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| In
those areas where the deck was replaced, the newly installed Hyload membrane
was securely tied into the field of the existing roof, resulting in an
effective long-term repair. |
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Hyload
Inc. offers products that provide effective long-term repair solutions for aged
coal-tar and asphalt-based built-up roof systems. Hyload’s products are totally
compatible with the existing roof. The membrane sheet is a thermoplastic
material with coal-tar and KEE elvaloy polymers. This formulation provides
long-term waterproofing protection with thermoplastic capacity to heat-weld the
seams for greater seam strength, durability and longevity. The membrane can be
applied in hot asphalt, cold adhesive or self-adhered. Properly installed, it
can extend the service life of the existing roof a long, long time with minimal
disruption to operations.
Hyload offers a wide variety of environmentally friendly adhesives that are
specially formulated to tie into all conventional low-slope roof materials and
systems. Hyload also offers white membranes and coatings that comply with all
reflectivity rates. In addition, Hyload can provide assistance in developing
specifications that can break the expensive repair cycle, giving you an
effective, long-term solution.
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| Leak
areas that resulted from blistering, ridging, or floating plies were
effectively repaired with a watertight tie-in to the adjacent existing roof
areas that were still performing well. |
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Opting
for Repair
An automotive plant in Indianapolis was looking for help with a
1,800,000-square-foot aggregate-surfaced coal tar built-up roof that was more
than 20 years old. For the past several years the plant had spent $500,000
annually on a traditional approach for ongoing leak repairs. The common method
used primarily involved a coal-tar saturation application. These repairs were
neither effective nor long-lasting. The owner had been told that the roof was
finished — deteriorated beyond any hope of effective repair. Although much of
the roof was still serviceable, there were several scattered problem areas. The
most significant problems on the roof involved approximately 60,000 square feet
of total roof area that had leaked to the point of deck deterioration. These sections
of roof were safety hazards and were flagged off to traffic due to the rusted
and weakened metal deck. Additionally, there were numerous blisters, ridging
and other problems that all contributed to many leaks throughout the facility.
The replacement cost was estimated to be $20 million.
Because of this large capital cost, the plant facilities management team was
open to an alternative long-term repair approach. Hyload Inc. provided a
long-term repair solution for less than 10 percent of the replacement cost.
Because the Hyload Coal Tar Elastomeric Membrane (CTEM) and adhesive products
are totally compatible with coal tar, tie-in specifications were easily
developed to address all the problem conditions.
The rusted sections of decking were totally cut out and removed. New decking,
insulation and recover board were installed, then covered with a self-adhering
Hyload membrane. The replaced area was stripped and tied into the spudded field
of the existing roof using Hyload’s adhesives and strip-in plies. In the areas
of blistering and ridging, the problem areas were spudded and covered with
Hyload membrane set into adhesives. All edges were dressed with a sealant to
create a watertight repair.
The repair solution not only provided long-term waterproofing protection, but
the ease of application. No heavy equipment was required, and the lack of fumes
allowed the contractor to work in different areas of the roof without
interrupting plant operations. The Hyload material is environmentally friendly
and is compatible with all roofing materials. The material is currently the
only product on the market that is compatible with coal-tar and is effective
for repairing coal-tar problems such as “floating plies.”
The success of this repair program has eliminated the leaking that plagued the
plant for years. It has taken a roof that presumably was finished and extended
the life for an additional 10 to 12 years of service. The same techniques can
be employed as needed to additional roof areas should problems occur in the
future. A large capital outlay was avoided and dry conditions were restored.
Management is very pleased.
