I. INTRODUCTION

1.1
SUNLIFE Systems International, Inc. submitted their SUNLIFE Roof Coating Roofing System for testing to determine if it meets the Approval requirements of Factory Mutual Research Corporation (FMRC) Standard 4470 for Class I Fire when applied over an existing BUR in recover roof deck construction.

1.2
Examination included ASTM E-108 (87) Fire Tests of Roof Coverings, simulated hail damage testing, resistance to foot traffic testing and susceptibility to leakage testing.

1.3
Tests show that SUNLIFE Roof Coating Roofing System meets FMRC Standard 4470 Approval requirements for Class I Fire and is Approved as such when installed as described in the CONCLUSIONS of this report.


II. MATERIALS TESTED

2.1
SUNLIFE Roof Coating Roofing System is a field applied, liquid, coating. It is applied in four layers.

2.1.1
The base coat layer is an elastomeric coating applied with a trowel or squeegee, to an existing BUR, at a rate of 7 gallons per square (26 l per 9.3 m2) for smooth roof, and 13 gallons per square (49 l per 9.3 m2) for a gravel topped BUR.

2.1.2
A polyester fabric mat is embedded in the wet base coat as the second layer. The polyester mat is a stitch bonded polyester based material with strength properties that allow elongation for thermal stresses, weighing 2.13 lbs. per square (.96 kg 9.3 m2).

2.1.3
A two coat application of SUNLIFE Roofing Compound is applied at 2 gallons per square (7.6 l per 9.3 m2) per each application, on both smooth or gravel BUR previously coated surfaces. These two coats make up the third and fourth layers. The SUNLIFE Roofing Compound is a water soluble acrylic based liquid.


III. TESTS: CRITERIA AND PROCEDURES

3.1
Tests conducted were as required by FMRC Standard 4470 Ð Roof Covers.

3.2
ASTM E-108 (87) Fire Test

3.2.1
The exterior fire tests were conducted in accordance with the ASTM E-108 (87) Fire Tests of Roof Coverings, Class A, noncombustible deck test procedure. The wind velocity over the top of each sample was adjusted to 12 ± 5 mph (5.4 ± 0.2 m/s). The tests were conducted at a slope of 1:12 in. (25:305 mm).

3.2.2
Spread of Flame Tests-The flame was adjusted to 1400 ± 50¡F (760 ± 28¡C) as determined by a thermocouple located 1 in. (25 mm) above the surface and 1/2 in. (13 mm) toward the source of the flame from the lower edge of the panel. Sample size was 40 in. x 10 ft. (1.0 m x 3.0 m). The flame was appliedcontinuously for 10 minutes. During and after the application of the flame, the panel was observed for distance of maximum flame spread, glowing brands and other damage.

3.3
Simulated Hail Damage Tests

3.3.1
The simulated hail damage tests were conducted using the FMRC simulated hail damage test apparatus to evaluate the ability of the roof covering (coating) to withstand a hailstorm without damage to the membrane. The Test criteria state that there must be no evidence of splitting or rupture of the roof cover.

3.3.2
A 1-3/4 in. (49 mm) diameter steel ball weighing 0.78 lbs. (0.4 kg) was dropped from a 17 ft. 9-1/2 in. (5.4 m) height through a 2 in. (51 mm) ID PVC tube. This procedure was repeated several times on various sections of the sample. After each drop the sample was inspected for any cracks in the weatherproof membrane. Initially, the sample was tested after a 28-day cure period. Following the initial testing, the sample was conditioned (weathered) for 1,000 hours in the FMRC Ultraviolet Weatherometer. The test procedure was then repeated on the conditioned sample.

3.4
Resistance to Foot Traffic Test

3.4.1
The test was conducted to evaluate the ability of the roof cover (coating) to withstand simulated foot traffic without damage to the weatherproof membrane. The test criteria state that there shall be no tearing or cracking of the protective cover.

3.4.2
A 3 in. (76 mm) square steel plate with rounded corners was placed on the test sample. A 200 lb. (91 kg) load was imposed on the plate, then reduced to zero. This cycle was repeated four additional times. After each cycle, the coating was inspected for damage.

3.5
Susceptibility to Leakage Test

3.5.1
The leakage test was conducted in accordance with the FMRC Susceptibility to Leakage Test procedure.

3.5.2
The test apparatus consists of top and bottom sections which are bolted together with the specimen being evaluated placed as a diaphragm between the sections. The top and bottom sections consist of 9-1/4 in. (203 mm) diameter caps cemented to 7-3/4 in. (197 mm) diameter clear acrylic pipe. An 11-5/8 in. (295 mm) diameter pipe flange is cemented to the other end of each with the cover (coating) being evaluated placed between them. The apparatus is fabricated to allow both a standard head of water above and additional air pressure below the test sample. Each section is fabricated with two 1/2 in. (13 mm) diameter pipe outlets to allow connection of an air pressure inlet and pressure gauge.

3.5.3
The 10 in. (254 mm) diameter specimen is bolted in place between the flanges of the test apparatus. Water is placed over the sample to a depth of 6 in. (152 mm) and maintained for a period of 7 days. At the end of the 7 day period, air is introduced below the water to a 1 psig (6.8 kPa) level and cycled 25 times from 1 psig (6.8 kPa) to ambient. Test criteria state that there shall be no signs of water leakage during the 7 day period. In addition, there shall be no signs of water leakage during or after the pressure cycles.


IV. TEST SAMPLES

4.1
ASTM E-108 (87) Spread of Flame Test Samples Ð Two identical 40 in. x 10 ft. (1 m x 3 m) test decks were constructed on 1/2 in. (13 mm) thick plywood (non FMRC-Approved) as follows: A 3 ply BUR applied directly over the plywood deck with the coating system applied as outlined in paragraph 2.1.

4.2
Simulated Hail Damage Test Sample Ð One 2 ft x 4 ft (0.6 x 1.2 m) sample was prepared. The construction was identical to paragraph 4.1.

4.3
Resistance to Foot Traffic Test Sample Ð One 2 ft x 4 ft (0.6 x 1.2 m) sample was prepared. The construction was identical to paragraph 4.1.

4.4
Susceptibility to Leakage Test Sample Ð One 18 in. (45 mm) diameter sample was prepared as follows: The coating and fabric were applied to a polyethylene ÒreleaseÕÕ backing as outlined in paragraph 2.1. After curing, the backing was removed and the sample conditioned in the FMRC Ultraviolet Weatherometer for 1,000 hours. The sample was then cut to a 10 in. (254 mm) diameter size and placed in the leakage test apparatus.


V. RESULTS

5.1
The ASTM E-108 (87) Spread of Flame Test results are given below:

Sample No. 1: Max. Flame Spread: 2 ft.-3 in. (0.7 m)

Sample No. 2: Max Flame Spread: 2 2 ft.-0 in. (0.6 m)

At no time during the spread of flame tests was the deck exposed, flying brands developed or excessive lateral flame spread observed.

5.2
After each drop of the simulated hail impactor, the Simulated Hail Damage Test samples were examined for cracking. There was no evidence of any cracking in the coating during each test.

5.3
After each test cycle, the Resistance to Foot Traffic Test sample was examined. There was no evidence of damage to the coating.

5.4
The Leakage Test sample showed no signs of water leakage during the 7 day period or during or after the pressure cycles.


VI. CONCLUSIONS

6.1
Test results show that the SUNLIFE Roof Coating Roofing System, manufactured by SUNLIFE Systems International, Inc. meets FMRC Standard No. 4470 Approval requirements for Class I Fire in Recover Construction when applied as outlined below:

6.1.1
The elastomeric base coating is applied to an existing smooth surface BUR at 7 gallons per square (26 l per 9.3 m2) or to a gravel surfaced BUR at 13 gallons per square (49 l per 9.3 m2), the polyester mat is embedded in the wet base coat and allowed to cure for 7 days. The first coat of SUNLIFE Roofing Compound is applied at 2 gallons per square (7.6 l per 9.3 m2) and allowed to cure for 24 hours before applying the second coat of compound at the same rate.

6.1.2
The above construction meets ASTM E-108 Class A, noncombustible deck rating at a maximum slope of 1 in. per 12 in. (25 mm per 305 mm).

6.2
The roof cover system described above is Acceptable over either a Class I or II rated existing roof construction. Application of this system over an existing Class II rated roof deck will not upgrade the construction to Class I.

6.3
The roof cover must be installed using an FMRC-Approved Roof Perimeter Flashing System (see FMRC Approval Guide) or in accordance with FMEA Data Sheet 1-49.

6.4
The construction described above meets FMRC Approval criteria and, when Approval is effective, will be listed in the FMRC Approval Guide in the Roof Cover category.

6.5
Approval is effective when the Approval Agreement is signed and returned to FMRC. Continured Approval will depend upon satisfactory field experience and periodic Quality Audit Inspections.


VII. MARKING

7.1
The manufacturer shall mark each packing container or label with the manufacturerÕs name and product trade name. In addition, the container must be marked with the FMRC Approval mark and words, ÒSubject to the conditions of Approval as a roof cover when installed as described in the current edition of the FMRC Approval Guide.Ó

7.2
The manufacturer agrees that use of the FMRC name or Approval mark is subject to the conditions and limitations of FMRC Approval. Such conditions and limitations must be included in all references to FMRC Approval.


VIII. MANUFACTURER'S RESPONSIBILITIES

8.1
To assure compliance with his procedures in the field, the manufacturer shall supply to the roofer such necessary instruction or assistance required to produce the desired performance achieved in the tests.

8.2
The manufacturer shall notify the Factory Mutual Research Corporation of any planned change in the Approved products, using Form 797, Approved Product Revision Report, prior to general sale or distribution.


X. QUALITY AUDIT INSPECTION AND REEXAMINATION

A re-examination and manufacturing inspection will be conducted periodically at SUNLIFE Systems International, Inc.Õs facilities in Charlotte, N.C. and Monsey Products Co. facilities in Rock Hill, S.C. on the Approved products to determine that the quality and uniformity of the materials have been maintained and will provide the same level of performance as originally Approved.

TESTS BY: D. A. Kettle

REPORT BY: APPROVED BY:
D. A. Kettle
Engineer
Materials Section

APPROVED BY:
G. A. Smith
Manager
Materials Section (Approvals)

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  Sunlife Systems International, Inc.
5301 Nations Crossing Road
Charlotte, NC 28217
(800) 328-5885
Tel: (704) 527-2480
Fax: (704) 527-0534

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