This post is actually an email conversation with a customer, regarding Tapered Insulation and our flat roof installation in Cambridge, MA done in the summer of 2010. This email conversation is posted as is with the customer’s permission – the only editing on this post was done to remove any personal information, and spelling :). I thought this would be helpful to our readers, who are interested in tapered insulation and/or have ponding water problems with their flat roofs.
Here is the original roof video, so you have a better idea about this roof:
Senior project written by Riess Stanley
Nov 4, 2010
With economic strife on the rise, it has now become necessary to seek out ways to save money, as well as to find ways to “stay green”, and to do what you can to help the environment. Unfortunately, accomplishing both at the same time seems to be very difficult. Believe it or not, there is a smart, fairly simple, and very efficient way to succeed in these two areas in a way not often looked upon as a money saver, but rather a necessary and costly project when it doesn’t need to be; the roof. When you really get down to it, the roof is either costing too much, or saving plenty.
First off, if a building with a flat or low-sloped pitch was to have a black tar roof, it would be taking more money than one would realize. In warm weather, the black roof will absorb so much heat that an abundance of energy and money would need to be invested into cooling down the building. Moreover, all that heat beating down on the roof will make it crack, which in turn will cause it to leak once the rainy weather begins. This defeats the entire purpose of a roof. So, what is a low cost alternative for a black tar roof, that can keep the roof cool during summer months and can keep out the rain? The answer; PVC (Polyvinyl Chloride) single-ply membrane. Continue reading →
We installed this flat roof near Harvard Square in Cambridge, Massachusetts in the summer of 2010. The installation consisted of four separate roof sections on different levels of this house, which at the time was undergoing major renovations inside and out, including total new insulation in walls and between roof rafters, a new heating system with radiant floor heat, new energy efficient windows, and a new IB PVC flat roof (which we installed of course).
The old rubber roof was leaking and we had to remove it, including the wet roof insulation. We installed a new 50-mil white IB Flat Roof, with 4 inches of tapered insulation (4 inches at the highest point and 1 inch at the lowest level). The tapered insulation system was utilized to eliminate ponding water on the two bigger sections of the roof. At the deepest point, there was as much as 2 inches of ponding water, and a puddle with at least 12 feet diameter. This ponding water caused both roof leaks and the roof rafters settlement.
Update – Oct 26, 2011: Exactly 2 years after the initial Sarnafil PVC Roof repair (read details below) I went back to that roof. This time, there were 17 new holes in the roof. I repaired it once again with IB PVC flat roofing material. Check out the full review of this latest PVC roof repair in Needham MA.
Update 2: a Trocal roof repair also reviewed below – a section of that roof has completely shattered over the past winter, and we had replaced it with an IB PVC Flat Roof in the spring of 2011.
Check out the video of this new PVC Roof repair:
Original PVC Roof repair article
PVC roofing is one of the longest lasting flat roof membrane systems, and most PVC roofs installed, will last in excess of 25-30 years. PVC roofing utilizes Hot-Air welding of the seams, which allows the roof to remain watertight for many years, as there is no adhesive to fail ( as is the case with EPDM rubber roofing ). Still, even PVC roofs can leak. Sometimes because of poor installation, and sometimes because of physical damage to the roofing membrane. You may have heard about the Trocal PVC roof failures, which was the only major case of PVC roof failures (below we will explain how Trocal roofs failed).
In this article we will discuss and demonstrate the PVC roof leaks and repair procedure, based on two recent repairs we have done. First, please note that even if your PVC roof leaks – you should not be too worried – PVC roofs are rather easy to repair, and you will rarely need to replace your entire roof.
As promised – a quick look into why Trocal PVC roofs failed on a massive scale, forcing the company to be sold to another large roofing materials manufacturer.
Trocal PVC roofing was one of the first commercially available PVC roofs in the US, and they worked great at first. But they had one major drawback – they were unreinforced (today, most PVC membranes are reinforced with polyester scrim sitting between the top and bottom ply of the membrane). When the ambient temperatures were below freezing, a Trocal roof could crack or shatter if you simply stepped on it. Later, all PVC manufacturers switched to reinforced membrane, and some would add special chemicals to increase the elasticity of the membrane. Today, unreinforced PVC membrane is used only for flashing accessories such as inside / outside corners, pipe flashing, etc.
Repair of a Trocal PVC Roof
This Trocal roof sustained damage from a falling tree branch in December of 2009, and cracked along the edge. Although the roof was over 20 years old, it was still fully weldable and we were able to repair it with a new IB PVC roofing membrane in Jan. 2010. We removed the damaged section of the roof, cleaned the surface with MEK solution, installed new PVC coated IB Drip Edge metal, and welded a 50-mil white IB roofing membrane. The repair was performed in a 25 degrees outside temperature, so we had to take special care not to damage the rest of the original roof. Continue reading →
Last week, Boston was a host to hordes of roofing sales people, roof manufacturers’ reps and local roofing contractors from all over Massachusetts and New England. It was the NERCA (North East Roofing Contractors Association) annual convention, where most roofing materials, tools and equipment manufacturers were present, promoting their new products and services.
After being to a few of these shows already, I have found that they don’t get any more exciting, but it’s always nice that NERCA sets up up open bars with semi-decent wine, and cheese / crackers / fresh veggies & berries tables. I think that for roof sales professionals, these roofing conventions have become a boring necessity, as all they do is schmooze with each other and talk about competition. As for me and other roofing contractors, we can always find some new and exciting roofing materials, tools, equipment and services, such as infra-red roof scanners, roof lifts, a hydraulic-powered dumpster, which can be lifted to the roof level to speed up roof tear-off and clean up process.
As a Flat Roof contractor we were there supporting IB Roofs, which had a booth there, and I got to meet IB’s new Regional Manager, Dana Spurgeon, as well as IB’s local reps in Massachusetts – Jerry Lang and Kevin Laprte (whom I already know of course).
Roofing Equipment Presented at the Show
Besides the obvious and now ritualistic visit to the IB Roofs stand, I wanted to find as many cool, interesting and innovative roofing products at this show, and quickly wondered off, to explore the unknown. My first find was an excellent new automatic hot-air welder by Leister – the new Varimat V2. Continue reading →