KC Pool Roofs

Sikaplan PVC material used in this project
Sikaplan 1.5mm PVC Membrane to internal and curved gutters and lap welding and detailing of Kingspan Topdek Panels, a single component factory pre-engineered roof-deck comprising a high performance single-ply membrane with insulation and a trapezoidal steel structural deck for high humidity environments.
Panels were installed by Lanwoods of Palmerston North.
No edge protection was provided by the main contractors on this project, so all work was done while wearing full body safety harness attached to our own safety ropes throughout the project. Everyone working on the roof structure, (except for on the a/c roof), had to have a Height and Harness Training endorsement on thier Site Safe Pass.
hover cursor over image for text, click on them for larger version

Amenities Roof

The Kingspan Panels have been laid on the framing by Lanwood and screw fixings installed through the panels. The holes are filled with expanding foam. As a temporary measure Lanwood taped over the seam edge with Duct Tape to keep water out of the building. When removed the tape left an adhesive residue that had to be cleaned off.
Initial membrane work for our company involved hot-air hand welding 80mm diameter Sikaplan PVC membrane patches (dots/discs/circles) over the filled holes. On the whole project there were 1070 of these!.
The panel membrane overlap seams were solvent cleaned and then a 40mm wide hot air weld completed. On this roof it was done by hand welder, so a double weld involved.
amenities roof, kingspan panels installed amenities roof, kingspan panels installed panel ends lifting panel to tower fixing holes filled with foam view over amenities roof mike welding dot patches example of welded dots seam overlap layout, click image to see details panel end strip amenities roof

a/c Roof

This roof, which links the Amenities and Retail Block with the main Pool Building, has all the air-conditioning and air pump machinery on it. There was more detailing work on this roof then all the rest of the flat roofs or gutters combined. Work was tight in some places, due to poor scheduling by the main contractor.
ac bridge roof ac bridge roof ac stand view SW from dome gutter view from dome gutter SE ac unit duct feet typical ac post boot dome wall upstand large internal gutter in ac roof membrane folded back and glued really tight work low view completed sump finished west end of gutter completed from east end ac cluster east to west view

Main Pool Building Curved Dome Gutter, South Side

These were built using metal covered wall insulation panels, cut and formed into the curved shape with multiple joints and angle pieces. We laid the membrane in such a way that the seams gave a double layer over the panel end joints (stronger to allow for expansion and contraction).
south side dome curved gutter before membrane south side dome curved gutter before membrane south side dome curved gutter down part glued south side dome curved gutter up part glued south side dome curved gutter up membrane laid in south side dome curved gutter east side before membrane south side dome curved gutter down part done south side dome curved gutter se down low south side dome curved gutter lower se end done south side dome curved gutter se pieces laid south side dome curved gutter se pieces laid low south side dome curved gutter se lower end from bottom welded south side dome curved gutter se lower welded from bottom south side dome curved gutter se over part done south side dome curved gutter vectors flaps welded down south side dome curved gutter up eastside with term bar south side dome curved gutter top of gutter finished south side dome curved gutter flashing on inside and out

Main Pool Curved Gutter, North Side

Same as south side, but wider.
north side dome curved gutter view down from tower north side dome curved gutter east view from crest north side dome curved gutter first step of install north side dome curved gutter second step north side dome curved gutter third step north side dome curved gutter edge glued up north side dome curved gutter uphill from east north side dome curved gutter up west side part done north side dome curved gutter up west side part done windy north side dome curved gutter up wside part done welded north side dome curved gutter down west end part done north side dome curved gutter up se with term bar north side dome curved gutter up se term bar north side dome curved gutter flashing on vector north side dome curved gutter metal cap on north side dome curved gutter raining

Plant Room Roof and Internal Gutter

Dot patches, hot air lap welding, internal gutter in Sikaplan 1.5mm PVC membrane.
mike robot welding $15,000 varimat robot welder plant-dome gutter drip aluminium edge primed drip edge glued up drip edge done plant-dome gutter membrane in rollering gutter sheet plant gutter almost done

Entry Roof, with Skylights

Dots, lap welding, vertical installation of Sikaplan 1.5mm PVC membrane to sides of skylights,
entry roof  from dome rollering up wall two skylights at once two skylights at once part done west skylight one skylight two skylight wall finished northeast view walls finished northwest view walls finished south west view point of skylight raining on entry roof vector pipe work between skylights vectorpvc flashing flaps welded down aluminium flashing on skylight

Main Pool Building, eastern eyebrow gutter

Steep curved gutter, install Sika Sarnafil 2.0mm PVC membrane.
east eyebrow gutter bottom up east eyebrow gutter down to north east eyebrow gutter top down south east eyebrow gutter membrane glued up east eyebrow gutter with membrane on, view from north

Retail Roof

retail roof from amenities roof early in project retail roof from dome gutter lanwood guy washing seams lanwood guy taping under seams small skylight installed small skylight typical skylight flashed in with pvc membrane

Final Images

As can be seen in some of the later photos the PVC membrane on the Kingspan Panels picked up a lot of dirt during the project.
south gutter ac roof-se roof dirty roof view down from dome gutter washed edge retail roof washed edge retail roof

and thats it!
The last 2 photos show the edge cleaned ready for the edge waterchecks to be covered with PVC membrane. That was on Waitangi Day Feb 2013, the day Mainzeal Construction and Property Ltd announced that it was going into Receivership.
Lanwood Manufacturing also went into receivership a month later, owed $800,000+ by Mainzeal.
We never got paid for our last months work in January 2013, and are still owed $9951.03 for our work.
The Receivers offered us nothing, but did ask if we would come back and complete the project, the forward work to be guarantee paid by the KCDC. We declined.

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