Rubber to TPO

Failed 5 year old Trelleborg Grey Butyl rubber membrane replaced with Lexcan 1.1mm Grey TPO (Carlile).
Reason: Lap tape failure, membrane stretched at internal corners, rubber hardened, curling at edges.
Location: New Plymouth
Labour only subcontract to Central Roofing Company Ltd
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overview of existing 5 year old rubber roof membrane, looking west overview of existing 5 year old rubber roof membrane, looking east view of sloping section into external gutter a/c fan unit corner detail at sloping section into external gutter west end of roof a/c unit and internal gutter edge of rubber is curling up at gutter turndown joint/seams are pulling apart all over the roof first section of rubber being torn up good part of the old rubber removed, new materials on roof first section/area of rubber has been removed, view to east first section/area of rubber has been removed, view to west first area ready for new membrane, view to west first area ready for new membrane, view to east first sheet of TPO is glued up and tacking off first sheet of TPO is glued up and tacking off three pieces set to match junction of slope change end of first days work second section/area old rubber has been removed, first sheet in position ready to glue down second section ready for new TPO west end of second section view to second section part sheet laid out some repair to the plywood required, delaminated while tearing up old rubber second section first half glued up and tacking off, view to east second section first glued up and tacking off, view to west Joe hot air welding one of the cross seams whle waiting for the glue to tack off on another sheet view across second sheet on second section, looking east view across second sheet on second section, looking west a/c kerb has been dressed with TPO view across roof end of second day, to the east view across roof end of second day, to the east first piece of upstand installed TPO strip is tucked 90mm under metal flashing and glued TPO strip is tucked 90mm under metal flashing and glued switch box on a/c unit is bedded in TPO compatible sealant area under larger a/c unit replaced view into corner by a/c unit, pipe and wire penetration cluster top of TPO collar is sealed with sealant PVC sleeve slid down over TPO collar parapets dressed with TPO pieces, west end parapets dressed with TPO pieces, east end roof at end of work third day, some lap welding to do at wall upstand view of small section at west end of roof, old rubber view of small section, internal gutter during tearing off the old rubber some plywood delaminated rubber removed, delaminated plywood repaired Scupper internal corners installed one piece laid into internal gutter end section completed, metal capping back in place view into small end section, a/c unit back in place view into small section, vent yet to be collared view across roof end of day four day five, rain, view to east day five, rain, view to east day five, rain, view into small section day five, rain, view out from small section to south internal gutter end junction, fluted corners to be installed scupper completed internal corner, metal capping temporarily back in position another internal corner, metal capping temporarily back in position view across roof to east during rain closer view down sloping section on south side of main roof during rain view across roof, work on hold due to rain last section to be removed when weather improves temporary seal new to old, end of roof

text for images
overview of existing 5 year old rubber roof membrane, looking west
overview of existing 5 year old rubber roof membrane, looking east
view of sloping section into external gutter
a/c fan unit
corner detail at sloping section into external gutter
west end of roof a/c unit and internal gutter
edge of rubber is curling up at gutter turndown
joint/seams are pulling apart all over the roof
first section of rubber being torn up
good part of the old rubber removed, new materials on roof
first section/area of rubber has been removed, view to east
first section/area of rubber has been removed, view to west
first area ready for new membrane, view to west
first area ready for new membrane, view to east
first sheet of TPO is glued up and tacking off
first sheet of TPO is glued up and tacking off
three pieces set to match junction of slope change
end of first days work
second section/area old rubber has been removed, first sheet in position ready to glue down
second section ready for new TPO
west end of second section
view to second section part sheet laid out
some repair to the plywood required, delaminated while tearing up old rubber
second section first half glued up and tacking off, view to east
second section first glued up and tacking off, view to west
Joe hot air welding one of the cross seams whle waiting for the glue to tack off on another sheet
view across second sheet on second section, looking east
view across second sheet on second section, looking west
a/c kerb has been dressed with TPO
view across roof end of second day, to the east
view across roof end of second day, to the east
first piece of upstand installed
TPO strip is tucked 90mm under metal flashing and glued
TPO strip is tucked 90mm under metal flashing and glued
switch box on a/c unit is bedded in TPO compatible sealant
area under larger a/c unit replaced
view into corner by a/c unit, pipe and wire penetration cluster
top of TPO collar is sealed with sealant
PVC sleeve slid down over TPO collar
parapets dressed with TPO pieces, west end
parapets dressed with TPO pieces, east end
roof at end of work third day, some lap welding to do at wall upstand
view of small section at west end of roof, old rubber
view of small section, internal gutter
during tearing off the old rubber some plywood delaminated
rubber removed, delaminated plywood repaired
Scupper internal corners installed
one piece laid into internal gutter
end section completed, metal capping back in place
view into small end section, a/c unit back in place
view into small section, vent yet to be collared
view across roof end of day four
day five, rain, view to east
day five, rain, view to east
day five, rain, view into small section
day five, rain, view out from small section to south
internal gutter end junction, fluted corners to be installed
scupper completed
internal corner, metal capping temporarily back in position
another internal corner, metal capping temporarily back in position
view across roof to east during rain
closer view down sloping section on south side of main roof during rain
view across roof, work on hold due to rain
last section to be removed when weather improves
temporary seal new to old, end of roof

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