Nuralite Repair with Easygum

This 35 year old Nuralite roof has multiple tears/splits in the Nuralite bitumen sheet membrane.
These vary as to severity, from peaking and surface splitting to ripped right through, some have been repaired with fibreglass and have ripped apart again.
The Nuralite had been overcoated with acrylic at some time in the past.
There are some soft spots, indicitive of rotted substrate.

Scope and Method of Repair Work

To the 27 lineal metres of splits;
prime with solvent based bitumen primer
apply by light torching 200mm wide x 2mm thick strips of Jaydex Nova SK polyester reinforced membrane.
Over the torched membrane strips, apply 3 coat Jaydex Eazygum fibreglass mesh/bitumen rubber refurbishment repair system, 300mm wide.
Coat all of above with Jaydex Alumicote UV protective coating.

To the soft substrate areas;

Carefully cut out the Nuralite membrane with a sharp knife around the suspect area. Bag Nuralite membrane on the roof in HD sealed plastic bags.
Carpenters to remove and replace defective plywood substrate.
Prime new plywood area with bitumen primer.
Appy by torchon method one layer of Jaydex Novater 3mm thick sand finished membrane, lapped onto the old Nuralite by 100mm
Over the torched membrane, apply 3 coat Eazygum fibreglass mesh/bitumen rubber refurbishment/repair system, with 200mm lap onto old roof membrane.
Coat all of above with Jaydex Alumicote UV protective coating.

Roof Top Breather Vents.

Install one rooftop mushroom type vent (300mm high by 80mm) approx every 50m2.(i.e. 5 vents)
When positioned, cut a 80mm hole through the Nuralite membrane and remove the cutout.
Position the vent and mechanically fix to the substrate with SS large head roofing clouts.
Cut and install a piece of Novater membrane to cover 100m bigger than the flange of the vent, torch this to the vent flange and to the roof.
Over the torched flashing piece, apply 3 coat Eazygum fibreglass mesh/bitumen rubber refurbishment/repair system, with 200mm lap onto old roof membrane.
Coat the bitumen products with Jaydex Alumicote UV protective coating.

Repair Process

hover cursor over image for text, click image for larger version (800×600 pixels)
typical split in Nuralite membrane typical split in Nuralite membrane splits promed with solvent primer jaydex nova sk reinforced strips applied over splits sk strips overcoated with jaydex easygum and fibreglass sk strips overcoated with jaydex easygum and fibreglass easygum 2nd coat closeup of easygum and fibreglass repair more jaydex nova sk reinforced strips applied over splits more splits primed more jaydex nova sk reinforced strips applied over splits more jaydex nova sk reinforced strips and easygum repairs applied over splits more jaydex nova sk reinforced strips and easygum repairs applied over splits more jaydex nova sk reinforced strips and easygum repairs applied over splits more jaydex nova sk reinforced strips and easygum repairs applied over splits area of rotted substrate 12mm plywood same area opened up for inspection same area cut out plywood same area closer view same area repaired with new H3 plywood area primed and 3mm torched on membrane being installed easygum and fibreglass bandages being applied around perimeter of repair easygum and fibreglass bandages around perimeter of repair another area of rot cut out plywood replaced same area repaired with torchon membrane and easygum bandages same area finished with jaydex alumicote UV protective coating another area of rot cut out plywood replaced and torchon membrane repair same area finished with easygum , fibreglass and alumicote UV protective coating one of 5 typical breather vents being installed, 2 layer torchon flange torchon flange installed and base coated in easygum and fibreglass rusted wall flashing under window (one of 2) wire brushed, primed, sk patch, easygum and fibreglass and alumicote repaired overview of completed work looking south overview of completed work looking north

text for images
typical split in Nuralite membrane
typical split in Nuralite membrane
splits promed with solvent primer
jaydex nova sk reinforced strips applied over splits
sk strips overcoated with jaydex easygum and fibreglass
sk strips overcoated with jaydex easygum and fibreglass
easygum 2nd coat
closeup of easygum and fibreglass repair
more jaydex nova sk reinforced strips applied over splits
more splits primed
more jaydex nova sk reinforced strips applied over splits
more jaydex nova sk reinforced strips and easygum repairs applied over splits
more jaydex nova sk reinforced strips and easygum repairs applied over splits
more jaydex nova sk reinforced strips and easygum repairs applied over splits
more jaydex nova sk reinforced strips and easygum repairs applied over splits
area of rotted substrate 12mm plywood
same area opened up for inspection
same area cut out plywood
same area closer view
same area repaired with new H3 plywood
area primed and 3mm torched on membrane being installed
easygum and fibreglass bandages being applied around perimeter of repair
easygum and fibreglass bandages around perimeter of repair
another area of rot cut out
plywood replaced
same area repaired with torchon membrane and easygum bandages
same area finished with jaydex alumicote UV protective coating
another area of rot cut out
plywood replaced and torchon membrane repair
same area finished with easygum , fibreglass and alumicote UV protective coating
one of 5 typical breather vents being installed, 2 layer torchon flange
torchon flange installed and base coated in easygum and fibreglass
rusted wall flashing under window (one of 2)
wire brushed, primed, sk patch, easygum and fibreglass and alumicote repaired
overview of completed work looking south
overview of completed work looking north

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