RAMCON tests it’s robot welder settings every morning, afternoon, and after any major temperature change throughout the day. We perform practice robot welds on scrap membrane, changing only one variable at a time, either temperature or speed. After the welds have cooled, we cut a one-inch strip across each weld for each change in temperature or speed. Then we perform a pull test. If a cold weld or a partial weld happens those temperatures and speeds are not at the proper setting for the current climatic conditions. Once a full or perfect weld is accomplished, the welding robot is set to the perfect speed and temperature.
4. Probing For Voids
After the seam has cooled, we come back and probe those seams. If a void occurs, we patch it with an unsupported membrane on the same day; ensuring the installation is perfect before we leave the roof.
3. Improper Perimeter & Corner Enhancement
Roof failures are most common at perimeters and corners due to the lack of enhancements.
The most crucial items are:
• Adding the correct amount of additional fasteners to an insulation for full adherence
• The proper number of perimeter sheets for a mechanically attached roof system.
The biggest mistake contractors make is improper installation of attaching perimeter sheets at the corners. Fasteners need to “box” in the corner area. The following pictures show where the fasteners are required to go and which were missing on this project.
4. Base Fastening at Curbs & Penetrations
The end of a membrane (termination) requires termination fasteners and plates. Prior to flashing installation penetrations (pipes, curbs etc.) they must be terminated. Base fastening and termination are typically required regardless of the manufacturer to properly secure the
membrane.
5. "Drain Bolts" Attached Properly
Tightening drain bolts on a roof is one of the most easily forgotten items by contractors. Without tightened drain bolts, water can get into the system or, as shown in the example, can actually lift up and cause a catastrophic failure.
6. Priming "Pitch Pockets" Before Sealing
Pitch pockets must be primed before adding pourable sealer or grout. If it is not primed, it will not stick to the penetrations allowing leaks to develop. Missing this step is a leading source of water intrusion.
7. Cleaning
If a TPO membrane experiences exposure for over 24 hours or gets dirty before welding begins to avoid seam failure clean the membrane. Therefore, it is ideal to do all welding and flashing on the day of installation. The picture shows both a properly cleaned area and an improperly cleaned area. Unfortunately, the un-cleaned seams will fail.
8. T-Joint Patches
There is always confusion over when and where T-joint patches are applied. The first place is at any horizontal transition where the end lap of a roll intersects with the side lap of another roll, or the T-joint intersection. The second place to use a T-joint patch is at a start or stop for the robot. This will ensure there are no voids left eliminating water intrusion. For quality control, we regularly inspect all lap runs and flashings wherever a welded lap terminates at a wall or roof edge.
Quality Control Makes The Difference
When choosing a contractor to install your roof, price certainly is a factor. However, it’s not the only factor. Subpar work is substantially more expensive in the long run and reduces return on investment significantly (not to mention the headaches that come from roof leaks). With RAMCON, you receive a superior installation, by dedicated quality control teams (who know what to look for), and inspects each project without exception.
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