Polycomp Products Limited

CERTIFICATE DOWNLOAD

PolyFlat / PolyFalls Irish Agrément Board Certificate

PART 1 - CERTIFICATION

1.1 Assessment

In the opinion of the Irish Agrément Board (IAB), Polyflat Roof Insulation Boards 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

Polyflat Roof Insulation Boards are acceptable materials as indicated in section 4.5 of this Certificate.

Regulation D4 - Resistance of Roofs to Moisture

Polyflat Roof Insulation Boards 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 Wm^-1K^-1, of the polyurethane foam core, roofs incorporating Polyflat Roof Insulation Boards, can meet the current U-value requirements.(See section 4.2 of this Certificate).

Regulation N3 Fire Performance Criteria

When used with appropriate roof decks and roof finishes in accordance with this certificate Polyflat Roof Insulation Boards 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

The surface spread of flame ratings depend on the ratings of the continuous deck supporting the insulating panels.

PART 2 - TECHNICAL SPECIFICATION AND CONTROL DATA

PRODUCT DESCRIPTION

Polyflat Roof Insulation Boards, consist of plane and tapered sections of a strong, lightweight, polyurethane closed-cell foam core with a range of facings. The foam core is autohesively bonded on the top side to bituminous impregnated fibreboard, plywood or foil faced kraft paper finished on the lower side with foil faced kraft paper or bitumen felt facings as required for built-up bitumen felt or single or multiple ply roofing membranes. The system is completed with Polycricket and Polygutter modular insulated local drainage components.

The boards are available in the following nominal dimensions.

Polyflat:

Tapers:

2.2 MANUFACTURE

The foam core is manufactured by discontinuous polyurethane laminating process and autohesively bonded to various facings during manufacture. Panels are cut to size, before being stacked and packaged with shrinkwrap 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

Polyflat Roof Insulation Boards are shrinkwrapped in polyethylene and should where possible be stored inside a building. However storage outside a building is possible provided the boards are kept securely covered and stacked clear of the ground.

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

Polyflat Roof Insulation Boards must be laid in accordance with the manufacturer's instructions by bonding in hot bitumen (max. 240°C) or by using a mechanical fixing system and waterproofed with a built-up bitumen felt or any 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.

Where the vapour barrier is to be bitumen bonded to the substrate, the deck joints and the deck must be coated with a bitumen primer to BS 3416: 1988 Specification for bitumen based coatings for cold application, suitable for use in contact with a potable water.

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 and before the application of the waterproofing, or to lay the roof covering at the same time as laying the boards.

- Mechanical Fixings

Panels should be fixed using approved fixings with large diameter washers evenly spaced, at the rate specified by the manufacturer. Depending on the size and location of the building, extra fixings, particularly around the roof perimeter may also be necessary. Fixings should be designed to resist wind loads calculated in accordance with CP 3 Ch. V: Part 2: 1972 Wind loads.

- Metal Decks

The vapour barrier is bitumen bonded over the metal deck and the laps are sealed. The panels are lightly butted and laid, break bonded where possible, diagonally across the roof. At all times, care must be taken to ensure that panel joints are supported by the deck. Troughs must not exceed the values given in table 5. of BS 4841: Part 3: 1987 Rigid polyurethane (PUR) and polyisocyanate (PIR) foam for building applications.

- Concrete Decks

When installed on concrete decks care must be taken to ensure that all concrete decks are clean and dry without large projections. The deck should be primed with a suitable primer, used in accordance with the manufacturer's directions. The vapour barrier should be fully bonded to the deck and in turn the Polyflat Roof Insulation Boards bonded to the vapour barrier. The boards should be lightly butted and laid break-bonded where possible. Alternatively the boards may be mechanically fixed to the concrete using approved fixings.

- Timber Decks

(e.g. tongued and grooved boards, plywood, woodwool slabs) The vapour barrier should be nailed or bonded to the deck as defined in cl. 4.6.1 of CP 144: Part 3: 1970, and then the Polyflat Roof Insulation Boards should be fully bonded in hot bitumen (max 240°C) or mechanically fixed (not woodwool) with all joints lightly butted and laid, break-bonded where practical.

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

Polyflat Roof Insulation Boards are suitable as a thermal insulation and to provide a fall for surface water drainage on limited access flat roofs with concrete, timber or metal decks. The boards must always be used with a suitable vapour barrier and waterproof covering.

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 CP 144: Part 3: 1970 Roof coverings - Built-up bitumen felt and BS 6229: 1982 Code of practice for flat roofs with continuously supported coverings.

3.3

When vapour barriers are bonded they 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. Alternatively a polyethylene membrane can be used where mechanical fixing is employed.

3.4

Polyflat Roof Insulation Boards are for use with:

3.6

Adhesion between the foam core, the vapour barrier and the overlay is adequate to resist the effects of the wind suction and thermal cycling, likely to be experienced in practice. In areas where high wind speeds can be expected, mechanical fixing should be considered, and the manufacturer's advice should be sought as to the methods of fixing. Fixings should be designed to resist wind loads calculated in accordance with CP 3 ch. V: Part 2: 1972 Wind loads.

PART 4 - TECHNICAL INVESTIGATIONS

4.1 Behaviour in Fire

1. The fire rating of roofs incorporating s Roof Insulation Boards depends on the waterproofing layer and the surface finish used.

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 Polyflat roof boards, when measured at a density of 36kgm^-3 in accordance with BS 874: Part 2: Section 2.1: 1986 Guarded hot-plate method, is .020Wm^-1K^-1.

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

Calculated U-values for typical roof constructions are listed in the table below.

Typical U-Values
Nominal or average Foam Thickness (mm)
25	35	45	55	65	75	80	85
U-value (Wm-2K-1) Based on metal deck, vapour barrier.
Polyflat boards with 3 layers felt chippings.
0.61	0.47	0.38	0.32	0.28	0.24	0.23	0.22

4.3 Condensation Risk

Polyflat Insulation Boards when used with a vapour barrier as described in 3.3 above are unlikely to be affected by interstitial condensation.

4.4 Maintenance

No maintenance of the insulation layer will be required, provided that the waterproof covering remains intact.

4.5 Durability

Polyflat Roof Insulation Boards are rot-resistent and durable and will have a life at least as long as the waterproofing.

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

Tests/units	Method	Mean result
Dimensions	MOAT 28 4.2.2.1	Length 1350 Width 1170
Polyflat (mm)	Thick. Insulation Composite	43/52
Density (kgm-3) Compressive Strength At 10% Compression (kPa)	ISO 844	36 > 175
Bending Strength (kPa)	MOAT 28 4.2.2.8	Long 1060 Trans. 1290
Dynamic Impact (when covered with 2 layers of 1.5mm felt)	MOAT 28 4.1.5.3 MOAT 27 5.1.10	Satisfactory I4
Dimensional Stability	ISO 2796	0.5%
Behaviour under Distributed Static Load	MOAT 28 4.1.5.1	Class C*
Thermal Movement Polyflat:	MOAT 28 4.1.3.1

Coefficient to thermal expansion (mm/mm/°C x 10-6)
	Length	Width
-20°C to +23°C	10	16
+23C to +80C	16	14
Residual Variation %	-0.12	-0.19
*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 quality 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. 90/0008 is accordingly granted to Polycomp Products Ltd. on behalf of the Irish Agrément Board.

Date of Issue: 24th January 1990