Polycomp Products Limited

PART 1 - CERTIFICATION

1.1 Assessment

In the opinion of the Irish Agrément Board (IAB), Polydec Insulated Structural Panels are satisfactory for the purpose defined above, and meet the requirements of the proposed Building Regulations as indicated in section 1.2 of this Certificate.

1.2 Proposed Building Regulations

Regulation B1 - Fitness Of Materials

Polydec Structural Insulated Panels are an acceptable material as indicated in section 4.5 of this Certificate.

Regulation D4 - Resistance of Roofs to Moisture

Polydec Structural Insulated Panels when used in accordance with Part 3 of this Certificate will prevent the passage of moisture from whatever source and will prevent surface or interstitial condensation occurring.

Regulation H3 - Maximum U-Values of Walls, Floors and Roofs.

Based on the measured thermal conductivity of λ = 0.020 W/m^-1K^-1, of the Polyurethane foam Core, roofs incorporating Polydec Structural Insulated Panels can meet the current U-value requirements. (See Section 4.2 of this Certificate).

Regulation N3 Fire Performance Criteria

When used in accordance with this Certificate, Polydec Structural Insulated Panels will contribute towards enabling a roof to satisfy the requirements. (See Section 4.1 of this Certificate).

Regulation N14 Restriction of spread of Flame Over Surfaces of Walls and Ceilings

Polydec Structural Insulated Panels having a class 1 surface spread to flame rating, are (except in circulation areas and protected shafts, where a class 'O' ceiling is required), suitable for the roofs of buildings of, purpose group II, III, IV, V, VI, VIII, buildings of purpose group I less than two stories and in small rooms (< 30 m²;) of buildings of purpose group VII ( See Table to Regulation N14).

A plasterboard ceiling may be added to give a Class O rating.

PART 2 - TECHNICAL SPECIFICATION AND CONTROL DATA

2.1 Product Description

Polydec Structural Insulated Panels consist of a composite structural roof deck on a closed - cell rigid polyurethane foam core laminated on the under side with a foil faced multi - ply sarking board and on the top side with 6 mm exterior grade WBP plywood. It is suitable for most types of single or built - up weathering systems. The panels are available in the following nominal dimensions:

Size:	2440 mm x 1220 mm
Thickness:	Plywood - 9 mm

Nominal Foam Thickness (mm) 43 65 75

Overall Panel Thickness (mm) 50 72 82

2.2 Manufacture

The foam core is manufactured by a discontinuous Polyurethane laminating process. After manufacture the core is autohesively bonded on the upper face to 9 mm WBP plywood and on the bottom face to a foil faced multi - ply roofing board with integral vapour barrier. Panels are cut to size, before being stacked and packaged with shrink wrap for dispatch.

Quality control checks are operated on a continuous basis and include board dimensions, foam density, foam dimensional stability and thermal conductivity.

2.3 Delivery, Storage and Marking

Polydec Structural Insulation Panels are shrink wrapped in Polyethylene and should, where possible, be stored inside a building. However, storage outside a building is possible provided the boards are kept under cover stacked clear of the ground on battens at 400 mm centres.

Each pack carries a label bearing the manufacturer's name, product description, quantity per pack, IAB identification mark, IAB Certificate number and essential instructions for storage and installation.

2.4 Installation Procedure

Polydec Structural Insulation Panels must be laid in accordance with the manufacturer's instructions by using a mechanical fixing system and waterproofed with built-up bitumen felt or any suitable single or multiple ply roofing membrane. Installation to be in accordance with CP 144: Part 3 : 1970 Built - up bitumen felt, or the relevant Irish Agrément Certificate depending on the waterproofing applied.

Surfaces must be kept clean and dry and the ambient temperature must be above freezing for effective bitumen bonding.

It is important to seal any exposed edges of the board (e.g.. at roof vents, upstands and other details), with waterproofing in accordance with normal practice and the manufacturer's instructions. An effective vapour barrier should be maintained at all panel joints.

To prevent moisture being trapped on or in the insulation it is essential to protect the boards during laying, before the application of the waterproofing, or to lay the roof covering at the same time as laying the boards.

Polydec Structural Insulated Panels should be laid with the plywood face up on joists at 610 mm centres, with the long edge along the length of the joists. Noggins should be inserted along the short edge of the boards. All boards should bear a minimum of 20 mm on to the joists/noggins and be fixed with a gap of approximately 2 mm between adjacent boards.

Panels must be fixed with 11 swg round headed, galvanised, ring shank nails with a minimum penetration of 50 mm, and not exceeding spacings as indicated by BS 5268 Part 2: 1989 around the edges and on the intermediate joists. The nails should be staggered. (Fixings should be designed as indicated in section 3.5 of this Certificate).

Panels should not be nailed within 50 mm of sheet corners or within 10 mm of sheet edges.

Where the finished deck appears excessively springy, this can be corrected by use of additional nails.

Nail heads should be flush with the plywood surface and care must be taken not to over nail.

Once installed, access to the roof should be restricted in accordance with section 3.1 of this Certificate.

PART 3 - DESIGN DATA

3 General

3.1

Polydec Structural Insulated Panels are for use as an insulated structural roof deck on limited access roofs.

Where traffic is in excess of access loads only, special precautions should be taken to protect the waterproofing membrane.

3.2

Decks should be designed in accordance with the relevant clauses of CP144 : Part 3: 1970 Roof Coverings - Built up bitumen felt. CP 144: Part 4: Mastic Asphalt, and BS 6229: 1982 Code of Practice for flat roofs with continuously supported coverings.

3.3

When additional vapour barrier is used it should consist of a coated felt complying with BS 747 type IB and should be laid in accordance with the recommendations of CP 144 Parts 3 and 4 1970.

3.4

Polydec Structural Insulated panels are for use with: Bituminous felt roofing conforming to I.S. 36: Part 1: 1986 Bitumen Roofing Felts, Part 1, Fibre and Glass Fibre Based Felts and I.S. 36: Part 2 1987 Bitumen Roofing Felts, Part 2, Polyester Based Felts.

Other single or multiple ply roofing membranes which are the subject of a current Irish Agrément Certificate and laid in accordance with and within the limitations imposed by, that Certificate.

3.5

The design of fixings should be checked using the data for nail withdrawal loads, contained in BS 5268 part 2: 1989 Code of practice for permissible stress design, materials and workmanship, to ensure that the boards are adequately anchored. Wind loadings should be calculated in accordance with CP3: Chapter V: Part 2: 1972 Wind Loads.

Where traffic is in excess of access loads only, joist centres should not exceed 407 mm.

3.6

Falls should be not less than 1 in 80 and lesser falls should not be adopted unless, a detailed analysis of the direction of falls and overall and local deflections is carried out.

3.7

Adhesion between the foam core, the vapour barrier, the plywood decking and the overlay is adequate to resist the effects of wind suction and thermal cycling likely to be experienced in practice.

PART 4 - TECHNICAL INVESTIGATIONS

4.1 Behaviour In Fire

1. The fire rating of roofs incorporating Polydec Structural Insulated Panels depend on the water proofing layer and the surface finish used. A flat roof comprising:

2. The designation of other specifications should be confirmed by test or assessment.

4.2 Thermal Insulation

The thermal conductivity "λ value" of the polyurethane foam core of Polydec Structural Insulated panels when measured at a density of 36 kgm-3 in accordance with BS 874: Part 2: Section 2.1: 1986 Guarded Hot - Plate method is .020 W/m^-1K^-1.

Schedule 6 of the Proposed Building Regulations gives guidance on the selection of thicknesses of insulation required to achieve the required U-value.

Calculated U-values for typical roof constructions are listed in Table 1 below.

Typical U-Values
Nominal or average Foam Thickness (mm)
43	55	65	75
U-Value (Wm-2K-1) Based on Polydec Structural Insulation Panels on timber joists with 3 layers felt, chippings and plasterboard ceilings.
0.35	0.29	0.25	0.23

4.3 Condensation Risk

Polydec Structural Insulated Panels which have an integral vapour barrier are unlikely to be affected by interstitial condensation, when laid in accordance with section 2.4 above.

4.4 Maintenance

Polydec Structural Insulated Panels will require no maintenance provided that the waterproof covering remains intact.

4.5 Durability

When installed in accordance with this Certificate and adequately protected by the waterproofing system, Polydec Structural Insulated Panels will have a life equivalent to that expected from traditional plywood decking.

4.6 Tests and Assessments Were Carried Out To Determine The Following:

Tests/units	Method	Mean result
Dimensions (mm)	MOAT 28 4.2.2.1	Length 2400 Width 1220 Foam Thick
Density of Insulation (kgm-3) Compressive Strength of insulation at 10% compression (kPa)	ISO 844	36 > 175
Bending Strength (kPa) .8	MOAT 28 4.2.2	Long 995 Trans. 1525
Dynamic Impact (when covered with two layers of 1.5mm felt)	MOAT 28 4.1.5.3 MOAT 27 5.1.10	Satisfactory I4
Bowing (mm)	MOAT 28 4.1.3.2	15
Dimensional Stability	ISO 2796	0.5%
Behaviour under Distributed static Load	MOAT 28 4.1.5.1	Class C*
Thermal Movement	MOAT 4.1.3.1

Coefficient to thermal expansion (mm/mm/°C x 10-6)
	Length	Width
-20°C to +23°C	24	12
+23C to +80C	24	9
Residual Variation %	0.15	0.10
*UEAtc classification C of the insulation indicates that a distributed load of 4 (Ncm-2) causes deformation < 5%.

4.7 Other Investigations

1. Existing data on properties in relation to fire, toxicity, and the effect of the product on structural stability and durability were assessed.
2. The manufacturing process was examined including the methods adopted for equality control, and details were obtained of the quality and composition of the materials used.
3. A site visit was conducted to assess the practicability of installation.
4. A condensation risk analysis was performed.

PART 5 - CONDITIONS

5.1 Conditions of Certification

This Certificate is issued on behalf of the Irish Agrément Board by the National Standards Authority of Ireland (NSAI) and shall remain valid so long as:

1. The product remains identifiable with the product assessed.
2. The Proposed Building Regulations and Standards affecting the subject remain un changed.
3. The product continues to be assessed for the quality of its manufacture and marking by NSAI.
4. No new information becomes available which in the opinion of the NSAI, would preclude the granting of the Certificate.
5. Where reference is made in any certificate to any Act of the Oireachtas, Regulation made thereunder, Statutory Instrument, Code of Practice, National Standards, Manufacturer's instructions, or similar publication, it shall be construed as reference to such publication in the form in which it is in force at the date of this Certificate.
6. In granting Certification, the NSAI makes no representation as to the absence or presence of patent rights subsisting in the product and/or as to the legal right of the Certificate holder to market, install or maintain the product.
7. Any recommendations relating to the safe use of the certified product/process, refer to the minimum standards required to be met when the product is used. They do not purport in any way to restate requirements of the Safety in Industry Act 1980 or of any other statutory or Common Law duties of care, or of any duty of care which may in the future statutory or Common Law duties of care.
8. In granting this Certificate, the IAB is not responsible to any person or body for loss or damage incurred as a result of the use of this product, in accordance with Article 47 of the Industrial Research and Standards Act, 1961.

This Certificate No. 90/0007 is accordingly granted to Polycomp Products Ltd. on behalf of the Irish Agrément Board.

Date of Issue: 24th January 1990