Supporting the roofing SMEs in the development and use of a new generation of roofing materials applicable with fault tolerant procedures, reducing the use of petroleum-based products

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NU-ROOF

• Supporting the roofing SMEs in the development
  and use of a new generation of roofing materials
  applicable with fault tolerant procedures,
  reducing the use of petroleum-based products
• (Grant Agreement No. 243616)

TASK 1.1 1.2 FIRST FINDINGS 13th April 2010
DAppolonia
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Objective of the presentation task 1.1 1.2
T1.1 COMPETITORS AND TECH TRENDS (Leader DAPP)
T1.3 STANDARDS AND LEGISLATION NEEDS (Leader
STFI)
T1.2 CUSTOMER NEEDS AND PROMISING MARKETS
(Leader IFD)
Proactive feed backs
T1.4 CONCEPT DESIGN TECHNICAL
SPECIFICATIONS AND MATERIAL DESCRIPTION
(Leader TNO)
Proactive feed backs
T2.1
T2.2
T2.3
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Waterproof membrane is part of many different
flat roof systems, each one with different
requirements
Solar cells roofs membrane must be like non
trafficable allowing an excellent grip for
solar cells
Non trafficable roof membrane must be heat
reflective, easy to clean, many colors, resist to
wind and punctures,..
Heavy duty (car park decks, pedestrian,..)
membrane must be compatible with the external
layers, very thick, long rolls, flexible, extra
strong, well fastened
Green roof membrane must be root resistant
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Since the 70s the following technologies have
been established
Roofing membranes
Plastic membranes
Bitumen membranes
Spray Polyurethane Foam Based
Liquid Applied Resins
BUR
Single layer
Single layer
Thermoset
Thermoplastic
Traditional
Modified bitumen
EPDM
CR
PIB
PVC
TPO
APP
SBS

• Bitumen based membrane are mainly of two
  typologies both used in multi layers structures
  also defined as Built Up Roofing (BUR) or in
  single layer
• Traditional bitumen
• Modified bitumen based
• Plastic Based membrane are mainly of two
  typologies applied in single lay
• Thermoset membrane
• Thermoplastic membrane
• Spray Polyuretane Foam is a rigid, closed cell,
  spray polyurethane foam insulation. The foam is
  composed of two components isocyanate and
  polyol. A second protective layer, typically is a
  spray applied elastomeric coating
• Liquid applied resins reinforcement fleece

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Emerging market needs for waterproofing
membranes (1)
Sources cool roof rating council catalogues,
interviews to NU roof project partners and
roofing associations, users forums
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Emerging market needs for waterproofing
membranes (2)
Sources cool roof rating council catalogues,
interviews to NU roof project partners and
roofing association, users forums
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Summary of Interesting Technology Trends
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Key players and interesting products
Carlisle offers a variety of EPDM, TPO, PVC
membranes Carlisle also offers a full line of
roof garden systems and energy-saving
polyisocyanurate insulation to complement any
membrane installation. CCW MiraDRI 860/861 CCW
MiraDRI 860/861 are self-adhering sheet membranes
consisting of 56 mils (1.4 mm) of rubberized
asphalt laminated to 4 mils (0.1 mm) of
polyethylene high-performance, extremely durable
waterproofing barrier, cost effective but not
reflective
Single-ply PVC roofing system ideal for
commercial or industrial The Duro-Last vinyl
roof membrane is a proprietary thermoplastic
formulation consisting of PVC resins,
plasticizers, stabilizers, biocides, flame
retardants and U.V. absorbents. A weft-insertion
knitted scrim that is laminated between two
layers of PVC film gives the membrane its
strength and durability. reflects 88 of the
sun's energy
TPO and PVC technologies and insulation When
properly formulated, VERSIFY  based TPO
formulations allow for faster installation with
less room for errors versus incumbent TPO resins.
Excellent flame retardant incorporation
High temperature range Modified Bitumen
membranes Diamond Elastoplastomeric BPP with
spunbound polyester reinforcement
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Key players and interesting products
DERBIGUM SP FR modified bitumen 4mm-thick with
30 years guarantee -A tough sheet of non woven
polyester provides resistance to perforation. -
Just under the surface, a fiberglass layer
protects against UV radiation while assuring
perfect dimensional stability. - The bitumen is
mixed with high-grade APP polymers to protect
against aging and UV radiation.
CertainTeed Flintlastic SA is a premium,
self-adhering SBS modified bitumen roofing system
comprising a nailable base or self-adhering ply
base with a top surface designed to accept
self-adhering membrane, a self-adhering mid ply
and a self-adhering cap sheet.
RubberGard EPDM High flexibility and elongation
Firestone RubberGard EPDM remains highly flexible
even at temperatures down to -45 C and can also
elongate over 300 to accommodate building
movements.
OTHERS
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Attachments
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Built-up Roofing (or BUR)

• Built-up Roofing (or BUR) is the popular choice
  for roofing used on commercial, industrial and
  institutional buildings.
• BUR is used on flat or low-sloped roofs and
  consists of multiple layers of bitumen and ply
  sheets. Components of a BUR system include the
  roof deck, a vapor retarder, insulation, membrane
  and surfacing material.
• The components are assembled at the job site to
  actually form the built-up roof. At the heart of
  this roofing system is the roofing membrane,
  which consists of roofing bitumen and multiple
  reinforcing plies of roofing felt.
• Roofing bitumen is the primary adhesion/waterproof
  ing agent used between roofing plies. Bitumen
  arrives at the job site in solid form, but is
  heated and applied as a liquid. Roofing bitumens
  may be either a product of petroleum refining
  (asphalts) or a product of the coal-cooking
  process (coal tar pitch).
• Multiple reinforcing plies are asphalt-coated
  roofing sheets or felts installed in three or
  more layers to strengthen and stabilize the BUR
  membrane. These multiple reinforcing felts also
  make the membrane more pliable and resilient,
  protect the bitumen from water degradation, and
  serve as a fire-retarding element in the membrane
  system.
• BUR roofing membranes can be protected from solar
  radiation by embedding gravel in the bitumen,
  applying a surface coating or applying a
  granular-surfaced cap sheet. Light-colored
  surfacing materials can be used to reflect heat
  from the building. In addition, surfacing agents
  can provide additional fire protection.

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Modified bitumen membrane

• Modified bitumen membranes -- MBS -- combine the
  features of a built-up roof with the added
  tensile strength from its polymer modification.
  Using a reinforced sheet that is prefabricated in
  the plant, modified bitumen systems require a
  less labor-intensive application and can be
  applied cross-platform in both commercial and
  certain residential applications.
• A modified bitumen roofing system is composed
  primarily of polymer-modified bitumen reinforced
  with one or more plies of fabric such as
  polyester, fiberglass or a combination of both.
  Factory surfacing, if applied, includes mineral
  granules, aluminum or copper. The bitumen
  determines the membrane's physical
  characteristics and provides primary
  waterproofing protection, while the reinforcement
  adds strength, puncture resistance and overall
  system integrity.
• Factory-assembled, modified bitumen membranes
  undergo strict quality control standards to
  ensure uniform thickness and consistent physical
  properties throughout the membrane. The finished
  roofing system is usually a two- to four-ply
  system consisting of a modified bitumen membrane
  and a base sheet, with additional plies for added
  strength if needed. The substrate often
  determines which ply system is best specified.
• The finished roofing membrane may consist of one
  or more modified bitumen sheets, or it may be
  comprised of a combination of built-up roofing
  (BUR) felts and one or more modified bitumen
  sheets. The type of substrate and the performance
  objectives influence the specification of the
  modified bitumen membrane system.

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Modified bitumen membrane

• Modified bitumens generally use a traditional
  waterproofing medium -- asphalt -- modified with
  atactic polypropylene (APP), styrene butadiene
  styrene (SBS), synthetic rubber or other agents
  that create a uniform matrix that enhances the
  physical properties of the asphalt.
• SBS (Styrene-Butadiene-Styrene) modifies the
  asphalt by forming a polymer network within the
  bitumen. SBS gives the bitumen rubber-like
  characteristics and improved resistance to aging
  and weathering. Most SBS-modified bitumen sheets
  are either set in hot mopping asphalt,
  torch-applied or adhered with cold-process
  adhesives. SBS-modified bitumen sheets that do
  not have factory applied granule or foil
  surfacing need some form of field-applied
  ultraviolet protective coating.
• APP (Atactic Polypropylene) is a thermoplastic
  polymer which forms a uniform matrix within the
  asphalt. This enhances the bitumens performance
  by increasing its UV resistance, increasing its
  flexibility at low temperatures and improving its
  flow resistance at high temperatures.
  APP-modified bitumen sheets are generally applied
  using a propane-fueled torch. Applicators use the
  heat to soften the modified bitumen on the
  underside of the sheet. The sheet's bottom
  surface becomes a molten adhesive which flows
  upon the substrate and then cools to form a
  waterproof adhesive bond. Some APP sheets can
  also be applied with cold process adhesives.
• Ref http//www.asphaltroofing.org

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Thermoset (TS) membranes

• Thermoset (TS) membranes incorporate principal
  polymers that are chemically cross linked or
  vulcanized. Membranes that are vulcanized also
  may be referred to as cured. One characteristic
  of true thermoset polymers is once they are
  cured, they only can be bonded to similar
  materials with adhesives.
• There are five common subcategories of thermoset
  roof membranes
• Ethylene Propylene Diene Monomer (EPDM)
• Chlorosulfonated Polyethylene (CSPE)
• Epichlorohydrin (ECH)
• Neoprene (CR)
• Polyisobutylene (PIB)
• The most common thermoset roof membrane is EPDM.
  EPDM principally is composed of two compounds,
  ethylene and propylene, that are derived from oil
  and natural gas. The following are some
  characteristics of EPDM roof membranes
• Sheet widths range from 7.5 feet to 50 feet wide.
  
• Sheets are typically 1,5 to 2,5 mm thick.
• Seams are sealed using liquid adhesives or
  special formulated tape.
• The membranes commonly are black, but white is
  available.
• REFwww.nrca.net

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Thermoplastic (TP) membranes

• Thermoplastic (TP) materials can be repeatedly
  softened by heating or hardened when cooled.
  Because of the materials chemical nature,
  thermoplastic membranes typically are seamed by
  heat welding with hot air or solvent welding.
• There are different common subcategories of
  thermoplastic roof membranes.
• Polyvinyl Chloride (PVC)
• PVC Alloys or Compounded Thermoplastics
• Copolymer Alloy (CPA)
• Ethylene Interpolymer (EIP)
• Nitrile Alloys (NBP)
• Tripolymer Alloy (TPA)
• Thermoplastic Olefin (TPO)
• Chlorinated Polyethylene (CPE)
• Polyvinyl Chloride (PVC) PVC sheets are produced
  by calendering, spread coating or extruding, and
  typically are reinforced with polyester or
  glass-fiber mats or scrim. PVC sheets contain
  plasticizers and stabilizers, as well as other
  additives to impart flexibility and achieve other
  desired physical properties. Some membranes are
  available with nonwoven fleece backing adhered to
  the underside of a sheet.
• Sheet widths range from 6 feet to 12 feet wide.
• Sheets are typically 1,2 to 1,8 mm mils thick.
• Seams are sealed by heat or chemical welding.
• PVC membranes are produced in numerous colors,
  though gray and white are the most common.
• REFwww.nrca.net

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SoA Interesting competitive technologies

• DESCRIPTION MiraCLAY membranes, manufactured by
  Carlisle Coatings and Waterproofing (CCW)
• REF  http//www.u15287495.onlinehome-server.com/D
  oco/brochureMiraclay.pdf
• RELEVANT ASPECT for the project
• Offers significant improvements over traditional
  bentonite cardboard panels
• combines the latest in geotextile technology with
  the proven waterproofing capabilities of sodium
  bentonite.
• The Infrabond process thermally fuses the
  needle-punched fibers to the polypropylene
  fabric.
• This locks the sodium bentonite into place
  regardless of incline or hydration cycles,
  providing a permanently bonded membrane

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SoA Interesting competitive technologies

• DESCRIPTION INSULATION MATERIAL COMPRISING PHASE
  CHANGE MATERIAL (PCM) FOR BUILDINGS
• REF  WIPO Patent Application WO/2007/082559
  Applicant MEINECKE, Bernd (DE)
• RELEVANT ASPECT for the project
• Insulation material for the thermal insulation of
  buildings, in particular roofs and/or walls, with
  at least one carrier material and at least one
  heat storage material.
• Heat storage material comprises a phase change
  material (PCM), making possible keep temperature
  fluctuations low even at the event of changing
  climate conditions, for example due to different
  seasons or due to day and night rhythm and, thus,
  to improve heat protection in summer as in winter
  times

Bulk material
Heat storage material
PCM in form of beads
Carrier material
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SoA Interesting competitive technologies

• DESCRIPTION New 'Smart' Roof Reads the
  Thermometer, Saves Energy in Hot and Cold
  Climates
• REF  http//www.sciencedaily.com/releases/2010/03
  /100321203506.htm
• RELEVANT ASPECT for the project
• Scientists reported the development of a "smart"
  roof coating, made from waste cooking oil from
  fast food restaurants, that can "read" a
  thermometer
• The coating automatically switches roles,
  reflecting or transmitting solar heat, when the
  outdoor temperature crosses a preset point that
  can be tuned to the local climate

• bio-based intelligent roof coating, compared with
  a traditional cool roof, could reduce both
  heating and cooling costs as it responds to the
  external environment
• It will help save fuel and electricity and reduce
  emissions of volatile organic compounds from
  petroleum-based roofing products. In addition, it
  will provide a new use for millions of gallons of
  waste oil after it is used to cook

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SoA Interesting competitive technologies

• DESCRIPTION SOY-BASED SEALANT FOR BUILDING
  CONSTRUCTION
• REF  compendexhttp//www.engineeringvillage.com
  (Author Green Products LLC)
• http//www.greenproducts.net/pages/roofingsolution
  s.htm
• RELEVANT ASPECT for the project
• Alternative solution to repair lacks
• The recent hike in oil prices has made a strong
  case for adhesives obtained from natural
  materials
• Plant oil-based adhesives can cut down cure times
  
• advantages in elongation properties, low
  permeability, low-volatile organic compound
  levels, and 100 resistance to stain, mildew, and
  molds and to ultraviolet light.
• Applied in tandem with Environmental Liquid
  Membrane Systems ELMS products that are designed
  for restoration of roofs and walls
• ELMS are applied by brush, roller, or
  conventional or airless spray equipment

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SoA Interesting competitive technologies

• DESCRIPTION Experiment of geosynthetics
  improving asphalt pavement performance
• REF www.engineeringvillage.com  (author Key
  Laboratory of Traffic Engineering, Beijing
  University of Technology, China )
• RELEVANT ASPECT for the project
• prevent rutting and decrease water damage
• application research of four kinds of
  geosynthetics such as glass-fibre geotextile,
  polyester-fibre geotextile, big-hole geogrid and
  small-hole geogrid
• Contrast reflective cracking defined as the
  propagation of cracks from the movement of the
  underlying pavement or base course into and
  through the new overlay as a result of
  load-induced and/or temperature-induced stresses.

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SoA Interesting competitive technologies

• DESCRIPTION Solvent type heat insulation
  fluorocarbon exterior wall and roof coating
• REF Patent CN20081239554 20081212 
• RELEVANT ASPECT for the project isolation
  coating which uses hollow glass micro-beads,
  hollow ceramic micro-beads

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SoA Interesting competitive technologies

• DESCRIPTION New DERBIGUM NT range
• REF  http//www.derbigum.com/EN/EN_solutions-eco-
  solutions-NT.html
• RELEVANT ASPECT for the project
• With the NT range, DERBIGUM introduces a new
  generation of ecological and sustainable products
  generation, while anticipating the more demanding
  European directives.
• The NT range is based on new compositions which
  reduce DERBIGUMs impact on the environment
• No Volatile Organic Compounds (VOC) replacing
  solvents by vegetable oils
• Diminished CO2 emissions
• Diminished energy consumption aimed at membranes
  production
• Diminish the use of non renewable resources
• membrane durability remains
• Products
• DERBIGUM NT ? Ecological new generation roofing
  membrane Solution
• DERBIBRITE NT ? white reflective energy saving
  roofing membrane.
• DERBICOAT NT ? universal ecological underlayer
• DERBIBOND NT ? Ecological bituminous cold
  adhesive without solvants
• DERBICLEAN NT ? Ecological cleaning product