Re roof of 30 year old Butynol rubber membrane with 1.52mm thick x 3.0 metres wide Carlile EPDM (supplied by Viking Roofspec in NZ as Epiclad).
To be on the safe side the work done in 3 sections over 3 days, in case there are any substrate issues, and to keep the building rain proof during the work.
Remove cement sheet cladding on inside of parapets and wall under metal roof on upper roof level.
Remove existing butynol rubber membrane from plywood substrate of both levels and dispose.
Inspect substrate for loose fixings or water damage and repair as necessary.
Rescrew plywood with stainless steel screws, punch in old nails and sand the existing plywood to remove sharp splinters and excess old adhesive.
Apply new 25mm silicone joint tape over the plywood sheet joints.
Install 1.52mm black Viking Epiclad EPDM rubber in 90-8-30A adhesive, tuck membrane edges under the existing metal roof flashings, and turn up 200mm at other walls and fix aluminium termination bar bedded in sealant to top edge.
Form new collar around one post and also form a new lap tape join to the old rubber on the narrow roof with the skylights.
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30 year old butynol rubber roof,
internal gutter at end of lower level, 50mm drain!
reverse view of lower level to the north
upper level south wall junction
view over upper level to the west
upper level fascia board and cement sheet cladding on upstand
view over upper level to the north
junction between narrow skylight roof and main flat roof
start on lower level, pulling up old butynol rubber
trying to remove in one piece, in case it rains during the work, use as temp cover
plastic tape was use over plywood joints
ready to sand plywood substrate
plywood sanded and one piece of old rubber ready for the landfill
closer view of sanded plywood
installing new stainless steel screws
new silicone tape over plywood joints
ready to lay EPDM, note internal gutter has been built out level with main roof
3.0 metre wide sheet of EPDM laid out to relax
first half of sheet is folded back and contact adhesive applied
90-8-30A bonding adhesive tacking off
first half is laid down in the adhesive and the second half being glued up
second half of sheet tacking off
forecast was for showers, had 3 short light sprinkles during the day
post boot formed from self adhesive detail tape
lower half of roof new EPDM installation is complete
upper level, fascia and cladding being removed
save for a 50mm gap, the framing behind the cladding is almost full height
back wall (west side) has cement sheet removed also
view into south corner, demolition done
temporary covered in for overnight with TPO membrane offcuts
next morning, wet from a light shower of rain overnight
water is squeeged off, still cold, about 6C
popping nail fxings on this section
half of upper section old butynol rubber being removed in strips
rubber is difficult to pull off in one piece
rusty nails along plywood sheet joint
nail head rust explosions
installing new stainless steel screws
sanding this section of plywood
plywood joint after sanding plywood
closer view of sanded plywood joint, nails are punched in, rust debris is gone and sealer applied
damn water pipe
EPDM sheet being glued up
reverse view of previous photo
closer view of adhesive tacking off
sheet is laid down and edge solvent wiped for taped overnight seal
tape applied for overnight seal
double seam taped junction between narrow skylight roof and main flat roof
150mm wide cover tape over junction between old and new
detail tape around complicated corner at level change
next morning, roof is soaking wet from a heavy dew and runoff from metal roof
temporary overnight seal did it’s job
flap of old rubber past the tape kept water away from joint
off with the last section of old rubber, temperature about 6C
cut in strips again to make it easier to remove
last section with old rubber removed
popping nails, not so rusty, but starting to corrode
plywood is rescrewed, sanded, joints taped. Note new plywood on upstand under metal roof
sheet in position, tucked under flashing and temporary cover over upstand
because of threat of rain, time for a lunch break
after lunch, scrubbing the seam joint with bonding primer
first half of sheet is glued up
first half laid down, seam formed and second half glued up
hold it here!, downpour of water
test of new seam joint!
almost got upstand under metal roof done
next day, tricky detailing at corner, concrete block overide
last part of EPDM sheet up wall glued and tacking off
termination bar fixed to north upper level wall
upper level south wall with bar on
upper level looking north west 5pm
lower level with termination bars on
completed south corner on upper level
view from upper level to south east corner
upper level looking north west
level change with new EPDM membrane