforced System 10 9N/mm2

Elongation (BS2782 : 320A)

Unreinforced System 300%

Reinforced System 10 30%

Tear Strength (BS2782 : 320A)

Unreinforced System 7N/mm

Reinforced System 10 25N/mm

Coating Adhesion (ASTM D4541)

Unprimed concrete 2N/mm2

Primed concrete 3-5N/mm2

Thermal Cycling/Low Temperature Flexibility(BS3900 : EI : 1992)

Thermally cycled film (16 hours @ -25ºC/8hrs + 80ºC. 7cycles)Tested a 0ºC. Pass 5mm dia. mandrel

Freeze/Thaw

Constant immersion, 16 hours @ +20ºC 8 hrs @ -25ºC. 5 cyclesNo significant changes in mechanical properties

Impact Resistance

ASTM G14-88 2.5 JoulesBS3900 : E3 No cracking

or detachment from substrate

Heat Ageing (56 days) @ 70ºC

No significant change in mechanical properties

Water Vapour Transmission (ASTM E96/1653)

Specific permeability 25g/m2/day

Resistance to Fire (BS476 : Part 3)

Ext. FAA FAA

Accelerated Weathering (ASTM G53 - 2000 hours)

Minor surface chalking, no blisters, no loss of adhesion

Salt Spray (ASTM B117 - 1000 hours)

Minor surface chalking, no blisters, no loss of adhesion

Water Absorption (ASTM D570)

7 days - 5% weight gain21 days - 6.5% weight gain

T E C H N I C A L D A T A

110mm

Butt strap required


Butt strap required







FILLET TRIM

100mm

DRIP TRIMS

FLAT TRIMS

75mm

300mm

P H Y S I C A L P R O P E R T I E SO P T I O N A L P R E - F O R M E DC O M P O N E N T S



ELASTEX

T Y P I C A L L I Q U I D A P P L I E D C O L D R O O F C O A T I N G S P E C I F I C A T I O N

T Y P I C A L N B S S P E C I F I C A T I O N F O R O V E R L A Y O F A S P H A L T R O O F

DRAWING REFERENCE(S):

N/A

BASE (SUBSTRATE FOR COATING):

Asphalt Flat Roof.

PREPARATION:

It is advised that the Polyroof contractor consults Polyroof Technical

Department (0800) 801890 for advice on detailing and preparation prior

to commencement of contract.

IMPORTANT - if any areas of aluminium solar reflective paint or

unidentified coatings are present, adhesion tests may be required.

Make good existing Asphalt

Any blistered or slumped areas of asphalt should be inspected and made

good as required. Should removal be required, replace with a suitable

repair compound. Allow repairs to cure prior to the system application.

Where required, use biocidal wash.

Remove debris and make good existing coverings, apply a biocidal solution

recommended by coating manufacturer to all areas previously subject to

organic growth. Allow to dry.

Powerwash roof areas.

To provide a contamination free surface for system application, clean all

areas using a water jet and allow to dry.

WATERPROOF COATING:

Seamless Liquid Applied Polyurethane.

MANUFACTURER:



Flintshire CH6 5XA

Tel: 01352 735135

Fax: 01352 735 182



PRIMER REFERENCE:

Polyroof Binder / Sealer.

COATING SYSTEM REFERENCE:

Polyroof Elastex System.

APPLICATION:

Laid by Polyroof Approved Contractor in accordance with Polyroof Products

Ltd Instructions.

Coverage Rates below are indicative and will depend on porosity / surface

roughness. Contractors should visit site to ascertain coverage rates –

consult Polyroof Products Technical Services for advice (0800) 801890.

10 Year System: Embedment Coat 1m2/litre

Protection Coat 2m2/litre

Embedment Coat to be fully reinforced using Elastex Mat.


Protection Coat 1.33m2/litre



Protection Coat (1st Coat) 2m2/litre

Protection Coat (2nd Coat) 2m2/litre



Protection Coat (1st Coat) 1.6m2/litre

Protection Coat (2nd Coat) 1.6m2/litre

REINFORCEMENT:

Elastex 100 gm-2 Glassfibre Mat.


10 Year System 1.1 mm 15 Year System 1.3 mm

20 Year System 1.5 mm 25 Year System 1.7 mm

SURFACE PROTECTION:

Maintenance Foot Traffic

No additional surface protection required, however a slip resistant finish

can be applied (consult Polyroof Technical Department for advice).

Regular Foot Traffic

Consult Polyroof Technical Department for details on protection or

alternative Polyroof systems.

ACCESSORIES:

Polyroof Pre-formed GRP Trims (if required).

Call or email for Inverted, Warm orGreen Roof specifications


ELASTEX



PIPE DETAILALUMINIUM TRIM DETAILING

RAINWATER OUTLET1. Existing substrate2. Elastex embedment

coat and glass reinforcement

3. Elastex protection coat

4. Rainwater outlet

Note: The Elastex systemshould be dressed into theoutlet as far practicable.

1. Existing substrate2. Elastex embedment



4. Aluminium trim5. Glass reinforced

Note: Aluminium trims tobe wiped with Elastexsolvent abraded andmetallic primed.

NB: System to be doubletaped at trim joints.

ROOF-LIGHT UPSTAND

1

1

2

2

3

3

4

4




4. Roof-light upstand

Note: It is preferable touse proprietary roof lightsincorporating a GRPupstand wherever possible.GRP upstand to beabraded prior tolaminating direct.




4. Weathering flange/seal

4

4

5

3

3

2

2

1

1

METAL GUTTER1. De-bonding tape2. Elastex Fibretex3. Elastex embedment



5. Metal Gutter

Note: Metal gutter to bewiped with Elastex solventand metallic primed. NB: Some metals willrequire abrading*

*Do not abrade galvanised metals.

5

1

23

4

WELTED DRIP1. Existing substrate2. Elastex embedment



4. Welted drip

Note: Existing felt andwelted drip to be cleanedand made good as required.

1

2

4

3




A NATIONWIDE NETWORK OF COMPANY TRAINED TECHNICIANSPolyroof is only supplied to and installed by contractors fully application trained and licensed by the company, to ensure consistent quality of installation. Contractors’ performance is regularly monitored and random inspection of installations carried out. Failure to comply with the Company’s stringent standards leads to withdrawal of certification.

QUALITY CONTROLPolyroof Products Ltd operates comprehensive and rigorous quality control procedures in accordance with ISO 9001:2000

The scope of this approval includes the design and installation of roofing systems, the provision of technical support, as well as the appointment and monitoring of installers.

Not only is the manufacture of Polyroof liquid applied roofing systems and accessories quality approved, but so too is the procurement, storage and supply of all related materials and consumables.

GUARANTEESManufacturers guarantees are available for 10 - 25 years subject to specification. Insurance backing available, please call 0800 801 890 for details.

ELASTEX


FURNESS HOUSE


FL INT FL INTSHIRE

CH6 5XA

Tel : 01352 735 135

Fax: 01352 735 182


www.polyroof .co.uk


0800 801 890

E S T. 1984


Associate Member


ELASTEX


1.1 Overview

1.2 Preparation

Surface Preparation

Priming

1.3 Main Elastex System

Local Reinforcement

Embedment Coat

Protection Coat

Anti-Slip Finish

1.4 General

Other Notes

Coverage Rate Guidelines

Thermal Performance

Falls

Guarantee Details

1.5 Appendices

Appendix A General Guidance Notes

Appendix B General Inspection & Preparation Notes

Contents Section Start Next Section Page Page

Asphalt


ELASTEX

1.1 Overview

Existing Construction (Assumed)

1. Asphalt

2. Existing Substrate

Note: Any unidentified coatings are subject to adhesion tests.


1 2 3 4

TYPICAL BUILD-UP






ELASTEX

1.2 Preparation

Surface Preparation

Special attention should be given to any solar reflective

coatings (especially aluminium pigmented). Adhesion tests

will be required to determine if full or partial removal of the

paint will be required. Please consult Polyroof Products

Technical Department on 0800 801890.

Remove chippings from roof surface, any embedded chippings should

be removed by a mechanical scabbling device or other means as

necessary. Ensure the roof is able to carry the weight of any equipment.

Thoroughly clean down all areas to be treated, removing dirt, debris,

surface lying water, mould growth and moss, etc.

Treat any areas of fungal growth or moss with Polykill “W” Anti-

Fungal Wash to ensure all spores are destroyed. Powerwash to

remove any residues.

Inspect all surfaces to assess soundness of existing substrates

including any existing coatings, repairs and any test areas. This is to

verify compatibility for the proposed coating system and to assess

the need for priming.

Any blow holes in asphalt are to be smoothed out or removed and

levelled off using a suitable repair compound, i.e. sand cement mix

with a suitable hardener. Allow repairs to cure prior to priming.

For wet or saturated insulation or decking, careful consideration

should be given to the installation of permanent roof ventilation.

Areas where the insulation or underlying substrate has collapsed or

is defective or decayed, should be cut out, repaired and reinstated to

provide a good solid base for the coating system.

NB: For general guidance and preparation information (please

refer to appendix).


ELASTEX

Priming

Apply by brush or roller one coat of MC Binder/Sealer to all prepared

surfaces at an approximate coverage rate of 6 - 10m2/litre. Rough or

highly porous surfaces will significantly reduce the coverage rate.

Visually check that all porous surfaces are adequately sealed. Touch-

in suspect areas where necessary. Allow to dry for at least 2 to 4

hours before overcoating.

Overcoat within 24 hours. After this period it may be necessary to

rub down and/or re-prime.


Local Reinforcement (Cracks/Voids, etc)

Apply de-bonding (masking) tape across all large splits/cracks. Then

locally reinforce with Elastex Mat and Elastex Embedment Coat.

Embedment Coat

Apply by brush or roller one overall coat of Elastex Embedment Coat

to the prepared surfaces at an approximate coverage rate of (see

below)** and whilst wet insert Elastex Mat Regular glass fibre

matting and thoroughly ‘wet-in’ using a short to medium pile roller.

Allow to dry before applying next coat.

Overlap adjacent reinforcement areas already laid by at least 50mm

ensuring sufficient extra embedment material is applied to these

areas. When embedding Elastex Mat into Elastex it may be necessary

to tamp the mat. Use a soft nylon brush or specialist roller ensuring

that there are no tented areas. Check for any upstanding glass fibre

strands and cut flush with surface with a sharp knife. Overcoat cut

areas. Allow to dry before applying next coat.

De-Chipped Asphalt 0.8 - 1.0m2/Litre (1.0 - 1.25Litre/m2)

Asphalt 1.0m2/Litre (1.0Litre/m2)

**Please note - rough or uneven or heavily mineralised surfaces may significantlyreduce the coverage rate - make further material allowances where necessary. All coverage rates are indicative only and it is the contractors’ responsibility toascertain their own coverage rates on site.


ELASTEX

Protection Coat (10 or 20 Year System)

10 Year System:

Apply by brush or roller one overall coat of Elastex Protection Coat at

an approximate coverage rate of 2.0m2/litre (0.5 Litres/m2). Allow to dry.

20 Year System:

Apply by brush or roller a first coat of Elastex Protection Coat at an

approximate coverage rate of 2.0m2/litre (0.5 Litres/m2). Allow to

dry.

Apply by brush or roller a second coat of Elastex Protection Coat at

an approximate coverage rate of 2.0m2/litre (0.5 Litres/m2). Allow to

dry.

Anti-Slip Finish

An extra application of protection coat will be required for an anti-

slip finish; this should be applied at a minimum rate of 4.0m2/litre

(0.25 Litres/m2).

General application of anti-slip material is broad cast onto wet

protection coat. Coverage rates may vary depending on requirements.

Consult Polyroof Products Technical Department for Advice on

0800 801890.


ELASTEX

1.4 General

Other Notes

The system should not be laid when the temperature is below 5 oC

or above 30 oC.

On completion of each coat check for pinholes and misses and rectify

appropriately.

Allow at least 7 days before replacing cables etc.


IMPORTANT: Coverage rates of all materials are indicative will vary

according to dimensions and nature of substrates. If in any doubt, it

is advised that the Contractor carries out a test patch to ascertain

coverage rates prior to commencement of the contract. Any

significant variations should be notified to the Polyroof Technical

Department immediately.

Thermal Performance

The Elastex system will not alter the thermal performance of the roof

and any existing condensation problems will remain. Options for

improving the thermal performance of the roof are available on

request.

Falls

This system will not alter the existing falls of the roof. However, you

may wish to note that standing water is not detrimental to the

Elastex System.

NB: Options for improving falls are however available on request.

Guarantee Details

10 or 20 Year Manufacturers Guarantee.


ELASTEX

1.5 Appendices

Appendix A - General Guidance Notes

Inspect roofing substrate to ensure suitability for coating.

Previously coated areas must be carefully checked to ensure integrity

and adhesion to the substrate.

Ensure by adhesion tests that the proposed coating system is fully

compatible with existing surfaces. Testing should include determining

the necessity/selection of a primer.

Check building for visible structural defects which may adversely

affect the stability of the roof.

All roof surfaces to be treated must be sound, dry and completely

free from all contaminants.

Inspect all roof fittings, i.e. trims, flashings, cappings, etc. Make

good all defective areas (renew if necessary) prior to coating.

Inspect all old remedial repairs, patches, cracks etc. Make good

where necessary. (remove unsound repairs) prior to coating.

Where air intake units of air conditioning/ventilation systems are

present, the client and coatings manufacturer should be consulted to

take any steps necessary to prevent entry of solvent vapours (where

applicable).

Inspect all upstands, vents and any other protrusions. Make good or

replace prior to coating.

Do not remove, or suspend cables, lightning conductors, wires, etc.,

without due authorisation. Lightning conductors should not be

coated under any circumstances. Other items should not be coated

unless agreed.

Before work commences ensure all health & safety data sheets are

read and understood.


ELASTEX

Appendix A - General Guidance Notes Continued

No provision has been made to alter roof falls (standing water is not

detrimental).

Coverage rates of all materials will vary according to dimensions and

nature of substrates.

On completion of all coating activity, dispose of all empty material

cans, material contaminated tools, overalls and site waste in

accordance with the relevant environmental regulations.

Completely clear site including scaffolding, etc.

All work should be carried out in a safe and tidy manner. Relevant

Health & safety/COSHH regulations should be observed at all times.

Note, The system should not be applied if the air or surface

temperature is outside the range of 5ºC - 30ºC; in damp or cold

conditions which could cause surface condensation; during frost or if

there is a risk of rain.


ELASTEX

Appendix B - General Inspection & Preparation Notes

Inspect all surfaces to assess soundness of existing substrates and

coatings, and any test areas, to verify compatibility and proposed

coating system to assess the need for priming.

Thoroughly clean down all areas to be treated, removing all loose

chippings, dirt and debris, surface lying water, mould growth, moss, etc.

Embedded chippings should be removed by a mechanical scabbling

device or other means as necessary. Ensure the roof is able to carry

the weight of any equipment.

After cleaning down, treat all areas of fungal growth or moss with

Polykill “W” Anti-Fungal Wash to ensure all spores are destroyed.

Remove all residues.

Any spalled, loose, unsound brickwork or concrete should be broken

out and repaired using a suitable repair mortar.

All screeds, concrete surfaces and repair areas to be treated should

be lightly abraded with suitable equipment (e.g. vacu-blast, diamond

disc grind etc) to remove all laitance and other contamination to

provide a clean, dry and open surface.

Special attention should be given to solar reflective (especially

aluminium pigmented) coatings. Adhesion tests may be required for

these areas.

Remove all loose, suspect and friable materials, cutting back to a

sound firm edge. Prepare all surfaces to a clean, dry and sound

condition to promote satisfactory adhesion, if necessary removing

existing coatings and test patches.




Areas of badly damaged or decayed felt should be replaced to

provide a sound substrate for the system.


ELASTEX


Continued

Loose or disbonded felt must be re-bonded to the substrate. Any

blisters should be made good by star cutting and re-bonding to the

substrate. Allow to dry out before re-fixing.

Scrape away volatile asphalt surfaces and stabilise with primer.

When preparing lead surfaces for treatment, ensure all precautions

are taken to avoid skin contact, ingestion, inhalation, environmental

contamination and unsafe disposal of debris etc.

Clean out and remove debris and dirt from the gutters and water

outlets to be treated. Ensure free drainage.

Make good or repair any defective areas of lead. Any unsound

remedial repairs should be removed prior to coating.

Scrub down all surfaces to be treated, completely remove all slats,

oxidations, dirt and debris.

Lead sheets must be wet-abraded, the residues collected and the

area subsequently washed again. The residues should be, once,

collected and disposed of appropriately.

All unsound remedial repairs should be removed and made good.

All large cracks and voids should be cleaned and made good using a

suitable repair compound.

For wet or saturated substrates careful consideration should be given

to the installation of permanent roof ventilation.

Areas where the insulation or underlying substrate has collapsed

should be cut out, repaired and reinstated to provide a good solid

base for the coating system.


ELASTEX


Continued

At all upstands, cut a chase at least 150mm above the roof surface

into which the reinforced coating should be taken. Re-point on

completion (allow a min 2 days to cure). Inspect all fixing bolts and

tighten or replace as required. Crop all protruding bolt heads.

Mechanically abrade to remove excess corrosion and remove debris.

Mechanically abrade any ferrous or other metal surfaces included in

the coating schedule and remove debris.

Advice on surface pre-treatment and priming of galvanised and other

non-ferrous substrates should be sought from the Company's

Technical Department.


ELASTEX


1.1 Overview

1.2 Preparation

Surface Preparation

Priming


Embedment Coat

Protection Coat

Anti-Slip Finish

1.4 General

Other Notes


Thermal Performance

Falls

Guarantee Details

1.5 Appendices




Felt


ELASTEX

1.1 Overview


1. Felt




1 2 3 4

TYPICAL BUILD-UP






ELASTEX

1.2 Preparation

Surface Preparation






Remove chippings from roof surface, any embedded chippings

should be removed by a mechanical scabbling device or other means

as necessary.

Ensure the roof is able to carry the weight of any equipment.












Loose or de-bonded felt must be re-bonded to the substrate. Any




ELASTEX






NB: For general guidance and preparation information (please refer

to appendix).

Priming

Apply by brush or roller one coat of MC Binder/Sealer to all prepared

surfaces at an approximate coverage rate of 6 - 10m2/litre. Rough or

highly porous surfaces will significantly reduce the coverage rate.


in suspect areas where necessary. Allow to dry for at least 2 to 4

hours before overcoating.

Overcoat within 24 hours. After this period it may be necessary to

rub down and/or re-prime.


ELASTEX


Embedment Coat


to the prepared surfaces at an approximate coverage rate of (see

below)** and whilst wet insert Elastex Mat Regular glass fibre

matting and thoroughly ‘wet-in’ using a short to medium pile roller.

Allow to dry before applying next coat.



areas.

When embedding Elastex Mat into Elastex it may be necessary to

tamp the mat. Use a soft nylon brush or specialist roller ensuring that

there are no tented areas. Check for any upstanding glass fibre



De-Chipped Felt 0.8 - 1.0m2/Litre (1.0 - 1.25Litre/m2)

Mineral Felt 0.8m2/Litre (1.25Litre/m2)

Sanded Felt 1.0m2/Litre (1.0Litre/m2)

**Please note - rough or uneven or heavily mineralised surfaces may

significantly reduce the coverage rate - make further material

allowances where necessary. All coverage rates are indicative only

and it is the contractors’ responsibility to ascertain their own

coverage rates on site.


ELASTEX


10 Year System:



20 Year System:


approximate coverage rate of 2.0m2/litre (0.5 Litres/m2). Allow to dry.

Apply by brush or roller a second coat of Elastex Protection Coat at


Anti-Slip Finish

An extra application of protection coat will be required for an anti-

slip finish; this should be applied at a minimum rate of 4.0m2/litre

(0.25 Litres/m2).

General application of anti-slip material is broad cast onto wet

protection coat. Coverage rates may vary depending on requirements.

Consult Polyroof Products Technical Department for Advice on

0800 801890.


ELASTEX

1.4 General

Other Notes

The system should not be laid when the temperature is below 5ºC or

above 30ºC.


appropriately.






coverage rates prior to commencement of the contract. Any significant

variations should be notified to the Polyroof Technical Department

immediately.

Thermal Performance

The Elastex system will not alter the thermal performance of the roof

and any existing condensation problems will remain. Options for

improving the thermal performance of the roof are available on

request.

Falls



Elastex System.


Guarantee Details



ELASTEX

1.5 Appendices






compatible with existing surfaces.

Testing should include determining the necessity/selection of a

primer.












applicable).






unless agreed.


ELASTEX





detrimental).














ELASTEX




















aluminium pigmented) coatings.

Adhesion tests may be required for these areas.









ELASTEX


Continued

















area subsequently washed again.

The residues should be, once, collected and disposed of appropriately.







ELASTEX


Continued






completion (allow a min 2 days to cure).

Inspect all fixing bolts and tighten or replace as required. Crop all

protruding bolt heads. Mechanically abrade to remove excess

corrosion and remove debris.



Advice on surface pre-treatment and priming of galvanised and

other non-ferrous substrates should be sought from the Company's



ELASTEX


1.1 Overview

1.2 Preparation

Surface Preparation

Priming


Lap Bridging

Embedment Coat


1.4 General

Other Notes


Thermal Performance

Falls

Guarantee Details

1.5 Appendices




Galvanized Steel Gutters (Weathered)


ELASTEX

1.1 Overview


1. Weathered Galvanized Steel Gutters

Note: Any unidentified or solar reflective coatings are subject to

adhesion tests. Please consult Polyroof Products Ltd Technical

Department for further advice.



METAL GUTTER1. De-bonding tape2. Elastex Fibretex3. Elastex embedment



5. Metal Gutter

Note: Metal gutter to bewiped with Elastex solventand metallic primed. NB: Some metals willrequire abrading*

*Do not abrade galvanised metals.

5

1

23

4

ELASTEX

1.2 Preparation

Surface Preparation

Important - Please note that the following is based on existing

weathered galvanised surfaces.

Thoroughly clean down all gutters and water outlets areas to be

treated. Remove any dirt and debris, oil and grease, surface lying

water, mould growth, moss, etc. Ensure free drainage.





including any existing coatings, repairs and any test areas.

Ensure the substrate to be treated is sound and free from defects.

Remove any existing loose or poorly adhering materials and repair

where appropriate. Repair, replace and reinstate any defective

fixtures and fittings (bolts, seals etc.).

All rust, loose and flaking materials are to be removed by wire brush

or other means and all debris removed.

Any areas of significant rusting which can not be removed should be

treated with a suitable proprietary rust converter. This should be

applied in accordance with the manufacturer’s recommendations.

Thoroughly degrease by wiping with clean Elastex TH99 solvent.

Allow to dry.


to appendix).


ELASTEX

Priming

Apply by brush or roller one coat of MC Metallic Primer to all

prepared surfaces at an approximate coverage rate of 8 - 12m2/litre.

Rough or porous surfaces will significantly reduce the coverage rate.

Allow to dry for at least 2 hours before overcoating. Overcoat within

24 hours. After this period it may be necessary to rub down and/or

re prime.


Lap Bridging

Once gutter has been fully prepared and primed insert a 25mm de-

bonding tape on the joint (1/3 on top sheet 2/3 on bottom sheet)

prior to the application of local reinforcement.

Apply by brush or roller a coat of Elastex Fibretex to all gutter joints

and bolts at an approximate coverage rate of 6 lm/litre.

The gutter joints are then to be fully reinforced with Elastex

Embedment Coat and 75mm wide Elastex Mat prior to the

application of the main system.


ELASTEX

Embedment Coat


to the prepared surfaces at an approximate coverage rate of 1.0 -

1.33m2/Litre (0.75 - 1.0Litre/m2)** and whilst wet insert Elastex Mat

Regular glass fibre matting and thoroughly ‘wet-in’ using a short to

medium pile roller. Allow to dry before applying next coat.



areas. When embedding Elastex Mat into Elastex it may be necessary

to tamp the mat. Use a soft nylon brush or specialist roller ensuring

that there are no tented areas. Check for any upstanding glass fibre



**Please note - rough or uneven or heavily mineralised surfaces may

significantly reduce the coverage rate - make further material

allowances where necessary. All coverage rates are indicative only

and it is the contractors’ responsibility to ascertain their own

coverage rates on site.


10 Year System:


an approximate coverage rate of 2.0m2/litre (0.5 Litres/m2). Allow to

dry.

20 Year System:



Apply by brush or roller a second coat of Elastex Protection Coat at an



ELASTEX

1.4 General

Other Notes


above 30ºC.


appropriately.






coverage rates prior to commencement of the contract. Any

significant variations should be notified to the Polyroof Technical


Thermal Performance

The Elastex system will not alter the thermal performance of the

gutter and any existing condensation problems will remain. Options for

improving the thermal performance of the gutter are available on

request.

Falls

This system will not alter the existing falls of the gutter. However, you


Elastex System.


Guarantee Details



ELASTEX

1.5 Appendices







Testing should include determining the necessity/selection of a primer.












applicable).






unless agreed.




ELASTEX



detrimental).














ELASTEX






























ELASTEX


Continued




























ELASTEX


Continued









Advice on surface pre-treatment and priming of galvanised and other

non-ferrous substrates should be sought from the Company's



PROTEC

PROTECA D V A N C E D L I Q U I D R O O F I N G S Y S T E M S



MINERAL FINISH(OPTIONAL)

To provide anti-slip surface if required.

PROTEC RESINHighly durable and

flexible resin.

PROTEC RESINHighly durable and

flexible resin.

REINFORCEMENTReinforcing mat offers

strength plus flexibility properties.

PRIMER

EXISTING SUBSTRATE OR NEW TIMBER


PROTEC


Protec is part of ourrange of liquid appliedroofing systems.


RELATED BROCHURESPOLYROOF 185 (GRP System)ELASTEX (Overlay)EBS (Balconies)ROOFCOAT PLUS (Overlay)ROOFCOAT (Repairs)PRODUCT SELECTOR

C O N T E N T S

PROTEC

APPLICATIONS

DESIGN CONSIDERATIONS & PRODUCT DATA

GENERAL GUIDELINES

OPTIONAL PREFORMEDCOMPONENTS

PHYSICAL PROPERTIES


DESIGN DETAILING

PROTEC

■ COLD APPL IED ■ 10 - 20 YEAR GUARANTEE ■ SEAMLESS ■ SINGLE SYSTEM ■ MINIMAL DISRUPTION ■ COST EFFECTIVE



0 8 0 0 8 0 1 8 9 0


PROTEC




0 8 0 0 8 0 1 8 9 0

P R O T E C

TECHNICALLY ADVANCED OVERLAY SYSTEM

Protec is a cost-effective, single coat, fast curing polyester

overlay system that is ideal for new roofs and for

extending the life of existing roofs and gutters.

This tough membrane provides a resilient long lasting

barrier to water penetration and is resistant to UV

degradation. The toughness and flexibility of the system

easily accommodates surface movement and it is also

resistant to occasional foot traffic.

Protec is the ideal refurbishment system for any size of

roof and can be applied to a variety of roof surfaces,

including built-up felt, concrete, and asphalt. The system

can also be used in conjunction with a new timber deck,

which allows the product to be used for applications such

as new build, deck replacement, or warm roof upgrades.

It is effective on complex areas such as valley gutters,

extraction units, coping stones and parapet walls. In most

cases there is generally no stripping of the old roof, therefore

Protec is ideal for projects that require a fast solution with

minimum disruption. It is cold applied and rapidly becomes

weather resistant, providing high levels of UV protection.

Suitable for both warm and cold roofs, flexible Protec can

also withstand maintenance foot traffic, and through the

addition of various aggregates, provide an anti-slip surface.

■ For waterproofing flat roofs and gutters

■ Refurbishment or new build applications

■ Suited to large or small projects


■ Quickly weather resistant

■ Seamless cold liquid applied membrane

■ Durable finish

■ Choice of colours including a slate finish

■ 10, 15 or 20 Year Guarantee

PROTEC IS COLD APPLIED FOR SPEED AND SAFETY

Like all Polyroof systems, Protec is cold applied so there is

minimum disruption, without the fire and safety risks

associated with conventional systems that rely on boilers

and exposed flames. Indicative tests also show that the

system achieves FAA rating (to BS476 : Part 3).

GUARANTEES

Protec is fully backed with a manufacturer’s guarantee of

either 10, 15 or 20 years. All work is carried out by a

network of fully accredited Polyroof contractors. Polyroof

Products Limited is an ISO 9001:2000 approved company.


PROTEC


A P P L I C A T I O N S

PROTEC

OVERLAY APPLICATIONS

During refurbishment, care should be taken that existing

roofs have sufficient insulation and condensation control,

in accordance with correct Buildings Regulations Standards.

Advice on warm and cold roof designs can be found in

BS5250. The main types of substrates encountered in flat

& low-pitched roof refurbishment are:

Asphalt

All areas to be treated should be thoroughly cleaned and

a fungicide used if fungal growth or moss is present.

Any blistered or slumped areas of asphalt should be made

good. Should removal be required, replace with a suitable

repair compound. Allow repairs to cure prior to priming*.

Built-up Felt

Chippings should be stripped and removed from site.

All areas to be treated should be thoroughly cleaned

and a fungicide used if fungal growth or moss is present.

Areas of badly damaged or decayed felt should be

replaced to provide a sound substrate for the system.

Loose or de-bonded felt must be made good. Any

blisters should be made good by star cutting and

re-bonding to the substrate. Allow to dry out before

re-fixing. Apply primer*.

Liquid applied Polyesters and GRP

Thoroughly clean down all areas to be treated. Wipe

surfaces using Acetone.

Other Surfaces

Consult Polyroof Products Technical Department for advice.

GUTTER REFURBISHMENT APPLICATIONS

Protec is the ideal seamless membrane to line existing

concrete or timber box and valley gutters due to its

flexibility and resistance to standing water.

Concrete Gutters (Finlock)

Clean out and remove debris and dirt from the gutters and

water outlets to be treated, and ensure free drainage.

Remove any existing, loose or poorly adhering materials

and repair where appropriate and then treat with a

fungicidal wash* to kill off any moss or fungal spores left

in the gutters. Remove all residues and apply Primer*.

NEW BUILD APPLICATIONS

New build applications must be carried out in accordance

with current Building Regulations Standards and may be a

Warm Roof, Cold Roof or Inverted Roof design.

Timber Deck

A new timber deck is to be provided to BS 5268-2:2002

(EN13986 Structural 2+). Typical example is 18mm

finnforest Plywood Spruce Grade II/III. Boards to be

staggered (brick pattern) with long edges 90° to joists,

with 3mm gaps between boards and 20mm at wall

abutments. End joints to be centred over joists. Roofs in

excess of 100m2 require a specification from the Polyroof

technical department. New structural deck to be

mechanically fixed to a sound structure using appropriate

corrosion resistant timber, masonry or metal fixings.

Fixing heads must always be countersunk into the decking.

Apply primer*.

Inverted Roofs. New Concrete/Screed

All smooth concrete surfaces should be lightly abraded

with suitable equipment where necessary to remove

laitence and/or remove any other impervious matter,

concrete curing membranes etc., until a dry and open

surface is attained.

For newly laid concrete/screed, following general

guidelines allowing a curing time of 28 days or 1 week per

25mm. In the case of polymer modified screed, refer to

manufacturers instructions. Apply primer*.

*Consult Overlays Manual. Tel: 0800 801 890 or visit www.polyroof.co.uk

Call or email forInverted, Warm or Green Roof specifications


PROTEC


ROOF DESIGN

The design of the roof or gutter to which the Protec system is

to be applied should be in accordance with the relevant

regulations codes and good practice existing at the time of

construction. Since the Protec system is designed primarily as

an overlay membrane for existing constructions, care should be

taken to ensure that the existing construction is structurally

sound and is unaffected by problems such as condensation.

PREPARATION

This varies depending on the substrate type and the condition.

In general all areas need to be thoroughly cleaned to remove all

dirt and debris, mould growth, moss, etc. A fungicidal wash

may also be required. Any loose or flaking material must be

removed and any defective areas made good or replaced before

primer is applied. Certain metals will require abrasion or pre-

treatment, before application of the required primer. Adhesion

tests are recommended for solar reflective coatings or other

unidentified coatings or surfaces. New decks must be timber

panel to a structural grade BS 5268-2:2002 (EN13986

Structural 2+). It is strongly recommended that Polyroof

Products Technical Services are consulted at an early stage in

the design process to determine exact preparation and priming

required for any particular project.

FALLS

When applied to existing substrates no changes to falls are

usually necessary. Standing water is not detrimental to the

Protec system, but where it is seen as a problem - particularly if

the area is to be accessed - then cut to falls insulation or timber

firrings and plywood can be used. The minimum fall

recommended by the relevant British Standard code of practice

is 1 in 80, although a design fall of 1 in 40 is commonly

adopted to provide a construction tolerance. These guidelines

also apply to new builds.

PROTRUSIONS

The system can be moulded to suit penetrations such as soil

pipes, stanchions or machinery fixing positions.


Protec laid in accordance with specifications, will withstand

normal building movement.


Roof specifications over 100m2 require approval from Polyroof

Technical Services before the contract begins.

WALKWAYS / TRAFFIC

Protec is available with a slip resistant finish that is suitable for

light maintenance foot traffic. Please note that, although the

surface finish is slip resistant, it cannot possibly eliminate all risk

of slipping. This is particularly relevant in the event of ice forming

on the roof surface. If regular foot traffic is a requirement,

please consult Polyroof Products for advice on additional surface

protection or details of our specialist balcony / walkway systems.

DRAINAGE

Advice on roof drainage is given in code of practice BS.6367.

Protec is compatible with most standard rainwater outlets.


Indicative tests show that the system achieves EXT FAA in

accordance with BS476 Part 3.

WEATHERTIGHTNESS

Test data confirms that the system will adequately resist the

passage of moisture to the inside of the building and so meet

the requirements of the National Building Regulations.


Protec is a fully bonded system. Resistance to wind uplift is

adequate to meet the effects of likely wind suction.

DURABILITY

The Protec System has a minimum durability rating of 20 years.


Systems and components are produced to ISO 9001:2000

quality standards.

COLOUR

Protec is available in three standard colours.

Non-standard colours are available on request.



Due to limitations in the colour

printing process these colours

should be taken as a guide only.

Sample plaques of the actual

colours are available on request.

Dark Grey

Mid Grey

Light Grey



0 8 0 0 8 0 1 8 9 0


PROTEC


PROTEC

G E N E R A L G U I D E L I N E S

PROTEC

OVERLAY SYSTEMS

Overlay systems offer an alternative to the complete

replacement of existing flat roofs, as they minimise

disruption and in most cases keep the building fully

operational during the refurbishment.

An overlay system is usually considered when the existing

roof covering is showing early signs of breakdown: e.g. a

felt roof where bubbles or blisters are starting to appear, or

a single ply or gutter installation where seams or joints are

beginning to fail. The condition of the existing roof largely

determines the required level of preparation.

Most common roof coverings can be overlaid but care

should be taken to ensure that the existing underlying

substrate is sound and of reasonable quality.

We recommend that a site survey is carried out by Polyroof

Technical Services if there is any doubt about the condition

of the substrate. Existing detailing is usually retained, but new

detailing can be integrated into the system if required.

It is advisable that, where possible, the whole area is

overlaid rather than carrying out localised repairs. This

ensures that the system is completely seamless throughout

and offers a fully guaranteed solution. Localised repairs

are, of course, possible if a short-term solution is required.

Overlay systems should not be considered a ‘cure-all’ for a

badly designed roof, care should always be taken to ensure

that any underlying problems are first addressed - such as

condensation or insufficient insulation (Poor U-Values) –

before work begins. Advice on upgrading to a warm roof

design can be obtained from Polyroof Technical Services.

DECK REPLACEMENT WORK / WARM ROOF UPGRADES

Where the existing roof decking is found to be in poor

condition, it will not be possible to use an overlay system.

The roof deck should be stripped and replaced with a

structural grade timber panel to BS 5268-2:2002 (EN13986

Structural 2+). Where the roof is over a dwelling or other

building that is heated, a warm roof upgrade may be required.

The new roof should be reconstructed to part L building

regulations standards and insulation provided accordingly

to meet required U-Values. Further advice regarding this

subject can be obtained from Polyroof Technical Services.

NEW BUILD

Protec may be used in new build situations for new timber

decks or concrete inverted roofs. Timber decks must be

provided to BS 5268-2:2002 (EN13986 Structural 2+).

The new roof should also meet the thermal performance

requirements of current building regulations.

Further advice and specification information regarding new

build work may be obtained from Polyroof Products

Technical Services.

1 2 3

TYPICAL BUILD-UP

1 2 3 4 5

INSULATED DECK

1 Existing substrate made goodto form VCL or new metal lined felt VCL

2 Rigid urethane insulation core

3 Felt prepared/primed

4 Mat reinforcement

5 Protec system

1 2 3 4

TIMBER PANEL SUBSTRATE

1 Timber joist 3 Mat reinforcement

2 Prepared/primed 4 Protec system

Plywood

1 Existing prepared /primed substrate 3 Protec system

2 Mat reinforcement


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0 8 0 0 8 0 1 8 9 0

The Polyroof range of rigid GRP trims offers a fast, reliable way of

installing finishing trims and ensuring perfect detailing. These trims are

optional as, in many cases, the existing detailing can be retained. A

wide range of non standard profiles exists. Consult Polyroof with your

specific requirements.


and are supplied in 2.44Im lengths. NB. Drawings are not to scale.

110mm

Butt strap required


Butt strap required







FILLET TRIM

100mm

DRIP TRIMS

FLAT TRIMS

75mm

300mm

P H Y S I C A L P R O P E R T I E SO P T I O N A L P R E - F O R M E DC O M P O N E N T S

C O M P O S I T E

TEST UNITS METHODMEANRESULT

Thickness 1.5mm

Tensile strength 58 (MPa) (Nmm-2) (ISO 3268)

Elongation 1.7% (ISO 3268)

LOI 24.1% 02 (ISO 4589)

Hardness 67 (Shore A)

L I Q U I D R E S I N


Specific Gravity 1.32 (ISO 2811)

Viscosity 200 mPa.s (ISO 3219)

Thixotropic Index 4.2 (ISO 9219)

Gel Time (25ºc) 13.5 mins (BS 2782.835c)

P R O T E C T E S T D A T A

STANDARDMETHODTEST

C A S T R E S I N


Tensile strength 7.0 N/mm2 (ISO R527)

Tensile Modulus 2.1 N/mm2 (ISO R527)

Elongation 70% (ISO R527)

ANSI/UL 790PU Foam Class A

Fire Tests DensDeck Prime Class A

ASTM E108-06PU Foam Class ADensDeck Prime Class A

FM Calorimeter Test Class 1

Wind Uplift FM Test Up to Class 1-990

Foot Traffic FM TestPU Foam (91kg) Pass

Hail Damage FM TestPU Foam Pass(0.4kg from 5.4m)

Concrete Pass(0.4kg from 5.4m)

Water FM Test

Leakage 150mm head of water Pass7 days (After 1000 hrs accelerated weathering)


PROTEC


T Y P I C A L L I Q U I D S U P P L I E D C O L D R O O F C O A T I N G S P E C I F I C A T I O N

T Y P I C A L N B S S P E C I F I C A T I O N F O R O V E R L AY O F B U I LT- U P F E LT R O O F

DRAWING REFERENCE(S):

N/A

BASE (SUBSTRATE FOR COATING):

Built up Felt.

PREPARATION:

It is advised that the Polyroof contractor consults Polyroof Technical

Department (0800) 801890 for advice on detailing and preparation prior

to commencement of contract.

IMPORTANT - if any areas of aluminium solar reflective paint or

unidentified coatings are present, adhesion tests may be required.

Make good existing felt.

Star cut blisters, dry out and re-bond. Cut back to base badly cracked and

defective areas of felt where instructed. Dry out base and patch level with

existing surface with layers of matching felt lapped not less than 100 mm

onto existing felt.

Where required, use biocidal wash.

After cleaning down and making good existing coverings, apply a biocidal

solution recommended by coating manufacturer to all areas previously

subject to organic growth. Allow to dry.

Powerwash roof areas.

To provide a contamination free surface for coating application, clean all

areas using a water jet and allow to dry.

WATERPROOF COATING:

Liquid Applied Polyester Overlay System.

MANUFACTURER:



Flintshire CH6 5XA

Tel: 01352 735135

Fax: 01352 735 182



PRIMER REFERENCE:

Polyroof Uni-Primer.

COATING SYSTEM REFERENCE:

Polyroof Protec System.

APPLICATION:

Laid by Polyroof Approved Contractor in accordance with Polyroof Products

Ltd Instructions.

Coverage Rates below are indicative and will depend on porosity / surface

roughness. Contractors should visit site to ascertain coverage rates –

consult Polyroof Products Technical Services for advice (0800) 801890.

Protec Resin: 1.8 - 2.0 litres/m2 (0.55 - 0.63m2/litre)

Protec System must be fully reinforced using Protec Mat reinforcement.

REINFORCEMENT:

Protec Mat Reinforcement.


> 1.5mm

SURFACE PROTECTION:

Maintenance Foot Traffic

No additional surface protection required, however a slip resistant finish

can be applied (consult Polyroof Technical Department for advice).

Regular Foot Traffic

Consult Polyroof Technical Department for details on protection or

alternative Polyroof systems.

ACCESSORIES:

Polyroof Pre-formed GRP Trims (if required).

F O R S P E C I F I C AT I O N A D V I C E C A L L T H E T E C H N I C A L H E L P L I N E O N 0 8 0 0 8 0 1 8 9 0

Call or email for Inverted, Warm or Green Roof specifications


PROTEC




0 8 0 0 8 0 1 8 9 0


PIPE DETAILALUMINIUM TRIM DETAILING

RAINWATER OUTLET1. Existing substrate2. Reinforcement3. Protec membrane4. Rainwater outlet

Note: The Protec systemshould be dressed intothe outlet as far practicable.

1. Existing substrate2. Reinforcement3. Protec membrane4. Aluminium trim5. Protec reinforced

at joints

Note: Aluminium trimsto be wiped with Protecsurface rejuvenaterabraded and metallicprimed. NB. System to be doubletaped at trim joints.

ROOF-LIGHT UPSTAND

1

1

2

2

3

34

5

4

1. Existing substrate2. Reinforcement3. Protec membrane4. Roof-light

Note: On new build it is preferable to useproprietary roof lightsincorporating a GRPupstand whereverpossible. GRP upstand tobe abraded prior tolaminating direct.

1. Existing substrate2. Reinforcement3. Protec membrane4. Additional

reinforcement5. Weathering

flange/seal

Note: A flashing detailshould be created with aweathering flange/seal.

4

4

5

3

3

2

2

1

1

WELTED DRIP1. Existing substrate2. Reinforcement3. Protec membrane4. Welted drip

Note: Alternatively, if drip is in poorcondition this may bereplaced with a Polyroof GRP trim.

1

2

4

3

CONCRETE FINLOCK GUTTER1. Additional

reinforcement to joints

2. Reinforcement3. Protec membrane4. Concrete Gutter

Note: Refer topreparation notes on page 4.

1

2

3

4


PROTEC

A NATIONWIDE NETWORK OF COMPANY TRAINED TECHNICIANSPolyroof is only supplied to and installed by contractors fully application trained and licensedby the company, to ensure consistent quality of installation. Contractors’ performance is regularly monitored and random inspection of installations carried out. Failure to complywith the Company’s stringent standards leads to withdrawal of certification.

QUALITY CONTROLPolyroof Products Ltd operates comprehensive and rigorous quality control procedures in accordance with ISO 9001:2000

The scope of this approval includes the design and installation of roofing systems, the provision of technical support, as well as the appointment and monitoring of installers.

Not only is the manufacture of Polyroof liquid applied roofing systems and accessories quality approved, but so too is the procurement, storage and supply of all related materials and consumables.

GUARANTEESManufacturer’s guarantees are available for 10 - 20 years, subject to specification. Insurance backing available, please call 0800 801 890 for details.




FURNESS HOUSE


FL INT FL INTSHIRE

CH6 5XA

Tel : 01352 735 135

Fax: 01352 735 182


www.polyroof .co.uk


0800 801 890

E S T. 1984


Associate Member


PROTEC


1.1 Overview

1.2 Preparation

Surface Preparation

Priming

1.3 Main Protec System

Preparation

Application

Notes

1.4 General

Other Notes


Thermal Performance

Falls

Guarantee Details

1.5 Appendices




Asphalt


PROTEC

1.1 Overview


1. Asphalt





1 2 3

TYPICAL BUILD-UP


2 Mat reinforcement

PROTEC

1.2 Preparation

Surface Preparation







should be removed by a mechanical scabbling device or other means

as necessary.

Ensure the roof is able to carry the weight of any equipment.














PROTEC







to appendix).

Priming

Apply by brush or roller one coat of catalysed Uni-Primer to all

prepared surfaces at an approximate coverage rate of 4-5m2/litre.

Rough or highly porous surfaces will significantly reduce the

coverage rate. Visually check that all porous surfaces are adequately

sealed. Touch-in suspect areas where necessary. Allow to dry for at

least 1 hour before overcoating.

Overcoat within 7 days. After this period it will be necessary to

solvent wipe with acetone prior to application of the system.

Temperature (ºC) Catalyst Addition %

3 -10 6

10 - 20 4

20 - 35 2


PROTEC


Product Preparation

Pigment should be added to the resin first. The pigment should be

mixed thoroughly. One standard pigment container is required for

each 10 litre container of Protec resin.

The required quantity of resin should be poured into a calibrated

bucket. The Catalyst can then be added to the pigmented resin. NB,

The minimum level of catalyst is 2% (2 measuring spoons per litre

of resin).


5 -10 4

10 - 15 3

15 - 20 2.5 – 3

20 - 30 2 - 2.5

.


PROTEC

Product Application

Local Reinforcement (Cracks/Voids, etc):


locally reinforce with Protec resin and Protec Mat.

First Coat Application:

Roller apply 1st coat of Protec resin directly on to the prepared

surface to a width of approximately 1 metre. Roll out the 450 gm

chop strand matting and then apply extra resin immediately to

achieve a closed pinhole free surface. (Please note that the quantity

of resin required for embedment will vary depending on the surface

roughness and will typically vary between 1.25 and 1.5 litres/m2 -

very rough or heavily mineralised surfaces may require up to 2.0

litres/m2). Allow to cure.

Second Coat Application:

Roller apply 2nd coat of Protec resin at a coverage rate of 0.5

litres/m2. Repeat process on the next width, ensuring a 50mm lap is

achieved with the previously laid area.

Notes:

• On Horizontal surfaces, the majority of the Protec resin should

be applied to the substrate prior to embedding the mat.

• On Vertical work, care should be taken to avoid slump. The

initial application of Protec resin prior to embedding the mat

should therefore be reduced. An increased quantity will

therefore be required thereafter to achieve the required

coverage (and pinhole free surface).

• All flashing details should be completed prior to the main area.

• All matting should be laid with 50mm side laps and 50mm

end laps.


PROTEC

1.4 General

Other Notes


or above 30ºC.


appropriately.



according to dimensions and nature of substrates. If in any doubt,

it is advised that the Contractor carries out a test patch to ascertain

coverage rates prior to commencement of the contract. Any significant

variations should be notified to the Polyroof Technical Department

immediately.

Thermal Performance

The Protec system will not alter the thermal performance of the

roof and any existing condensation problems will remain. Options

for improving the thermal performance of the roof are available

on request.

Falls


may wish to note that standing water is not detrimental to the Protec

System.


Guarantee Details

10 Year Manufacturers Guarantee.


PROTEC

1.5 Appendices







Testing should include determining the necessity/selection of a

primer.












applicable).






unless agreed.


PROTEC





detrimental).














PROTEC




















aluminium pigmented) coatings. Adhesion tests may be required for

these areas.









PROTEC


Continued




























PROTEC


1.1 Overview

1.2 Preparation

Surface Preparation

Priming


Preparation

Application

Notes

1.4 General

Other Notes


Thermal Performance

Falls

Guarantee Details

1.5 Appendices




Felt


PROTEC

1.1 Overview


1. Felt



Proposed Construction.


1 2 3

TYPICAL BUILD-UP


2 Mat reinforcement

PROTEC

1.2 Preparation

Surface Preparation







should be removed by a mechanical scabbling device or other means as

necessary. Ensure the roof is able to carry the weight of any equipment.












Loose or de-bonded felt must be re-bonded to the substrate. Any









to appendix).


PROTEC

Priming

Apply by brush or roller one coat of catalysed Uni-Primer to all

prepared surfaces at an approximate coverage rate of 4-5m2/litre.


coverage rate. Visually check that all porous surfaces are adequately

sealed. Touch-in suspect areas where necessary. Allow to dry for at

least 1 hour before overcoating. Overcoat within 7 days. After this

period it will be necessary to solvent wipe with acetone prior to

application of the system.


3 -10 6

10 - 20 4

20 - 35 2


PROTEC


Product Preparation





bucket. The Catalyst can then be added to the pigmented resin.

NB, The minimum level of catalyst is 2% (2 measuring spoons per

litre of resin).


5 -10 4

10 - 15 3

15 - 20 2.5 – 3

20 - 30 2 - 2.5


PROTEC

Product Application











Roller apply 2nd coat of Protec resin at a coverage rate of 0.5 litres/m2.

Repeat process on the next width, ensuring a 50mm lap is achieved

with the previously laid area.

Notes:










end laps.


PROTEC

1.4 General

Other Notes


above 30ºC.


appropriately.




it is advised that the Contractor carries out a test patch to

ascertain coverage rates prior to commencement of the contract.

Any significant variations should be notified to the Polyroof Technical


Thermal Performance




on request.

Falls



System. NB: Options for improving falls are however available on

request.

Guarantee Details



PROTEC

1.5 Appendices



















applicable).






unless agreed.




PROTEC



detrimental).














PROTEC






























PROTEC


Continued




























PROTEC


1.1 Overview

1.2 Preparation

Surface Preparation

Priming


Preparation

Application

Notes

1.4 General

Other Notes


Thermal Performance

Falls

Guarantee Details

1.5 Appendices




Concrete Deck


PROTEC

1.1 Overview


1. Concrete / Screed




1 2 3

TYPICAL BUILD-UP


2 Mat reinforcement

PROTEC

1.2 Preparation

Surface Preparation






Thoroughly clean down all areas to be treated, removing any dirt and

debris, surface lying water, mould growth, moss, etc.








All smooth concrete surfaces to be treated should be lightly abraded

with suitable equipment (e.g. vacu-blast, diamond disc grind etc)

where necessary to remove laitance and/or remove other impervious

matter, concrete curing membranes etc, until a clean, dry and open

surface is attained.

Any spalled, loose, unsound concrete or brickwork should be broken


All large non-structural cracks and voids should be cleaned out and

made good using a suitable repair compound. The client should be

consulted and advice sought as how to best deal with structural

cracks or voids.

Wet or saturated substrates should be allowed to thoroughly dry out

before any products are applied.


PROTEC

Note:

For newly laid concrete/screed, follow general guidelines allowing a

curing time of at least 28 days or one week per 25mm, or preferably

follow manufacturer’s instructions.

In the case of polymer modified material, refer to manufacturers

instructions.


to appendix).

Priming

Apply by brush or roller one coat of catalysed Uni-Primer (Wood

Concrete) to all prepared surfaces at an approximate coverage rate

of 4-5m2/litre.


coverage rate.


in suspect areas where necessary. Allow to dry for at least 1 hour

before overcoating. Overcoat within 7 days. After this period it will

be necessary to solvent wipe with acetone prior to application of

the system.


3 -10 6

10 - 20 4

20 - 35 2


PROTEC


Product Preparation





bucket.

The Catalyst can then be added to the pigmented resin. NB, The

minimum level of catalyst is 2% (2 measuring spoons per litre of resin).


5 -10 4

10 - 15 3

15 - 20 2.5 – 3

20 - 30 2 - 2.5


PROTEC

Product Application

Local Reinforcement (Cracks/Voids, etc):


locally reinforce with Protec resin and Protec Mat.











Roller apply 2nd coat of Protec resin at a coverage rate of 0.5 litres/m2.

Repeat process on the next width, ensuring a 50mm lap is achieved

with the previously laid area.

Notes:










end laps.


PROTEC

1.4 General

Other Notes


or above 30ºC.


appropriately.




it is advised that the Contractor carries out a test patch to

ascertain coverage rates prior to commencement of the contract.

Any significant variations should be notified to the Polyroof Technical


Thermal Performance




on request.

Falls



System.


Guarantee Details



PROTEC

1.5 Appendices



















applicable).






unless agreed.


PROTEC





detrimental).














PROTEC






























PROTEC


Continued




























CASE FILES

Polyroof improves the home improvement marketPolyroof Products are the country’s leading producers of liquid applied fibreglass roofing systems.

We offer tough durable, seamless roofing solutions for the domestic home improvement market:

typical applications include extensions, balconies, dormers, garage roofs and conservatories.

Polyroof 185 is applied on-site ensuring a watertight custom fit and making it the ideal solution

for bespoke conservatories. Polyroof 185 is the ideal material for lean-to and flat roofed

conservatories. The latest product developed for this market is a simulated lead roll system for

traditional flat or pitched roof profiles.

Polyroof lead roll is proving especially popular with owners of period buildings and anyone else

looking for an elegant finish which complements the character of their home, and which blends

in with roof finishes.

Polyroof also shades the conservatory, preventing overheating in the summer. It also reduces

condensation, and can incorporate insulation to reduce heat loss during the winter months.

• Attractive appearance thatcomplements roof colour

• Tough, seamless integrated finish,no joints or loose panels to worry about

• Totally waterproof and weatherproof

• Custom-installed on site by accredited contractors

• 20 year independent guarantee

• Can be designed to incorporate insulation

Benefits for conservatories:


CASE FILES

Polyroof 185 isn’t just for roof

refurbishments. Leading developers

specify it for new build and

regeneration projects in applications

such as balconies and porches,

dormers and flat roofs.

• Totally waterproof, maintenance- free fibreglass membrane

• Tough and impact resistant:ideal and approved for balconies

• Exclusive finish in a varietyof colours

• Insurance backed guaranteed to last at least 20 years without any maintenance

• Independent 30 year durability rating

• Installation by approved local contractors

• It can incorporate insulation

• No messy stones, leaves,moss or lichen

• Specified by local authorities and housing associations throughout the country

• Proven history: over 5 million square metres laid

The Benefits:

Above: Garage roof before and after reproofing

with Polyroof 185 - in just one day.

Above: Polyroof is the ideal product for balconies

and walkways.

Before After


CASE FILES

ElastexElastex is a cost effective, flexible, reinforced polyurethane refurbishment system. It provides a durable,

seamless finish to pitched and flat roofs, bonding well to most existing roof substrates including

felt, asphalt, concrete, plywood, asbestos cement, galvanised metal, lead, aluminium and GRP.

Because stripping of the old flat roof covering is not always necessary, Elastex is ideally suited to

refurbishment work in domestic, commercial and industrial applications. It is cold applied and

rapidly becomes weather resistant, providing high levels of UV protection. Suitable for both

warm and cold roof designs.

Elastex accommodates structural movements and withstands regular foot traffic without any

additional protection. Elastex is guaranteed for up to 20 years subject to the condition of the

substrate and system specifications.

Refurbishment SystemsPolyroof offer a range of overlay systems to suit the budget, the substrate or the performance

requirements of each job. Elastex, Protec, Roofcoat and Roofcoat Plus are ideal solutions for roof

refurbishments requiring rapid protection and minimum disruption.

All Polyroof refurbishment systems are cold applied for maximum safety and are designed to

adhere to almost all roof substrates with minimum preparation.

The overlay forms a strong, permanent bond with the substrate and the end result is a tough,

seamless membrane, which - subject to the condition of the substrate - can be independently

guaranteed for up to 20 years.

Elastex used to overlay mineral felt on this

complex internally pitched roof at Castle Head

field studies centre.

The rapidly deteriorating roofs of these council flats were

renovated and made fit for another 20 years thanks to a

seamless membrane of Elastex overlayed onto the existing felt.


CASE FILES

ProtecProtec is a cost-effective single coat, fast curing polyester

overlay system that is ideal for extending the life of existing

roofs and for rehabilitating gutters. This tough membrane

provides a resilient long lasting barrier to water penetration.

The elasticity of the system easily accommodates surface

movement and it is resistant to occasional foot traffic and

UV degradation. Protec is the ideal refurbishment system

for any size of roof and can be applied to a variety of roof

surfaces, including built-up felt, concrete, and asphalt.

RoofcoatRoofcoat is an acrylic resin based coating

with a built-in fibre reinforcement. It’s ideal

for localised, short term repair and for the

weather proofing of most roofs – regardless

of the substrate.

Roofcoat PlusRoofcoat Plus has been specially modified for

the over coating of coated and composite

sheeted pitched roofs. Roofcoat Plus bonds

well to all substrates including asbestos

sheet, Plastisol coated sheet, aluminium

coated sheet and galvanised steel sheet.

Protec being applied to a roof protrusion

ensuring a totally water-tight seal.

All joints and laps were first sealed

with Elastex before the protective

coating of Roofcoat Plus was applied.

Case study: Roofcoat Plus and ElastexRoofcoat Plus was used to overcoat the composite sheeted roof at

the factory of Brixworth Engineering. Cracks were appearing on the

surface and water was leaking through the joints, laps and skylights

of the shallow pitched roof. What was needed was a cost-effective

flexible coating that would seal and protect the entire roof surface

against further deterioration and water ingress.

Roofcoat Plus was chosen for this particular project because of its

exceptional adhesion to composite substrates. The skylights were

sealed with Transglaze and the box gutters were relined with

Elastex. Almost 400m2 of overlay coatings were applied by Polyroof

approved contractors, Dryseal of Northampton. The client can now

rest assured in the knowledge that the roof’s new watertight

membrane is guaranteed for 10 years.

Elastex is here used for the internal

box gutters at Brixworth Engineering.


CASE FILES

Polyroof: cold applied for lower fire risk andlower insurance costsThe UK’s roofing contractors are being hit by tremendous hikes in insurance premiums.

Contractors, including those with a faultless claims history, are facing large rises and cases have

even been reported of a tenfold increase in premiums.

One of the best ways of reducing the claims risk for potential insurers is to move away from hot

works to Polyroof cold applied liquid roofing systems. Cold applied systems substantially reduce

the risk of fire since there are no heat or flames involved in the application and, once applied,

the systems achieve an external FAA Fire Rating of BS 476 Part 3. This is the highest rating

available for roofing membranes.

The risks associated with naked flames were dramatically highlighted recently with the fire at

Center Parcs in Suffolk, attributed to hot works being carried out on a flat roof. This case in

particular made insurers, specifiers and contractors seriously re-assess the use of a high fire risk

processes that involve bitumen boilers and hot air/gas guns (typically operating at between 500º

and 800ºC): especially in public areas and other highly fire sensitive applications.

For many years Polyroof cold applied systems have been the roofing material of choice for

optimal fire safety. Examples are shown opposite and overleaf. It is also worth remembering that

not only are Polyroof cold applied systems a much safer alternative to traditional felt bitumen,

but they also give a far more durable seamless and attractive finish that is independently

guaranteed for 20 years.

The shop roof on the BP filling station forecourt (opposite) was fitted with a new roof of Polyroof

185 fibreglass roofing system. Being cold applied meant here was no need to close the busy

station during installation so no losses in petrol or retail income. It was pigmented green to

match corporate colours.

Polyroof systems are based on thermoset resins that

have been fire tested to all relevant British Standards.

Thermoset resins are inherently fire retardant and

will char rather than melt, in a fire situation.

In applications such as this chemical plant roof (above) and

filling station (left), open flames and any other potential ignition

source are forbidden. Polyroof cold applied membrane is the

ideal alternative.


CASE FILES

Because of the potential fire risk of hot works, many airport authorities now specify cold applied

systems. Most naked flame processes also require a special, work permit, which can be a lengthy

process for contractors. Polyroof 185 also gives a very tough, durable and seamless finish

resistant to foot traffic, which is another reason why it was specified for the viewing platform at

Dublin airport, (shown below).

• Cold applied so no heat and nonaked flames, torches or boilers

• Systems are available for complete reroofing projects (Polyroof 185) or as an overlay to existing substrates (Elastex,Protec or Roofcoat)

• Tough, waterproof, impact resistant and seamless finish:ideal for balconies and walkways

• Available in a variety of colours and finishes (e.g. lead roll effect)

• Insurance backed andguaranteed to last 20 years without any maintenance

• 30 year durability rated by the BBA (Polyroof 185)

• Can be designed to incorporate insulation

• Specified by local authorities,housing associations and private companies throughout the country

• Polyroof is the UK market leader in fibreglass roofing systems,with a proven history:over 10 million square metres have been laid since the company was established in the 1980s.

Benefits of Polyroof cold liquid applied roofing systems:

Left: Viewing platform at Dublin Airport.

Above: refurbishment to existing flat roof using a Polyroof

overlay system cold applied onto existing substrate.

Polyroof was chosen for the major refurbishment

of this swimming baths / leisure complex because

of its durable, low maintenance, quality finish and

improved fire safety.


CASE FILES

Lead and copper reproductionFor the look of lead and copper at a fraction of the price, Polyroof Products offer highly authentic

looking liquid-applied alternatives. A distinctive and authentic lead roll finish for new build as

well as renovation work can be achieved using Polyroof 185. Attractive, tough and maintenance-

free, the Polyroof 185 system is guaranteed for 20 years and durability rated by the BBA for 30

years. In traditional lead colour, Polyroof 185 can be used on flat or pitched roofs and all forms

of internal guttering.

• Polyroof can be up to 40% cheaper than lead

• Polyroof is a single membrane which is totally seamless

• Polyroof is very strong and withstands heavy foot traffic

• Polyroof is highly vandal resistant

• Polyroof has no scrap value so attempted theft is futile

• Polyroof is much lighter than lead so the mechanical loading on the roof structure is greatly reduced

• Polyroof is installed via a network of fully trained and approved contractors, which means there is always someone available locally with the necessary skills - which is not always the case with lead

• Polyroof is independently guaranteed for 20 years

Although it looks remarkably like lead,Polyroof offers many distinct advantages:

Left: A Victorian style conservatory is given a Polyroof lead

roll effect roof which is in character with the property.

Above: Lead roll for commercial building.

Lead roll applied to a steeply pitched roof


CASE FILES

Lead roll applicationPolyroof provide a range of prefabricated

fibreglass trims and edging strips in a variety of

profiles. Special shapes and cladding sections

etc can also be prefabricated ready for on-site

installation.

The main picture (left) shows the lead-effect

flexi-resin topcoat during application onto a 30°

pitched roof. The roof has been re-boarded

using special exterior grade BCX plywood onto

which the glassfibre reinforced Polyroof 185 has

been applied, with prefabricated lead roll effect

strips bonded in.

Over-coating LeadPolyroof Products also offer systems for the over-

coating of existing lead roofs. This is an ideal solution

where you are looking to cure the leaks and restore the

looks of an authentic lead roof.

The example on the left shows a period mansion house

on the Scottish borders where, as part of a major

refurbishment project, the roof was repaired and

renovated using some 150 sq metres of Elastex

polyurethane overlay.

Elastex forms an excellent bond with most substrates and

can be applied with the minimum of surface preparation.

The aesthetic improvement over the old surface finish is

clear to see. The structure of the house, as well as the

interior, is thus being returned to its former glory.

Simulated CopperPPolyroof 185 was used on this

award winning renovation of a

derelict Victorian bandstand in

Wrexham, North Wales. The patina

of weathered copper is achieved by

using pale green pigment in the

resin. Since the roof has no scrap

value, it is no longer targeted by

vandals and will last for many

decades to come.


CASE FILE


F L A T R O O F S O L U T I O N S F O R D E V E L O P E R S

CASE FILE


Regeneration & New Build

CASE FILES

The balconies of these executive townhouses have a warm

roof construction of Polyroof for maximum efficiency and

durability. The Polyroof finish is attractive as a surface finish

but it also provides a reliable waterproof substrate where

concrete pavers or ceramic tiled finishes are preferred.

Polyroof has been used to waterproof and protect the

balconies and roofs of this apartment complex in Weston-

Super- Mare. A floating timber deck was laid on top to

form a roof terrace. The system provides a long lasting

water resistant substrate that is ideal for green roofs.

Polyroof laid onto a timber deck forms an ideal,

hardwearing, nonslip surface for these apartment balconies.

These balconies for a development of executive homes

were constructed using the Polyroof system for a tough,

waterproof, anti-slip surface. Since Polyroof flexi-resins

chemically fuse to the substrate there are no laps to come

loose or coverings to tear.

Totally seamless, highly durable liquidroofing systems for flat roofs,

balconies and gutters

Full range of products and solutions

Cold applied for maximum site safety

20 year insurance-backed guarantees

30 year durability rated by the BBA

Ideal for balconies and heavy foot traffic

Attractive choice of colours and finishes

Tough: withstands neglect by onsite trades

Warm or Cold roof designs

Ideal for green roofs and inverted roof designs

B A L C O N I E S A N D W A L K W A Y S




CASE FILES

Left: Being an in-situ, liquid

applied system, Polyroof is ideal

for complex or difficult

configurations such as the bay in

this brownfield urban

regeneration and, right, this

turret roof on a new school

media block in Wales.

Above: The dormer windows of this urban regeneration

and the flat roofs of these newbuild apartment blocks

(above right) are constructed in Polyroof.

D O R M E R S A N D F L A T R O O F S



Right: Polyroof gives

maintenance-free

protection and an

attractive finish to the

visible internal flat roofs

of this executive

apartment complex in

Chester.

Left: Dormer windows

and mansard roof in

Polyroof used in the

regeneration of old

brewery buildings in

Oxford city centre into

upmarket apartments and

townhouses. A Polyroof

flat roof is an ideal

solution wherever ridge

height restrictions apply.

Left: Extensive use of

Polyroof for the dormers,

bays and flat roofs for

this new build

development.


CASE FILES

ABOUT POLYROOF

Polyroof Products Ltd is one of the country’s leading producers of liquid applied roofing system

solutions. Some five million square metres of Polyroof have been laid since the company was

first established in 1984. The systems are widely used on new build and regeneration projects

throughout the country. Polyroof systems are applied via a national network of fully trained and

approved contractors.

POLYROOF ADVANCED ROOFING SYSTEMS

Polyroof 185 is a complete seamless GRP systemthat does not crack or blister. All Polyroof

systems are cold applied so there is less on-site disruption and fewer safety considerations.

Specially developed flexiresins fuse together with glassfibre reinforcement, on a high-grade

plywood deck, to form an attractive, tough and impervious skin that accommodates normal

structural variations and regular foot traffic, while resisting site abuse or neglect by other trades.

Polyroof 185 is supplied with independent and fully transferable 20-year guarantees. Colour

options, lead roll finishes and special balcony systems and finishes are available.

The Polyroof range of overlay systems, including Elastex and Protec are ideal for overlaying all

structural substrates and offer a cost-effective alternative for developments requiring refurb and

renovation as well as new build. Manufacturers guarantees from 10 to 20 years are available

with optional insurance backing.

CLIENTS NATIONWIDE

Many leading house builders and developers specify Polyroof. Over 100 local authorities as well

as housing associations, banks, airports, breweries and many other industrial and commercial

organisations throughout the country, also testify to the quality and versatility of Polyroof

systems.



POLYROOF 185


FURNESS HOUSE


FL INT FL INTSHIRE

CH6 5XA

Tel : 01352 735 135

Fax: 01352 735 182


www.polyroof .co.uk


0800 801 890

E S T. 1984


Associate Member


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