Document 82omKBbXbB3x4Kg41DN5kg7gB

Preface This manual contains recom mended roofing specifications and procedures based on accepted good roofing practices and Koppers years of experience. They are intended to provide the architect, engineer, general con tractor. and roofer with the proper information to plan and construct the best roof systems with the most time-proven materials available today. The availability of a Koppers surety bond or guarantee for roofing and flashing constructed according to the information contained in this manual under Koppers bond and guarantee procedure, and the publishing of these specifications and infor mation shall not be construed as creating any warranty, expressed or implied, with regard to any roofing or flashing for which a bond or guarantee has not been issued. This roofing manual supersedes ail previous roofing manuals published by Koppers in Sweets Catalogs. The specifications and details contained in this manual have been determined to cover the proper procedure for long lasting roofing systems for most areas of our country. In certain locations, minor varia tions in details and specifications may be appropriate due to unusual local conditions. $uch as wind, temperature, humidity, etc. To assure the best application of the proper specifications and details for your area we recommend you consult your Koppers representative. Copy in blue. ift-tbeJej&throuQbout this brochureHDdisafes where technical changes have been-ir . made from, the pfevie^lataiog.' ..-,r " Table of Contents 1983 3 Preface 4-5 Product Guide 6 Bonded & Guaranteed Roofing Program Specification Reference Guide BUILT-UP ROOFING SYSTEMS 7 Koppers Coal Tar Built-Up Roofing Material and System Discussion 8-12 General Requirements & Special Conditions Coal Tar Built-Up Roofing 13-14 15 Roof Specifications Coal Tar Built-Up Roofing Special Applications Water Retaining Roof 16 Flashing Specifications Built-Up Roof Applications SINGLE-PLY ROOFING SYSTEMS 21-26 KMM Membrane Roofing Systems Materials and System Discussion Terminology Application 27-29 KMM Roofing Specifications Specifications No. 610-620 Specification No. 630 Specification No. 690 30-32 KMM Flashing Specification Specification No. 710 Specifications No. 720-730 Specification No. 760 Flashing Details WATERPROOFING AND DAMPPROOFING SYSTEMS 33-36 Waterproofing and Dampproofing Systems Coal Tar Membrane Waterproofing KMM Membrane Waterproofing Specifications No. 640-650 36 Liquid and Mastic Applied Waterproofing and Dampproofing Systems Hydroshield Mastic 451 Liquid Asphalt 480 ROOF INSULATION 37-40 Exeltherm Xtra Roof Insulation REINFORCEMENT FABRICS 41-43 Specification and-Technical Data ROOF MAINTENANCE PRODUCTS AND SYSTEMS T. ^ :' 44-47 RgtJfjMainteiwnca Pfoducti-and Systems RoofResiturants * - ,T Heavy:Qji*ty Roof Shield System ~ Koppers-Alummum Roof Coatings Notice:^ This roofing spaeificatforrjinanuaf as a guide for donsideration to contains the !afett^rJ- ,jr -assist the architect, owner and available information as'detnwj : .... roofer in an attempt to provide the from Koppers long Ixperjencfe;in -best roof possible. Responsibility, the roofing industry. The desigft however, for design of any roofing criteria and details contained herein system, remains with the architect have been compiled and are offered or engineer and building owner. The contents.<of:tttts manual- areajfc. subject to change at the discreti^ of Kpppd Gompany;4nc. as future deveiopmentS'.and experience are achieved. --a. ~- 3 Product Guide The products listed below are manufactured to meet the highest quality standards set by Koooers Company. Inc. They are formulated specifically for use in roof ana roof main tenance and waterproofing applications Additional information on these oroducts may be obtained in other sections of this manual or by contacting your Koooers representative. The products listed below are manufactured to meet applicable Federal and ASTM specifications. If a certification is required on any of these products, it must be requested at the time of order placement. Products Bitumens Coal Tar Bitumen Asphalt Type III Description Coal Tar based roofing and wateroroofing bitumen Petroleum derived asohalt suitable for roofing abdications (Type ill--SteeD asphalt) Federal Spec. ASTM Spec. Page No. e 0-450-78 12 Type III D-312-78 12 Tyoe III Felts 15 Tarred Felt Coal Tar Saturated Organic Fiber Felt #15 Aspnalt Felt #15 Asphalt Asbestos Felt AsDestos Base Flashing Vented Base Sheet Asphalt saturated organic felt Asphalt saturated asbestos felt for flashings Asphalt saturated--Fabric reinforced, base flashing Perforated asphalt saturated and surface coated organic fiber felt. #43 Coated Base Sheet Asohalt Saturated and Surface Coated Organic Fiber Felt Single-Ply Membrane systems KMM' Aluminum Aluminum Surface--Single Ply--Five layer laminated Membrane roofing membrane KMM' Standard Membrane Bituminous Aggregate Binder BAT) KMM Adhesive Single Ply--Five layer laminated roofing and waterproofing membrane For use with the KMM BATToooing only A tenacious asphalt adhesive formulated specifically for adhering KMM membrane Insulations Exeitherm Xtrar Closed cell phenolic foam with 'ntegrally bonded faces Fabrics Tar or Asonalt Saturated Cotton Std. Grade; Tar or Asohalt Saturated Cotton Spec Grace: Glasfao' Glascoat' Jute U F Mat White; U F Mat -Coated) Standard Mesh Heavy Duty Mesh A woven cotton fabric saturated with tar or asohalt A woven cotton fabric with higher thread count than above grade A woven glass membrane available m 20 x 10 or 20 x 20 threads per inch--asohalt or tar coated Same as above, except coated with white resin Asphalt saturated jute, commonly referred to as treated burlap A white, lightweight mat comprised of fine glass filaments in a random arrangement reinforced with a swirl pattern Same as above, coated with asphalt Medium weight, white glass strands bound together in a random pattern Heavy asohalt saturated glass fibers in iacKstraw pattern HH-Ft-595 B Type 15 C Style A HH-R-595B HH-R-59QA * * * * * * D-227 12 D-226 D-250 D-2626 Except for perforations D-2626 8 16 16 11 12 * 21 * 21 26 21 e* V SS-C-450e HH-C-4666 * HH-B-00800 * * m 0-173 D-1668 * D-1327 e e * 37 42 42 42 42 42 43 43 43 43 Patching Glass Stonemat Same as heavy duty mesh -- cut into convenient size rolls A polyester underlayment for KMM loose aggregate topping * 43 * 2i 4 KOPPERS 7 1,KOP Architectural and Construction Materials Products Description Federal Spec. ASTM Spec. Page No. Root cements Flash-on *441 Flashing Cement Hydroshield Tar Roof Cement Flashing cement formulated for weathering and flow resistance' *' & Not as heavy consistency as Flaslwjn *441 Asohait cutback. Formulated for application in all weather. Readily bonds to wet surface. Trowel or brush grades. Tar based plastic cement ... SSi>1S3-" ' D-2822 Type H "sSfc Type 1 SS-C-153 Type 1 D-2822 Type 1 * SS-C-153 Type II 36 - Roof coatings Emulsions Liquid Asphalt 480 r-;_~ ' Asohait emulsion. Will not alligator if properly applied. Heavy bodied, exceptionally high quality, non-fibrated clay emulsion. Liquid Asphalt 472 Liquid AsDhalt 484 Asohait emulsion. High quality asbestos fibrated, medium body, clay emulsion Fiber glass reinforced, asphalt emulsion Cutbacks Asphalt Roof Coating 454 FiBSr'Cbaiiiig 415 :1 ~ ' 1 '4 Medium body, asbestos fibrated cutback coehng-.-' - ' :n Tar cutback. Penetrates and resaturates tar and gravel roofs Resaturants Roof Resaturant 425 Asphalt Cutback. Combines maximum penetration and coating properties Roof Resaturant 410 Highest quality tar resaturant available. Excellent penetration and softening qualities. Primers High-Pen Primer 452 Thin asphalt cutback primer with maximum penetrating capabilities Coal Tar Concrete Priming Oil Coal tar based primer for roofing and waterproofing applications Adhesives CP Adhesive Superior asphalt cutback adhesive for asphalt felt applications SS-R-1781 Type 1 *- " J.V 'SS-A-eWQ. SS-C-540b SS-A-701 * D-1227 Type III D-1187 Type A ' D-1227 Type 1___ 36 ", ~ 5* *' . D-2823' -" c - Xypel- T*- r ' ' N/A 45 e 45 D-41 D-43 16 3-1 - Reflective roof coatings Alum Roof Coating 434 Contains 3 lbs. aluminum paste per gallon Non-fibrated. Alum Roof Coating 435 Reinforced with asbestos fibers. Contains 3 lbs. aluminum paste per gallon. Alum. Roof Coating 444 Contains 2 lbs. aluminum paste per gallon. Non-fibrated. Alum. Roof Coating 445 Contains 2 lbs. aluminum paste per gallon. Reinforced with asbestos fibers. Colored Roof Coating (White) White acrylic emulsion decorative coating. To be used over new Liquid Asphalt 480. Csulkings Acrylic *400 One part, gunnable. acrylic caulking. 'AppliesM Federal and/or ASTM QuMe Specifications are net available for this produet. TT-C-00493 TT-C-498B D-2824 Type 1 D-2824 Type II e * e * 47 47 47 47 -- - S Koppers Roof Bond/Guarantees Program Bonds and/or Guarantees are available for listed roofing soecifications in this manual To qualify for a Hoppers Roofing Bond or Guarantee, roofing and flashing must be constructed in accordance with Koppers Specifications, with Koppers materials, and by a roofing contractor authorized by Koppers. Prior to the beginning of any bonded or guaranteed roof application, the contractor must apply for the required document in accordance with Koppers standard procedures. Roof Bond Program Koppers bonds are available for 10.15 or 20 year terms, and only cover coal tar built-up roofing and flashings where approved. Roof Guarantee Program Built-Up Roof Guarantees 10-Year Guarantee A ten-year guarantee with a ten-year renewaf oDtidn--for 4 and 5 ply Coal Tar Bitumen roofing systems only. 5-Yaer Guarantee A five-year guarantee with a five-year renewal option--for 4 and 5 oly Coal Tar Bitumen Built-up Roofing Systems only Single-Ply KMM Guarantee A five-year guarantee with a five-year renewal option. KMM memorane applica tions only KMM/IRMA Guarantee A ten-year guarantee covering watertight ness ana insulation efficiency (80% of the original thermal resistancei. General requirements for bonded or guaranteed roof applications: 1. All roofing to be bonded/guaranteed must be constructed in conformance with Koppers specifications 2. Koppers bonds/guarantees are not avail able for residential roofing. 3. Koppers bonds/guarantees are transferable upon timely wntten notice of change of prop erty ownership. 4. Koppers bonds/guarantees are available within the Continental Unitea States in all cases except those areas where Koppers does not presently provide inspection service. 5. Approved flashings may be bonded/guaranteed for terms up to but not exceeding the term for whicn the roof is bonded. 6. Charges tor roofing bonds/guarantees are made on a oer square (100 sq. ft.) basis of the roofing membrane. Coverage: Koppers roof bonas. guarantees provide for repairs of leaks to the roofing not occasioned by defects m the building, abuse or extreme weather conditions during tne term of *he bond/guarantee up to the monetary limit specified m the bond Roof bonds/guarantees DO NOT cover the repair installation or reoiaeemenf cost of the following 1. Decking materials. 2. Vapor barriers. 3. Insulation products lexcept KMM. IRMA system) 4. Metal work. 5. Products in the roof assembly furnisned by others. 6. Damage to the bonded roofing or flashing caused by the use of the products iistea in ' through 5 above, their installation or attach ment 7. Vandalism or owner abuse Koppers reserves the ngnt to cancel any bond/guarantee if the roof is damaged due to causes not covered by the bond/guarantee if it is determined that the roofs satisfactory performance (or the remaining term of the bona/guarantee is impaired Cancellation due to damage of this type does not provide for any refund of the original cost. Specification Reference Guide Type System Coal "far Bitumen Coal Tar Bitumen Loose Laid Membrane Aggregate Topping Loose Laid Membrane 3itummous Aggregate Topping Aohered Membrane Aluminum Surface insuiateo Roof Memorane Assembly Deck Slope Spec. No. COAL TAR BUILT-UP ROOFING SYSTEMS Nailable '4 max. 210 Non-nailaole & insulation '/i max. 220 KMM ROOFING SYSTEMS Nailable. Non-Nailable and Insulation V max. 610 Nailable. Non-Natiabie and insulation 1V max. 620 '.V Minimum with 630 Positive Drainage 2" Maximum 690 Positive Drainage Construction Page 4 and 5 oly tarred felt 4 ply tarred felt 13 14 KMM Standard Membrane 27 KMM Standard Membrane 27 KMM Aluminum Membrane 28 KMM Standard Membrane 29 BUILT-UP ROOFING SYSTEMS Coal Tar Bitumen Built-up Roofing Materials and System Discussion KOPPERS 7 1/KOP Acorcnhsittreuccttuioranl "an*d<"*'* c Description Koppers Coat Tar Bituman built-up roofing systems consist of alternate layers of Kopoers Coal Tar Bitumen and Koppers tarred felt, surfaced with a heavy top pour ing of Koppers Coal Tar Bitumen into which is embedded an aggregate. Koppers Coal Tar Bitumen built-up roofing systems are used whenevera roof is exposed to water and/or corrosion, and on all level or low sloped roofs where minimum main tenance is required. Featur*^ Coal Tar Bitumen built-up roofing provides one of the most durable roofing systems known due to its inherent superior water proofing and weathering characteristics.This is THE time proven roofing system for level and low sloped roofs. Coal Tar Bitumen provides numerous advan tages to an owner. The superior performance of coal tar roofing systems in the areas listed below make coal tar roofing systems unique in the roofing industry. 1. Coaf Tar Bitumen has natural reslstanee to water, air and water vapor penetration. A tight molecular structure enables Coal Tar Bitumen to resist water penetration and oxidation of the roof surface. 2. Another unique feature d coal tar roofing is its seif-healing ability. Alligatonng and hairline cracks common to most matenals. eventually cause damage to the roofing membrane. Coal Tar Bitumen has a property known as "cold flow" which automatically corrects these conditions before serious damage takes place. This "cold flow" feature heals small mechanical fractures at normal temperatures. 3. Application Improvements. Because Koppers has expertise in the chemistry of aromatic coal tars. Coal Tar Bitumen was developed with the beneficial features of low fume evolution at applica tion temperatures, thus reducing potential irritation during application. These features represent significant improvements which are in consort with the aims of government, labor, and industry in the areas of reduced air pollution and im proved worker conditions. Uses 1. All dead' level roofs 2. All water cooled roofs 3. Low sloped roofs with occasional ponding 4. Low sloped roofs with retarded drainage 5. All buildings with level or low sloped roofs that are built for long service life 6. Roofs in most highly corrosive atmo spheres Slopes Koppers recommends that the maximum roof slope be one-half (4) inch per foot for all built-up Coal Tar Bitumen roof systems. Kopoers does, however, permit slopes up to two (2) inches per foot at flashings that incorporate tapered cants and for short run crickets or saddles for drainage, provided there are provisions for adequate back nailing, and these crickets or saddles do not cover more than 1556 of the roof area. All felts must be backnailed on slopes onehalf (4) inch per foot or more. For recom mendations on roofing procedures for slopes over 4 inch per foot, consult your Koppers representative. Underwriters Laboratories Underwriters Laboratories. Inc. Building Materials Directory. TFJR-Built-Up Roof Covering matenals lists Koppers Coal Tar Bitumen and tarred felts for use in construction of Class A and B built-up roof coverings. Additional References: Roof Deck Con structions are listed under U. L. Guide No. (360 RO) TGKX. Roof deck construction materials, such as vapor barriers, insula tions. and adhesives are listed under U. L. Guide No. (360 R13) TGYV. Bonds/Guarantees Koppers Bonds/Guarantees are available for 5.10,1S. and 20 year terms. Roof bonds/ guarantees cover ONLY thebuilt-up roofing and flashing membrane. For further details, please refer to Page 6 of this manual. Note Due to varying architectural designs. Koppers built-up roofing products snould not be used on single family residential construction. 7 BUILT-UP ROOFING SYSTEMS (Cont.) General Requirements and Special Conditions Roof Structure System In any building the performance of the Built-Up Roofing will be affected to some degree by all of the parts of the roof structure system as well as the inside and outside atmospheric environment. Each component should be investigated for its compatibility with each of the others. The roof structure system may include any or all of the following: Outside Atmospheric Conditions Roofing System Peripheral Details (Flashings) Insulation (if present) Vapor Barrier (if present) Structural Deck including sub purlins (supports) Structural Framing Air Space (if present) Ceiling (if present) Interior Air Conditions You will find information in this manual per taining to materials and application methods other than for built-uo roofing. They are offered to assist the designer in establishing their normal position in the roof structure system. They should not be construed as oart of the built-up roofing system, as endorsement, nor as part of the designated specifications other than to establish a suit able roofing base in the root structure system. The proper design, specification and posi tioning of the various components of the roof structure system is the responsibility of the building owner or his designer. Any subsequent failures, due to either the instal lation or lack of installation will not be Koppers responsibility. Decks The deck is the base over which the built-up roofing, or insulation and built-up roofing is aoolied. Where the term deck is used m this manual without reference to insulation, it shall designate the surface over which roof ing is to be aoolied All decks shall be clean, smooth, dry.- rigid and free of debris. Any deck defect shall be corrected before appli cation of roofing All decks shall be installed m accordance with the deck manufacturer's specifications and shall be in compliance with Koppers General Requirements. In aoorovmg any deck as satisfactory to receive a Koppers roof, only the deck sur face is accepted. It is the responsibility of the building designer and the deck manu facturer to provide for expansion and con traction m a manner that wiil provide a stable base for the roofing: for support of maximum anticipated loads: secure attachments vertically and laterally, and the selection of the deck material and construction details including their ability to contain bitumens. (KOPPERS WILL NOT ASSUME RESPON SIBILITY FOR DECK DEFECTS OR BITUMEN SEEPAGE.) The placing of conduits, bolt heads, etc., above the roof deck and below the roofing membrane is not recommended. All oroiections or openings in the deck should be completed prior to the application of the roofing. 8 Optimum adhesion to the deck is necessary for good roof performance. Where Koppers Bitumen or steep asphalt is used as an adhe sive. questionable decks may be tested for dryness and adhesion by pounng one pint of the bitumen, heated to application tem perature. over a representative area or areas of the deck. The deck is not satisfactory if the bitumen foams or bubbles, or upon cooling to ambient temperature may be stripped dean of the deck. When decks can not be sufficiently cleaned to permit adequate adhesion a primer is required. Metal Decks Metal Decks: Oecks of this type must also be free from loose rust and oily substances. It is absolutely necessary to install board type insulation on a metal deck before the Koppers roofing is applied. A metal deck must be clean, smooth, and properly anchored to the steel purlins and all joints correctly lapped and fastened. Type of metal deck, flute opening and vari ous other factors determine the type and thickness of insulation required. Consult your Koppers representative for recom mendations. Metal roof decks shall be designed so that they will not have a deflection exceeding 1/240 of clear span under all types of loads (live & dead). Designer should take into account roof traffic conditions including mechanical equipment used for roof application. Note: When applying insulation and roofing over a perforated or acoustical type metal deck, it is recommended that a vapor retarder be installed prior to the application of the insulation or that a base sheet set in steep asphalt be utilized as the first ply of Built-Up Roofing. This is to reduce the possibility of Bitumen drippage. Application of Vapor Retarder Below Ineutetlon (Fed Type Vapor Retarder) Coat the nbs of the metal deck with Steep Asphalt and then install two (2) full thick nesses of Koppers No. 15 Asphalt Felt lapping each sheet nineteen (19) inches over the preceding sheet, mopping with Steep Asphalt the full width of the nineteen (19) inch lap. Extend and adhere all felt up vertical surfaces to a dimension 6" above the plane of the insulation surface. Attachment of Insulation Install insulation with approved mechani cal fasteners or Steep Asphalt. See "Attachment" Page 10. a. When attachment is made with steep asphalt it shall be applied to deck at rate of 12 to 15 lbs. per 100 sq. ft., place insulation while steep asphalt is still molten to provide good adhesion. b. I f slope of deck is one-half ('4) inch per foot or more, insulation must be able to retain nails. In addition to being set irt steep asphalt, insula tion must be fastened to me metal deck with approved mechanical fasteners m accordance with FM requirements. If two layers of insula tion are specified, top layer must be set in steep aspnait. making sure that the joints m the top layer do not coincide with the loints of the bottom layer. c. If UL and FM requirements are a factor for insurance reasons, the insulation and its method of attachment must be listed and approved in accordance with their current data. In arses that may exceed the V per foot maximum slope requirements (short run crickets, saddles or cants), all plies of tarred felt must be back nailed. Wood nailing strips must be provided when the substrate is not considered capable of retaining nails. Application of RooSng Membrane For application of roofing materials over the insulation, follow Specification No. 220 Page 14. Precast Structural Concrete Sections Precast concrete structural sections demand the same recommendations as poured concrete decks, although the presence of moisture, due to insufficient drying time, is not likely. If the contractor finds one or more siaos resting unevenly, with edges projecting above the surface, this should be corrected by resetting or leveling off. Leveling off should be gradual and smooth to permit insulation full contact with the substrate. Ail insulation joints must .be even and smooth. Open-cell aggregate concrete is not acceptable for filling or leveling low areas. All joints, grouted or not. must be caulked with trowel-grade asphaltic plastic cement. As additional protection from bitumen dnppage centered on the |omt. an 8 inch wide (min.) felt stripping must oe totally embedded in a troweling of plastic cement. Slab sides and ends should be square, rest firmly and evenly on supporting members, and be installed to prevent lateral and vertical movement Application of Vapor Retarder Below Insulation 1. On precast concrete decks, solid mop the surface with Coal Tar Bitumen. 2. Lay over the entire surface two (2) full thicknesses of Koppers Tarred Felt, lapping each sheet nineteen (19) inches over the preceding sheet--mopping with Coal Tar Bitumen the full nineteen (19) inches so that in no place shall felt touch felt. 3. Extend and adhere all plies of felt up to vertical surfaces to a dimension 6" above the plane of the insulation surface. Application of Insulation: Over Vapor Retarder Apply a uniform coating of Coal Tar Bitumen over the entire surface. While hot. embed the insulation. If there are two-(2) layers of insulation (e.g. as required for pre-stressed concrete sections) mop the entire surface of the first layer with Coal Tar Bitumen While hot embed the second layer of insulation. Application of Insulation Directly to Deck Over precast concrete, solid mop with Coal Tar Bitumen. While the bitumen is still hot. embed the insulation. See Insulation section. Page 11. Insulation joints snail not coincide with joints of the precast units. Application of Roofing Matters!* to Deck On precast concrete sholid mop with Coal Tar Bitumen. Built-Up Roofing Systems (Cont.) KOPPERS 7 1/KOP Architectural and Construction Materials Complete the system in accordance with 2. Extend and adhere all plies to vertical sur grout or other suitable material, and all Specification No. 220. faces to a dimension 6" above the plane of the cracks pointed up In areas that may exceed the '<4" per foot insulation surface. Application of Membrane Below Insulation maximum slope requirement (short run For vapor barrier provisions contact your 1. Apply over entire surface one (i) ply of cnckets. saddles or cants), all plies of tarred Koppers Representative. Koppers coated base sheet, lapping each felt must be back nailed. Wood nailing strips must be provided when the substrate is not considered capable of retaining nails. Application of Board-type Insulation Over Membrane Apply a uniform coating of Coal Tar Bitumen over the entire surface and. while hot. sheet four (4) inches over preceding sneet and nailing at lac no less than nine (9) inches and stagger nailed down center of each sheet on nine (9) inch centers. Lightweight Insulating Concrete Lightweight insulating decks include light* embed the insulation. If there are two (2) layers of insulation mop the entire, surface of the first layer with Coal Tar Bitumen and. while hot, embed the second layer of insu 2. Extend and adhere all plies to vertical sur faces to a dimension 6" above the plane of tne insulation surface. weight aggregate concrWU20 to 40 ibs:. per lation. For vapor 'retarder provisions contact your cu. ft. oven dry density): foamed concrete, gypsum and thermosetting asphaltic decks. Except for Dycon* Concrete, lightweight insulating deck systems must be capable of For application of roofing matarielfl over insulation follow Application Specification No. 220. Koppers RepfVsentative. el Application of Insulation Over Membrane Apply a uniform coating of coal tar bitumen venting excess water vapor to the under Application of Roofing Materials to Deck over the entire surface, and. while hot. embed side. Koppers will not accept these light 1. Apply over entire surface one (1) ply of the insulation. If there are two <2) layers of weight insulating decks to be placed over Koppers coated base sheet, laoping each insulation mop the entire surface of the first vapor barriers, poured concrete substrates, sheet four (4) inches over preceding sheet layer with steep asphalt, and. while hot. embed unvented metals, or any type of base which and nailing at lap no less than nine (9) inches, the second layer of insulation, insulation |omts will not permit these materials to vent from and stagger-nailed down the center of each shall not coincide with joints of precast units. the underside. This is necessary to prevent sheet on nine (9) inch centers. a water vapor pressure build-up under the built-up roofing. Occasional, or soot vents through the roofing as the only venting method are not satisfactory substitutes for underside. 2. Over the base sheet apply three (3) plies of Koppers Tarred Felt, lapping plies twentyfour and two-thirds (24%) inches. Where slope of deck is one-half (%) inch per foot or more, nail each sheet of felt six (6) inches For application of roofing materials over insulation follow Application Specification No. 220. Application of Roofing Materials to Deck 1. Apply over entire surface one (1) ply of in addition, lightweight insulating decks from the back edge on twenty-four (24) Koppers coated base sheet, lapping each shall have sufficient cohesive strength to inch centers. sheet four (4) inches over preceding sheet C provide firm attachment of the roofing to the deck and framing to prevent wind uplift damage or blow-offs. Nailable decks must be capable of developing at the very mini All laps shall be mopped with Coal Tar Bitu men the full twenty-four and two-thirds (24%; inches.so that in no place shall felt touch felt. and nailing at lap no less than nine (9) inches, and stagger-nailed down the center of each sheet on nine (9) inch centers. 2. Over the base sheet apply three (3) plies mum. a 40 pound nail pull-out or withdrawal 3. Complete the system in accordance with strength. If the materials do not achieve thii - Specification No. 210. of Koppers Tarred Felt, lapping plies twentyfour and two-thirds (24%) inches. Where value, additional fasteners will be required Note: In arses that may exceed the V per slope of dock is one-half (%) inch per foot or over and above those quantities described foot maximum slope requirement (short run more, nab^Sach sheet of felt six (6) inches m the ensuing specification (standard i cnckets. saddles or cants). aH plies of tarred from the back edge on twenty-four (24) approximately 100 fasteners per square) to felt must be back nailed. Wood nailing stripe' ' inch centers. achieve a minimum attachment standard of 40 lb. per square foot. Koppers will not be responsible for failureof^the insulating deck must be provided wnen the subetmte is mot considered capable of retaining nails. X Complete the pystem in accordance with Specification No. 210. to remain integral or for disbonding of the roofing from the surface of the deck. Provisions should be made wherever possi ble to provide additional venting such as notched wood perimeter nailers, etc., in coniunction with the venting from the under Poured Gypsum Precast Gypsum The same recommendations applying to precast concrete slabs apply to precast gypsum slabs and gypsum metal bound Note: In areas that may exceed the V per foot maximum slope requirement (short run crickets, saddles or cants), all plies of tarred felt must be back nailed. Wood nailing strips must be provided when the substrate is not considered capable of retaining nails. side of the deck. If board type insulation is planks, except that the first ply of the roof to be applied over a lightweight insulating ing membrane must be a coated base sheet deck, provisions must be made between the fastened in accordance with the base sheet fill and the board insulation to prevent fill alternate. See Page 12. All uneven slabs moisture from affecting the insulation and should be reset or leveled off so that the roofing. roof will be laid on a flat and even surface, free from projectionsand lowareas. Because Thermosetting Asphaltic Concrete When applying the roofing membrane directly over a thermosetting Asphaltic Concrete, follow Specification 210 except the first ply of the roofing membrane must be a base sneet set in a solid mopping of steep asphalt. these slabs are precast, the possibility of a high moisture content being present is more remote than in the poured gypsum roof or lightweight insulating concrete roof deck. Poured gypsum decks sometimes cause trouble because the built-up roofing is laid before the deck is thoroughly dry. When this happens the result is a blistered and buckled Application of Membrane Below membrane, or, just as serious, insulation- Board-type Insulation curls and makes an unsatisfactory job. The 1. Apply over entire surface one (1) ply of roofing contractor, backed by the architect, Koppers coated base sheet, lapping each must insist on a thoroughly dry-ggqi^before sheet four (4) inches over preceding sheet beginning work. He should also'lee to it that. and nailing at lao no less than nine (9) inches the deck is free of loose sand, frozen scale and stagger nailed down center of each and other foreign matter. Projections should sheet on nine (9) inch centers. be removed, low points filled with cement 9 Built-Up Roofing Systems (Cont.) Poured Portland Cement Concrete The deck surface must be smooth, dry. and free of dirt, dust and debris. Projections should be removed, low points filled with cement grout or other suitable material, and all cracks pointed up. Roof deck shall be properly graded to outlets. Application of Vapor Ratardar Below Insulation 1. Apply a uniform coating of Coal Tar Bitumen to the deck. 2. Lay over the entire surface two (2) full thicknesses of Koopers Tarred Felt, lapping each sheet nineteen (19) inches over the preceding sheet--mopomg with Coal Tar Bitumen the full nineteen (19) inches so that m no place shall felt touch felt. 3. Extend and adhere all plies of felt to vertical surfaces to a dimension 6" above the plane of the insulation surface. Application of Insulation Apply a uniform coating of Coal Tar Bitumen over the entire surface into which, while hot. embed the insulation. If there are two (2) layers of insulation mop the entire surface of the first layer with Coal Tar Bitumen into which, while hot. embed the second layer of insulation. Application of Roofing Materials Over Insulation or Deck Install the roof in accordance with Specifica tion No. 220. In areas that may exceed the V per foot maximum slope requirement (short run crickets, saddles or cants), all plies of tarred felt must be back nailed. Wood nailing stnps must be provided when the substrate is not considered capable of retaining nails. Wood Plank/Plywood Wood shall be well seasoned, dry and preferaDiy treated. End joints shall have aaeauate oearing. Loose or void knot holes, large cracks, etc., shall be covered with sheet metal. Lumber shall be a minimum of 1" nominal thickness. Plywood (exterior grade) Shall be a minimum of -2' thickness. Hot Coal Tar Bitumen should never be applied directly to a wood ceck. Sandwiched between the heat from above and the heat from below, such material finds its way through the boards into the building. Good practice demands the cushioning and blotting effect of a layer of sheathing paper followed by layers of dry felt. Shiplap and square edge boards should be avoided where possible. If the underside of me roof deck is exposed to air pressure created from open doors or windows, tongue-and-grooved lumber should be used. Preparation Below Insulation 1. The wood roof deck shall be covered with one (11 layer of approved rosin-sized sheath ing paoer weighing approximately five (5) pounds per one hundred (100) square feet. The sheathing paper shall be lapped two (2) inches and secured to the deck by occasional nailing. 2. Apply over entire surface one (1) ply of Koppers coated base sneet. lapping each sheet lour (4i mcnes over preceding sneet and nailing 10 at lap no le s than nine (9) mcnes and stagger nailed down center of each sneet on nine (9) inch centers. When the roof insulation is to be nailed and a vapor retarder is not required, the one ply of base sheet may be omitted: however, the sheathing paoer is required. Application of Vapor Retarder Below Insulation Note: When vapor retarder is required, use these procedures in addition to Preparation Batow InaulaMn noted above. Lay over me entire surface two (2) full thicknesses of Koppers Tarred Felt, lapoing each sheet nineteen (19) inches over the preceding sheet--mopping with Coal Tar Bitumen the full nineteen (19) inches so that in no place shall felt touch felt. Application of Insulation I.Moo the entire surface with a uniform coating of Coal Tar Bitumen into which, while hot. firmly embed me insulation. For application of roofing materials over insulation follow Application Specification No. 220 on Page 14. Application of Roofing Materials Directly on Wood For application of roof materials directly on wood decks follow Specification No. 210 on Page 13. In areas that may exceed the W per foot maximum slope requirement (short run crickets, saddles or cants), all plies of tarred feft must be back nailed. Wood nailing strips must be provided when the substrate is not considered capatxe of retaining nails. Structural Wood Fiber All decking must be installed in strict accor dance with the oarticuiar deck manufacturer's recommendations for installation Deck material must be protected during shipment, job site storage and prior to roofing application. No planks which have become structurally weakened due to moisture, fractures or muti lated edges may be used. All joints must be level and preferably grouted full and level with plank surfaces as recommended by the deck manufacturer. All planks must be well anchored to supporting members to resist movement in a fashion recommended by the deck manufac turer. Any planks which bow or deflect or do not seat securely must be replaced. Responsi bility for the selection of a oarticuiar type of wood fiber deck, its installation, provision for expansion and contraction, its suitability to |ob requirements, and its ability to support antici pated loads in its environment rests with the designer and deck manufacturer. Decks of these types, whether grouted or not. shall be caulked with Koppers Flashing Cement which shall be applied so that the top surface is level and smooth. Felt strip ping four (4) to six (6) inches wide set in a troweling of the cement is required to assist in leveling uneven joints and bridge the joint openings thus providing a better sur face for the roofing materials. Caution: care must be taken to avoid bitu men drippage. Application of Vapor Ratardar Btlow Insulation Install two (2) plies of No IS asphalt felt lapped nineteen (19) mcnes in Type III steep asphalt Plies snail be moppeo solidly so that in no place snail felt toucn felt, install insulation m solid mopping of steeo asohalt. Application of Insulation Over Vapor Ratardar Install insulation in a uniform coating of Type ill steep asphalt. Installation of roofing over insulation shall oe as per specification outlined below with base sheet mopped solidly to the insulation in steep asphalt as the first ply. Application of Roofing Materials Install roofing in accordance with Specifica tion No. 220 except that a base sheet, set in steep asohalt. must be substituted as the first ply. See "Base Sheet Alternate' Page 12. Comolete the system m accordance with Specification No. 220. In areas that may exceed the 'i" per loot maximum slope requirement (short run crickets, saddles or cams), all plies of tarred felt must be back nailed. Wood nailing strips must be provided when the substrate is not considered capable of retaining nails. Material Protection it is the responsibility of the roofing con tractor to protect ail roll roofing materials and roof insulation from ground or con struction moisture and weather before and during construction. Attachment Maximum adhesion or secure attachment of all components in the roofing assembly is necessary for satisfactory long term performance of the roofing membrane. Bitumen adhesive and/or fasteners quantities specified by the manufacturer must be capable of passing a minimum uplift resistance of 40 pounds per square foot (psf). When Building Code requirements dictate a higher uplift resistance than our minimum requirement, additional fasteners or adhe sive will be required over and above the quantities described m the ensuing specifi cations. Solid moppmgs of hot applied bitumen have been found to provide an uplift resistance in excess of 120 psf. When nails or fasteners are used, they must be nailed through disks or have sufficiently large heads to prevent fracture or puncture through the roofing, felts. When possible mechanical fastening of insulation is the preferred means of attachment. However, if properly applied hot applied bitumens are also acceptable Contact the insulation manufacturers literature for requirements. Cold applied adhesives are not acceptable. Koppers will not be responsible for any damage caused by or the result of unsatis factory attachment. For further information contact your Koppers representative. Built-Up Roofing Systems (Cont.) KOPPERS 7 1/KOP Architectural and Construction Material* Expansion Joints (Building) Since all materials expand and contract due to temperature and/or moisture, the use. location, and design of building expansion loints. especially in the roof structure system, should be taken into consideration at the time of original building design. Although provisions for adequate expansion joints are the responsibility of the building designer. Koooers offers the following recommendations for the protection of the roofing system against splits caused by expansion and contraction of the building. Building expansion joints should be installed. 1. On roof areas larger than 200 feet in each direction 2. At all places where the structural supports and roof assembly change direction 3. Where tyoe of adjoining deck materials change Where control or expansion-contraction joints are provided in the structural steel, deck material, or deck system, provisions must be made for continuation of this relief through the built-up roofing system. Koppers realizes that in a climate controlled building there may be little or norexpansion AFTER the building is in use. however, building expansion joints are *tiH- recommended based upon the following points: 1. During construction theibuilding will not be under a steadystate temperature/humid ity condition so that thermal and moisture movement can be sufficient to fracture the roofing. 2. If no building expansion joint is provided, the owner must keep the building at the steady state temperature and humidity con dition at all times, as holiday shut-downs can fracture the roofing due. to the move ment of the roof system resulting from temperature/humidity variation. 3. if the occupancy is fairly large, the sudden entrance on a rainy day of many rain-soaked employees may cause moisture movement in the roof structure system which can fracture the roofing. Water Stops (Temporary Protection) Water stops consistingofwrcajfrplies of tarred felt and mopping^.oGCatfpar Bitumen extending onto the deckifid tmEiation at least 6" and 4". snail be applMd-at-the end of each days s work over exposSBSdgeS of insulation. These tempomy prnl*r*vi measures must be removed cleanly from the insulation (top surface and vertical joint) and from the deck to ensure tight insulation joints and level insulation surfaces. Improperly corrected water stops have been determined as a cause of roof splits and have prevented moisture vapor movement to vented edge detaie. Cut Offs (Permanent Installation) Venting of roof insulation at walls, curbs, eaves, etc. is recommended for all but a few special roof structures. Therefore, cut-offs should not be installed at edges of insulation adjoining these areas for venting purposes. consult the manufacturers' literature for specific information. Cut-offs may be installed however, provided Woo#Nailing'Strips they are constructed to run in one direction continuously'to vented edges end provided no section of the roofing it isolated or blocked from venting. All norwtailable decks require woodtaalling stripe at eaves, edges, walls, roof openings., etc: for proper securement of metal flanges.' Nailers must be securely and firmlyattached Vapor Retarders g- to the deck or through to its supporting members. Nailers shall extend not less than Vapor retarders are normally used where the. 1* beyond the apron or flange. . heat flow direction and/or humidity within the building, during any climate or occu Rocag fette for all deck areas having a pancy cycle, might cause the dew pomt or slope'of H' per foot or more must be back condensation to ocair under the built-up nailed and therefore non-nailabie decks roofing within the insulation chamber, it is must be furnished with treated wood nailing important mat the vapor retarder, when -strips treated with a material compatible installed, provide'a continuous seal, (indud-- with bituminous roofing. " ing ventilators, skylights', peripheral weua... and othar termtnaflontrftom the source of'" Cold Storage and the water vapor. . ... j* ~ ' .. Fraezor Buildings ~ ^ . Insulation ^- Keepers will not. boqd its kuitt-tw roofing- Insulations come irrvarying thicknesses and. over these Structures if mauWiQn or insula- sizes. Should the manner of-attechment as" . tlon and vap9r.berr1er .is installed over, the suggested conflict with thtf spebified by the deckunieasthereraan adequately ventilated individual insulation manufacturer, the in&i-' -air apace betweervlhe flEfc and insulated lation manufacturers specifications shell be - ` grfrtgerstedArtHt , ^ - r..~ ' followed and hteddition. shall be in comptt- ` TkSr prbcifcre* on rion-bonded "Built-up" ance with Koppers General Requirements. roofing applications, consult a Koooers Good roofing practice dictates that the fol lowing points be considered when specifying board type roof insulation. representative. When a guaranteed system is required, refer to KMM Specifications. Page 23. 1.The roofing insulation must be kept dry at all times. It must be of a type approved by Koppers for use with a Koooers built-up roof, it should only be applied over a deck com plying with all of Koppers General Require ments. 2. If the roof deck slope is one-half 04) inch per foot or more, the insulation must be able to retain nails or wood nailers must be installed peroendicuiar to the slope at each course of insulation. Spacing of nailers must be such that the insulation fits snugly with the nailers but must not be force fitted. 3. No more insulation shall be laid at any one time than can oe protected by bitumen and felt in case of sudden weather changes. 4. Edges of insulation shall be brought closely together and shall not be forced into place. Where insulation loins vertical sur faces. the insulation shall be cut in a neat manner allowing approximately one-half (H) inch clearance. 5. When more than one (1) layer of insulation is used, joints m each layer shall not coin cide. All layers shall be parallel to preceding layers. Nola: When urethane or urethane composite roof insulation is specified, it must be installed in a double layer application The appropriate Water Retaining and Retarded Drainage When the roofing system is subjected to common standing water or retarded drain age referto the Special Applications Section. Page 15. Temporary Roofing Temporary roofing specifications are avail able for alt Koppers Coal Tar Bitumen BuiltUp Roofing Systems. Consult your Kopoers representative for recommended specifica tions over various type decks for temporary roof construction. Reroofing Design Considerations: During the reroof design and specification phase, and prior to commencement of reroof ing work, it is the building owners responsibil ity to have his architectural or consulting representative ascertain if the existing roof structure, with the new roof system installed, will meet all local building structural codes. If additional insulation is to be a part of the new roof system, an evaluation of the dew point and its effect on the roofing system should be determined. urethane product must be installed direct to the root deck and a second layer of fiberboard. perlite board or glass fiber roof insulation installed over top. The loints of the second layer must not correspond with that of the first. In lieu of the second layer of insulation, a Koopers vented base sheet must be used as the first ply of the membrane. When using other than Koppers Exeltherm Urethane Insulation. Reroofing application can be complicated since many factors must be considered. For more specific informatiog pertaining to special situations, contact your Koppers representative. Note: Koppers will not be responsible for any damage caused by excess loads on structural systems or damage due to rate or change in location of new dew point. .. BUILT-UP ROOFING SYSTEMS (Cont.) General Application Procedure Application of Bltumona Recommended Weights per 100 sq. ft. (for estimating purposes only) Koppers Coal Tar Bitumen Steep Asphalt Average Interply 25 lbs. 23 lbs. Top Coating 75 lbs. 60 lbs. Average interply weights are based on long years of experience in good roofing practice, and take into account a reasonable variation in the amount of bitumen absorbed in differ ent substrates, and the type of specification. Mopping* of bitumen between felts shall be continuous. FeK Shall Not Touch Felt It is generally agreed that maximum strength between layers of felt is achieved by the thinnest practical glue line of bitumen. Too thin a layer starves the lap, whereas an excessive layer can permit interply move ment on sloped roofs. Flood Coat The too pouring is most important, it must be thorough and uniformly covered with specification aggregate embedded into the bitumen while the bitumen is stUI hot. Recommended Temperature Limitations: Kettle Temp. Koppers Coal Tar Bitumen 300-425F Point o1 Application Temp. 350-400F Steep Asphalt 350-475F 400-450F When roofing bitumens overheated and/or held for long periods of time,their waterproofing qualities are greatly reduced, and at the same time the volume of fuming is increased. In order to achieve the maximum benefits of low fuming and uneauaied waterproofing performance, it is imperative that Koppers Coal Tar Bitumen be heated within the temperature limitations listed above Close supervision of heating is also good roofing practice for all bitumens. If heat is desired during a holding period at the jobsite while material is not being drawn off and replenished as under normal usage, kettle temperature should be reduced and not permitted to exceed 350F for Koppers Coal Tar Bitumen or 425F for steep asphalt. The kettle should be full lid closed. These temperatures are applicable to job condi tions and do not apply to holding or storage in kettles in excess of 4 hours. If bitumen is not to be used for periods over 4 hours, the kettle should be shut off. Koooers Coal Tar Bitumen may be contained m 1000 gal. or greater capacity heated and automatically controlled closed vessel tankers at 375F for periods not exceeding 96 hours. Application of Felt Plies of felt must be laid shingle fashion. Where a water flow direction exists, felts snould be applied so that the direction of flow is not against the laps. Broom or press all plies of felt into the hot bitumen and lay without wrinkles, buckles or kinks, so that the finished roof is free of pockets or blisters. Each felt ply shall be completely covered with a complete mopping of bitumen. 12 m 3 2 1 I The number of plies are controlled by vary ing widths of the edge laps. Four-ply (4) roofing, for example, is achieved by lapping each ply approximately twenty-seven and one-half (27,4) inches. Koppers felts are marked at the factory with lap lines for this purpose. Except as specifi cally provided for in Koppers specifications, application of felt lapping methods other than shingle fashion will not be permitted. When beginning a membrane roofing instal lation, appropriate width starting strips of felt shall be used at the starting point to achieve the specification ply build-up at that point so that successive felt applications will produce the ply requirements. Overlap ends of all connecting plies of felt (end laps) not less than 10 inches. End stripping or taping of these laps is not permitted. Application of Koppers Bitumen end AQflWQitt Surtac* The final application of Koppers Roofing is a triple weight application of Koppers Coal Tar Bitumen (approximately 75 Ibs./sq.) into which is distributed an approved aggregate while the Bitumen is still hot. Benefits of aggregate surfacing 1. Protection from foot traffic of other trades during construction and afterwards for routine roof maintenance. 2. weight as additional protection for wind uplift. 3. Reduced surface temperature. 4. Even flow of water to the drains. 5. Fire protection from burning brands. 6. Protect bitumen from the actinic rays of the sun. 7. Most important--by using an aggregate surface, an additional 75 Ib./sq. of Coal Tar Bitumen (the waterproofing agent) is included in the installation. The application of Koppers Coal Tar Bitu men and aggregate must be done at the time the felts are applied: except in penods of hot dry weather, wnen morning dew is not expected, the top surfacing may be delayed overnight. When the specifier desires glaze coating and/or all work to be completed the same working day. he shall be responsible to so state this requirement m his specifications. The aggregate surfacing must be applied into the top pouring while the bitumen is still hot so that a uniform layer will be embedded and adhered. The completed roof assembly will have a uniform aggregate surface. Depending on slag weights in certain parts of the country 400 lbs. of slag per square may be required. Cktcasionally on well applied roofs, small black globes known as "raspberries'' or "blackberries" will form in the roof surface. These are not detrimental to the roof. Aggregate Surfacing The aggregate to be used should meet the ASTM Specification D1863-64, The basic requirementfor this aggregate are as follows: Sieve Size Total Passing, Percent vr 100 if 90-100 H" 40-70 No. 4 0-15 No 8 0-5 Dust. max. pet. 0.5 Moisture, max. % crusned stone and gravel 0.5 Crushed roofing slag 5.0 Unit weight (loosei min. lb. per cubic ft 60 Note: in areas where ASTM D-1863-64 quality aggregate is not practically available. ASTM D-448 aggregate gradation sizes 6. 7 or 67 will be acceptable, providing that the aggregate has no more tnan 3% moisture by weight and meets all other requirements of ASTM D-1863-64. Cold Weather Application When roofing is aoplied at temperatures below 45F. special precautions must be taken to insure the satisfactory performance of the finished roof. Before applying roofing, moisture, ice. snow, surface water, etc., must be removed from the deck. Hot applied bitumens tend to congeal rapidly in cold weather. Extra care must be taken to set insulation or roofing as quickly as pos sible while the bitumen is still hot. When temperature is below 45*F. felt must be embedded in bitumen while it is still hot and broometHn immedtaMy with solid pressure to ensure necessary embedment into bitumen. Do not hoot bitumens above the maximum temperature limit listed above to compen sate for rapid chilling. Insulated containers along with carefully timed material delivery methods, must be employed. Note: Bitumen temperatures below those recommended at the "point of application' can result in heavy interply quantities which in turn can potentially contribute to the cause of membrane slippage. Base Sheet Alternate When substituted for the first ply in a solid mop application specification, the Base Sheet shall be embedded in a solid mopping of Koppers Steep Asphalt followed by thorough brooming to eliminate air pockets, wrinkles, fish mouths, buckles, etc. The remaining three (3) plies of tarred felt shall be solid mopped with Coal Tar Bitumen m accordance with the specification. When rosin sized or sheathing paper is a part of the original specification it shall remain and be applied beneath the Base Sheet. Edge laps shall be 4" and end laps shall be 6". The nailing pattern for the Base Sheet shall be 9" on center through the lap and 2" from the edge lap and stagger-nailed down the center of each sheet on 9" centers. (Note: This is approximately 100 nails per square.) After applying a base sheet as the first ply on the four (4) ply roofing membrane, three (3) additional plies must be installed at once. When applying the additional three (3) plies of tarred felt, lap each ply shingle fashion 24H inches. Each ply must be solid mopped with Coal Tar Bitumen. When specifying the Base Sheet alternate, use the designation BS as a subscript to the specifi cation number. 210 BS (structural wood fiber deck). Note: If Koppers Asphalt Coated Base Sheet (ASTM D-2626) Is substituted tar the first ply of the Coal Tar Bitumen roofing specifica tions, It must not be left exposed or used as a work surface or temporary roof prior to roof completion. Good roofing practice dictates that the total roofing membrane be complete the same day. - . Built-Up Roofing Systems (Cont.) Koppers Coal Tar Bitumen Specification No. 210 Supersedes Specs. No. 1, No. 12 KOPPERS 7 1/KOP Architectural and Construction Materials Nailable decks without insulation: Plywood, wood plank, lightweight insulating concrete, poured and precast gypsum. Slope requirements: per foot maximum. V b-- .1 - - --------------------------------------- Materials Required per 100 sq. ft. of roof area (for estimating purposes) Rosin Sheathing Paper' (1 ply) Coated Base Sheet" (1 ply) Tarred Felt (Mopped in Bitumen) (3 plies) Roofing Bitumen (3 moppings @ 25 lbs. each) 5 lbs. 43 tbs. 45 lbs. 75 lbs. 5 lbs. 43 lbs. 45 lbs. 75 lbs. Top Pour Coat Surfacing: Slag r Gravel X. Wood Decks only. Approximate Total Weight 75 lbs. 75 lbs. 300 lbs. -- -- 400 lbs. 543 lbs. 643 lbs. "Unless otherwise indicated. Procedure 1. General Requirements on Pages 8 through 12 and Plashing .Detail Specifica tions on Pages 16 through 20 are a part of this specification and must be adhered to where applicable. 2. When a vapor retarder and/or roof insula tion are required, install in accordance with the manufacturer's instructions and comply with Koppers General Requirements and Special Conditions. Follow Specification No. 220 for roofing materials applied to insulation. Application of roofing direct to roof deck: I.Over the surface of the roof deck install one layer Rosin Sheathing Paoer weighing approximately S lbs. per 100 sq. ft. Lap each sheet at ieast two (2) inches and nail suf ficiently to hold in place. (Wood decks only.) 2. Apply over entire surface one (1) ply of Koppers coated base sheet, lapping each sheet tour(4) inches over preceding sheetand nailing at lap no less than nine (9) inches and stagger nailed down center of each sheet on nine (9) inch centers. No:: (This is approximately 100 nails per 100 sq. ft.) Nail shanks are to be of required length for maximum holding power. 3. Over the entire roof area, aopiy three (3) plies of Koppers Tarred Pelt lapping plies twenty-four and two-thirds (24?5) inches. All laps shall be mopped with Coal Tar Bitumen the full twenty-four and two-thirds (24fj) inches, so that in no place shall felt touch felt. 4. On short run slopes, such as on crickets and saddles, one-half inch per foot or more, nail each sheet of felt six (8) inches from the back edge on twenty-four (24) inch centers. 5. Pour over the entire surface of the roofing membrane, a uniform coating of Coal Tar Bitumen, and, while hot. embed not less than four hundred (4001 pounds of gravel or three hundred (300) pounds of slag for each one hundred (100) square feet. V, 13 Built-Up Roofing Systems (Cont.) Specification No. 220 Supersedes Specs. No. 5, No. 10, No. 23, No. 17wi, No. 27 Non-nailable decks Precast Concrete. Poured Concrete. Structural Wood Fiber*. Roof insulations: Various Decks. Slope requirements: Hi" oer toot maximum. 1________ H Material Required per 100 sq. ft. of roof area (for estimating purposes) Tarred Felt (Mopped in Bitumen) (4 plies) Roofinq Bitumen (4 moppings @ 25 lbs. each) 60 lbs. 60 lbs. 100 lbs. 100 lbs. Top Pour Coat Surfacing: Slag Gravel 75 lbs. 75 lbs. 300 lbs. -- -- 400 lbs. Approximate Total Weight 535 lbs. 635 lbs. `NOTE: On structural wood fibor docks, the first ply must bo a Koppers cootod boss shoot sot in a solid mopping of stoop asphalt (see structural wood fibor, pago 10). Procedure General Reauirements on Pages 8 through 12 and Detail Specifications on Pages 16 through 20 are a part of this specification and must be adhered to whore applicable. When a vapor retarder andi'or roof insulation are required, install in accordance with the manufacturer's instructions and comply with Koppers General Requirements and Special Conditions.* 1. Mop deck (or insulation--as applicable) completely with Coal Tar Bitumen. 2. Apply over the entire surface four (4) plies of Koppers Tarred Felt, laoping plies twentyseven and one-half (27^) inches. Mop solidly between each 27Hi inch lap with Coal Tar 8itumen so that in no place shall felt touch felt. 3. On short run slopes of one-half (H) inch per foot or more, such as on crickets and saddles, and when the deck permits nailing, nail along back of upper edge of each sheet on twenty-four (24) inch centers.- Where deck does not permit nailing, nailing strips are required and each sheet must be nailed along back or uooer edge at soacings to assure penetration of nailers. 4. Pour over the entire surface of the roofing membrane a uniform coating of Coal Tar Bitumen, and. while hot. embed not less than four hundred (400) pounds of gravel or three hundred (300) pounds of slag for each one hundred (100) square feet. 14 Built-Up Roofing Systems (Cont.) Water Retaining Roofs KOPPERSI 7.1/KOP Architectural and Construction Material* ( Water Cooled Roofs Soray Systems Ponded Systems Water Retaining Roofs Process Water hundred (300) pounds of slag for each one hundred (100) square feet. 2. All loose gravel or slag shall be swept from surface and a second uniform pouring of approximately eighty-five (85) pounds of Coal Tar Bitumen shall be applied over the gravel or slag, into which while hot, shall be load bearing decks must be specified. Wood or metal decks should only be considered where ponded or standing water is at a minimum. Note; Decks requiring a base sheet as the first ply of the roofing system are not per mitted for this application. Retarded Drainage Systems Controlled Flow applied a second layer of three hundred (300) pounds of gravel or two hundred (200) pounds of slag for each 100 square feet. The entire surface shall then be thoroughly 2. Roof Structure design live loads for this application snail be a minimum of 50 psf and deflection shall not exceed 1/360 of the span, both in addition to the anticipated broomed free from all loose gravel or slag. weight of the water. Insulation joints must Discussion ue to Coal Tar Bitumen's natural resis tance to water, it may be utilized in the construction of built-up roofing membranes that will be expected to hold water over long periods of time. When applying a membrane that is required to hold water, follow Spec ification 220 for applications over nonnailable decks (four plies of No. 15 Tarred Felt set in solid moopings of Coal Tar Bitu men) It is advisable to roll the finished surface with a light roller so that aggregate is thoroughly embedded. 3. All flashings will be KMM membrane similar to Specification No. 710 on Page 30 except that a layer of Standard Grade KMM membrane must be installed totally substrate fused prior to the application of the KMM Aluminum membrane top pty. NOTE; Roots equipped with controlled flow drainage systems do not require the be taped in single layer applications. Vapor barriers must be two ply and solid mopped. Use steep asphalt over metal decks. Wood must be. treated to prevent warping (see "wood nailing strips'"). 3. At points where water pressure from a spray system may be excessive, the roof surface should be protected with treated board platforms or other suitable construc tion to break force of the water. These olatforms should be laid on top of the roof Note; The base sheet alternate shall not extra top pour and gravel application. surface and not fastened to the deck. be used. Design consideration 4. Insulation under a Water Cooled Roof should be of a type which is rigid, dimen When the roof is water cooled or has been When designing a water cooled, water sionally stable with high comoressive designed to be continuously wet the top retaining or retarded drainage roof assem strength. V surfacing of bitumen and gravel muat be applied as follows; bly. certain design criterion must be considered. 5. IT IS MANDATORY THAT THE WATER COOLING SYSTEM* BE CLOSED DOWN 1. Pour over the entire surface of the roofing Note: AND THE ROOF DRAINED PRIOR TO membrane a uniform coating of Coal Tar 1. Due to the extremely heavy weight loads COLO WEATHER. Neither roofing nor the Bitumen. While hot. embed not less than normally associated with retained water, structure will withstand the expansion four hundred (400) pounds of gravel or three pour and precast concrete or other heavy caused by ice formation. 15 Built-Up Roofing Systems (Cont.) Flashing Specifications General Flashings are the terminal closures of a roofing system which perform a waterproofing, and m some systems, a decorative function. Flashings must be installed at all intersections formed by vertical surfaces. Their importance cannot be stressed too strongly. Water entering the roofing system through flashings can result in water vapor forces which will destroy the effectiveness of the roofing. Koppers flashings are an integral part of a Koppers roof. Designed for flexibility so that slight movements oo not dislodge them and fastened securely to the wall, they give many years of service. It is particularly important that the top edge of the flashing be protected by counter flashing, which will insure a diversion of the water away from any opening which might develop between flashing and wall. NOTE: In any case where the design or anchoring system of metal counter flashing is difficult, the top of the flashing system should be stripped with Koppers KMM Aluminum Membrane (8" wide min.) centered and totally heat fused over the top edge of the flashing system. Metal work is only useful for decorative, water shedding, or protection against mechanical damage, and is not a waterproofing part of the flashing system. Because of the high coefficient of expansion of sheet metals and the large temperature changes experienced on a roof, sheet metal or exposed metal components must be isolated from the waterproofing components of the roofing and flashing system as efficiently as possible to prevent the metal from splitting the membrane. Flashing should be installed as roofing progresses to prevent water damage to insulation or deck under the roofing. If this is not possible water cut-offs must be installed and later removed when flashing is installed. Metal counter flashing or a top seal of KMM Aluminum Membrane must be installed as flashing progresses. The basic Koppers flashings require a metal cap flashing to be inserted in the raggie immediately upon completion of base flashing. The cap flashing is to have not less than a four (4) men exposed apron extending down over the base flashing. NOTE: 1. If bonded/guaranteed flashing is required, it must be installed in conjunction with a Koppers bonded/guaranteed root and can be bonded/guaranteed for standard periods up to but not greater than the period for which the roofing is bonded/guaranteed. To be bonded/ guaranteed, composition flashings must be set at least 7V above the roofing base. 2. Metal Cap flashings are not included under any flashing bond/guarantee. 3. Metal work of any description used as flashing or a'part of a flashing system is not included under any flashing bond/ guarantee. NOTE: Koppers KMM Flashing Systems are also available for use with Koppers Built-Up Roofing Systems. Specific details and specifications can be found on Pages 30 and 31 of this manual. Application Extend plies of roofing felts and bitumen moppings up ail walls, parapets and curbs for a distance of two (2) inches above cant strip. A raggie not less than seven and one-half (7'.-) inches or more than twelve (12) inches above the roof deck is to be provided. 1. Prime all masonry walls from top to roofing felts to raggie with Koppers Asphalt Primer. Allow to dry thoroughly. 2. In a uniform coating of Koppers Flashing Cement.' install one (1) ply of Koppers No. 15 Asphalt saturated asbestos felt extending from the raggie to not less than four (4) inches from the base of the cant onto the roof 3. On top of this apply a second uniform coat of Koppers Flashing Cement into which embed one (1) ply of Koppers reinforced asbestos base flashing (reinforced fabric side down). 4 Nail with one and one-half (I'l) inch masonry roofing nails through flat tin discs along upper edge eight (8) inches o.c. maximum into mortar |omts. For concrete construction, nail to treated wood nailing strips set in flush with the surface with appropriate nail through flat tin discs. End laps for each ply shall be not less than three (3) inches. End laps between plies shall be staggered not less than twenty-four (24) inches. 5 The top edge of the flashing felts are to be sealed with flashing cement. (Stripping of this top edge with Koppers Glasfab Fabric, set in the cement is preferred, but remains optional.) 6. Coat entire surface of flashing with Koppers Aluminum Coating *445 applied at a rate of 2 gal/100 sq. ft (including nail caps along top edge of flasnmg as well as top edges of feitsi Specification No. 108 Application Detail Reggie to b* SuM i/ J/ V*TT - Metal Countar Flashing--Extend Downward 4". Seal off Edges of Plies with Koppers Flashing Camant. 1 Ply of Koppers Reinforced Asbestos Flashing set in Koppers Flashing Cement -1 `V Barbed Roofing Nails through Tin Disks on 8" Centers--Max. 1 Ply Koppers No. Z5 Asphalt Saturated Asbestos Felt Set in Koppers Flashing Cement. Koppers Roofing Felts to be Carried up Cant Strip and Wall 2" mm. -CementitiousType Wall 7. Interpiy cement shall be troweled uniformly, full height and continuously approximately one-eignth ('>) inch thick. Plies must be laid in smoothly with no pockets, wrinkles or buckles, install metal cap flashing. `NOTE: Koppers steep asphalt may be used as an alternate to the two (2) Interpiy trowelings of asphaltic plastic cement. All other requirements of this specification must be adhered to. 18 r~ Built-Up Roofing Systems (Cont.) KOPPERS 7 1/KOP Architectural and Construction Materials General information There are numerous flashing details that have been oroven byexperience over the years. There are normally a number of acceptable construction details for accomplishing one purpose. The architect should select a detail that best serves the purpose under the various and different conditions concerned with the specific job at hand. In certain cases, slight modifications are necessary to adjust a proven detail to job conditions or one method may serve better than another. The details shown in this manual are some suggestions based on experience. Space limitations prohibit listing many others. Design or selection is a responsibility of the architect. Koopers representatives are available to review flashing details to assist the architect in providing the best details for soecific jobs. Parapet/Precast or Poured Concrete Matai Countar Flashing, to Da Saajad and Tightanad with Lsadad Waogaa. Raised Edge Matai Cap Sat in Hoppers Flashing Camant Nails tpacsd i" from adga of mataJ ship and 3" apart through neo prene washers. -Pta-Cast or Poursdin-Ptsce ^ a | ConerataWall Traatad wood Nailar Nota: WaM Shall ha Praparad to Siminata Watar Penetration Through Concrata to Unoeraioe of Rooting 4" x 6" Wood Cant Ffaahmg Spec. *108 Parapet/Metal Curtain Wall Membrane Flasning Material latt Dry at r Vertical Faca * and Nailsd 6" O.C at Bottom Koppars Roofing Otcorative Wall Cap 2 Plias ot Mamhrana Sat in Koppais Flashing Camant. Turn Oown ovar Saga Traatad Wood Nailar Fastanara Spacad 1" from adga of Matai Strip and 3' Apart tnraugn Naoprana Waahara Nail 3* O.C. Traatad Wood Nailar Relief Joint Min. 7'V 2 Plias of Mamhrana Sat in Koppara Flashing Camant Turn Down ovar Edga Traatad Wood Nailar Fastanad to Oack wood Cant 4* x 4' Equipment Support Parapet/Wall Cap Matai Countertlashing (Whan Reguired) Extand Oownward 4" Sat in 2 Plias ot Mamhrana Set in Koppara Flatting Camant Flashing Camant. Tumtd Oown ovar v_ -Nota: Whan composition (lathing doaa not axtand up lo wall cap or wall cap doss not pravids watar egress protection, a matai coumerfiaanmg must be installed according to procedures found in liasning specifications. 17 Built-Up Roofing Systems (Cont.) Flashing Details (continued) Structural Attachment with Watar Seal tag. bolt tfirougn Naoprana Waanart Naoprena Pad 2 Piles of Membrane in Plashing Cement Turned Down Over Edge Plashing Specs. *108 Koppers Roofing Structural Section WeM Plate Watertight Cant Treated Wood Nailer Surrounding Column Stub Column Attached to Structural Framing Future Columns, Sign Supports and Angle Irons At all locations wtire stub or future columns, sign supports and angle irons are to penetrate built-up roofing, Koppers recom mends woooen curbed base units witti cant strips to be installed to accept KMM flashing systems. Where structural steel section extends beyond "stub" height, metsl cap flashing with tight fit to the structural section must be fabricated and continuously welded to the projection to assure a watertight metal cap. Curbed Expansion Joint Curb expansion joints are to be flashed in accordance with Koppers specifications for parapet walls. Metal cap must be designed to expand so as not to disturb flashing. It is the responsibility of the designer of the building to provide for adequate expansion joints. For the protection of the roofing system against splits caused by expansion and contraction. Koppers recommends that an expan sion joint be installed: (1) on roof areas larger than 200 feet in each direction, (2) at all places where the structural supports and roof assembly change direction. (3) where type of adjoining deck materials change. Where control, expansion, or contraction joints are provided in structural steel, deck material, or deck system, provisions must be made for continuation through the roofing system. See (Expansion Joints) Page 11. 18 Roof Drain All roof drains shall be provided with metal roof drain flashing flanges which extend at least 12* beyond drain opening and shall be stripped with felt in accordance with drain detail. Ail drains should be provided with expansion joint sleeves. The sheet metal flange furnished with the drain must be cemented to the surface of the felt with hot Coal Tar Bitumen or flashing cement. Over the flange apply, with alternate moppings or trowelings. two (2) reinforcing plies of felt so that the first extends not less than three (3) inches beyond the outer edge of the flange, and the second not less than six (6) inches. Roof drains must be of a type provided with a wide lead or cooper flange. Strainer construction should provide adjustment for meeting variations in roof level or slops. To obtain proper drainage, roof drains should be located at points of lowest expected deflection in roof deck. Note: Special care must be taken to prevent bitumen migration into drain openings. KOPPGR*1 7 1/KOP Architectural and Construction Materials OotKXisl: For added protection a metal cao flaanmg may be atteetied and sealed to me protection Metal Pan Set in Bitumen and Filled mm Bitumen or KoopotsTarOaoeC Cement a-- --m. ''.-i-....................................... A' ~ Roof Vent Koppers does not recommend occasional or spot vents through the roof as the only venting method or a substitute for underside or continuous vented systems. There may be certain instances where spot or mushroom type vents might be deemed advisable by the designer for a new building (eg. at expansion joints for vent relief on long run underside continuous venting systems, etc.) Walkways (Treated Wood Walkway) Pitch Pocket Although controversial, the "Pitch Pocket" is one of the most frequently used design details. The sheet metal flange must be cemented to the surface of the felt with hot coaMar-bitumen or flashing cement. Over the flange apply, with alternate moppings. two (2) reinforcing plies of tarred felt so that the first extends not less than three (3) inches beyond the outer edge of the flange and the second no less than six (6) inches. Pill metal pan with hot coaMar-bitumen or fleshing cement. Paint exposed sections of all reinforcing rods with dampproofing paint. ( Traffic Pad Ceramic GDrmanteueleeiM Aflgf#Ct# Non Wall Support Flashing Roof Opening Curbs extending a nominal 10 inches to 14 inches above roof surface shall be provided at all openings for skylights, ventilators, expansion joints, etc., to provide for installation of KMM flashing. Note: Suggested detail where poMitxMy exett met differential movemant will occur oetwesn dacx and vertical surtaca. Thta detail is intandad as a guidt only. 19 Built-Up Roofing Systems (Cont.) Flashing Details (continued) Tapered Cant Tapered Cant Fling* width 4" minimum Grtvtl Stoo Minimum -- f Hugnt Matat Gravai Stoo Sat m Koooara Flaming Camant Naila soaead 1" from adga of matat atno and 3' loan m traatad wood nailing stnp ' Two Piias of Fait Faatntrad / ovor Flanga m Coal Tar Situman or Tar Bata Camant Taoared Cant Max. mclma 2' oar foot Roohng Mtmbrana Systam FaltEnvafooa Not i** turn U-41'--| DCK .J iNom) puui \ insulation Treated Wood Nailer Flange width 4" minimum Gravai Stoo Minimum r Haight Metal Gravai Stop, Sat m Koooara Flathing Camant Matat Pitch Oam Sat in Koooara Fiathmg Camant Traatad Wood Nailer Nail* soaced r from toga of metal stnp and 3* aoat in treated wood nailing ttnp. Two Pliaj of Fait Feathered ' over Flanga m Coal Tar Situman or Tar Bata Cement ' Taoared Cant Max incline 2* oar foot Roofing Membrane System Hanging Gutter Vented Edge Koooara Roofing Two Plies of Felt Appropriate Nails and Length For Maximum Anchorage Matat Gravai Stoo With 4' Flanga Badded in Koooara Flashing Cement Felt Snvaiooe Sat in Mm 4" Wide Troweling of Koooara Flashing ~y~ Cement r Mm. EdgeStrip. Nailed6*0 C j Hangers. 30* O C._____ i Metal mi Braces Gutter --*f// 30' O C Gravel Stop nailed 1* from inner edge of Flange and 3' 0 C. -Flange width 4* minimum rKoooara Roofing -Two PIlet of Faff Feathered Over Flange in Coal Tar Bitumen or Tar Bata Camant .Tapered Cant Maximum incline--2* oar foot Flanga Set in Koooara Flashing Cement Felt Envelope insulation Treated Wood Nailer Vent Hole Openings ts* to 24* O.C. Vent Pipes, Stacks, Flagpoles, and Other Projections Lead Sleeve with Flange set m Kopoei Flashing Camant Matat Hood Lead Sleeve with Flange sat m Koooara Flashing Cement Koooara Roofing Metal Bitumen Oam __ Sat in Koooara Flashing Cement All vent pipes, stacks, flagpoles, or other projections penetrating the built-up roofing, whether indicated on drawings or not. must have a proper metal sleeve flashing with flange, pan flashing with flange or other flanged flashing installed. Behind metal sleeves and beneath the roofing membrane next to deck install a metal bitumen dam as shown in detail. The sheet Matat Bitumen Dam Set in Koooara Flashing Cement metal flange must be cemented to the surface of th.e felt with a mopping of hot Coal Tar Bitumen. Over flange apply, with alternate moppings. two (2) reinforcing plies of felt so that the first extends not less than three (3) inches beyond the outer edge of the flange and the second not less than six (6) inches. 20 SINGLE-PLY ROOFING SYSTEMS KMM Membrane Systems s~~\ Materials and System Description KMM membrane is a versatile. prefabricated sheet of cold-applied roofing and water proofing material, it .is designed for applica tion in roofing, reroofing, maintenance roofing, foundations, plazaa and various other areas of construction where effective waterproofing is reauired. KMM membrane is supplied in two types. KMM Standard Membrane KMM Standard membrane is a five-layer laminate composed of a thick, flexible plastic core protected on each surface by a layer of modified bitumen and an outer film of polyethylene. KMM Aluminum Membrane KMM Aluminum membrane is a five-layer laminate composed of a thick, flexible plastic core which is protected on each side with a layer of modified bitumen. The top surface is a heavy, embossed aluminum sheet and the bottom surface is a film of polyethylene. is afforded to the KMM surface by other means. KMM Standard membrane is appro priate for use in vertically as well as hori zontally aoplied waterproofing systems where surface protection is specified. KMM Aluminum membrane is ideally used in roofing systems in which the root slope is too steep to permit aggregate surfacing. It is also employed in flashing systems. KMM membrane has good elongation prop erties to withstand normal structural move ment when recommended architectural practices are followed. It is suitable for application over most decks and commonly used insulating materials which provide con tinuous support for the KMM membrane. KMM membrane is simple to install. It results in a completely waterproof system. It is factory-made and provides a factory-assured quality material of uniform thickness and composition. The function of the bitumen covenng is to serve as a earner and protector of the central plastic core, to provide the basis for the heat fusion between the sheets and to add to the water resistance of the laminate. EmComa Aluminum Sheet Bffumtn Plastic Core Bitumen Polyethylene Product Information KMM Membrane Roll Size Thickness (nominal) Weight (nominal) KMM Standard Membrane *3" x 33 LF. 118 sq. ft. 107 sq. ft. coverage 160 mils 99 ibsVroll (includes packaging & core) KMM Aluminum Membrane 43" * 33 L.F 118 Id. ft. 107 sq. ft. coverage 120 milt 76 lbs./roll includas packaging & core) Both versions of KMM membrane are sup plied in the form of compact, ready-to-apply rolls. Both KMM membranes are designed for use in various roofing and waterproofing applications. KMM Standard membrane, loosely laid, is normally used in roofing systems which incorporate an aggregate surface or where protection from the atmospheric elements KMM Adhesive A rapid setting, asphalt base adhesive that bonds KMM Membrane to most surfaces. Package Size 5 and 55 gal. containers. Weight Approx. 55 lbs. per 5 gallon container and 600 lbs. per 55 gallon drum. Stonemat A polyester mat of high burst strength used under stone topping. Rolls are 8' x 450*. Color Coatings for KMM Aluminum Membrane Field applied coatings for KMM Aluminum membrane are available in 14 colors. For color selection consult Koppers Master Color Selection Chart 560-L under Koppers Acrylic Emulsion Nos. 600 and 610. 21 Single-Ply Roofing Systems (Cont.) KMM Roofing Systems General Requirements The data contained herein is pnmarily oriented toward roofing systems. However, much of the information is also applicable for waterproofing systems. Contact your Koppers representative for specific data concerning KMM waterproofing and/or further information pertaining to KMM roofing systems. KMM Membrane la not Intended to offer chemical resistance and muat not be used on roots suofected to corrosive or otherwise damaging solutions, vapors, etc. Roof Structure System in any building, the performance ofthe roofing will be affected to some degree by all of the parts of the roof structure system as well as the inside and outside atmospheric environment. Each component should be investigated for its compatibility with each of the others. The roof structure system may include any or all of the following: Outside air conditions Roofing system Peripheral details (Hashings) insulation (if present) Vapor retarder (if present) Structural deck, including subpurtins (supports) Structural framing Air space (if present) Ceiling (if present) Interior air conditions You will find information in this manual pertaining to materials and application methods other than tor KMM roofing. They are offered to assist the designer m establishing their normal oosition in the roof structure system. They should not be construed as part of the KMM roofing system, as endorsement or as part of the aesignated specifications, other than to establish a suitable roofing base in the roof structure system. The proper design, specification and positioning of the various components of the root structure system are the responsibility of the building owner or his designer. Any subsequent failures due to either the installation or lack of installation will not be Koppers responsibility General Deck Requirements The deck is the base over which the KMM memorane is applied. Where the term deck is used without reference to insulation, it shall designate the surface over which roofing is to be applied. Any deck defect shall be corrected before application of roofing. All decks shall be installed in accordance with the deck manufacturer's specifications, and shall be in compliance with Koppers General Requirements. In approving any deck a* satisfactory to recetve a KMM system, only the deck surface is accepted. It I* the r**poctsi6#rty of the building designer and (he deck manufacturer to provide for expansion and contraction in a manner that will provide a stable bate tor the KMM membrane, for support of maximum anticipated loads, tor secure attachments vertically and laterally, and for he selection of the deck material and construction details Including their ability to contain bitumens or adhesives used for attachments of the KMM msmbrene oroilier componentsof * system. Koppers wM not assume responsibility tor deck defects, or the effect of dock delects on Koppers roofs. The placing of conduits, bon heads, ate., above the roof deck and below the roofing membrane is not recommended. All projections or openings in the deck should be completed pnor to the application of the roofing. Insulate ail hot water and steam pipes which project through or are near the surface to be roofed or waterproofed. This is to prevent possible damage to the KMM system. Condition of Roof Surfaces to Receive KMM Membrane All surfaces must be dry, frost free, reasonably smooth, clean, rigid and free from debris, loose materials, protections, holes, release agents or other contaminants which might cause rupture of the membrane and/or adversely affect the KMM membrane application and performance. Oust shall be removed from the surfece immediately before application of the KMM membrane system, especially from those which incorporate the use of KMM Adhesive to adhere the membrane to its substrate. METAL DECKS Decks of this type must also be free from loose rust and oily substances. Deflection should not exceed 1/240 of the span Decks of this type are not suitable for application of KMM membrane without insulation being placed between the deck and the KMM membrane. POURED STRUCTURAL CONCRETE Where insulation is specified on concrete slopes exceeding 2" per foot, insulation stops snail be installed to retain insulation in place. Treated wood insulation stops2" (nom.) wide, and equal to the thickness of the insulation, shall be installed to the top of the surface of the deck by means of bolts, screws, or other acceptable fastener, countersunk to be flush with surface of insulation stop. All concrete and masonry surfaces must be cured, dry and free of loose material. All cracks, holes, voids and open areas snail be wetted with water and then carefully filled with Portland Cement Mortar, struck flush, and permitted to dry. When KMM Adhesive is to be applied directly to the concrete surface, the concrete must be cured, free of moisture, dust and other contaminants including curing agent and form release agents. Over freshly poured concrete or wnere a curing agent has been used, apply a glass base sneet. strip mopped in steep asphalt (12-15 ibs.'sq.) or mechanically fastened with approved fasteners, prior to the application of KMM Adhesive. Concrete surfaces to which KMM Adhesive is directly applied must be primed with Koppers High-Pen Primer 452 at the rate of 1/2-3/4 gal. per square. PRECAST CONCRETE DECKS All joints must be grouted smooth and level with the deck surface. All slab surfaces must be even with the surface of the adjacent slab, or edges must be gradually and smoothly tapered to adjacent slab. When KMM aluminum membrane is to be applied directly to deck surface, prime the surface with Koppers High-Pen Primer 452 at the rate of t/2-3/4 gal. per square, strip all joints with with 6" wide felt stnppmg set in Koppers Plashing Cement or 6" wide KMM Standard membrane substrate-fused. WOOD FWER DECKS KMM Aluminum Membrane should not be applied directly over wood fiber decks. A glass base sheet set in steep asphalt must be applied pnor to the application of KMM Aluminum Membrane. The base sheet shall be laid unattached prior to KMM Standard application. WOOO DECKS Plywood shall be extenor grade. All wood shall be well seasoned, dry. and preferably treated. End joints snail have adequate bearing. Loose or void knot holes, large cracks, etc., shall be covered with appropnate material. All nail heads must be flush with surface of wood decking. KMM* Aluminum Not to be applied directly to wood decking. Where specified over wood decks, the wood surface shall be covered as follows: 1. Plywood (V mm.), or wood plank, or tongue and groove (f nominal mm.). a. Starting at the low edge of the deck, nail an 18" width of No. 15 asphalt felt to the deck. Nail along both lower and upper edges, spacing the nails approximately 18" on centers in staggered fashion. b. Coat the top of the starter strip with 2V3 gals, per 100 sq. ft. of CP Adhesive (steep asphalt is an acceptable substitute). When the edheelve is tacky, place a full 36" width of No. 15 asphalt felt to completely cover the starter stnp keeping the lower edge of the 36" width even with the lower edge of the starter stnp. Broom the felt thoroughly into the adhesive with a stiff bnstie brush. Nail the upper part of the first full ply to the deck at 18" intervals 4" down from the upper edge and t8" intervals 14" down from the upper edge of the felt c. Coat the upper 19" of the first ply of felt with 2'.-i-3 gals, per 100 sq. ft of CP Adhesive. When the edheelve has become tacky, embed the second ply in the adhesive, lapping it 19" over the first ply. Be sure that the second ply covers all nail heads In the flat ply. Broom lower half of felt carefully into adhesive to eliminate wnnkles and fishmouths. Nail the upper portion of the second pty to the deck in the same manner as the fiat. Proceed up the slope m this manner, lapping each sheet 19" over the preceding sheet. There shall be no exposed nail heads In the finished felt application. 22 Single-Ply Roofing Systems (Cont.) KOPPERS 7 1/KO< Architectural and Construction Materials 4 The end of the underlying felt shall be nailed to the deck at 9" intervals approximately 2" in from the end. The end of the overlapping felt snail overlap 6' and shall net be nailed to the deck, but shall be carefully cemented to the underlying stnp making sure that no nail heads are exposed. End laps of any ply shall be staggered at least 2" from end lap of preceding ply. ALTERNATE METHOD: Glass base sheet overlapped 4" at side and 6" at ends, fastened with Berryfast Tapefast System with tape stnps over side laps and two strips in the field equally spaced, or nailed as per Fastener Chart using 100 nails per square. 2. Wood Planks or tongue and groove (2" nominal mm.). A glass base sheet shall be nailed over wood planks with approximately 100 nails per square as per Fastener Chart or fastened with Berryfast Tapefast System using a tape over 4" overlap of base sheet and two tapes m the field equally spaced. KMM* Standard Membrane: When applied over wood decks, lay a glass base sheet unattached over the deck surface, lapping 4" on side and 6" on end laps. POURED GYPSUM Deck must be cleared of dirt and debris and all other foreign matter and all holes, cracks or other voids must be filled flush with the surface. Poured gypsum decks sometimes cause trouble because the roofing is laid before the deck is thoroughly dry. When this happens the result is a blistered and buckled membrane, or. just as serious, insulation curls and makes an unsatisfactory |Ob. The roofing contractor, backed by the architect, must insist on a thoroughly dry deck before beginning work. PRECAST GYPSUM DECKS All joints must be grouted smooth and level witn the deck surface Slab surfaces must be even with the adjacent stab surface or the edges must be gradually and smoothly tapered to the adjacent slab. KMM Standard may fie loose laid directly over the deck surface. Prior to the application of KMM Aluminum, nail a glass base sneet terminating at the base of the cant or at the perimeter of the deck under metal edges. Lightweight Insulating Decks Lightweight Insulating decks include iigntweignt aggregate concrete (20 to 40 lbs. per cu. ft. over dry density); foamed concrete, gypsum and thermosetting asphaltic decks. Except for Dycone Concrete, lightweight insulating deck systems must be capable of venting excess water vapor to the underside. Koppers will not accept these lightweight insulating decks to be placed over vapor barriers, poured concrete substrates, unvented metals, or any type of base which will not permit these materials to vent from the underside. This is necessary to prevent a water vapor pressure build-up under the built-up roofing. Occasional, or spot vents through the roofing as the only venting method are not satisfactory substitutes for underside venting. RECOMMENDED FASTENERS FOR BASE SHEET ATTACHMENT Unless otherwise specified, when a nailed base sheet is to be used as an underlayment for KMM membrane, the base sheet must be a glass base sheet. Side laps are to be 4" and end laps are to be 6". The base sheet shall be fastened with approved nails and the pattern shall be on 9" centers. 2" from the edge lap and staggered down the center of each sheet.. (Note: This is approximately 100 nails per square. Roof PeckFastener Instructions Special Wood-Planks or Tongue & Groove 11, 13,14. 16. 17. 18________ None Plywood. 1/2" min. I.3. 4, 7,8 II,13,14.16. 17.18 See Note 1 None Gypsum. Poured (1-7 Days) Poured (Dry) Structural Wood Fibqr Concrete. Poured -^55. Concrete. Precast Lt. Wt. Insulating Concrete-Poured LL Wt. Insulating Concrete-Precast 6.9 12 2.5.6 15.19 15.19 2. 5. 6. 10 2. 5.6 See Note 1 See Note i See Note t See Note 1 None None See Note 1 See Note 1 Note 1 -- Heads of nails must be covered by one of the following methods: 1) No. 15 asphalt felt or base sneet solid mopped in not asphalt (20 lbs. $q.). 2) 6" squares of base sheet adhered with KMM adhesive. 3) 6" squares of KMM Standard fused in place._____________________ ________ __________________ Typa of Fastener and Source of Supply 1. Roofing nails. 3/8"-7/i6" head. 11 or 12 gauge. 2. Insuldeck hoe-nail-E.G. Bldg. Fasteners. 3. Roofing Nail Annular thread. 3/8" dia. head. 11 gauge. 4. Roofing Nail Spiral thread. 3/8" dia. head. 11 -gauge. 5. Capped ES-Nail. 1" cap -- ES Products. 6.. Tube-Loc Nail, 1" dia. cap -- Simplex. 7. Squarehead Cap Nail, annual thread. 1" cap. 8. Squarehead Cap Nail, spiral thread, i" cap. 9. Nail-Tite Type A, 1 1/4" dia. cap-ES Products. 10. Zono-tite or Nail-Tite MK III, W. R. Grace of ES Products. 11. Roofing Staple. Berryfast Tapefast System. Berryfast. 12. Gypsum Roof Deck Nail (old gypsum decks), Simplex. 13. Dekfast. (steel plate). Construction Fasteners. 14. Dekfast P-(plastic plate). Construction Fasteners. 15. Dekfast C. for concrete (steel or plastic plate). Construction Fasteners. 16. Grefco Perma-fastener, Grefco. 17. GAF. Gaftite, GAF. 18. Fabco Insulfix Type P. Fabco. 19. Fabco Confix (Type P plate), Fabco. In addition, lightweight insulating decks shall have sufficient cohesive strength to provide firm attachment of the roofing to the deck and framing to prevent wind upliftdamageor blowoffs. Nailable decks must be capable of developing at the very minimum, a 40 pound nail pull-out or withdrawal strength. If the materials do not achieve this value, additional fasteners will be required over and above those quantities described in the ensuing specification (standard is approximatety'100 fasteners per square) to achieve a minimum attachment standard of 40 lb. per square foot. Koppers will not be responsible for failure of the insulating deck to remain integral or for disbonding of the roofing from the surface of the deck. Provisions should be made wherever possible to provide additional venting such as notched wood perimeter nailers, etc. in conjunction with the venting from the underside of the deck. If board type insulation is to be applied over a lightweight insulating deck, provisions must be made between the fill and the board insulation to prevent fill moisture from affecting the insulation and roofing. KMM Standard may be loosely laid directly over the deck surface. When KMM Aluminum is specified. .A^glass base sheet must be nailed as per the Fastener Chart, terminating the base sheet at the base of the cant or at the permeter ofthe deck under metal edges. Precast Lightweight Insulating Decks All joints must be grouted smooth and even with the surface of the deck. Slab surfaces must be even with the surface of the adjacent slab or the edges must be gradually and smoothly tapered to the adiacent slab. 23 Single-Ply Roofing Systems (Cont.) Expansion Joints (Building) KMM roofs, especially those employing the loose laid membrane concept, are able to wittistand butiding movement to a greater degree than conventional materials, but good design practices dictate that expansion joints snouid be employed for protection of the overall roofing system. The use. location and design of building expansion |Oints should be taken into consideration at the time of the onginai building design. Although provisions for adequate expansion joints are the responsibility of the building designer. Koppers offers the following recommendations for the protection of the roofing system due to stresses caused by expansion and contraction of the building. Building expansion joints should be installed: 1. On large roof areas at least 200 feet in each direction. 2. At all places where the structural supports and roof assembly change direction. 3. Where types of adjoining deck materials changes. Where control, expansion or contraction joints are provided <n structural steel, deck materials or deck system, provisions must be made for their continuation through the roofing system. Koppers realizes that in a climate-controlled building there may be little or no-expansion attar the building is in use. However, building exoansion loints are still recommended based upon tne following points: 1. Dunng construction, the building will not be under a steady-state temperature/ humidity condition so that thermal and moisture movement can be sufficient to disturb and possibly injure the roofing system. 2. If no building expansion joint is provided, tne owner must keep tne building at the steady-state temperature and humidity condition at all times, as holiday shutdowns may miure the roofing system due to the movement of tne building system resulting from temperature/humidity variation. 3. If the occupancy is fairly large, the sudden entrance on a rainy day of many ram-soaked employees may cause rapid moisture movement m the roof structure system which may damage the roofing system. Underwriters Laboratories Underwriters Laboratories. Inc. Building Materials Directory. Built-up Roofing Covering Materials, lists KMM Membrane for use m construction of class A. B. or C built-up roof coverings. Specifier should consult this directory for complete details. Guarantee A guarantee is available on KMM Membrane roofs when applied by a KMM Qualified Applicator. See page 6 for further information. Wood Nailing Strips All non-nailable decks require wood nailing stnps at eaves, edges, walls, roof openings, etc., for proper securing of metal flanges. Nailers must be securely and firmly attacned to the deck or through to its supporting members. Nailers shall extend not less than 1" beyond the apron or flange. Nailers should be treated to preserve their condition and hence their nail retentive power for the expected life of the roofing. Creosote or oilbom preservatives may affect the roofing they contact and should not be used. Nailers should be pressure-treated with a waterbom preservative such as Wolman* salts or with penta applied in a liquified petroleum gas earner such as the Cation* process. Wolman* and Cation* ar* registered trademarks of Koppers Company. Inc. Traffic Surface Where heavy traffic is anticipated over KMM Membrane, a suitable traffic surface such as Careytrad should be provided. inspection and Patching All KMM membrane must be carefully inspected for construction damage and imperfect heat fusion pnor to the installation of the protective topping, it is advisable to inspect lap fusions at the end of each work day. Any holes or tears must be patched with the appropnate KMM membrane. The patch must extend at least 4" in all directions from the edges of the tear or puncture. Seal into position with interpiy fusion and top sealing for Standard KMM membrane. Seal Aluminum KMM membrane by inter-ply fusion. Streaks or seams of bitumen on Aluminum KMM membrane may be touched up by high quality varnish-base aluminum paint. Waterstops (Temporary Protection) At the end of each day's work, waterstops must be installed to protect the insulation or substrate against water penetration. Waterstops consist of a single ply of KMM membrane (Standard of Aluminum Grade) extending a minimum of 6" beyond the terminal edge of the insulation. The leading edge of the membrane is then substrate-fused to tne deck and top-sealed. Water-stops should be continuous and tight These temporary protective measures must be detached cleanly when work is resumed. KMM Membrane must be removed from the deck back to the top of the insulation. Board Type insulations These insulations come in varying thick nesses and sizes. The insulation manufacturer's specifications shall be followed and. in addition, shall be m compliance with Koppers General Requirements. Roofing equipment must be of a type which will not damage the insulation used. Broken or damaged insulation sheets can only be used when the damaged portion is cut out. No mors insulation shall be laid in a day than can be protected by KMM membrane in case of sudden weather changes. Edges of insulation shall be brought closely together and shall not be forced into placed. Where insulation toins vertical surfaces, the insulation snail be cut in a neat manner, allowing at least V clearance. Insulation joints must be staggered. When more than one layer of insulation is used, joints in each layer shall not coincide. All layers shall be parallel to preceding layers. Vapor Retarder Vapor retarders are normally used where the heat flow direction and/or humidity within the building, during any climate or occupancy cycle, might cause moisture to migrate upward into the insulation chamber. It is important that the vapor retarder provide a continuous seal around ventilators, skylights, peripheral walls, and other terminations from the source of the water vapor. Other Requirements Materials Protection Although KMM membrane is waterproof in the roll. good, practice dictates that it should be protected' when stored outside by raised platforms and adequate cover. Cold Storage and Freezer Buildings KMM roofing systems may be used in cold storage and freezer building applications; with or without a ventilated air space between the deck and the insulated refrigerated area. For specific recommendations, consult your local Koppers representative. When applying KMM Aluminum over rigid insulation boards on roofs with lees than 2" per foot stop*, all insulation joints shall be taped with 6" wide (min.) asphalt felt, reinforced kraft paper tape, embedded in KMM Adhesive (1'i gals/square) or steep asphalt. Glass fiber roofing tape embedded in steep asphalt or 6" wide KMM Standard, fused and featheredged may also be used. When taping is required, insulation joints should be laid continuous to facilitate taping. This procedure also applies to top layer of multi-lay.ers of insulation when taping is required. Insulation applied over roofs with a barrel configuration snail be covered with a ply of base sheet set in steep asphalt and glaze coated, prior to the application of KMM. When slope is under 2"/fl and a ply of base sheet is applied over the insulation, taping may be omitted. However, all insulation and felt must be roofed over with KMM. and not left uncovered overnight 24 Single-Ply Roofing Systems (Cont.) General Terminology and Reroofing Application information Fiberglass insulation boards are approved underiayments tor KMM Aluminum and Standard. Perlite insulation may be used under KMM Aluminum only when a No. 15 aspnalt felt is firmly attached to the perlite with steep asphalt, prior to the application of KMM Aluminum KMM Standard may be loose laid directly over the perlite insulation. Polystyrene Is not acceptable under KMM Aluminum. Polystyrene witn minimum 1.5 lb. density is acceptable under KMM Standard when polystyrene is covered with a loose laid base sheet. No. 15 aspnalt felt may be used instead of the base sheet, over polystyrene with minimum 2 lb. density. Fiberboetd insulation may be used under KMM Standard only when a No. 15 asphalt felt is laid loose over the fiberooard or under KMM Aluminum if the No. 15 asphalt felt is firmly attached with steep asphalt. Under loose laid KMM Standard Membrane, insulation other than urethane, urethane composite, and isocyanurate may be laid loose if the thickness of the board is minimum 3/4". Care must be exercised to insure snug joints. Terminology Heat Fusion Heat fusion is a general term used to descnbe specific metnods of adhesion of one layer of KMM membrane to another surface. In the process of heat fusion, the bitumen of the membrane is neated with a direct flame until it is plastic enough to flow under pressure. When pressure is immediately exerted to this softened bitumen, it fuses to the surface to which it is applied. Specific types of heat fusion are described below. It should be noted that the external plastic film present will break and draw apart with the proper application of the flame. Urethane and urethane composite insulation boards over metal decks must be mechanically fastened with 5 approved fasteners per 3' x 4' board. Fasteners must be located at each comer and in the center of the board. For double layer applications, it is acceptable to fasten the first layer and solid mop the second layer in steep aspnalt at the rate of 30 lbs. per square. On other decks and over existing smooth surface, urethane and urethane composite boards may be mechanically 'astened as stated above, or solid mopped m steep asphalt at the minimum rate of approximately 30 lbs. of asphalt but of sufficient quantity to insure maximum attacnment. Over existing gravel surfaces, insulation must be mechanically fastened. Uretnane and urethane composite ooards must not be applied over existing roofs if the existing insulation is not dry. Consult your Koppers Representative for use of other types of insulation. insulation Attachment Where attachment of insulation is required in these specifications, adhesive and/or fasteners must posses a minimum uplift resistance of 40 pounds per square foot (PSF). Suitability of the kind of attachment is dependent upon the type of insulation and its substrate This should be investigated by the specifier along with the various requirements, including wind uplift resistance, as descnbed m the local building code and/or policies of the insurance agencies involved. Koppers will accept the use of mechanical fasteners providing insulation manufacturer recommendations are followed, and Ihe fastener is one of the following Deklast Crelco Perma-lastener GAF Gafite or FASCO insui-Fixx Type P Other types ol FM Approved fasteners may be used providing 11 a No 15 Aspnait Felt or base sheet is solid mopped m aspnalt to cover all insulation or 2) an lasiener neaos are covered with 6' squares or Base sneet adhered wnn KMM Adhesive, or 3i 6" squaie ol KMM are fused over fastener nuaos Substrate fusion is the specific type of heat fusion used to secure the KMM membrane to a substrate. The underside of the KMM membrane is heated until plastic. The heated underside is then quickly pushed or forced against the substrate surface so that a slight "run-out" of bitumen from beneath the edge of the membrane is observed. A 4"-wide fused seal is to be obtained. Inteipiy fusion is the specific type of heat fusion used to obtain a waterproof seal between two overlapping sections of KMM membrane. In practice, the flame is applied simultaneously to both surfaces' of KMM membrane until each becomes plastic. For KMM Aluminum membrane end laps, heat the bottom of the overlapping section until it becomes plastic. The two surfaces are pressed together to form a fused lap or seam of at least 4" m width. A slight "run-out" of bitumen from the lap joint is to be obtained. Top seating is the specific type of heat fusion used to make the second seal at substratefusad and mterply-fused iomts. It la applicable only to KMM Standard membrana. Top sealing is accomplished by heating a 2" to 3" section at the edge of the top sheet until plastic. To develop a smooth, continuous filled joint, move the softened bitumen from the top sheet over the |Oint and onto the overfapped membrane with a roundnosed trowel. Heat fusion equipment The recommended torch equipment for fusing KMM laps is the KMM Torch Tip attached to the Goss AP-8 or Ap-12 handle. A rqundnosed KMM Trowel is recommended for substrate fusion, interply fusion and top sealing. KMM Aluminum interplay Fusion The watertight lap is obtained on Aluminum KMM membrane by the heat-fusion attachment of the upper sheet to the exposed 4" selvage edge of the lower sheet. Overlapping membrane must extend over the selvage edge and approximately V onto the aluminum surface. Curing interply fusion of this lap. a bitumen bead shall be forced from between the mated edges. A slight heating of the edge of the upper aluminum surface while pressing with a trowel will also De beneficial in obtaining a uniform waterproof bond. KOPPERS 7 1/KOP Architectural and Construction Materials Bituminous Aggregate Topping (BAT) BAT consists ot a combination of graded gravel and KMM aggregate binder. See Page 26 for complete description. Recommenaed quantity of gravel is 650 to 700 lbs. per square (approximately V to v thickness). Loose Aggregate Topping Loose aggregate topping consists of a stone aggregate applied loose over. Koppers Stonemat and the KMM membrane at a minimum rate of 1.000 lbs per square (approximately IV thickness of loose stonei. Note: Slag, soft limestone, and crusned coral are not permissible aggregates. Reroofing Specifications Rerooting Design Considerations: Dunng me reroof design and specification phase, and prior to commencement of roofing work, it is the responsibility of the building owner to nave his architectural ana/or structural consultant ascertain if the existing roof structure with the new roof installed will meet all local building codes, including structural limitations. If additional insulation is to be part of the reroof, an evaluation of the dew point location and its effect on the roofing system snail be determined by the owner. Note: Koppers will not be responsible for any damage caused by excess loads on structural systems or damage due to rate or change in location of dew point. Condition of Surface to Receive KMM Membrane a. Gravel Surfaced Roofs: Remove loose gravel and repair any existing blisters, buckles, etc. Apply a minimum V approved insulation, mechanically fastened, prior to application of KMM Membrane. b. Smooth Surfaced Roofs: Remove or repair, as necessary, any blisters or other abnormality of the existing membrane to give a surface which is free of sharp edges prior to the application of KMM membrane. Repairs must be made with layer of Standaro KMM membrane substrate-fused and top sealed at the edges. Prior to applying KMM Adhesive for KMM Aluminum Membrane application, prime roof surface with Hi-Pen 452 Primer at the rate of approx. gallon per 100 ft/ c. Moisture in the Existing Roof: KMM Aluminum membrane (Specification No. 630) is always adhered to the substrate, it is not recommended for application directly over roofs wmch contain moisture without taking precautions to allow venting of the entrapped water vapor pressure. KMM Standard membrane (Specification Nos. 6f0. 620 and 690) is.lqosely laid and ballasted by an aggregate topping. This system will tolerate Oampness in tne substrate and. depending upon the existing situation, extra precautions may be required such as spot or penmeter venting. Note: For recommendations regarding specific precautions to be taken, see your local Koppers sales representative. Single-Ply Roofing Systems (Cont.) Loose Aggregate Topping and BAT Installation Information Loose Aggregate Top Surfacing for Specification 610 A. Aggregate Washed round river gravel graded to V nominal size (S.P No. 57 -- U.S. Department of Commerce Simplified Practice Recommendation R-163). See "Aggregate Size Table" below. Where washed round nver gravel is not available, aggregate samples must be submitted to Koppers representative for approval. B. Application 1. Stonemat must be installed prior to aggregate surfacing, overlaying 4" minimum at end and side laps. Stonemat must extend at least 2" beyond edge of aggregateat perimeter of roof but in no case should it extend beyond outside edge of gravel stop. Stonemat must completely cover KMM Standard. 2. Over the Stonemat. apply loose aggregate at the rate of 1000 lbs. min. per sq. (approx. 1W thickness of loose stone). 3. Aggregate application by gravel buggy is recommended. Slag is not a permissible aggregate. Koppers Bituminous Aggregate Topping (BAT) --Top Surfacing for Specification 620 BAT topping consists of graded gravel and KMM Aggregate Binder. The BAT is applied to the roof as tooomg at the rate of 650 to 700 lbs. per square lapproximately X" to 1" thickness). A. Materials KMM Aggregate Binder was formulated for binding the specified aggregate applied over KMM Standard roof systems to protect the KMM membrane. KMM Aggregate Binder is not intended for use as an adhesive or repair matenal. Binder should be kept in warm storage dunng cold weather. Aggregate: The gravel aggregate is to be clean and size graded to nominal H" round gravel. (This is equivalent to S.P. No. 8-- U.S. Department of Commerce Simplified Practice Recommendation R-163). spray equipment. Keep KMM Aggregate Binder at room temperature prior to pumping dunng cold weather. 3. An additional layer of aggregate is then applied over the binder at the rate of 200-225 lbs. per 100 sq. ft. to achieve a finished surface. Aggregate application by gravel buggy >s recommended. Heavy accumulations of aggre gate should be evenly distributed. Wooden or steel implements snould not be used Aggre gate should be applied immediately after applying KMM Aggregate Binder Paver Stones B. General Application Instructions Preparation: 1. BAT is applied when the KMM roofing and flashing applications are complete. 2. Roof surface must be free of ponded water. 3. Lay No 15 non-perforated asphalt felt loosely over KMM Membrane prior to BAT topping. Paver stones are acceptable ballast as long as minimum weight is 1000 lbs. per square. A. Application: 1. Pavers must be set on pedestals such as Terring Rings. Pavers must fit sncigiy against spacers. 2. As an alternative to above-mentioned pedes tals. pavers may be set on 6" squares of v." thick traffic pad such as Careytred. Corners of pavers must be centered on 6" squares allowing Application of BAT Topping: BAT is applied m three steps resulting in a protective topping weighing 650-700 pounds per square. The steps are as follows: an approximate 7<" gap between pavers. B. Maintenance: Regular inspections (twice annually) must be made to ascertain that pavers and pedestals remain intact. Deteriorated and broken pavers 1. Gravel aggregate is applied at the rate of and pedestals must be replaced to prevent 450-175 lbs. per 100 sq. ft. on the No. 15 damage to the KMM membrane If deteriorated felt. Aggregate application by gravel buggy or broken pavers and/or pedestals are discov - is recommended. ered. inspect KMM for damage. 2. KMM Aggregate Binder should be stirred thoroughly until the material is of uniform consistency. KMM Aggregate Binder is spray ed on the aggregate at the rate of approxi mately 3 gallons per 100 sq. ft. using suitable Aggregate Size Table Grading Requirements for Coarse Aggregates from ASTM Standard C 33--Standard Specification for Concrete Aggregate Use Size 48 in making Bituminous Aggregate Topping (BAT). Use Size 457 for Loose Aggregate Topping. Size Number 57 8 Nominal Size (Sieves with Square Openings) 1 in to No 4 (25 0 to 4 75 mm) X in to No 8 '9 5 to 2.36 mm) 1)4 in. (37.5 mm) 100 Amounts Finer than Each Laboratory Sieve (Square Openings), Weight Percent i m. X in. X In. X in. No. 4 No. 8 (25.0 (19.0 ' (12.5 (9.5 (4.75 (2.36 mm) mm) mm) mm) mm) mm) 95 to 100 _ 25 to 60 Oto 10 Oto 5 100 85 to 100 10 to 30 Oto 10 No. 16 (1.18 mm) Oto 5 26 F Single-Ply Roofing Systems (Cont.) KMM Roofing Systems KOPPERS 7 1/KOP Architectural ind Construction Materials Loose Aggregate Topping System Specification No. 610 Bituminous Aggregate Topping (BAT) System Specification No. 620 General Information A. Pnor to beginning installation of the KMM roofing system substrates shall be inspected by the roofing contractor for dryness, smoothness, rigidity and freedom from debris. All projections and holes which might cause rupture of the membrane are to be repaired. Review "Conditions of Surface to Receive KMM Membrane". Page 22. B. End laps of KMM Standard membrane shall be staggered a minimum of 6". Interply fusion of side lap shall be completed before fusing end lap of the same sheet. Procedure General Requirements on Page 21 through 26 and Flashing Oetaif/Specifications on pages 30 through 32 are a part of this specification and must be adhered to where applicable. 1. Prior to starting the application of the roofing membrane, cushioning or stripping layers of Standard Grade KMM membrane snail be applied in areas of potentially high stress or sharp edges. These areas include interior and extenor corners, maior changes in directions of slope, metal flanges, etc. Cushioning layers snail be applied prior to the mam KMM membrane system and shall be fused m place, and then top-sealed to form a smooth transition surface. 2. Determine the direction of water drainage and the low point of the deck. The direction of laps snail be such that the water flow is not against the laps. The direction of the overlap shall be changed as the direction of the water flow changes. 3. Beginning at the low point of the roof slope, install one ply of KMM Standard membrane. The membrane snail be laid in a fasnion which does not cause water to pass against the lap. 4. Each sheet of KMM membrane shall be set m place for 30 minutes and shall be stretched to remove any wrinkles prior to fusion. 5. All side and end laps shall be 4" and interply-fused and top-sealed. Pressure shall be applied to the top of lap to insure solid fusion. 8. Extend the KMM Standard roofing membrane a minimum of 4" above all cants. Substrate-fuse to face of cant and wall, and top-seal along the upper terminal edge. When fusing KMM to wood or other matenals that easily burn, apply torch to KMM only and press KMM into place. Wood surfaces must be primed with High Pen Pnmer 452 and allowed to dry, prior to fusion of KMM. 7. The contractor shall thoroughly inspect completed KMM membrane at the end of each day's work as well as just before top sealing. 8. Install KMM Aluminum flashings in accordance with flashing specification described on Pages 30 to 32. 9. When the flashings have been completed, lay Stonemat to completely cover KMM that will receive loose aggregate or No. 15 nonperforated asphalt felt when BAT is used. Install a loose aggregate over Stonemat or bituminous aggregate topping over No. 15 non-perforated aspnalt felt. Refer to Page 26 for topping information. C. Any KMM Standard membrane which will not otherwise be covered by a topping shall be protected with a layer of Aluminum KMM membrane extending a minimum of 4" beyond the edges of the unprotected membrane and substrate-fused around its perimeter. Specific details of the installation must be agreed upon between the architect and Koppers prior to installation. 0. Coat face of fiber cant strip with kmm Adhesive (approximately 2 gals/squarei and allow to dry before fusing KMM roofing membrane to cant. E. At the end of each day's work, temporary waterstops must be installed to protect them from water penetration. Waterstops must be completely removed before continuation of application. See Page 23. F. Prime new and existing metal, porous walls including wood with High Pen Primer 452 at the rate of gal/square. Allow to dry. G. For reroofing information, refer to Page 25. Materials Slope requirements: per 100 sq. ft. of roof 1" per foot maximum with loose aggregate KMM Membrane (Standard) 1 ply topping. IV per foot maximum with BAT Stonemat or No 15 Non-Perforated topping. 1" per foot maximum with Paver Asonait Felt 1 ply Stones. Surfacmgs Loose Aggregate 1.000 lbs. min 8AT System 650 lbs. min. Paver Slones 1 000 lbs mm 27 Single-Ply Roofing Systems (Cont.) Specification No. 630 Procedure General Requirements of Pages 21 through 26 and Fiasnmg Oetail/Specifications on Pages 30 to 32 are a part of this specification and must be adhered to where applicable. 1. Prior to starting the application of the roofing membrane, cushioning or stnpping layers of Standard Grade KMM membrane shall be applied in areas of potentially high stress or sharp edges. These areas include interior and exterior corners, major changes in directions of slope, metal flanges, etc. Cushioning layers shall be applied prior to the main KMM membrane system and shall be fused in place and top-sealed to form asmooth transition surface. 2. Determine the direction of water drainage and the low point of the deck. The direction of laps shall be such that the water flow is not against the laps. The direction of the overlap shall be changed as the direction of the water flow changes. The selvage edge of the Aiuminum KMM membrane shall be positioned on the high Side so that the direction of the flow of water is not against the laps. 3. Starting at the low point of the deck, set the KMM Aluminum membrane into a full bed of KMM Adhesive (application rate of 1 to 1 '`i gaf. per square)' while the adhesive is still slightly wet Stiff broom thoroughly moving broom from center to edges of membrane to obtain proper adhesion and to remove all entrapped air from under the membrane. The use Of a linoleum roller is also acceptable. 4. Subsequent courses are to be laid with 4" end and 4W side laps, from the first course progressing to tne high point Allow laps to remain open as long as possible before fusing. Side lap shall be interply fused prior to mterpty fusing of the end lap of the same sheet. Pressure shall be applied on the top of the lap to insure solid contact. 5. Extend the KMM Aluminum roofing membrane a minimum of 4" above all cants. Substrate fuse to face of cant and wall. When fusing KMM to wood or other materials that bum easily, apply torch toKMM only and press KMM into place. Wood surfaces must be primed with High Pen Pnmer 452 prior to fusion of KMM. t. The contractor shall thoroughly inspect the completed KMM membrane at the end of each day's work and when the iob is finished. 7. Install KMM Aluminum Flashings in accordance with flashing specifications described on Pages 30 to 32. .8 Alter completion of the Aluminum KMM roof and flashing system, a high quality "chrome paint" may be applied toan^xposed streaks or seams of bitumen. General Information A. Prior to beginning installation of the KMM roofing system, substrates snail be inspected by the roofing contractor for dryness. Smoothness, rigidity and freedom from debris. All protections and holes which might cause rupture of the membrane are to be repaired. Review "Conditions of Surface to Receive KMM Membrane". Page 22. B. End laps of KMM Aluminum membrane shall be staggered a minimum of 6" Interply fusion of side lap shall be completed before fusing end lap of the same sheet. C. Coat face of fiber cant strips with KMM Adhesive (approximately 2 gaisr square) and allow to dry before fusing KMM roofing membrane to cant. O. Prime new and existing metal, porous walls and decks including wood to which KMM Aluminum or KMM Adhesive will be applied, using Htgh-Pen Primer 452 at the rate of Ys-% gal/square. Allow to dry. E. Valleys of roofs sloped 2" per foot or more shall have a layer of KMM Standard applied prior to application of KMM Aluminum. KMM Standard shall be set m KMM Adhesive (I'j-2 gals/square) and top-sealed. KMM Standard shall extend a minimum of 12" up the roof slope and 6" up vertical surfaces. Laps shall be 4" at side and end laps, interpty-fused and topsealed. F. Leave laps of KMM Aluminum membrane open and delay fusion as long as possible. Be certain that all laps are fused before leaving |Ob for the day. G. At the end of each day's work, temporary waterstops must be installed to protect from water penetration. Waterstops must be completely remoVikl before continuation of application. See Page 23. H. KMM Adhesive can be applied by brush, roller, or squeegee. Do not thin adhesive. Mix thoroughly. f. KMM membrane shall be set into adhesive while adhesive is still slightly wet. J. Adhesive application to porous insulation boards will require approximately 50% more tnan specified amount of adhesive. K. For reroofing information, refer to Page 25 L. Overlap of side laps must extend ." onto aluminum surface. M. Adhesive should be stored at room temperature to facilitate application. Oo not apply to frosty or moist surfaces. Materials per 100 so. ft. of roof KMM Adhesive KMM Membrane (Aluminum) Slope Requirements v" per foot with positive drainage. Koppers will not be responsible for damage caused by 1-1)4 gal.* ponding water. 1 ply 'Depending upon the porosity of the roof deck or insulation, additional KMM Adhesive may be required. 28 Single-Ply Roofing Systems (Cont.) KMM Insulated Roof Membrane Assembly Specification No. 690 KOPPERS 7 1/KOP Architectural and Construction Materials 4. Aggregate Surfacing After placement of STYROFOAM RM. install Stonemat over insulation overlapping 12" ana immediately place aggregate over Stonemat. No fabric |Oints within 6' Of perimeter At root penmetef. Stonemat snail extend a minimum of 2"-3" beyond edge of foam. An additional 4piece of fabnc is required around protections. Aggregate shall comply with ASTM C-33 Size Number 57 or v crushed stone. Apply the aggregate at the rate of 1000 lbs. per square (10 PSF). As a general rule. V stone at 1000 lbs. per square will be approximately iv thick. Place 2000 lbs/ square of ballast or 17 Ibs/ft* paved around perimeter, drams, and large penetrations. Concrete pavers may be substituted tor the stone to provide added usefulness to me roof area and to provide resistance to extreme winds. Pavers must sit on pedestals. Oecorative stone top surfacing of the correct gradation can be used for architectural impact. General Information Not*: The following general specification is intended only as a guide. For more specific' information, consult your Koppers represen tative. Procedure General Requirements on pages 21 to 26 are a part of this specification and must be adhered to where applicable. 1. Decks A. Poured and precast concrete, gypsum and lightweight concrete decks shall havt KMM Standard Membrana laid-directly on the deck following guidelines on page 22. B. Wood and wood fiber decks shall have a base sheet laid over deck unattached to the deck. C. Steel Decks shall be no lighter than 22 gauge. Install a rigid board of W min. gypsum or v min. mineral board. Be certain thick ness of insulation board is adequate for flute span, 'n gypsum board shall be firmly at tached to deck with steep asphalt at the rate of 15 lbs. per soutre. cow adhesive as per manufacturer's instructions, or mechanical fasteners approved by Koppers. Minimum of four fasteners per board is required and shaft be located at the comers. 12" from the edge*. Rigid board V." or thicker shall be attached with steep asphalt, cold adhesive, or two approved fasteners per board, or may be laid loose. 2. KMM* Standard Msmbrans Application KMM* Standard Membrane shall be applied as per KMM Roofing System Specification No. 610. Flashing shall be in accordance with appropriate KMM Flashing Specification. 3. Installation of Styrofoam RM* Brand Plastic Foam It is recommended that STYROFOAM RM brand plasticfotm be placed on the membrane aa the membrane is completed. Install the boards CHANNELED SIDE DOWN with doted jomts: stagger end joints. The maximum acceptable opening on a random basis is V. Install the foam to within V." to V." of projection and cant stripe. WARNING: STYROFOAM brand insulation is combustible and may constitute a fire hazard if improptrty used or installed. It should be adequately protected. Use only as directed by the specific instructions for this product. STYROFOAM brand insulation contains a flame retardant additive to inhibit accidental ignition from small fire sources. During ship ping. storage, installation and use. this material should not be exposed to open flames or other ignition sources. For proper protection of STYROFOAM brand plastic foam in storage, consult the National Fire Protection Association (NFPA) standards or the authority having jurisdiction. Materials per 100 sq. ft. of root KMM Standard Styrofoam RM Stonemat Aggregate ipiy Desired Thickness i ply 1000 lbs. minimum Slope Requirements 2" Maximum Positive drainage is required. Thermal value of STYROFOAM brand plastic foam insulation. Average values based on five year aging of one inch samples at 75'F when tested by ASTM C177 and/or C518. ThickniH "R* c* 1 5.00 0.20 I'/. 6.25 0.16 1% 750 0.133 IV. 8.75 0.114 2 10.00 0.10 Z'tt 12.50 0.08 3 15.00 0.067 3'A 17.50 0.057 2. Expoaad STYROFOAM RM is subject to yellowing due to direct radiation of sunlight. If STYROFOAM RM is exposed for longer than 3 weeks it is necessary for a Koppers repre sentative to authonze continuing the instal lation. 3. Roofs must be designed and constructed to drain completely free of water within 48 hours following a rain. Due to the deflection of sM decks, it is almost always necessary to provide slopes to property placed drams. The drain must be set directly on the deck so that the clamping nng is not nigher man the ngid board. Sumps are recommended. 4. All flashing must be completed in each area prior tp installing STYROFOAM RM. 5. Because me stone is not applied in bitumen it need not be dry and installation can occur in any weather. 8. The wood or plywood deck must be properly attached to supporting members and must be of sufficient thickness to prevent excessive deflection between-supporting members. Wood roof decks shall consist of well-seasoned lumber, and edges of the board snail be tongued and grooved, ship-lapped or splined to prevent differential flexing of the boards. Any significant voids shall be covered with sheet metal. `Trademark of the Dow Chemical Company 29 Single-Ply Roofing Systems (Cont.) KMM Flashing Specifications KOPPERS 7 1/KOP Architectural and Construction Materials Description Flashings are the terminal closures of a roofing system which perform a waterproof ing. and m some systems, a decorative function. Flashings must be installed at all intersections formed by vertical surfaces. Their importance cannot be stressed too strongly. Water entering the roofing system through flashings can result in water vapor forces which can destroy the effectiveness of the roofing and insulation. Koppers flashings are an integral part of a Koppers roof. Designed for flexibility. KMM Aluminum flashings will provide many years of service. Flashings should be installed as roofing progresses to prevent possible water damage to insulation and/or deck under the roofing. General Requirements 1. AH surfaces must be dry. frost free, reasonably smooth, clean, rigid and free from debns. loose matenais. proiections. holes, release agents or other contaminants which might cause rupture of the membrane and/or adversely affect the KMM membrane appli cation and performance. Dust shall be removed from the surface immediately before application of the KMM Flashing system. 2. If bonded/guaranteed flashing is required, it must be installed in coniunction with a Koppers bonded/guaranteed roof and can be bonded/guaranteed for standard periods up to but not greater than the period for which the roofing is bonded/guaranteed. To be bonded/guaranteed, flashings must be sat at least 12" above the roofing surface. 3. Metal Cap flashings are not bondabie and are not included under any flashing bond/guarantee. 4. Metal work of any description used as flashing or a part of a flashing system is not bondabie _and is not included under any flashing BMMguarantee. 5. vertical flashing that terminates without use of metal counterflashing, must be stripped with S" wide KMMi Aluminum Membrane totally fused 4" onto mis wall and 4" onto the KMM Aluminum Membrane. 6. Cant strips snail be set firmly into place with mastic or hot bitumen prior to laying roof membrane. 7. Porous walls including wood must be primed with High Pen Primer 452 at a rate of V gal/square. Allow primer to dry. (Minimum 4 hours). .8 Corners shall be lapped a minimum of 6" in each direction. 8. All metal and wood to .jtfitch KMM membrane wiH be fused shall pifSioated with High Pen Pnmer 452 or KMM Adhesive and allowed to dry before fusion of KMM membrane. 10. Where KMM flashing is to be installed on a building with a non-wall-supported deck (tilt slab precast masonry, curtain wall, etc.) refer to Non-Wall Support flashing detail on page 32. 11. Copper must not come in direct contact with the aluminum surface of KMM. When there is a possibility of such contact, coat the underside of the copper with Koppers Aspnait Roof Coating 454 or KMM Adhesive. Flashing Specification No. 710 Base Flashing For flashing with maximum height of 14" from roof surface Application Detail Haggle to Be Sealed Metal Counter Flashing Extend Downward 4" Min (optional) Prime with Koooers High-PEN Pnmer 452 KMM Aluminum Cant Stno io Be Set in Bitumen or Mastic Koooers KMM Rooting System KMM to Extend a Mm of 4-on to Roofing I-- Deckormautation Cementitious Type Will 1. KMM Aluminum membrane shall be unrolled and cut to desired width and maxi mum lengtn of 11 feet. Note: KMM Aluminum membrane is available in precut rolls 9". 12" and 18" wide by 33' long 2. No 710 Base Flashing shall be fused in place so that it extends a m'inimum 4" onto surface of roof and a minimum of 4" above termination of roofing membrane on wall. 3. Apply pressure to KMM Aluminum mem brane to obtain maximum contact to surface 30 to which it is applied. There shall be no voids under the Base Flashing membrane. It is imperative that complete attachment be obtained to roof surface, roofing membrane over cant, and the wall. A small bead of bitumen should be squeezed out at edges. 4. Subsequent stnps of Base Flashing shall be fused in place in the same fashion over lapping preceding strip 4" Overlap shall be mterply fused to preceding stnp Pressure shall be applied to surface of lap to insure adhesion 5. There shall be no adhesive used m No. 710 Base Flashing application 8. The flashing must not remain open at the end of the work day. 7. The contractor shall thoroughly inspect the completed flashing system at the end of each day's work. 8. A high quality ''chrome'-) paint may be applied to any exposed streaks or seams of bitumen. 9. Install metal counterflashings as required 10. Complete the top surfacing of the roofing membrane to the base of the cant strip as may be specified. Singie-Ply Roofing Systems (Cont.) V HOPPERS 7 1/KOP Architectural and Construction Materials Flashing Specification No. 720 Wall Flashing For flashing with maximum height of 28" from surface of roof num membrane to obtain maximum contact to the wall. There shall be no voids under the Wail Flashing membrane. It is imperative that the membrane is completely and tightly fused to the wall. A small bead of bitumen should be Squeezed out at edges. 5. 4" overlap shall be interply fused to the Base Flashing, applying pressure to the surface of the lap to insure adhesion. 6. Subsequent strips of KMM Aluminum membrane shall be fused into place over lapping the preceding Wall Flashing 4". Overtap shall be interply fused and pressure applied to the surface of the lap to insure adhesion. 7. The contractor shall thoroughly inspect the complete flashing system at the end of each day's work. Procedure 1. Apply Base Flashing in accordance with Flashing Specification No 710. Note: KMM Aluminum membrane is available m precut rolls of 9". 12" and 18" wide by 33" long. 8. A high quality "chrome" paint may be applied to any exposed streaks or seams of bitumen. 2. KMM Aluminum membrane used in No. 720 3. KMM Aluminum membrane strips shall be 9. Insult meui counterflashing as required. I Wall Flashing specification shall be unrolled and cut to a maximum length of ii feet and maximum width of 18 inches. Selvage edge should not be used. fused into place, overlapping Base Flashing 4". Total substrate fusion to the wall must be achieved. 4. Apply pressure to the fused KMM Alumi 10. Complete the top surfacing of the roofing membrane to the base of the cant strip as may be specified. Flashing Specification No. 730 High Wall Flashing For flashing with a height in excess of 28" from surface of roof Alternate Method No. 1: Apply flashing using procedure outlined in Flashing Specification No. 720. overlapping 4" onto previously applied lower course, and base flashing. 1. Apply Base Flashing in accordance with Flashing Specification No. 710. 2. KMM Aluminum membrane used for High Wall Flashing shall be unrolled and cut into lengths not exceeding 48" Remove the selvage edge, leaving a maximum width of 39". 3. Totally substrate fuse KMM Aluminum Membrane to the wall m pieces not to exceed 39" wide by 48" nigh with 4" overlaps on base flashing and previously applied pieces. 4. Each piece of KMM Aluminum membrane shall be applied with the 48" maximum length extending vertically up the wall. It shall overlap the previously applied course of Base Flashing Alternate Method 2: Apply KMM Adhesive over surface to which the High Wall Flashing is to be applied at a rate of 1 to 1 1-2 gallons per 100 square feet, applying half on primed wall and halt on underside of membrane. Permit volatiles to leave adhesive after application (S to 20 minutes depending on temperature and atmospheric condition). BEFORE adhesive has filmed over and while slightly wet. set KMM Aluminum membrane into place. 5. Rub, brush or roll thoroughly to obuin proper adhesion and to remove all entrapped air from under the flashing membrane. 6. The contractor shall thoroughly inspect the completed flashing system at the end of each day's work. 7. A high quality "chrome" paint may be applied to any exposed streaks or seams of bitumen. Note: At temperatures below 40' F tack time of adhesive will be extended considerably and special care must be exercised to insure adhesion of membrane. KMM Aluminum membrane used for High Wall Flashing shall be unrolled and cut into lengths not exceeding 48". Remove the selvage edge, leaving a maximum width-of 39" Each piece of KMM Aluminum membrane shall be applied with the 48" maximum length extending vertically up the.wall, it shall overlap the previously applied course of Base Flashing or High Wail Flashing a minimum of 4". 8. Install metal counterftashing as required. 9. Complete the top surfacing of the roofing membrane to the base of the cant stnp as may be specified. Substrate fuse complete perimeter of each piece of Wall Flashing 4" to wall, and interply fuse to previously applied High Wall and/or Base Flashing. 31 Single-Ply Roofing Systems (Cont.) Flashing Specification No. 760 Horizontal Hashing Horizontal Flashing KMM Adhewve or "umnum M*mor*n* AS2 Pnmtron Metal / Asph4rt\ ROOf \ maatic\ \ / / KMM Standard Mamorane / Topping aa / Reqtarsd f\ ^ ^ aPs Trtatadwood nailer <4? Stonemat Insulation Procedure 1. All mai to be covered witti KMM Mem brane shall be coated with High Pen Pnmer 452 or KMM Adhesive. Allow to dry thoroughly. 2. Stop metal flanges using 4" minimum widths of KMM Standard membrane as a cushioning stop centered along the length of the entire edge of the flange. The cushion ing must cover the edge of the metal where it meets the roofing membrane a minimum of 2" and must cover all nail heads. The balance of the width of the cushioning strip must extend a minimum of 2" onto the roofing membrane Cushioning stnp shall be fused to the roofing membrane and the metal flange and top sealed at edges. 3. Fuse a stnp of KMM Aluminum membrane fapproximately 10" wide) to the cushioning strip, roofing membrane, and metal flange so that it extends 4" beyond edge of cushion ing stnp onto roof membrane and to the outer edge of metal flange 4. Apply pressure to surface of fused KMM membrane to insure adhesion and solid fusion 5. Apply surfacing to roof membrane as may be required. Hanging Gutter Refer to Specification No. 760 KMM Aluminum Mtmbnne KMM Asphalt Standard Roof m*mc KMM Standard Cushioning Memoran* Suosuate-tusedi Metal Brace 30" O.C. \ ---------- Hatch--Curb--Expansion Joint Togging** Requrad Substrate-fund KMM AHaninuin MUtemaolurwawu iftwprjMuMQ KMM Standard Mamorand SubMrsts-fund Inttrply-fuaid Non-Wail Support Flashing Haggle to be Sailed Metal Reglet insert for removable eountirflahing Fasteners - approx. 24' O.C. Removable counwrfieshmg Flexible vapor retarder to am as insulation retainer. ComprseaiWe insulation KMM Flashmg Soecificspon No. 710 Cant stnp set in bitumen or mastic. Traaied wood nailer (Fastan to deck only) Not* Suggaaiad Oeuii where possibility eitsta mat ditferentiai movement will occur between deck and vertical surtaca. The detail mianoedasa guide only ___________ Roof Drain Stonemat interpty-fused Cushion Stnp Lead flashing set in mastic Interply-fused Substrate-fused Note: Do not apply flame directty to lead flashing 32 \ KOPPERS 7,1/KOP Architectural and Construction Materials ations and related e poesibilities of a XXication. yean experience in the waterproofing field and offers the specifier engineering assistance in achiev ing the best possible waterproofing systems. Waterproofing and Dampproofing Systems (Cont.) Coal tar pia2a deck and wall waterproofing systems Membrane Waterproofing Materials a. Coal Tar Waterproofing Bitumen A.S.T.M. 0450 Type III. b. Membrane (Select one or combination). GLASFA8--A.S.T.M. 01668. Tar Saturated Cotton Fabric--A.S.T.M. 0173 Tarred felt -A.S.T.M. 0227. c. Concrete Priming Oil--A.S.T.M. 043-41. General Requirements a. Preparation of surfaces: Surfaces to be waterproofed shall be reasonably smooth and free from holes or projections which might cause puncture of the membrane. The surface shall be dry and thoroughly cleaned to remove dust and loose materials imme diately before application of the waterproof ing. Do not apply waterproofing where effects of freezing or moisture will adversely affect the waterproofing application. b. Applicator All membrane waterproofing shall be aoplied by an experienced roofing and waterproofing contractor. Application Precautions a. Waterproofing bitumen shall not be heated above 425F b. Roll or press firmly all plies of membrane into the hot bitumen and apply without wrinkles, buckles or kinks. c. On vertical walls apply hot bitumen with cotton roller mops or by other suitable application techniques. d. Apply membranes on vertical surfaces in courses not exceeding ten feet in length where immediate and careful backfilling is not possible. After each course of the water proofing system is completed and before the top mopping is applied: nail each course at the upper edge before the.next course is applied. Nail each succeeding course endlapping not less than 10 inches. e. Reinforce wall angles, comers or any place the waterproofing membrane course may be subject to unusual stresses with not less than 2 additional olies of fabric or GlASFAB reinforcement and moppings of bitumen. f. Insulate and protect all hot water and steam pipes which project through or are near the surfaces to be waterproofed. Take the necessary precautions to prevent water from getting between the waterproofing and the waterproofed surface at all points where the membrane is penetrated by drains, pipes, etc. Apply extra plies of reinforcing membrane and bitumen moppings in these areas. g. Carefully examine laps which have been exposed for any length of time, such as at the junction of a vertical wall and a slab, for defects and insufficient lap areas and repair as necessary before proceeding with further application. h. Apply all membrane waterproofing systems in a workmanlike manner and use wood nailers treated with a water-borne preservative for all vertical wall water proofing. I. Protect the membrane from damage by other trades after installation to maintain the integrity of the waterproofing throughout the structure. j. Ventilation should be DKWidecf&i enclosed spaces during application^ - - Horizontal waterproofing applications: (1) Beginning at the low point of the slab mop the surface with hot Koppers Water proofing Bitumen and immediately apply die reinforcing membrane over the entire area. (2) Be sure that each ply is solidly mopped and adhered. (3) For the various waterproof ing systems lap the reinforcing .-piles as follows: (a) Two Ply Systamr-Mb 19 Inches. (b) Three Ply System--lap 24%_ inches. (c) Four Ply System--tap ZlVt nchsa. (d) Five Ply System--tap 29 inches- (4) Mo# the entire top surface with Koppers Water proofing *8itumen. The completed water proofing forma a firmly bonded system and the reinforcement shall net be exposed at any place. (5) As soon as any portion of the waterproofing has been completed, cover it with the protection course specified, such as brick, tile, concrete, rigid insulation or other specified material. Plaza deck waterproofing applications: When membrane waterproofing is used m plaza construction with interior drains and the finish slab does not rest immediately on the waterproofing, but on concrete pedestals, in addition to the application pre cautions above the following additional precautions shall be taken: (1} If deck is sloped to interior drams, specify water proofing Bitumen conforming to ASTM Specification D-450 Type III. (2) Before the pouring or placing of pedestals supporting preeast finish slabs, additional reinforcement shall be installed under each pedestal over existing membrane. (3) Extreme care should be taken to protect the finished waterproof ing from damage by other trades during construction of towers, etc. Place a pro tective course over the finished membrane until the wearing surface is placed. (4) On precast concrete systems all joints should be grouted with flashing cement and stripped with a reinforcement fabric. Below grade wall waterproofing application: (1) Apply a uniform brush coat of Koppers Concrete Priming Oil over the entire sur face to be waterproofed (approximately 1 gallon for each 100 square feet). (2) Mop wall completely with Koppers Waterproofing Bitumen. (3) Starting at the most practical place, install the desired number of plies lapping -them as follows: (a) Four Ply--lap 27$S inches, (b) Three Ply--lap 24% inches, (c) Two Ply--iap=T9 inches, (d) When more than 4 plies tee used in a membrane, it is recommended that they be installed in at least two operations, i.e.. 2 plies over three. 3 plies over three, etc. maintaining the shingle fashion method in each operation. (4) Nail membrane with concrete naiis 8 inches on centers through flat tin discs at the end lao horizontally across the mem brane. If wood nailers are installed, nail membrane to nailer with Mi inch roofing nails through flat tin discs 8 inches on centers. (5) Moo the entire surface with Koppers Waterproofing Bitumen. The com pleted waterproofing forms a firmly bonded system and the reinforcement shall not be exoosed at any place. (6) As soon as any portion of the waterproofing has been com pleted. cover it with a protection course and backfill. v 34 KMM Membrane Waterproofing Systems KOPPERS 7 1 -KOP Architectural and Construction Matanals Materials and System Discussion KMM waterproofing specifications are categorized as vertical and horizontal to differentiate between slight differences in application procedures dictated by the orientation ofthe surface to be waterproofed. The vertical specification is written for foundation wall waterproofing, but may be modified for other vertical or steep surfaces to be waterproofed. The horizontal specifi cation is written for split-slab or plaza deck applications but can also be modified for other tow slope or flat surfaces. Consult your local Koooers sales representative for assistance with these modifications. Vertical KMM Waterproofing System Specification No. 640 General Requirements 1. Surface to which KMM or KMM Adhesive s to be applied must be free of all dirt, debns. release agents, oils, or other contaminants Description Koppers Vortical Waterproofing Specifica tion No. 840 consists of KMM Standard end and side laps shall be mterply-fused and . top-sealed. Bottom of first course snail oe suostrate (used 4" that would impair the proper application and membrane applied to a vertical surface performance of KMM. Cracks or other defi in a full bed of KMM Adhesive. The KMM 4. Substrate-fuse me KMM membrane at all ciencies must be corrected before starting membrane forma a waterproof system protections. application. through the use of joint heat fusion, a unique 5. Subsequent sheets snail be set m a full ( Z Ail surfaces that receive KMM adhesive and/or substrate fusion must be primed with Koppers High-Pen 452 Pnmer at the rate of 'W gallon per 100 square feet. Primer must be allowed to dry completely before proceeding. process whereby all contiguous joints are affixed together to develop a monolithic waterproof membrane, in addition, the entire system is completely adhered to the vertical surfaca to eiimmata any voids which might permit collection of water between me bed of adhesive, from the first course to the high point of the area to be waterproofed. Each course shall end lap the lower course 4" and side laps shall be 4" The top ends of each sheet. of KMM membrane snail be substrate-fused and top-sealed. 3. inside and outside comers must have a surface and membrane. double thickness of KMM. This can be accom plished by 1) installing cushion stnps of KMM that extend at least 4" in each direction from the comer, or 2) lapping each course of KMM around comer 4" in each direction. 4. Courses may be run honzontilty orvertieaHy: however, tne top edge of each count must be This system is applicable for use with any vertical structural surface which provides continuous support for me KMM membrane. The general neeimna and appdcafllon procedure* on Ms peg* si* part of this aiecWciSon and must be adhered to where 8. The contractor shall thoroughly inspect the completed KMM membrane at the end of each day's work as well as before the back filling phase. 7. To eliminate potential abrasions, breaks and punctures, it is strongly recommended mat me completed KMM waterproofing suostrate fused 4" onto the wall. system be completely covered immediately, 5. All exposed edges must be top sealed poor Procedures to leaving the |0b overnight. 1. If cushioning stnps are used they must be 8. Protection board must be placed as eoon - applied poor to the installation of the KMM as possible to protect KMM membrane. waterproofing membrane. with a V minimum thickness protective board, it should then be permanently back filled. tamping the backfill as required Pro tective board can be installed m KMM Adhesive. 7. Horizontal waterproofing system must begin at the low point in the deck and layed up the slope. 8. KMM membrane applied vertically in lengths exceeding if may oe difficult to hold in place. It is for the discretion of the applicator to determine the appropnate length for his particular application. 2. Apply adhesive tt the rate of 2 to 3 gal. per square after pnmer nas dried. 3. Starting at the low point set the first course of KMM Standard membrane into a full bed of KMM Adhesive while me adhesive is still slightly wet. Rub and/qr brush thoroughly to remove all entrapped air from under the membrane. End and side laps shall be 4". All 8. Any KMM waterproofing membrane left exposed after backfilling shall be protected with KMM Aluminum membrane or other suitable sunugnt-protective materials. t. when any portion of the membrane is to be permanently exposed, it must be covered with KMM Aluminum Plashing. Specification No. 710 for protection. 35 Horizontal KMM Waterproofing System Specification No. 650 Slope Applicable tor deck slopes of 0" to 4" per foot. When slope exceeds *" per foot see Specifica tion No. 640 on Page35. General requirements The general requbaments and appdcedon procedures on the preceding page are part of Ms specWcsden aid must be adhered to where appdrehla 6.Extend the KMM waterproofing mem brane. at flashing, up vertical surfaces to a height above the water level expected at the wearing slab. The top of me KMM membrane shall be suosirate-fused and top-seeled to the wall. All side laps shall be mterpiy-fusea and top-sealed. When vertical waterproofing is^required, continue me upturn a minimum of V above the height of me weanng surface and subetnte-fuee to me wall, vertical water proofing membrane shall overlap upturn 4" Koopers Honzontal Waterproofing Sp*cittcatioo No. 650 consists of KMM Standard membrane applied to a plaza deck or non* zontai surface m a full bed of KMM Adhesive. The KMM membrane forms a waterproof system througn the use of |oint heat fusion, a unique process whereby all contiguous joints are affixed together to develop a mono lithic waterproof membrane. This system is applicable over any structural deck and/or approved rigid board insulation where the substrate provides continuous suooortfor the KMM membrane. It is ideally suited for application directly to poured structural concrete decks. Procedures - 7. The contractor shall thoroughly inspect 1. If cushioning stnps are used, they must . eomptogd KMM membrane at me end of ba applied poor to the instaltohon of the KMM each dejfa work as well as before application waterproofing membrane. at protective board. 2. Apply adhewve at the rate of 2 to 3 gal. par square after primer has dried. a. Proceed with application of me remaining phase of the horizontal system. Care must be taken to eliminate any puncture or 3. Starting at the low point of the deck, sat the first course of KMM Standard membrane intoa fun bad of KMM Adhesive while theadhesiveis still slightly wet. Rub and/or braeh thoroughly to obtain proper adhesion and io remove ad entrapped air from under the membrane. End and side laps shad be 4". Ad snd mjfaids laps damage of me KMM waterproofing mem brane system by other trades. 9.It is reauired mat a suitable protective layer be placed over me entire membrane oft both horizontal and vertical surfaces to pranSe-puncture resistance during con shall be mterptyfuaed and top ledled struction and during placement of me wear ing surface as soon as possible. 4. Subsume luw the KMM membrane at all tCWhen any portion of me membrane is to proiactiona. be permanently exposed, it must be covered 5. Subsequent sheets shall be set In a fuff bed with KMMAluminum Flashing, Specification of adhesive, from the first course to the hign 9710 for protection. point of the area to be waterproofed. Side laps and end laps shall be 4" Liquid and Mastic Applied Waterproofing and Dampproofing Systems Hydroshield Mastic 451 Aii-weather cold process mastic membrane system Hydroshield Mastic 451 is a solvent based asphalt mastic which is unaffected by immersion in water either before or after curing, it will adhere tightly to damp or even wet surfaces. Hydrothield is not damaged by soil aikiiimty, acidity or minerals. This unique mastic may be aoolied under an extreme range of weather and temperature conditions. Application Guide 4*2 PrenerVer 100 ft* (When Needed) HydroehMd Mastic for Dempprooflng. When applied to masonry or concrete con struction. Hydroehieid Mastic serves as an effective damporoofing barrier to prevent the entrance of moisture by capillarity. .Usually only one coat it necessary for damporoofing. Hydroshield Mastic goes on cold and may be applied to a wet or dry surface. Hydroshield Mastic for Waterproofing. When s permanent vapor Darner to prevent the entrance of water under a head of oressure is required. Hydroshield Mastic, combined with Koopers Heavy Duty Glass Fiber Mesh, produces a tough, durable waterproofing membrane that cannot rot or deteriorate at sub-grade levels. For details of waterproofing applications, consult your Koopers representative. nyvom*-m-o-* rW wff o, .n. Far 100 ft* Kdpean Heavy Out? Qisai HydraaMetd Top Coat Per 100 ft.1 Oamooroofing Wataroroofing a to a gal. K to H gal. 2 gal. 3 gal. Non# 1 ormorscHiM None 3 gal. Liquid Asphalt 480 A cold-applied asphalt emulsion dampproofing. Liquid Asphalt 480 is a filled, cold-applied, high-quality asphalt emulsion containing 8entomte clay. When applied to masonry or concrete con struction. Liquid Asphalt 480 serves as in effective damporoofing barrier to help prevent the entrance of moisture by capil larity. Usually two coats are necessary for damporoofing. Liquid Asphalt 480 goes on cold and may be applied to a wet or ary surface. For detailed specifications consult your Kocoers representative. Application Guide 462 Primer Per 100 fi.J Liquid Aapfte* 460 Pari Q0IL> (2 coats) Oamooroofing 36 to n gai 3 gai. ROOF INSULATION EXELTHERM Xtra5 Insulation KOPPERS Architectural ana Construction Materials The thermally efficient roof insulation with fire resistant properties. General Description Exeitherm Xtra roof insulation witn fire resistant properties is a rigid, thermoset pnenonc foam wmen will not melt or soften. Compliance Exeitherm Xtra roof insulations meet Factory Mutual test requirements as a component for Class I Insulated Steel Deck Roof Construction When secured to the steel deck with FM approved mechanical fasteners. Exeitherm Xtra roof insulation qualifies for a Class 1-90 Windstorm sesistance Classification Sizes Exeitherm Xtra is avanaoie m board stock s.ze of 36 mcnes by 48 rnenes. in nominal .'icxnesses ol 1 2. 1.4. 1.6.1-75. 2. 2.5. and"_ 2 0 -nches. - Comparative Performance (inches) -- PM Class I Type insulations -C" value -R" value Exeftherm Xtra Urethane Partita Composita Fibrous Glass 10 10.00 1.2 1 7 2 44 .09 11.11 1.4 1 8 2.75 .08 12.50 1.6 2.0 30 07 14 30 1 75 2.2 3.56 06 1666 2.0 2.5 4 07 05 20.00 2.5 2.9 4 88 04 25 00 3.0 -- 6.0 1t ! Perlite 1 1 36 * V ! i *5 ; 5'5 | 60 j "2 ! 90 | Typical Physical Properties Compressive strength i00,a consolidation, psi Water vapor permeaoihty. perm mcnes Oimensionai staoility i7 days 158* F.95"ttR.H.). "'ll Teat Method ASTM D 1621 ASTM C 355 ASTM D 2126-75 Water absorption increase by volume (two-hour immersion), "b Density ib.tt. (nominal) Service temperature F Coefficient of linear thermal expansion, per "F Fire resistance properties t3" thickness) Flame spread Smoke aeveiopment 'Manufacturers puonsnea cata ASTM C 209 ASTM D 1622 -- ASTM D 696 ASTM E 34 Exeftherm Xtra 25 8.19 <1 0 (length) <1 0 (width) <1 0 (thickness) 8 3.0 -100 to *300 13 x t0-= 20 5 'Urethane 25 <1 0 15 15 <40 <1.0 2.0 -' 'tsocyanurate 25 <1 0 25 15 40 <1 0 2 35 30 -- 80 x 10-' 30 -- 30 x 10-- 36-7S 450 20-25 45-: 05 37 Roof Insulation (Cont) Suggested Application Procedures 1. Steel decks -- Steel decks suitable for the installation of the Exeitherrnaura insulation shall be ciean. dry and progsBfaceoed to all outlets. Apply Exeitntrm 'lWa insulation with long edges parallel to the flutes and oeanng on the surface of the steel deck. Secure tne msuiatiorrts the steel deck with five Factory Mutual approved mechanical fasteners per 3-foot x 4-foot boatf or one fastener per every 2.4 square feet. Fastener placement must be m accordance with FMrequiremsnts. Wood nailers snail be treated with a water-oased preservative, have a nominal width of six inches and .be the same thickness as'the tnsulattOf&They shall be securely fastened to tne deck." 2. Wood Decks--All nailable decks sultabtj for the installation;-of Exe)therm-~Xtri` insulation shall be clean, dry. and property graded to all outlets. ' 'jr Wood and p/ywooefe- CovSr the deck with one layer of rosin sheathing paper-, lappmg each layer not leas than 1 men and naif sufficiently to hold in place. Over tne roof area install Exeitherm insulation. Stagger end |0ints jn adiommg courses. Secure each msuiation panel with five fasteners per 3-foot x 4-foot board, or one fastener per every 2.4 square feet. Faatsner must have sufficient length to penetraite the structural deck at least inch Put must not protrude mrougn underside of the deck. Set fastener heads flusn to the surface of roof insulation. 3. Other type decks -- For the application of Exeitherm Xtra insulation to decks other than listed aoove. consult your Koopers Representative- Slopes -- On decks with siopesgreater than two inches'per foot, wood insulation stops should be used. They should be,treatedwith- a water-based preservative and should-be ' tne same thickness as the insulation. They ' must .be securely fastened to the deck.,.,- --22-- perpendicular to the slope tine of roof. The ' maximum spacing of the stops should be. ,, ~%c;. 48- , inches from face to face..-:- * - - value -R" value HOnMNI . thickness Sspnchee) Placer P* pallet Sq-JJ. p--Pm**rm- - Weight Fktla spanability (pounds) (inches) Bitumen -- Exeitherm Xtra roohtnsuiabon. ' manufacturea with facers integrally-bopoed 0.10 0.09 10.00 11.11 ,, * 12 14 75 65 900 780 417.00 2.5 404.00 ; 2.5 s compatible with agtypes of ByRBitumen 0.08 12.50 and can oe laid dirfjptty in hot'bittimen. 0.07 14.30 1.5 1.75 55 660 379.00 25 50 600 369.50 425 Recommended pomt-of-appiication 0.06 T. '16.66 2.0 s. 45 540 36930 . 425 bitumen temperatures are Steep asphett iType nil 400* - 4S05F- Coal Tar Bitumen ''0.05 0.04' 20.00 25.00 2.5 "T" - 10 35 30' 420 345.50 ' 4 25 360 345 00 4 25 350 - 400 F - ... -- Note: "ft" value means resistance to heat flow. The rwgner the R" value, the greater Vapor Retarder thejpsulatmg power. "R" * i. "C" Vapor retarders are used to control the flow of water vapor from the ' interior of the -The thermel value was determined by-ASTM-C 518. All test specimens were prepared building into the roofing assembly .Vapor in accedence with RIC/TIMA conditidfting prooytire as outlined m their'Buiietm 281-1 retaraers are located between the cMWand . me roof insulation m root assembMWr The use of a vapor .retarder. with*--the roofing assembly usually depends upon tne occupancy conditions, whether the outside mean January temperature is below 40 and if the interior winter conditions are expected to be aoove 45ao reiativenumiaity. ' -b 35 -- Roof Insulation (Cont.) KOPPERS ? ! KOP Architectural and Construction Materials S.nce "-e architects ana ouiiaing cesgners are aware of the actual conditions o' re soecifiC nstaiianon. tney nave tne '"sccs-ou-tv `or determining if a vaoor etarce'' snouic ce -sea. The aconcation of -e .aocr 'etarcer snouic oe m accoroance .v:n t"s 'ec o'" men oat ions of tne ~anj'act.re' c; me vaoor retaraer scec ` eo ano Koooers general -aCo.rements A " e n F M Class I construction -ecuires a vapor retaraer it -us: oe a F.Vt approved vapor retarder System nstanea in accordance witn FM loss -evention Oata Sheet 1-28. Hot oitumen is tne preferred method for attacmng Exeitnerm Xtra to the vapor -etarcer system Cold Adhesives are not acceptable for the installation of Exeftherm Xtra. Typical Steel Roof Deck Application Aggregate Roof Memorane Exeitnerm Xtra Roofing insulation Steel Deck For approved Class I roof system as illustrated, specify ooarc on tne steel deck accors.ng :o Factory Mutual Approved Guide tor Class I. Insulated Steel Decx See aiso Sunetms :--8 1-29. 1-48. 1-49. 1-52). Precautions Protection of Material Exeitnerm Xtra roof insulation must toe protected from the weather at all times. No more -nsuiation should oe laid tnan can oe completely covereo with roofing memorane svstem whicn mciudes aggregate) the same day At tne end of each day s work, or m tne event work is stopped aoruptly. temporary watertight cut-offs must Oe nstaued at an exposed .nsuiation edges. Cut-offs must Oe removed when work is started again Cold Weather Application - Roofing installation at temperatures below 453 F requires special precautions to insure satisfactory performance of the finished roof The deck surface must be dry and free from all traces of ice, snow and moisture before applying roof insulation. Any moisture present on the deck at the time the root insulation is applied may result m poor adhesion of materials to the deck and blistering of the memorane. 39 Roof Insulation (Cont.) Important Notes: Not* 1: Koppers acceptance of any cecK as satisfactory ro receive Exeitnerm Xtra roof insulation involves tne aecx surface only, it is tne responsibility of tne bunding designer ano trie aeck manufacturer to estaoiisn tne requirements for a Expansion and contraction .n a manner tnat win create a staoie base for tne roof insulation b Support of maximum anticipated loads. Not* 2: Koooers will not assume responsibility for decK defects, bitumen drippage. or tne placement of conduits, bolt neads. etc., above the roof deck ana below the roofing membrane. Not* 3: All projections or openings m the deck should be completed before tne application o* tne insulation and roofing Not* 4: Optimum adhesion to the deck is necessary for good roof performance Koooers will not be responsible for any damage caused by. or the result of unsatisfactory attachment. Not* 5: The application technique and specification included m tms section apply to conventional built-up roofing. Some specialized singie-piy roofing systems may not require attacnment of the membrane to the insulation in this case, the roofing system manufacturer snail be consulted for detailed specifications. Not* 6: Where mecnanical fasteners are required, five fasteners must oe installed per 3-foot x 4-foot board. One fastener snail be located at each corner and one in the center of tne ooaro. Suggested Short Form Sp*ciDcations For Standard Built-Up Roofings Systems Roof nsuiation shall oe Exeitnerm Xtra foam panels factory laminated to form an integrat bond with tne surfacing skins, as supplied by Koppers Company. Inc.. P'ttsourgn Pennsylvania. Foam density, is to oe m excess of two pounds per cubic foot R" `actor snail oeinstalled thicknessiesi snail oe as indicated on drawings or specifications, insulation panels must oe laid perpendicular to the direction of the roofing membrane insulation snail oe laid in parallel courses with cross joints broken Edges must oe butted Good roofing practices for adhering rigid board insulation to the deck snail be used. Koppers Company. Inc., supplies rigid phenolic insulation materials It does not practice architecture or engineering. Roofing tnat incorporates Koppers insulation products, the company believes, results in a satisfactory installation when properly applied. Characteristics properties or performances of materials or application specifications herein described are based on data obtained under controlled test conditions. Koppers makes no warranties, expressed or implied as to the characteristics, properties or performance of its products under any variations from such conditions in actual construction. Koppers assumes no responsibility for th* effects of structural movement and makes no implied warranties whatsoever. No agent, salesman, .representative or employee is empowered to change, alter or amend this provision unless it is done in writing by a duly authonzed officer or employee of Koppers Company, inc. 40 N y REINFORCEMENT FABRICS KOPPERS 7 1 <C= Architectural and Construction Materials The extra strength needed for all roofing and waterproofing systems. Reintorcemont Fabric* are necessary lor with aopiicanons of Giasfao' memoranes sealing ano orotecting them from water and wateroroofmg ana roofing systems oecause coated with bituminous or synthetic sealers. Chemical penetration me waterproofing agents bitumens i nave oracncaiiy no strengtn by themselves. This waterproofing combination eliminates When a reinforcing memorane s -eouirec the recurrence of cracks, thereoy preventing that is not coated with asonait or -ar Kocoers Kcooers Reinforcement Faeries orovioe this extra strength .n a manner similar to water from seeping under tne asonait and fills the'need with Giaseoat* <e Giasfao gradually breaking uo tne oase Glascoat is a woven glass fabric out s that of 'einforcing rods in concrete Some Tunnels are effectively orotectea against coated with white resin Giass mats anc times caned membranes, tnese faeries serve water seeoage mto ano tnrougn the concrete cotton faDrics may be neeoeo m soecific as mechanical reinforcement for not or ccic aooneo bituminous coatings m roofing and waterproofing systems. They also oro ide the `ramework to build uo coating thicknesses achieving longer lasting waterorcof'ng systems Once aooiiec. they form stress-resistant onaoie sneers that withstand stresses and strains from wind, vibration, ana exoansion or contraction due to temper ature changes Applications Ot Koopers Reinforcement Fabrics are many. ;ne largest eemg with not or cold aooiied bituminous coatings in roofing ano .vateroroofing. shell with Koooers Reinforcement Fabric emDeodeo m a bituminous comoound A oroDerly installed tunnel wateroroofmg sys tem prevents rapid deterioration of reinforc ing rods, heaving of concrete and the formation of icicles on tne underside. Pipeline orotection has oeen achieved tnrougn an application consisting of a bitu minous coating .KoDoers Tar Enamel' and a reinforcement fabric 'Giasfao membranes) to successfully orevent corrosion and soil stress. Ptaza Deck Waterproofing provides sub terranean structures with needeo orotection cases. Koooers makes these oroaucts avail able as wateroroofmg memoranes. also Bridge Deck Waterproofing effectively orotects bridge surfaces ano substrates from premature deterioration Koooers Rein forcement Fabric, used m coniunction with coal-tar coatings, rebels the adverse effects of weather, salt, gasoline and oil soiiiage. m addition, the wateroroofmg prevents soai-img of concrete ano the corrosion of onage reinforcing rods .caused by oenetration of moisture and de-icmg chemicals The woven glass reinforcement faoric serves a function similar to that of steel mesn m Other aooucations include bridge dec* against moisture Any subterranean con concrete Forming a stress -esistant suable .vateroroofing and flashings, foundations, struction. wnether used for office space, sheet, the suooomng membrane aaos siaos tunnels. suDways. oioeime wraoomg. classrooms, storage or a parking garage, strength ana serviceability to the mnerent oioeime joint wrao oaraoet wall treatment, must be watertight: including walls and top water resistance of the coal-tar emulsion asonait caving repair ana Detection, arive- surfaces. Landscaped oiazas are often con Foundation Waterproofing And Oampproof(' ways, oarking areas ana tennis courts. structed on these too surfaces, it is here ing at the time of construction can eliminate Many of the reinforcement faerie systems that Glasfab' is used as the reinforcing the orooiems of damage-causing leaks installed over 25 years ago are still in use memorane m the waterproofing systems Architects and engineers nave :ong realized today m large construction Droiects such placed under the Diaza surface. the advantages of waterproofing comoounds as highway ondges. their applications have Glasfab is available with a coating of asphalt m preventing or retarding the passage of nsureo comolete orotection against mois or tar. to be compatible with the specified water The reinforcement faoric enables ture penetration that ultimately leads to bitumen Possessing the highest tensile waterproofing compounds to remain station corrosion, ano the weakening of the strength of any reinforcing membrane ary while being ouiit-uo to the soecific structure currently in use. Glasfab orovides a strong duantities desired, thus allowing the speci Roof Repairs are long lasting when Koooers waterproofing system it strengthens and fier to achieve the buiio-uo necessary to Reinforcement Faoric is used Quick reoairs secures the waterproofing agent oetween resist existing hydrostatic pressure. to roofing and flashing membranes are slabs and on walls under the olaza deck. oossioie if a oiy of faoric is embedded in the 'irst aooncation of roof coating A second aooncation then completely seals the area ,vnere ousters ano cracxs once aooeared. Roof Resurfacing with reinforcement fabric acos strength to existing built-uo roofs._ Since it is important to select the membrane nat oerfe-ms oest with a particular coating. Kcooe's manufactures fabrics that can be ,,tmzec with coic-aooiieo products or hot o<t,,men Coateo giass fabrics are available as weii as glass mats ano saturated cotton 'aor-cs Glass memorane s non-rotting 'eature .rs anility to conform to irregular surfaces, anc rs mgn tensile strength makes t a memy desirable reinforcement. Cotton faepc is often used for striODing-m and covering corrugated metai roofs. \ When selecting tne orooer root resurfacing reinforcement, it is imoortant to also use the orooer amount of coating to assure a long service ufe Other Uses for Koooers Reinforcement Faorics exist wnerever waterproofing sys tems are required Tennis courts can better maintain their tight smooth oiaymg surfaces Reinforcement Fabrics (Cont) Specifications and Technical Data Koppers Asphalt Or Coal Tar Saturated Cotton Fabrics aro avaiiaoie m Doth standardana specification grade. The primary differ* ence Detween the rwo grades is weight. Cotton Fabric has the longest successful for Testing Materials ;ASTM). mr American application record. Specification grade Railroad and Engineering Association cotton complies with specifications from the ' (AREA! and me American Association of federal government, the American Society State Highway Officials iAASMOi. Product AppUcsM* Spacifications Nominaf S*. rd.0rywateht. Sq.Yd. Saturated*!. BraeUng Strength of Saturated Fabric Nofliimi TTtmd Count Coating Color Specification .Cotton Fabric Pad. Spec.. SS-C-450A ASTM 0-173-74 ~rj area and AASHO= for vanS&a states. 3.3 oz. jMt:' 10 oz. minimum 50 Warp 50 Fill Minimum 26 to 32 Warp 24 ro 32 Fill Atonalt or Tar 8lack Standard Cotton Paeria " "Nona - 2.0 oz. -**5 0z.TyptcalAnalytis 40 warp 20-Fill- ` 27War*^.. ts Fdt-:: Typical Aneiyaii " . Typical Ansfys* Aspnan tAlack #or Tar *5*"1'3 **-' >-. m: ^ ,, C". . Koppere Glasfab* And Ofaaocat* Woven Glascoat. a white' rasin-coatefr.fibfic ere. glassiabnc is greater thancotton fabric or Glasa^Fsbrtca are both well-known _and inorganic .woven glass membrane* which jute. ." ^ widely accepted mm* construction,industry,^ will pot rot. ara lightweiggtanO conform tarv _ Qitsfab. an asphalt or tar costed fabric,stiff- irregular surfaces. The "tensile strength of - -- ---r. ................. ^ - : Product ^pDd|)|f SpacWloationa nominal So. TO. Ory Weight So. Yd. Saturated Wt. Ifniijoi drsniftli of Saturated Faftrit ^Thread Count Coating Color Qlaatab* Fad.Soec. HH-C-e66 astm o-iees-eo TypalAII ' 1.2 oz. to 2.0 os. 't * oz. mm. 1.5 oz. to 2.6 oz. 2oz.to3o&' ajsyjte* ' tsW - Tdftwnum 2* 0oXr tO 50X20 Aswan-: 3ikk ' or Tr-dfe ' Glaacoat* vwuta " s^._ f*oz. to 2.0 oa. 1.5 0Z. t0 2-0Z.- - .. eSWup. ... #AFi# NHmmum "Sox to Or- . 20X20 ~PfWjF ~ White ' ` Koppers Jute (Burfip) Fabric is asphalt resulting m t.hesvier buildup of coding in embankment erosioncontrol ana ditch liners saturated. Commonly known as treated fewer aooliedions. It is quite often specified for holding planted materials m oiace until burlap, it is a coarse fabric wnich tends to for roofing and wat*roroofing Jute is also' growth dans, hold more bituminous roof coatmg material. used for protection of newty-seeded areas. aer- -"wit ------------- ~ AppllcaMe NonUnatSe. So. Yd. Breaking Strength Product Specifications TO. Ory Weight Saturated Wt. of Saturated Fabric Hominul Thr--d Count ^ Coat** Color Jim Fed Soac. 7 5 OZ. 9.73 minimum . SOWara 9 WtfO Asonalt 3iacn HH-a-00800 Typical Analysts 50 Fill 9 FiH ASTM 0-1327-59 TypiquAnalysis Types) Analysis . ,y sr yi'Ti ' ' * Jr. *' - db - < ir'-t _ " "W . *a=.- ' ' -*^fr-- ''bn- - - ~z,. t . tf 4 z* * . V-- * = 42 Reinforcement Fabrics (Cont.) KOPPERSj 7.1/KQf- Architectural and | Construction Materials ] Kooperc Glass Mats are wiceiy used with ccta-aoonefl 'cofing proaucts. They are nonsnrmKihg. possess excellent embedment cuanties anc conform to irregular surfaces. T*'e U F Glass Mat is white, lignrweight, comprised cf fine glass filaments m a "ancom swirl arrangement, 'etnforceo with glass stranas at the esges and oonaed with urea formaldehyde. An asphalt coated U F Mat is also available. Standard Glass Fiber Mesh consists of chopped mono-filaments formed mro a random pattern and bonded with a resinous binder. Heavy Duty Glass Fiber Mesh is constructed of heavy glasa yam. chopped in two men engtns and formed into a lacxstraw caner" s oonceo ano coatee with a ouaoie ason^it The open oattern permits excellent aieeo- tnrougn of me asphalt .nto which, it s. emoeoded ._ Product U- F. Mat-White U. F. Mat--Asphalt Standard Maah Heavy Duty Maah Binder Urea Formsiaenyde Uraa Formaiaanyda Resin Asonalt Gian Weight 100 ip. ft. 9 ib*. 9 lbs. 1 39 lbs. 2.22 lbs. Total Weight 100 Id. ft. i Otbs. 3 5 lb*. i 44iba. 2 98 lb* Tensile Strength Width 4 16$. 31 lbs 10 lb*. 2Sibs Tensile Strength Length 1 3 :0S *7 `OS * '8 '03 34 'OS PACKAGING INFORMATION Fabrics j Glasfab' 1 1 1 j 1 j j Glaaeoet' U. F. Glass Mat Asonilt White Heavy Duty Gists Fiber Mesh Std. Glasa Fibtr Maah Roll Width (1S0` Long) Nominal 48" 3624" 18" 12" 9" 8" 4* 3* 38" 24" 18" 12" 9" 6" 4H 3" 36" X 180' 36" x 180' Rolls oer Carton 4 8 8 12 18 24 38 54 72 6 6 12 18 24 36 54 72 1 1 27" X 96' 4 38" X 180'.- - 1 Carton WatQftts 489 52* 40* 52* 52* 52* 52* 52* 52* 42* 28* 42* 42i 42 42* 429 429 21* 79 409 119 Fabric* Standwd Cotton * Cotton < Jut# Roll Width (150' Long) Nominal 38" 24" 18" 12" 9" 6" 4" 3" 36" 24" 18" 12" 9" 8" 4" 3" 36" 24" 18" 12" 9" 6" 4" 3" Rolls oar Carton 1 t 2 4 A 8 12 IS 1 1 2 3 4 6 9 12 1 1 2 3 4 6 9 12 Carton Watgms 1 22* 14a 22* 30* 22* 30* 30* 30* ' .. 40a 26* ' L 40* 409 40* 40* 40* 40 44# 28* 44# 44a 44# 44# 44# 44# 43 INCE PRODUCTS . .\ ' ie .3 nt if m e td :r e is :h > r- d 1 o s d 0 if s s B H 3 3 If S t 1 n. 3 3 S Roof conditions 3 Dry F*lts A Bar* Spot*: are caused by the oxidation of surface situmen on f gravel roofs. Roof Felts becarpe exposed to attack ey the sun s ultra vioiet rays, and rapid deterioration follows. Koppers roof restaurants help avoid this situation. Blitters: usually are formed.by the presence of moisture resulting in vapor pressure that has oeerrtrapped -between plies of felt on either gravel or smooth surface roofs-. Koppers roof cements and membranes can solve tnis problem " ; Alllgatoring: is a condition almost universal to smooth surface not asphalt roofs. Attack from me sun starts immediately and progresses to the formation of deep roof alligators as time goes by The appropriate Koppers asphalt emulsions will provide a smboth't`6p surface that will not alligator m the future. Splits: are the result of excessive movement in tne roof system Freeze-thaw cycles, and expansion and contraction may cause roof splits <f proper expansion joints have not been provided. Koppers Stripshieio and other systems can help control this- condition. W*t Insulation: writ greatly effect the performance.of any built-up root Hydrostatic pressure trapped within the roofing system must oe released Certain types of insulation can oe successfully vented. This can neip eliminate costly membrane deterioration. Worn Flashings: can lead to a total roof failure. Koppers cements and membranes offer a system to restore worn flashings to a "like new' condition if damage is more severe, our KMM aluminum flasntng system offers an approach mat will provide a completely new flashing with a durable aluminum top surface ROOF MAINTENANCE PRODUCTS AND SYSTEMS (Cont.) Effective Maintenance with Tar and Asphalt Roof Resaturants Lowers the softtningpoint of the top pour of bitumen, .. Restores flexibility to dried or otherwise brittle felt. Adds additions waterproofing to the. surface. Provides a mesns of new gravel embedment - ( Purpose: Tart. . .. Procedure: Many factors day a oart w the service life of Koppers Roof Reeaturant 41J) hqj a base. of_ 1. All loose gravel must oe removes 'rom a 'oof Some factors are uncontrollable. coal tar roofing oitumen. blended with non roof If existing gravel is to be 'eusea. >t Others can definitely be controlled. There volatile oils ana graded aseesfeefibers. Roof must fie washed free of silt. are some aspects of roof degradation mat will follow a recognized cam and the end -esuit can oe predicted. Tie normal degradation of a built-up roof begins at :ne top surface This is unoerstanaaoie since it is the'too surface mat is suoiectea to the deleterious elements of tne armcsohere As soon as a roofing bitumen is exoasea to these elements, an age hardenng orocess oegms As the softening point of Resaturant 410 provides^ me maximum softening effect and oenetratron obtainable from a product of this type. There is no addition of volatiles tnat would., rapidly evaporate. Koppgn Fiber Coating 415 is a tar base product specially formulated to meet Federal Specification SS-C-540 Fiber Coating 41S contains properly graded asbestos: fibers plus selected penetrating oill ~ 2. Silt is removed with water pressure, air.pressure or vacuuming, if water is useti tne` roof must be alloweo to dry completely before proceeding 3. Drains are covered with screens tc pre vent clogging of the drain system 4. After the roof is property cieaneo. an necessary repairs are made with compatible materials. me oitumen increases, cold flow propertiee 5. Kopoers Roof Resaturant is aooneo evenly c.minisn and 'esistance to moisture peneranon decreases. The voiatizing or sublimng of a roofing oitumen takes its toll on me oerformance characteristics of me bitumen. At some time prior to the roof reaching the. ooint when maintenance is no longer 'easisie. preventive maintenance should be estaoiisneo. even though tne roof may not oe leaking excessively After considering Asphalt: Koppers Roof Reeaturant 425 is an asphalt resaturant designed to have me greatest softening effect available m an asphalt base product. Roof Resaturant 425 is a blend of asohait and oils combined with asbestos fibers to provide a product suitaoie for flftt or sloped graveled roofs. onto roof at the rate of seven 7' gallons oer square The abdication rate may vary with the condition of tne roof 6. Gravel or slag is applied to cover the Koppers Roof Resaturant Gravel shall oe m the range, and must oe wasnea Care must be taken to avoid exceeding weight limits of the roof deck. Gravel should oe aooiied immediately after aodication of me age. type of Oitumen used to construct resaturant. V tne roof ana general condition, me use of 7. Precautions must oe taken to nose oh air Koooers Roof Resaturants offer's an conditioning air intake ducts during summer effective means of impiementmg.preventive heat-load peaks to minimize ooor infiltration ract maintenance into occupied buildings during abdication 45 Roof MaMten^ite flfoduots and Systems (Cont.^ Koppers Heavy Duty Roof Shield System... Description Koooers Heavy Duty Roof Shield System comDines two KoDoers tooting materials. Heavy Duty Glass Fiber Mesh ana Uauia Asonait 480. **' Lxsuid Asonaff-480 S a 'iiied. sola aooiied. nfgn-ouanty asohett emulsion containing Bentonite ciay it is trnj waterproofing eomo'onent of'the Heavy. Duty Roof Shield 3ystem The unique gei structuce of Liquid Asqr.aft'AdO vail not-afligator. ouster, or flow i a not weather Heavy Duty Glass Fiber Mesh is a patented reinforcing mat of a ncn-woven (aCKstraw sattem of sndrt cable strands of glass fiber. Each strand is composed of mote man 200 giass monofilaments and is completely.sur rounded witn the Liquid Aspnalt 480. thereby eliminating,water wicking by capillarity into :he waterproofed surface Applications 7/ ' T-- 1 . Surface Preparation, if there js a question toi the soundness of the..existing roof and insulation, a core cutihotiicf be made. Ail minor repairs must be made prior to priming. ANY blister containing moisture must be allowed to DRY Defore repair is made. 2. Priming. Every effort should be made to remove dust from the surface. If me dust cannot be completely removed. Koooers High Penetration Primer *452 shouid be aoDlieo at me rate of aooroximately H gallon per 100 sq. ft. if a primer is used, it must be allowed to dry thoroughly before proceeding with Roof Shield aooiication. * 4 gallons oar 100 so ft Do not acc-y f temperatures below 40F are ex.tcreo within 8 hours or if ram is expected cefore the emulsion has time to dry. While the emulsion is wet. emoeo `-eavy Duty Glass Fiber Mesn into it with firm brush pressure forcing the emulsion mrougn and around the glass stranas Eacn suc ceeding glass strip should jveriao me preceding one by. 2-jnches Roll'encs ;f Heavy Duty Glass Fiber Mesh snouid cverlaofl inches.Do not allow dry or starved aos Permit Liquid Asphalt 480 ana Heavy Duty Glass Fiber Mesh to dry sufficiently :c permit foot traffic. 3.Flashing. Flashing areas shall be exam ined. repaired and Drimed as required. Roof Shield snouid be aopned first to flashing areas. After me embedding coat is dry a too coat :f Liquid Asonait 480 is sorayea or orusnes on at the rate of 3 gallons oer 100 sa h 4. Application. Brush or soray-on an embed ding coat of LiquiO Asphalt 480 at the rate of /^ f. 4y. * ' I,*. ^ Qr conrjin^o n'fiipgi*A.'" <occ*Cs,**oa*v *"c 'at Company *nc 'n*Muf" r. if*v *t"anty gtarCtttHa'' mon*a - :::: a-*** <jltfr*dtnrovouoncation''rtotov -eactro<a*vnfttn .* *o' -^erreiw-ot^oypjijnt'tort'gnor '* * Koppers Aluminum Roof Coatings - m * ' KOPPERS o Architectural and Construction Materials ' ' Asphalt base high grads non-fibrated asphalt base. reflective coatings Aluminum Coating 445 is the same as 435 koooers asonait case aluminum coatings but contains two pounds of oasts per gallon. contain cure aluminum oaste consisting of millions of ;my oigment flaKes. When the. ^Application: '' .' coating is applied. tnese flaKes rise to tttf-r .T^rafwahonrThe surface to be coated surface and arrange themselves into many snouid be cleaned of set loos# material suoti shmgie-iike layers of aluminum The result as grayel. dirt. dust, rust or jcile. All breaks, s a reflective metal surface that protects the creaks.--holes and other structural defi substrate from the elements. With Koppers ciencies snouid be repaired prior t^applying aluminum coating's, mere is no peeling or me Aluminum Ccatirig. ; separating because the asphalt base securely bonds the aluminum to the pro tected surface. 2. Priming--Befdre applying'Aluminum Coatings to roofs, dry or dusty felts should be pnmed with Koppers High-Penetration There is an aluminum coating Pnmar 45?it the rate of approximately X gallon Dec T&^quare tegt. This preliminary to suit your needs: step insure* orooer adhesion of the Alumi Aluminum Coating 434 contains thrao num Coating:?' " pounds of extra quality aluminum paste per gallon of hign grade, non-fibrated asphalt Case. 3.Coatliuf--Stir thoroughly before and occasionally during application. Apply with spray.or bruehr* _ Aluminum Coating 435 contains three pounds of extra quality aluminum paste per gallon. This coating is reinforced with asbestos fibers for a thicker, tougher coating ana extra life. 4. Curing--AHOw one month, coring time before Implication over near asphalt emul sion coated roofs. Allow three months curing time before application over new asphalt or solvent typ%4spftaft coated roofs. Oo net Aluminum Coating 444 contains two pounds apply over 'dead level" surfaces subject to of extra quality aluminum paste per gallon of' standing watar. Guardi against moisture penetration Koppers asphalt aluminum roof coatings con tain millions of tinypigment flakes m an alumi num paste. Upon application, these hakes r<$e to me surface and arrange tnemseives into a shingle-like layer of aluminum. The asonait base m Koppers aluminum roof coatings orovtdes excellent adhesion to the existing sur face. The result is a reflective surface tnat guards tne substrate against moisture penetration. COVERING CAPACITY .Per 100 q. ft.) Type of * ' Surface . Meta) Comocsdion Non-fibr*tad . Aluminum KtoHgaUoo HmigaMcn Pibnped" Aluminum, 1 to 1)4 gallons. 2to3gaUons Protection agalnet sunNght Koppers aluminum roof coatings create a metallic surface that reflects sunlight. The reflective surface shields the substrate from ultraviolet carnage while providing additional defenses against cracking or drying. : >* Cooling energy swings Koppers aluminum coatings also help bunding interiors to stay cooler in the summer Alumi num roof coating reflects eight times more than me 8TU per hour, per square foot reflec ted by a black roof coating.' This translates into less demand being placed on the air con ditioning systam. in such instances. Koppers aluminum roof coatings represent an economic and efficient means of conserving energy 'Study results available upon request. 47 KOPPERS KOPPERS COMPANY, INC. Pittsburgh, Pa. 15219 82% of Koppers Manufacturing Sales Going to Growing Markets ' jisiribution of 1969 Manufacturing sales ", Sales to Consuming Industries (s Million) of total \CN-SL'iLC!NG CONSTRUCTION Bcacs. sewers, etcj 3 74.3 : 17% j CHEMICAL i RUBBER 1 PLASTICS ARCHITECTURAL CONSTRUCTION 'Structures. bouses, plants, etc.) S 54.6 12% S 49.1 i | n% i S 39.4 9% major kcpers rrcoucts uses CREOSOTES RILING PROTECTIVE COATINGS =CAO PAVING MATERIALS WATERPROOFING MATERIALS TREATED LUMBER RE N=Ca3ED P'-AST.C STRUCTURAL SHAPES SWIMMING =CCL PAINTS PAVEMENT SEALER AGG = 33A" = LAMINATED LIGHTING STANDARDS 4 STFUCTL'RA- ==OCUCT3 . DIM=NS CNA SPRUCE LUMBER CREOSOTES POSTS . ' A.NTICXIOA.NTS ELECTROSTATIC PRECIPITATORS MALEIC A.NHvCRiC= CCATNNG RESINS NAPHTHALENE =WTHAL'C AMHYC.RICE RESORCINOL ACH=5iV= == = INS STYRENE TAR ACIDS ALKYO RESINS REINFORCED =LAST'C STRUCTURAL SHA?=S TAR BASES INCUSTRIAL PANS =!3TCN 1 SEALING RINGS POLYESTER i AMINO RESINS POLYETHYLENE FILM CONVENTIONAL on' vs-vo= = . EXPANDABLE POLYSTYRENE POLYETHYLENE 'HIGH 4 LOW DENSITY) s = =c='''n7" CONTAINER CLOSURES * ABS RESINS E'HYLENE STYRENE " POLYETHYLENE FILM LAMINATED WOOD STRUCTURAL PRODUCTS RESORCINOL RESINS 4 AOHE5IVE3 TREATED LUMBER 4 POLES ROOFING 4 WATERPROOFING MATERIALS SOUND CONTROL =CUIPMENT CREOSOTE CREOSCTED FOUNDATION 4 MARINE PILING ?IRE-R=TAR~ANT * ,,VI3=R 1 SHAKES AND SHINGLES PROTECTIVE COATINGS ~" TRANSPORTATION S 38.6 9% CREOSOTE CREOSCTeO CRCSSTIES A PILING CAR DECKING * SCUNO CONTROL ECUIPMENT OTHER TREATED A UNTREATED WCCO PRC0UC7S RSlNPCPCED 31 A57IC R=rRlGcRATCR CAR LINER PANELS PANS PISTON RINGS COUPLINGS POLYESTER RESINS UTILITIES: ELECTRIC i TELEPHONE S 38.5 9% CREOSOTED UTILITY POLES 4 CROSSARMS REINFORCED PLASTIC STRUCTURAL SHA=S3 4 POLE LINE HARDWARE ELECTROSTATIC PRECIPITATORS TREATED 4 CCLCR-OOAT-D UTILITY POLES 4 CROSSARMS TREATED 4 CCLOR-COATED LAMINATED LIGHT,NG ' STANDARDS SCUNO CONTROL EQUIPMENT INDUSTRIAL FANS LAMINATED =CW=R TRANSMISSION STRUCTURES PISTON RINGS PROTECTIVE COATINGS PAPER CONTAINER MACHINERY COUPLINGS EXPANDABLE POLYSTYRENE SHEET S 35.6 3% POLYETHYLENE ELECTROSTATIC PRECIPITATORS LATEX PROTECTIVE COATINGS RESORCINOL REINFORCED PLASTIC STRUCTURAL SHAPES TREATED L'JMS== 4 ROOF DECKING LAMINATED STRUCTURAL PRODUCTS SODIUM SULFITE 4 SULFA" " IRON & STEEL MACHINERY S 24.3 S 13.3 ( 6% I 1 i 4% COKE PLANT EQUIPMENT CONTRACT FABRICATION COUPLINGS ELECTROSTATIC PRECIPITATORS FOUNDRY COKE MINERAL PROCESSING EQUIPMENT PITCH PISTON RINGS COUPLINGS PISTON 2 SEALING RINGS * SCUNO CONTROL EQUIPMENT INDUSTRIAL PANS PROTECTIVE COATINGS ELECTRONIC CONTROLS GOVERNMENT LUMBER S 12.2 3% S 10.2 2% PISTON 4 SEALING RINGS SCUNO CONTROL EQUIPMENT TREATED LUMBER LAMINATEO STRUCTURAL PRCOUCTS COUPLINGS ROAD MATERIALS 4 AGGREGAT=S REINFORCED PLASTIC PRODUCTS WATER 4 SEWAGE TREATMENT EQUIPMENT SEaIs CREOSOTE OTHER WOOD PRESERVATIVES DIMENSIONAL WHITE SPRUCE LUMBER COMMERCIAL TREATING SERVICE LAMINATEO BEAMS RESORCINOL RESINS 4 ADHESIVES TREATED LUM8ER NGN-METALLIC MINERALS (Mining) S 10.1 2% COUPLINGS ELECTROSTATIC PRECIPITATORS TREATED LUMBER MINERAL PROCESSING EQUIPMENT NON-FERROUS METALS S 9.5 2% ELECTRODE SINCER PITCH FOR ALUMINUM PRODUCTION INDUSTRIAL COKE RISTON RINGS MINERAL PROCESSING SCUIPMENT COUPLINGS pRCTECTIVE COATINGS TEXTILES UTILITIES: GAS S 6.8 S 5.5 LATCX 2% POLYESTER BUTTON BLANKS & BUTTONS * RESORCINOL ---------- ------------------------------------------------------------------------------------ -------- ------------ --------------------------------------------- GAS APPARATUS * INDUSTRIAL PANS ELECTRONIC CONTROLS 1% PROTECTIVE COATINGS T==A7SO LUMBER INTERIOR 2 EXTERIOR PRCTECTIVE PIPELINE COATINGS i PRIMERS - AGRICULTURE S 4.8 1% PISTON RINGS POLYETHYLENE FILM TREATED BUILDING POLES. POSTS 4 LUMBER MISCELLANEOUS j S 9.3 2% TOTAL MANUFACTURING SALES S441.7 100% -EGENO ;*?w.ng a: 3 rala tasjer than avea;e growth exsected for national economy aver next `sn /?3rs * growing at a rate slower than average exsected for national economy over next ten years. ann-jailvi 1967 5-50,495 S24.044 S4.600 S4.336 SI 4,608 S2.83 ` 51.40 512,598 52.56 4,957 16,959 57.243 530,118 5131,054 572.485 5117,100 5234.053 5115.630 535.65 1966 S445.779 S22.264 S3,347 S3,300 512,617 . S2.46 51.40 S14.381 S2.94 4,891 16,890 S5.342 S48.742 SI 21,837 557,966 S113,990 S282.036 $111,064 $34.32 1965 $386,436 $22,200 $1,123 S7.851 $13,226 S2.63 SI .20 SI 5,004 S3.13 4,795 15,646 $7,036 $29,808 $89,373 S34.298 SI 06,603 S239.023 S95.908 $34.25 1964 $346,025 $21,573 $1,355 S8.856 S11,361 $2.28 $1.20 $15,287 $3.24 4,715 16,183 $5,216 $15,720 $92,565 S28.062 $92,098 $213,271 $84,136 $33.42 1963 S302.500 SI 6,164 SI,241 $7,098 $7,325 SI.53 SI.00 SI 3,193 $2.79 4,733 15,818 S2.566 $18,334 S91.317 S22.738 $35,853 SI 80,891 S74.138 S32.32 . 1962 S312,718 $15,450 $1,252 S6.116 S3,082 $1.55 SI .00 Si 1,918 $2.48 4,812 16,307 $2,742 SI 3,744 $92,097 S29.711 S85.207 SI 93,261 S80.157 S31.63 1961 1960 $280,989 $14,644 $310,815 $16,352 $1,301 $959 $6,346 $7,529 $6,997 S7.864 $1.32 SI.50 $1.00 $0.95 $11,997 $13,316 $2.48 $2.75 4,846 4,839 16,434 16,983 $1,605 $127 $22,625 $20,118 S96.558 $97,598 $31,077 $23,497 $85,778 $88,389 SI 61,817 $187,317 S75.378 $75,048 $30.84. . . $30.75 uV. KOPPERS 1969 Annual Report i rolo out for Financial statements Koppers Company, Inc. and Consolidated Subsidiaries Ten-Year Financial Highlights (All figures in thousands, except per share information and number of stockholders) Revenue from sales and other income................................................................ Income before income taxes and interest charges and after minority interest .. interest charges.................................................................................................... Income taxes.......................................................................................................... Net income............................................................................................................ 'Earnings per share of common stock................................................................ Dividends declared and paid, per share of common stock................................ Total of all taxes.................................................................................................... 'Taxes per share of common stock...................................................................... 'Number of shares of common stock outstanding.............................................. Number of stockholders at year-end.................................................................... ' Earnings retained in the business........................................................................ Gross additions to fixed assets and investments................................................ Net book value of land, buildings, equipment and depletable properties.......... Term debt due after one year................................................................................ Wages, salaries and pension expense................................................................ Materials, supplies and services.......................................................................... Working capital at year-end.................................................................................. Book value per share of common stock outstanding at year-end...................... 1969 $536,369 $41,301 $6,690 $16,254 $18,357 $3.70 $1.60 $25,841 $5.38 4,802 16,437 $9,963 $39,913 $165,766 $92,889 $138,920 $329,398 $119,915 $39.16 'Based on average number of shares of common stock outstanding during year. 1353 S451,739 $29,472 $4,552 39.037 $15,383 33.18 $1.50 SI 7.139 S3.56 4,S11 16.331 S8.098 $31,662 $144,354 $76,396 SI 21,720 $275,469 Si 09,255 $37.19 Notes to Financial Statements December 31.1969 7. Principles of consolidation and change in accounting The consolidated statements include the accounts of the Com pany. ail of its subsidiaries (except one foreign company owned 52%) and the Comoany's 50% share of the assets and liabilities anc Income and exoenses of Sinclair-Kcppers Company, a partnersnio owned by the Comoany and Atlantic Richfield Company. The foreign non-consolidated subsidiary and 50% owned comcanies are carried at cost. One domestic company, approxi mately 30% owned, is carried at acuity in underlying net assets. In prior years the Company carried its investment in this com oany at cast and reflected dividends in consolidated income as they were received. In 1369 the Company retroactively adooted the ecuity method of accounting for this investment, under which the Comoany's share in its earnings is reflected in current income. The effect of this change was to increase net income for the years 1959 and 1963 by $7.17,000 and $653,000. resoectively. and to increase earnings retained in the business at January 1. 1S63oyS2.A32.399. The Comoany's acuity in the net assets of the foreign nonconsolidated suosidiary and 50% owned companies at Decem ber 31. 1369 exceeds the carrying value (cost) of the Company's investment therein by S3.900.000. The Company's equity in the net income of these companies in 1969 amounted to S1.550.CC0 and divicencs of S2C6.C00 were received and taken into consoiicated income. During 1969 one company was accuired in exchange for Com pany common shares held in treasury and was accounted for as a pooling cf interests. As a result, earnings retained in the busi ness at January 1. 1969 were decreased SI06.974 and caoital in excess of par value was increased S21.763. The financial state ments fcr 1963 were not restated because of the immaterial amounts involved. One other business was purchased in early 1969 and its operations, from date of acquisition, are included in tr.e consolidated financial statements. Caoital in excess of par value was reduced by S99.770 in 1969 reoresenting the cost of treasury shares issued as additional con sideration for a company acquired in 1965 and accounted for as a pooling of interests. 2. Pension plans The Company and its consolidated subsidiaries have several trusteed pension plans covering substantially all their employees. Tne total pension exoense for 1969 was $3,302,000. which in duces 3613.CC0 for interest on and amortization of oricr service cost over cencds ranging to 40 years. All pension orovisions are paid into trust funds. The unfunded prior service cost under all pians at December 31. 1969 approximated $11,030,000 which includes $1,000,000 resulting from increased benefits under cer tain oians fcr hourly employees grantea in 1969. 3. income taxes The previsions for income taxes have been reduced by S1.2J0.000 and S1.317.000 in 1969 and 1963. respectively, fcr the investment credit. The Ccmcany orovices deferred income taxes for income anc exoense items which are reilectec in tne financial statements in years different from those in which they are reflected in the Com pany's income tax returns. The principal items of difference are the excess of guiceline depreciation under an accelerated method claimed for tax purposes over book depreciation uncer the straight line method, earnings of consolidated foreign subsidiaries and deferred compensation. 4. Intangible assets Intangible assets consist of $1,196,006 unamortized cost cf patents and $3,205,945 excess of purchase price over net assets of a business acquired in December 1963. The excess of cost over net assets is not being amortized since there has been -no decline in value. 5. Term debt due alter one year The note agreements contain various restrictions as to dividend payments and incurrence of additional term debt. Under the most restrictive provisions at December 31. 1969. 336,319,000 of con solidated earnings retained in the business was available for cash dividends and the Comoany could incur additional term debt of f - $25,930,000. { The notes payable to banks bear interest at the prime rate in eifect on the date of the notes and are represented by 90-day notes which are renewable until April 30. 1971. at which time they can be converted into term notes, which will be payable in ten equal semiannual installments commencing October 31. 1971 and bear interest at the prime rate plus 'A%. The prime rate at December 31. 1969 was 8 Vi % per annum. 6. Stock option plan During 1969. under the Company's stock option plan for offi cers and key employees, options on 18,640 shares were granted, and 23.500 shares were issued on exercise of options at prices ranging from $19.25 to S30.50 per share. At December 31, 1969. ootions covering 63.365 shares v/ere outstanding and no shares were availacle for future grants. Ootions granted prior to January 1. 1964 were at 95% of mar ks! value at date of grants and are exercisable over a seven year period. Options granted after January 1, 1964 were at 100% of market value at date of grant and are exercisable over a five year period. The S353.348 excess of cost of treasury shares over the proceeds resulting from exercise of options during the year was cnarged to capital in excess of par value. 7. Commitments and contingencies The 1970 rentals on prooerties operated by the companies under long-term leases will amounno S2.190.000. In addition, the companies are required to pay taxes, insurance, recairs and maintenance and alterations under certain of the leases. The unexpended balance of coen fixed asset expenditure authorizations at December 31. 1969 amounted to 339.513.000. The Company has guaranteed S9.560.000 indebtedness of 50% owned companies and other corporations. Consolidated Balance Sheet December31.1969and 1963 (Seeaccompanying notes) LIABILITIES Current liabilities: Federal income tax................................................................................................... Other taxes............................................................................................................... Accounts payable and accruals other than taxes................................................... Advance payments received on contracts............................................................. Term debt due within one year............................................................................... Notes payable to banks........................................................................................... Total current liabilities............................................................................. Term debt due after one year (Note 5): 6% notes due 33,000,000 annually commencing August 1, 1377 ....................... Notes payable to banks........................................................................................... 5.8% promissory notes due S670,000 annually commencing August 15, 1972.. Other, including Euro-currency loans, average interest rate of 3% at December 31, 1969 ............................................................................................. Deferred compensation................................................................................................... Deferred income taxes (Note 3)..................................................................................... Minority shareholders' interest in subsidiaries............................................................. Total liabilities ......................................................................................... 1969 $ 6,672,544 5,304,468 49,589,167 7,454,731 2,430,268 1,463,998 72,915,176 50,000,000 22,000,000 10,000,000 10,888,658 92,888,658 3,446,345 11,191,851 960,527 181,402,557 STOCKHOLDERS' EQUITY Cumulative preferred stock, 3100 par value: Authorized 300,000 shares, issued 150,000 shares, 4% series.......................... Preference stock, no par value: Authorized 1,000,000 shares in 1969, issued--none............................................ Common stock, 35 par value, authorized 8,000,000 shares in 1969 and 6.0C0.C00 in 1968, issued 4,973.528 shares (Note 6).............................................. CaDital in excess of par value (Notes 1 and 6)............................................................ Earnings retained in the business (Notes 1 and 5)...................................................... Less 160,620 shares of common stock in treasury at cost at Decemoer 31, 1969.... Common stockholders' equity........................................................................................ Total preferred and common stockholcers' equity.............................. 15,000,000 -- 24,867,640 48,064,420 121,615,813 194,547,873 6,049,977 188,497,896 203,497,-896 3384.900,453 1958- 3 925,302 3,710,533 41,059.550 14,724,402 2,617,955 63,039,247 50,GC0,0G0 8,000,CC0 10,000,000 8,395.672 73.395,672 3,063,413 9,223,562 93,800 151,825,594 15,000,000 24,867,640 48,501,375 111,653,045 185,022,060 7,648,540 177.373.520 192.373.520 3344.199,214 o 'Uiv TATEMENTS--Koppers Company, Inc. and Consolidated Subsidiaries <r-s. Consolidated Balance Sheet December31. 1963 and 1963 (See acccmcanying notes) ASSETS Current assets: Cash ........................................................................................................................ Accounts receivable less allowance of $649,894 for doubtful accounts in 1969. Inventories, at lower of cost (first-in, first-out) or market: Product inventories- including work in process.......................................... Raw materials and supplies........................................................................ Prepaid expenses................................................................................................... Total current assets.............................................................................. 1969 S 12,051,214 100,130,475 59,759,652 15,665,143 5,223,149 192,829,633 Investments: Non-ccnsoiidated subsidiary and 50% owned companies (Note 1)................ Other investments, at cost.................................................................................... Notes and accounts receivable due after one year.................................................... 14,481,721 4,219,909 2.341,170 21,042,800 Fixed assets, at cost: Buildings.................................... Machinery and equioment Less accumulated depreciation Depletabie properties, less accumulated depletion Land ......................................................................... 45,788,175 306,065,526 351,853,701 200,310,377 151,543,324 4,428,208 9,794,647 165,766,179 Intangible assets (Note 4) 4,401,951 Oeferrec charces............ 859,890 1953* S 14,253.977 88,443,591 53,266,957 14/42,537 1,381,563 172,303.785 14,584,411 5,757,533 1,369.191 21.711,135 40,155.873 275.325.231 315,481,104 182,708,694 132,772,410 1,986,773 9,594,394 144,353.577 4.793.139 1.037.573 * Restated to conform to classifications ana accounting change acootec in 1969. S384.900.453 S344.199,214 '22 KOPPERS 1369 Annual Recort FINANCE Consolidated Statement of Income and Earnings Retained in the Business Years e.oced December 31,1S69 and 1963 (See accompanying notes) Met sales....................................................................................... Operating expenses (Note 2): Cost of sales......................................................................... Depreciation and depletion................................................. Taxes, other than income taxes........................................... Selling, researc.o, general and administrative expenses .. Operating profit................................................................... Other income (Note 1): Dividends, interest, etc......................................................... Profit on sale of capital assets........................................... Equity in earnings of company aoproximately 50% ovvnec, dividencs received 1969--S66.240. 1963--$109,440 .. Interest expense Provision for income taxes: Federal (Note 3): Currently payable............................................................................................. Deferred ........................................................................................................... State and foreign..................................................................................................... Income before extraordinary item.................................................................................. Extraordinary item, net of applicable income taxes...................................................... Net income for the year................................................................................................... Earnings retained in the business at beginning of period............................................ Increase resulting from accounting change (Note 1).......................................... Increase (decrease) resulting from pooling of interests (Note 1)........................ Cash dividends paid: On preferred stock, S4.00 per snare.................................................................... On common stock. SI.60 per share in 1969 and 31.50 per share in 1963.......... Earnmcs retained in the business at end of period 1969 3533,312,104 411,193,610 17,163,628 9,536,385 57,124,008 495.067,631 38,244,473 1,089,431 1,090,802 877,049 3,057,282 41,301,755 6,690,358 34.611,397 11,118,681 1,839,000 3,296,742 16,254,423 18,356,974 18,356,974 111.653.045 (106,974) 129.903.045 600,000 7,687,232 8,287,232 S121.615.813 Average number of shares ot common stock outstanding curing yeer . Per snare or common stock: Earnings before extraorainary item................................................ Extracrcinary item............................................................................ Net earnings...................................................................................... ' Restates to conform to classifications and accounting cr.ange acccted in :353 4,801,959 $370 $370 1963' 3448.695,339 348,979,157 14,625,119 8.101,4C3 48.210.191 419.918.903 28.776.935 1,070.275 1,198,563 824.G34 3.093.022 31,869,253 4,552.361 27,317.597 5,485,727 4,034,370 843,077 10.368.574 15,948,923 (1,066,000) 15,882,923 101,122.334 2,432,899 30.633 119.468.839 600,000 7.215,794 7,815,794 S111,653.045 4,811.42-1 $3.40 (.22) $3.18 Source and Disposition of Funds 'In ir.ousar.es ot collars) O'-/ -r~V-/C 1569 Net income.............................. .. Depreciation and cedetion ... Increase in Icnc-term debt.... .. Decrease in ether assets........ SI 3,357 17,164 15,493 6.836 S53.850 DiSPCSiT.CN Dividends paid........................ .. Capital expenditures and investments.......................... .. Increase in working capital ... S 8,287 39,913 10,650 553,850 ` 958 SI 5.333 14,523 3.911 (474) 333,948 S 7,816 31,532 (5.530) 333,943 Report of Certified Pubiic Accountants ARTHUR YOUNG & COMPANY CERTIFIED PU8UC ACCOUNTANTS 25C0 Keepers 3uilcfng Psttscurgn, Pa. 152*3 The Board of Directors and Siockholcers Koppers Company, Inc. We have examined the accompanying consolidated balance sheet of Koppers Company, Inc. and consolioated subsidiaries at December 31,1969 and the related consolidated statement of income and earnings retained in the business for the year then ended. Our examination was made in accordance with generally accepted auditing stancaras. and accordingly included such tests of the accounting records and such other auditing procedures as we considered necessary in the circumstances. In our opinion, the statements mentioned above present fairly the consolidated financial position of Koppers Company, Inc. and consolidated subsidiaries at December 31,1969 and tne consolidated results of their operations for the year then ended, in conformity with generally accepted accounting principles applied on a basis consistent with that of the preceding year after giving retroactive effect to the equity methoa of accounting for a company approximately 50% owned as described in No-e 1. i.Pittsburgh. Pennsylvania January 19. t970 A 20 HOPPERS r.I z. Other Financial Matters :n summarizing the Company's past oert'crmance ano its present financial pcs;t:on and outlook, the growth in earnings appears to management to ce of soecial significance. On a pershare basis, earnings in the 1960's have moves from SI.20 in 1959. to S3.70 in 1969. This represents a comocund growth rate of 12 cer cent oer year over tne ten-year period. Cash flew from Keepers ooerations --consisting of earnings applicable to common shareholders pius previsions `or cepreciaticn, cep'etion and der;">jferrep taxes--totaled S36.8 million in **/,"S63. ecuai to 37.65 per common snare. This comcares w'th cash flow in 1963 of 333.5 million or $6.96 per common share. Taxes hac a significant impact on the Company's earnings. The total of ail taxes tor the year 1969 was S25.3 million, up from SI7.1 million in 1963. These amounts represented S5.33 per common snare m 1969. as against 33.55 the year before. Dividends Paid to Common Stockholders dollars per snare 0 0.50 1.00 1.50 Net Income 1969 stajsr.oao 1963 sis.633.cao 1967 514,603,000 1966 ST2t617,000 1965 $11226,000 1964 S11.3S1.OaO 1963 , S 7,825,000 1962 S 3.032.000 1961 S 6.937,000 1960 |S 71864,000 Millions 0 II Il 8 12 Earnings Per Share Dollars 0 1.C0 2.00 3.00 Cash Flow 1969 S36.76O.Q0O si 1963 1967 .531,514,000. 1965 .326.296,000; 1965 -S26.396.000 1964 'S25,560.000. 1963 S24.126.000' 1962 322.672.000 1961 519.647.000 1960 520.473.000 Millions Q 30 'it* cccurrsc early in the year with the acouisiticn of Swanson Lumber Co., Ltd., of Edmonton. Alberta. Canaca, and TPL Industries. Ltd., of Vancouver, B.C. Swanson is one of the largest North American producers of dimen sional white spruce lumber, which is marketed primarily in the U. S, for use in framing in residential and mcoile housing. TPL Industries is the !arcesi Ca.nacian producer of giue-'aminated struc tural products and a leading manu facturer of chemically imoregnated wood products such as utility poles, piiinc. and fire retardant lumber, as well as corrugated steel culverts. Expansion a.oc mccermzaticn cf cur chemical facilities continued cur ing '569. Construction was startec on a new 130 million pcur.c per year phthalic a.nnydrice plan; .near Chi cago. On ccmciencn cf this new facility in mic-1970. Keepers will be the largest producer of this chemical in the U. S. Demand for phthalic an hydride continues to be strong for use in the manufacture of paints, polyester resins, and plasticizers. For the third consecutive year, work proceeded cn cur program to expand caoacitv to produce container machinery. With the completion cf tms latest expansion in 1970, Kcccers, capacity will be triple the 1956 level. This ecuipment is used by the pack aging industry to convert kraft pacer into corrugated board and suosequently into corrugated containers. Keepers capital expenditures in 1970 are exoected to continue a: aoproximateiy the 1969 level. A suostanial portion will be for the new pnthaiic anbyende plant and other chemical facilities, for road materials opera tions, for weed treating capacities anc facilities to process railroad crossties, for piston anc sealing rings, and fer Sinclair-Koppers polyethylene and polystyrene facilities. Manufacturing Sales 1963 $441,735,000 1S63 5365,163.000 ** 1=57 $3*1,682,000 1=55 5319,423.000 ! -1 . 1S55 52821730,000 * '.2 1964 5267,183,000. * 1963 5245580.000 - .. . .* " rr .-r._ j< *962 5245327,000 .. " - *' ' 196; 5228,500,000 r_*. 1960 523^497,000 ! __ .: ..a.'..-.: * *v- ' ;- i !'- 1 iti i i Millions 0 1 00 200 300 400 Total Sales 1969 'smst^ood'US! 1963 5448,630.030 *.=sr 5449,148,000. 1966 '$442,618X100.' *555 002.804,000 1964 '5343.064.000 1563 5299,736.000 1552 5306,071,000 1=51 5273.74^100 i960 S303,366.000 Millions 0 i1 100 j i i i-i - i 200 300 400 I i 1 l 1 500 HOPPERS `-2 -'."LS- "'3C-'* :cr,s. A large contract receives :n late December, however, significantly in creased the construction backlog at year-end, Tctai Company backlog on Decem.oer 31, 1959 was 3223 million, about equal to the S229 miilion on hand at the end of 1963. Record Manufacturing Performance The largest manufacturing sales in crease was recorded by Forest Prod ucts and was accounted for in part by the division's Canadian expansion discussed cn the following page. Strong gains in sales of chemically impregnated wood products to com mercial markets, along with increases in sales of laminated wood struc tural and railroad crossties, also con tributed to the division's 35 per cent sales improvement. Metal Products recorded a 23 per cent gain in sales on the strength of the division's expanded container machinery line and increases in pis ton rings and seals, power transmis sion couplings, and sound control equipment. Chemical sales continued on a good upward trend in 1969, particu larly for phthalic anhydride and poly ester resins. Both are important prod ucts in the fast-growing reinforced plastics industry. Foundry coke and construction materials also contribut ed to Organic Materials' SI 4 miilion increase. Sinclair-Kopoers continued to grow at a strong rate in 1969. A smooth start-up and sustained high level of operation of the 200 million-pound per year styrene monomer plant at Kobuta, Pa., had a significant effect on the year's results. Good sales in creases were achieved in other prod uct lines including expandable poly styrene. high and low density poly ethylene and polyethylene film. 7 565 1965 1964 1963 1962 1961 1960 S: 23.960 Si 17.390 S 96.124 S 95.537 Si 03.844 $100,863 $105,537 85.363 75.390 63.511 57.920 51.907 42.082 47,165 53.-50 51.973 40.754 37,194 37.153 34.348 31.092 *i-l 555 36.977* 61.794 54.929 52.423 51,617 52.652 5319.429 S232.730 S267.183 S245.530 $245,327 $228,910 S236.497 : 21,325 1.35! 98,233 1.341 74.303 1,573 52,352 61,680 49,365 72.105 1.864 1,064 965 764 5442.613 S382.S04 5343.064 S299.796 $308,071 $279,740 5309.366 Strong Construction Operations The strong performance of the Engi neering and Construction Division in 1369 was highlighted by the comple tion of several large steel installations. One of the world's most advanced steelmaking facilities, designed and engineered by Koppers, was com pleted and successfully started up in Spain. The facility includes a basic oxygen furnace shop and an 18-strand con tinuous casting plant. This is the first large integrated steelmaking complex designed for the entire output to be continuously cast. Koppers also de signed and helped build the blast fur naces which supply iron to the new one-million-metric ton-per-year steel facility. Capital Investment Remains High Capital investment continued at a high level in 1969 as Koppers invested S40 million in new plant construction ana expansion and modernization. A major diversification and expan sion of our forest products operations Operating and Financial Review Koppers manufacturing sales in creased in 1269 for the eighth straight year, to a 'scord S442 million, up from S362 million the previous year. Con struction sales increased to 521 mil lion. from S78 million In 1263. Koppers total sales reached an all-time high of S533 million, compared with S449 mil lion in 1263. Income csfcre "edera! income taxes in 1269 was S34.6 million, uo from 527.3 million the year before. Net in come totaled SI 3.4 million, a suostantial increase from 515.9 million in 1963. After provision for oayment of preferred stock divicencs. this was equal to earnings of 53.70 per share cf common stock outstanding, as against S3.13 per share in 1968. Net income in 1263 was reduced by a non-recurring write-off of assets of St .1 million on an after-tax basis, equal to 22 cents per common share. Kocpers income for 1968 has been restated to reflect the Company's adoption of the equity method of ac counting for its investment in Ameri can Amiine Pmcucts, Inc., as recortec at the end of the first naif c: 1269. This accounting chance affects earnings tor noth years by about the same amount. New orders for Koppers crccucts were strong throughout 1969: the year-enc manufacturing backlog was 23 per cent, aoove 1963 and estab lished a record. Order bookings in our construction business were low dur ing the year because of curtailment of capital exce.ncitures in the steei industry in the face of uncertain eco nomic outlook anc monetary ccnci- Net Sales by Division (Sales n tnousands of collars) 1565 Sales 3'b of Total so 'nersase 1350*1969 isea 1957 Orcanic Materials.............. S157.313 29% 49% SI 43,630 S133.2S9 vsry Division Contributed to Koppers :9% Sales Gain in 1S69 Forest Products.................. 127,123 Metal Products.................... 93.405 Plastics Ocerations* .. .. 63.8S9 Total Manufacturing......... S4-1.735 Engineering anc Construction.................... SO. 741 Other Sales......................... 836 24% 170% 13% 200% 12% 21% 83% 87% 17% -- 25% -- 94,518 93.793 75.999 63.-90 55.016 45.110 $369,163 S341.632 73.3-3 105.-27 1.135 1.039 TOTAL ................................. S533.312 100% 72% S448.696 S448.1-8 1 *m :955 :ne cce'afrons a? <:zz *'3 ='3s:.c; ^.vision .vs'e ansfe-vsc to :ne 3ic!air-.<occe's Ccr-.can/ a aartnersnic *sn Atlantic : i z Zznsa^y 3.nee :r.en tfie Ccmoany s P'asncs Oc'aiiO *: -ce Koooe's naif fa?s zt S-r.z z :CC-5'5 5*-53 w K-OPPE&5 Thcnas C. Keeiing, Jr. C'feciof Interraficnal Ocefations Dcrald E. Lemmon l.ic-jstrial Relations Oeoartment Edward D. losch Cofcoraie Davesosmenl -# Donald .VlacArthur 7/asnington Office Dr. William N. Maciay D<rec:or of nesaarcn Paul C. McCormaughey . C'ganic Materials Division Jack D. .Bics -.gi.-;e5,'ng and Construction Division Ccr.ald C. Smith =or3St Prccucts Division Rschard E. Soatz Organic Materials Division Paul Wayman D'gamc Materials Division B Otto Wheeiey Marketing Deoart.'rent Rcoert G Wiison Gene'a: Manager engineering anc Construction Division Other Officers "T-iomas M. St. Clair ComotrclJer Executive Changes Several major executive appointments were made during 1969. Nicholas Kay, 57, was elected vice presi dent and general manager of the Metal Products Division. He succeeded Harry B. Cummings who retired during the year. Mr. Kay has been assistant general manager of the division since 1959. He has held various operating and management responsibilities since joining Metal Products in 1940. Donald E. Lemmon, 46, was named vice president and manager of industrial rela tions. He has been with the Company for 14 years and was assistant manager of in dustrial relations with responsibility for all plant labor negotiations prior to his present assignment. Thomas M. St. Clair, 34, was appointed comptroller of the Company. In addition to internal control functions, his responsibili ties induce direction of other financial and accounting activities. Mr. St. Clair joined Koppers in 1958; since 1966 he has served as assistant to the general manager of.the Engineering and Construction Division. "Board of Directors Vanes Brand Pres.dent International Investment Co. Stanley N. Brown Former Vies President Koooers Comoany. Inc. Fletcher L. Byrom President KoDoers Comoany, Inc. Fred C. Foy Chairman of the Eoard Koooers Comoany, Inc. Douglas Grymes Executive Vice Presicent Koooers Comoany, Inc. Curtis E. Jones Vice President Meilon National Sank ana Trust Comoany Thomas C. Keeling. Jr. Chairman and President Koooers International. C.A. Andrew W. Mathieson */:ce P'esicent and Governor T. Mellon and Sons Robert H. McClintic Chairman of the Beard Gordon Terminal Service Ccmoany Robert S. Oelman Chairman of the Board National Cash Register Comoany Nathan W. Pearson Vice President and Governor T. Mellon and Sons Or. H. Guyford Stever President Carnegie*Me!lon University 0. P. Thomas Chairman. Executive Committee Atlantic Ricntieid Comoany 'See changes on pages 2 and 3. 'Crficars Free C. Foy Chairman of the Beard Fletcher L Byrom President Douglas Grymes Executive vice Resident Vies Presidents William VI. Barnes Forest P'ocucts Division Burnett G. Bartley. Jr. General Manager Forest Prccucts Division A. William Canons Treasurer Thomas C. Cochran, Jr. General Counsel and Secretary Arthur W, Cowles Executive Deoartment Donald L. DeVries Metal Products Qivision David L. Eynon. Jr. Corsorate Growth Planning John A. Hagan Engineering and Construction Division James F. Haley Transportation and Traffic Services Max C. Hanisch Forest Products Division William B. Jackson General Manager Organic Materials Division Alfred E. Jones Purchasing and Traffic Oeoartment Nicholas Kay General Manager Metal Products Division "Koppers can silence the noise of a gas turbine engine so that its operation in the middle of a town is not disturbing. Our capability in this area is outstanding and our growth shows it. Ws are now applying this proprietary technology to the development of solutions to the problems oi sound pollution in industry and other areas of our environment." Nicholas Kay Vice President and General Manager Metal Products Division Many exoerts warn that noise levels in cities are increasing and could some day become lethal. Electric utili ties, for example, have found that one way to meet the increased demand for power in cities is to add'gas turbines to their generating facilities. It's a po tentially noisy solution. Koppers is solving the problem with highly engineered sound control systems that reduce a turbine's noise to a whisper. Koppers sales of this type of equipment have doubled in the past two years. Koppers also silences the noise of iet aircraft engines being ground tested. Our latest design is being used This test ceil, which contains one of the engines used on the new jumbo jet aircraft, is equipped with Koppers sound control equipment. Koppers precision-made shaft seals are used inside the huge jet engines. in test cells to quiet the giant engines built for new jumbo jet aircraft. This same technology is a basis for economical solutions to many envi ronmental sound problems faced by U. S. industries. Environmental legis lation and public demand will expand the market potential in this area. Koppers is also involved in another important area of environmental con trol--air pollution abatement. The Company is a leading supplier of elec trostatic precipitators to the four major markets for this equipment: electric utilities, the steel industry, producers of rock products, and puip and paper manufacturers. Koppers has greatly expanded its line of machinery used by the packag ing industry to convert kraft paper into corrugated board and then into con tainers. Manufacture of this equipment also has been established within the European Common Market. Demand for such equipment is growing at a rate of about nine per cent annually. Koppers. however, has nearly doubled its sales of container machinery during the past three years and expects to continue to grow at a rate above the industry average. As industrialization progresses in other countries, worldwide demand for cor rugated containers will increase sub stantially. Koppers sales of industrial piston rings have increased by 50 per cent over the past four years. We have con centrated cur capabilities in recent years in the high-performance seg ment of this industry--in truck and offhighway high-speed diesel engine ap plications. Sales to this market are expected to double by the mid-1970's. In addition, a trend in farm machinery to higher powered engines will re quire use of the type of high-perform ance rings produced by Koppers. "Keepers has ceccrr.e the major U. S. designer and supplier of all-wood electric power transmission structural systems. Growth in this area will be substantial as the demand lor electric energy doubles in the next decade and triples by 1985. In addition, the basic capability to make wood a permanent and more versatile material oi construction for which new architectural uses can be developed will provide dramatic growth for the Company." Burnett G. Bartley, Jr. Vice President and General Manager Forest Products Division Construction cf high voltage transmis sion structures recresents a potential annual market in the U. S. of S2.5 Oiillcn. Wccc structures have outsta.ncing potential in this market be cause wood is economical and prov'oes excellent insulation capabilities. As the major U. S. wood laminating and chemical wood treating company, Keepers has a basic position in the electric power transmission structure rieic. For many years, we have been the largest supplier of electric power poles to the utility field. Since entering the high voltage fansmission market two years ago, Keepers has also become the leading supplier of weed structures for such lines. In late 1969, the Company re ceived the largest contract ever placed by a utility for all-wood struc tures--a contract to supply more than 2.600 wood structural towers for a During 1569, Koppers successfully built and tested the first Dreyfus design 345 kv transmission tower, created for high-voltage electric lines wnere pleasing appearance is a prime consideration. 368-mile long power line in Utah. Koppers sales to the architectural and construction market have grown rapidly during the past five years through the addition of new products. Sales to this market now represent more than half the division's volume. The strong upward trend is expected to continue. Sales of fire retardant shakes and shingles, introduced to the market late in 1968, doubled in 1969. Hun dreds of local building codes have been amended to permit use of these attractive roofing materials on com mercial structures in densely popu lated urban areas where there is a desire to improve appearance. In 1969 we introduced a new fire retardant chemical process of impreg nating wood exposed to weather which opens markets where wood could not previously be used. This process makes wood permanently fire retardant for use in virtually any type of exposed exterior application. Koppers has the annual capacity to produce more than 200 million board feet of dimensional western white spruce lumber. White spruce is used predominantly in the U. S. in the con struction of residential and mobile homes. Demand for this lumber is expected to be strong during the 197Q's to.fill requirements fer mobile homes and private residential and multiple family dwellings. Participation in the growing recre ation field has been increased with the commercial introduction of Koppers modular floating dock system. This proprietary design combines csllon treated decking and a flotation sys tem of Sinclair-Koppers plastics to form a high-quality dock system for the commercial marina market. The engineered modular dock system pro vides permanence, versatility, attrac tive appearance, and low installation and maintenance costs. Substantially increased demand for railroad crossties is expected during the 1970's. Since about 40 per cent of all crossties in the U. S. were installed 40 to SO years ago, a large segment will have to be replaced over the next ten years. Programs to improve rights of way so as to permit-carriers to in crease their carloadings and t'.eir vol ume of traffic will also be an important factor. / / KIPPERS about SI 50 million, or one-third or our total manufacturing sales, came from prccucts we did not produce ten years ago. Management Strength Koppers management team has ex panded as the Company has grown. Kopcers today is in the hands of young, knowledgeable and enthusias tic managers. Each division manager heads a group of experienced personnel. Many of these men neioed to plan and to carry out the caoital expansion pro grams that have produced Koppers growth during the past five years. Because of the opportunities cre ated by growth, the Corhpany is in a position to attract the capable person nel needed to contribute to its con tinuing progress. In this Annual Report, you w:il find statements by the general manager of each of Koppers divisions describing the progress that has been achieved by his division in specific ooeraticns. These statements precede reports on product lines that will significantly contribute to the Company's con tinued growth. Growth for the 1970's As Koppers enters the 1970's, continu ation of the Company's growth trend is expected for three main reasons: As our penetration increases in recently entered markets, Kop pers sales wiil grow at a substan tially higher rate than the markets generally. We will realize further benefits from new and exoanced facilities completed early in our invest ment program as piant opera tions approach optimum levels. Since annual levels of capital in vestment have remained high, more recent expansions wiil be gin to benefit earnings over the next several years. Annual levels of new capital in vestment are expected to in crease in the 1970's as projects now in the planning stage are carried out. Board of Directors Two recent developments have rscuced the membership of Koppers ooard of cirectors. It is with deep regret that we re port the death on January 25. 1370, of Robert H. McCiintic. who had served as a director of the Company for over 30 years. Mr. McCiintic was cnairman of the board of Gcrcon Terminal Service Company cf Pitts burgh and had been associated with Koppers-since 1931. He held the cositions of assistant to the cresicent and member of the executive committee while with the Company and was named to the board in 1938. Mr. Mc Ciintic later resigned his responsibili ties as a Koppers employee to devote more time to other business interests. 0. P. Thomas, chairman of the ex ecutive committee of Atlantic Rich field Company, has resigned from the board because of the increasing de mands of other business responsibil ities. Mr. Thomas served as a director since 1965. Outlook for 1970 Koppers sales and earnings are ex pected again to show improvement. Koppers total backlog of unfilled orders at the end of 1969 was essen tially the same as at the end of 1968. The manufacturing portion was at a record level and substantial improve ment occurred in the construction backlog late in 1969. = s.'C.'r'- 5.'0~ =;; e:`e:' .= rfc'_a-. ' 250 s" a- :ee" 55S.rC Z~S O' '"r SOS'S - SSZf -=-=s css.': e-ss;ce~to':re Ocmcsry s.rcs ;vce"'"a cas; me /ea:s 3"/~5s ' or: ~as see- e.-ec:ec s'is.ce-: a'-.v-v son:.rue ; ;e -Iscze's sr;e: acmr.srs: va s'ilcar. a s:s::;r -5 -55 -f.c j.rca 'r-55 Mr 2r/~ss. 55. ms seer esscsme v/cs sres:cer: :sr :rr=e /ears. Mr 5/'S--.. 51. stresses =rec C Foy sea:ec nr.c s 'errrs an.sr ser. -a as sr.sirmsn :or :r.a css; 12 years Mr. Foy. n'r.c --acres Ksssers .T.srcsro retirement age or 55 in January, 1970. vnil conur.se :o 55-/9 as a cirecror. *953 Amu SCCft January 26, 1970 To Our Shareholders: Koppers continued its growth in 1969. Income before income taxes rose 27 per cent from 1963; earnings per share increased over 16 per cent to 53.70. Total sales increased 19 per cent to S533 million. Growth was evident throughout the Company. Every division achieved in creased earnings and sales. Results \ *or are presented more fully in X'y the operating and financial review on oage 16. Improved earnings and sales in re cent years are the result of programs (outlined in previous annual reports) that were generated to strengthen, modernize and expand the Company. In the 1966 report to shareholders v/e stated that new-facilities under construction as part of Koppers in tensified capital investment program would have an increasing impact on performance and predicted that by 1969 Koppers would realize signifi cant improvements in earnings. We point this out now to emphasize how the basic character of the Com- oany has changed during the past cecade. Koppers has worked to achieve a leadership position in each of its major areas of operation. This has been accomplished in terms of cost . . . quality . . . market position . . . and technical services. As the result of the increased oper- ^ ating strength achieved in the decade of the 1960's, Koppers earnings have more than tripled since 1959, going from "SI .20 per share to S3.70 per share in 1969. Sales over the same period have more than doubled, from 5250 million in 1959 to 5533 million. This increased profitability has re sulted in a significant improvement in the return on the total common equity and total capital invested in Koppers. A Decade of Progress To help shareholders understand the nature of our strength, it may be help ful to summarize the Company's prog ress over the past decade to set the tone for Koppers entrance into the 1970's. At the start of the 1960's, the Company's manufacturing operations varied in size and in potential for profit and growth. A few product lines had good growth potential. Many, however, were commodities similar to products of competitors. Others v/ere directed to relatively static markets. At that time, Koppers depended heavily on its engineering and con struction business for a major por tion of total annual earnings. A pro gram was launched to strengthen and expand the Company's manufacturing businesses. Our objectives were: to concentrate only in those lines of business where Koppers had or could achieve a leadership position: to direct a high percentage of our products into markets that offered potential for significant growth. By 1965, all major product lines were on a sound and competitive basis. Each was believed to have good growth potential. Cyclical effects of the construction business on Kop pers overall performance were sub stantially reduced. At that point, Koppers intensified its capital investment activities. Sub stantial "manufacturing capacity was added to permit the Company to take advantage of its leadership positions in rapidly growing markets. We in vested more than 5180 million in the years 1965 through 1969. This aver age of 536 million per year was twice the average annual rate in the first five years of the decade. In 1969, we in vested 540 million for new plant fa cilities and for expansion and modern ization. Capital investment in 1970 is expected to continue at about the same level. The ability of our operating units to adapt and innovate products to meet market growth opportunities was im portant to Koppers growth in the 1960's. In 1969, 82 per cent of Kop pers manufacturing sales were in markets growing at a faster rate than the average growth expected for the national economy. In addition, in 1969 KOPPERS COMPANY, INC. Pittsburgh, Pa. 15219 Area code 412 391 -3300 Common Stock Symbol: KOP Exchange Listings: New York Stock Exchange Midwest Stock Exchange Pacific Coast Stock Exchange Transfer Agents Mellon National Bank and Trust Company, Mellon Square. Pittsburgh, Pa. 15230 Bankers Trust Company, 15 Wall Street, New York, N. Y. 1C015 Harris Trust and Savings 3ank, 111 W. Monroe Street, Chicago, ill. 60690 Bank of America National Trust and Savings Association, One South Van Ness Avenue, San Francisco, California 94120 Stock Registrars Pittsburgh National Bank, P. O. Box 746, Pittsburgh, Pa. 15230 Morgan Guaranty Trust Company, 23 Wall Street, New York, N. Y. 10015 Continental Illinois National Bank and Trust Company of Chicago, 231 South LaSalle Street, Chicago, III. 60690 Wells Fargo Bank. 464 California Street, San Francisco, California 94120 Dividend Disbursing Agent Mellon National Bank and Trust Company, Mellon Square, Pittsourgh. Pa. 15230 1969 at a Glance 1969 1963* . Income before extraordinary items............ Extraordinary items.............................. S 18,357,000 -- Net income .................................................. . S 18,357,000 Per share of common stock: Earnings before extraordinary items... S3.70 Extraordinary items.............................. -- Met earnings........................................ S3.70 Dividends per share of common stock .... SI .60 Manufacturing sales.................................... . $441,735,000 Total sales.................................................... S533,312,000 Cash flow pec share of common stock .... S7.66 Total taxes.................................................... . S 25,841,000 Caoital exoendituras.................................... . S 39,913,000 Backicc at year-end.................................... $227,706,000 Number of employees.................................. 15,361 S 16,949,000 (1,066,000) S 15,883.000 S3.40 (.22) S3.18 31.50 S369.163,000 S448,696,000 S6.96 S 17,139,000 S 31,662.000 S229,024,000 13,655 Resisted to conform to classifications and accounting changes adooted in 1963. 'BiuEAiAsuuay 'uSjnqsiiicj '6uip|inq aoijjo jaiuao lubuisuo aq) jc jooi; pucoas au: uo `ujoo.i||E8 WEqjEqo aq: ui '0/61 '0 udjbi'U 'Aepuoiaj uo 'uj'e u is piaq aq him Ausdujoo sin jo sjapjoqajeqs aq) 10 5ui)SSlu iBnuuB aqi :6u!}03I/\| |Bnuuv JOj uoijboot jbaoo xob8 eoisui........................saijjsnpui 5uiixinsuoo O) S9|BS 6uijnjOBjnuB(A| 52 ................................................S)q6i|u6iH lBiDUBuy lea^-uax XZ .......................................... S1USUJ8!E1S IBJPUBUy 0) S8)0N zz ............................. isaqs boubibs paiEpiiosuoo 11 ............................. 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