SUNLIFE SRCII Roof Coatings System For Use Over Existing EPDM Roof Covers

I INTRODUCTION

1.1
SUNLIFE Systems International, Inc. submitted their SUNLIFE SRC II Roof Coating System for use over existing EPDM roof covers for testing to determine if it meets the Approval requirements of Factory Mutual Research Corporation (FRMC) Standard No. 4470 for Class I Roof Covers when applied as recover over an existing FRMC Approved EPDM roof cover in insulated steel and concrete deck roof constructions.

1.2
Examination included ASTM E 108 Spread of Flame Fire Tests for potential exterior flame spread, simulated hail damage testing, susceptibility to leakage testing and foot traffic testing. All other tests were waived due to prior Approval examinations conducted on similar SUNLIFE Roof Coating Systems.

1.3
Tests show that the SUNLIFE SRC II Roof Coating System or use over existing EPDM roof covers meets FRMC Standard 4470 Approval requirements for Class 1 Roof Covers and is Approved as such when installed as described in the CONCLUSIONS of this report.


II MATERIALS TESTED

2.1
SUNLIFE SRC II Roof Coating System is a liquid applied acrylic coating applied over an existing EPDM roof cover in one of three methods described as follows.

2.1.1
Apply a base coat of SUNLIFE SRC II Roof Coating System (gray) to EPDM roof cover with a bristle brush or roller to a wet film thickness of 16 mils (8 mils dry) {0.4 mm (0.2 mm)}. While base coat is wet embed a polyester mat unto coating and broom in Apply a second coat of SUNLIFE SRC II Roof Coating System (gray) to surface of cloth to wet film of 16 mil (0.4 mm). Allow to cure for 24 hours. Apply a final coat of SUNLIFE SRC II Roof Coating System (white) to a wet film thickness of 16 mil (0.4 mm).

2.1.2
Apply a base coat of SUNLIFE SRC II Roof Coating System (gray) to EPDM roof cover with a bristle brush or roller to a wet film thickness of 16 mils (8 mils dry) {0.4 mm (0.2 mm)}. Allow to cure for 24 hours. Apply a final coat of SUNLIFE SRC II Roof Coating System (white) to a wet film thickness of 16 mil (0.4 mm).

2.1.3
Apply an 8 in (203 mm) wide by 8 mils wet film thickness (4 mils dry thickness) coat of SUNLIFE SRC II Roof Coating (gray) over the lap seam areas of an EPDM roof cover with a bristle brush or roller. While base coat is wet embed a 6 in (152 mm) polyester mat onto the coating and broom in Apply a second coat of SUNLIFE SRC II Roof Coating System (gray) to the surface of cloth to wet film of 8 mil (0.2 mm). Allow to cure for 24 hours. Apply a coat of SUNLIFE SRC II Roof Coating (gray) to the entire surface of the EPDM roof including the previously coated cloth strip to wet film thickness of 16 mils (8 mils dry) {0.4 mm (0.2 mm)}. Allow to cure for 24 hours. Apply a final coat of SUNLIFE SRC II Roof Coating System (white) to a wet film thickness of 16 mil (0.4 mm).


III TESTS: CRITERIA AND PROCEDURES

3.1
Tests conducted as required by FMRC Standard No. 4470-Roof Covers. All test panels were prepared in accordance with the manufacturerÕs instructions.

3.2
Simulated Hail Damage Tests

3.2.1
Tests were conducted using the FMRC Simulated Hail Damage Test Apparatus to evaluate the ability of the roof covers to withstand a hailstorm without damage to the membrane. After each drop the sample is inspected and there must be no evidence of splitting, delamination or rupture of the roof cover.

3.2.2
A 1-3/4 in (49 mm) diameter steel ball weighing 0.78 lbs (0.3 kg) was dropped on the test sample from a 17 ft 9-1/2 in (5.4 m) height through a 33 3/4 in (0.86 m) length of PVC pipe with a 2 in (51 mm) inside diameter. This procedure was repeated several times on various sections of each sample. After each drop the sample was inspected for damage to the weatherproof membrane. Following initial testing, each sample was conditioned (weathered) for 1000 hours in the FMRC Ultraviolet Weatherometer. The initial procedure was then repeated on the conditioned sample.

3.3
ASTM E 108 Fire Tests

3.3.1
The exterior fire tests were conducted in accordance with the ASTM E 108 Fire Tests of Roof Coverings, Class A, noncombustible deck test procedure. The wind velocity over the top of each sample was 12 + 0.5 mph (5.4 + 0.2 m/s). The tests were conducted at various slopes.

3.3.2
Spread of Flame Tests
The flame was adjusted to 1400 +/- 50 degrees F (760 +/- 28 degrees 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 3-1/3 ft x 8 ft (1.0 m x 2.4 m). The flame was applied continuously 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.

3.4
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 causing exposure of the insulation.

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 and 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 (235 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 pipe section. Both top and bottom sections are bolted together at the flanges with the cover (coating) being evaluated placed between them. The apparatus is fabricated to allow both a standing 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 gauge.

3.5.3
After conditioning (weathering) for 1000 hours in the FMRC Ultraviolet Weatherometer a 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 seven days. At the end of the seven day period air is introduced into the water to a 1 psig (6.8 kPa) level and cycled 25 times from 1 psig (6.8 kPa) to ambient. Test criteria states that there shall be no signs of water leakage during the seven 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 Spread of Flame Test Samples
Three, 3 1/3 ft x 8 ft (1.0 m x 2.4 m) test decks were constructed as follows:

Sample 1. 1/2 in (13 mm) plywood test deck.
Mechanically fastened 60 mils (1.5 mm) thick Firestone Standard EPDM. Sunlife Roof Coating (gray) Base Coat applied to a wet film thickness of 16 mils (0.4 mm). 40 in (102 mm) wide polyester mat broomed into wet base coat. SUNLIFE Roofing Compound (SRC) (gray) to surface of polyester with a wet film thickness of 16 mils (0.4 mm). Allowed 24 hours to cure. Final coat of SUNLIFE Roofing Compound (SRC) (white) with a wet film of 16 mils (0.4 mm).

Sample 2. 1/2 in (13 mm) Plywood test deck.
Mechanically fastened 60 mils (1.5 mm) thick Firestone Standard EPDM. SUNLIFE Roof Coating (gray) Base Coat applied to a wet film thickness of 16 mils (0.4 mm), allowed 24 hours to cure. Final coat of SUNLIFE Roofing Compound (SRC) (white) applied to a wet film of 16 mils (0.4 mm).

Sample 3. 1/2 in (13 mm) plywood test deck
Mechanically fastened 60 mils (1.5 mm) thick weathered existing EPDM. 8 in (203 mm) wide coat of SUNLIFE Roofing Compound (SRC) (gray) located down the center of panel and applied to wet thickness of 8 mils (0.2 mm). SUNLIFE Roof Coating (gray) Base Coat applied to the surface of the polyester strip with a wet film thickness of 8 mils (0.2 mm). Allowed 24 hours to cure. 6 in (152 mm) wide polyester mat broomed into wet base coat. SUNLIFE Roofing Compound (SRC) (gray) to entire surface of panel including over the polyester applied to a wet film thickness of 16 mils (0.4 mm). Allowed 24 hours to cure. Final coat of SUNLIFE Roofing Compound (SRC) (white) with a wet film of 16 mils (0.4 mm)

4.2
Simulated Hail Damage Test Sample
One 2 ft x 4 ft (0.6 m x 1.2 m) sample was constructed as follows:

Firestone Standard EPDM 60 mils (1.5 mm) thick. SUNLIFE Roofing Coating (gray) Base Coat applied to a wet film thickness of 16 mils (0.4 mm), allowed 24 hours to cure. Final coat of SUNLIFE Roofing Compound (SRC) (white) applied to a wet film of 16 mils (0.4 mm).

4.3
Resistance to Foot Traffic Test Sample
One 2 ft x 4 ft (0.6 m x 1.2 m) sample was prepared. The construction was identical to the test sample in Paragraph 4.2 above.

4.4
Susceptability to Leakage Test Sample
One leakage test was conducted on the sample described in Paragraph 4.2.


V RESULTS

5.1
ASTM E108 Spread of Flame Test

Sample No. 1
Slope: 1/2:12 (4%) Max Flame Spread: 1 ft 11 in (584 mm) Rating: Class A

Sample No. 2
Slope: 1/2:12 (4%) Max Flame Spread: 1 ft 3 in (381 mm) Rating: Class A

Sample No. 3
Slope: 1/2:12 (4%) Max Flame Spread: 1 ft 11 in (584 mm) Rating: Class A

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

5.2
Simulated Hail Damage Test
The sample was subjected to Severe Hail (SH) test. After each drop of the simulated hail impactor, the Simulated Hail Damage Test sample was examined for cracking. The test sample passed the SH test. There was no evidence of any cracking in the coating.

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

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


VI CONCLUSIONS

6.1
The results show that the SUNLIFE Systems International, Inc. SUNLIFE SRC II Roof Coating System for use over existing EPDM roof covers meets FMRC Standard 4470 Approval Requirements when applied in the following constructions:

6.1.1
Recover Construction-SUNLIFE SRC II Roof Coating applied over an existing EPDM roof cover in one of three methods described as follows:

6.1.2
Apply a base coat of SUNLIFE SRC II Roof Coating (gray) to EPDM roof cover with a bristle brush or roller to a wet film thickness of 16 mil (8 mils dry) {(0.4 mm) (0.2 mm)}. While base coat is wet embed a polyester mat onto coating and broom in Apply a second coat of SUNLIFE SRC II Roof Coating (gray) to surface of cloth to wet film of 16 mil (0.4 mm). Allow to cure for 24 hours. Apply a final coat of SUNLIFE SRCII Roof Coating (white) to a wet film thickness of 16 mil (0.4 mm).

6.1.3
Apply a base coat of SUNLIFE SRC II Roof Coating (gray) to EPDM roof cover with a bristle brush or roller to a wet film thickness of 16 mil (8 mils dry) {(0.4 mm) (o.2 mm)}. Allow to cure for 24 hours. Apply a final coat of Sunlife SRC II Roof Coating (white) to a wet film thickness of 16 mils (0.4 mm).

6.1.4
Apply an 8 in (203 mm) wide by 8 mil wet film thickness (4 mil dry thickness) coat of SUNLIFE SRC II Roof Coating (gray) over the lap seam areas of an EPDM roof cover with a bristle brush or roller. While base coat is wet, embed a 6 in (152 mm) polyester mat onto the coating and broom in Apply a second coat of SUNLIFE SRC II Roof Coating (gray) to the surface of cloth to a wet film thickness of 8 mil (0.2mm). Allow to cure for 24 hours. Apply a coat of SUNLIFE SRC II Roof Coating (gray) to the entire surface of the EPDM roof including the previously coated cloth strip to wet film thickness of 16 mils (8 mils dry) {(0.4 mm) (0.2 mm)}. Allow to cure for 24 hours. Apply a final coat of SUNLIFE SRC II Roof Coating (white) to a wet film mil (0.4 mm).

6.2
Tests show the above roof constructions in and of themselves would not create a need for automatic sprinklers.

6.3
For the recover applications noted above, the roof cover system is acceptable over either a Class 1 or 2 rated existing roof deck construction. Application of this system over an existing rated roof deck will not upgrade the construction.

6.4
The roof cover must be installed using an FMRC-Approved Roof Perimeter Flashing System (see FMRC Approval Guide).

6.5
The tested constructions meet FMRC Approval criteria and when Approval is effective, will be listed in the FMRC Approval Guide in the Roof Cover Category.

6.6
Approval is effective when the Approval Agreement is signed and returned to FMRC. Continued Approval will depend upon satisfactory field experience and periodic Quality Audit Inspections.


VII MARKING

7.1
The manufacturer shall mark each packing container with the manufacturer's name and product trade name. In addition, the container must be marked with the FMRC Approval Mark and the words "Subject to the conditions of approval as a roof cover when installed as shown in the current edition of the FMRC Approval Guide."

7.2
The manufacturer agrees that the 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 a ll references to FMRC Approval.

7.3
Markings denoting FMRC Approval shall be applied by the manufacturer only within and on the premises of manufacturing locations that are under FMRC's Facilities and Procedures Audit Program.

VIII MANUFACTURERS RESPONSIBILITIES

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

8.2
The manufacturer shall notify the FMRC of any planned change in the Approved products, prior to general sale or distribution to the general public. Notification shall be accomplished with Revision to Approved Product Form 797.


IX QUALITY AUDIT INSPECTION AND RE-EXAMINATION

A re-examination and manufacturing inspection will be conducted periodically at SUNLIFE Systems International, Inc., Charlotte, NC manufacturing facility on the Approved product 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
Project Engineer
Materials Section

APPROVED BY:
L.N. D'Angelo
Senior Engineer
Materials Section

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5301 Nations Crossing Road
Charlotte, NC 28217
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Tel: (704) 527-2480
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