Welding TPO and PVC Coated Metal
June 25, 2019
Welding Carlisle’s coated metal is quick and easy if you follow a few simple guidelines. Here are some useful tips for your next Sure-Weld® TPO or Sure-Flex™ PVC Coated Metal installation.

Product facts 
Description: 24-gauge hot-dipped G90 galvanized steel sheeting with a layer of 35-mil non-reinforced TPO or PVC flashing laminated to one side
  • Size: 4’ by 10’
  • Packaging: 10 or 25 sheets per pallet
  • Standard colors:
    • TPO – White, Tan, Gray, Bronze, Patina Green, Rock Brown, Terra Cotta, Slate Gray
    • PVC – White, Tan, Gray
  • Markings: The underside of each coated metal sheet is marked with “TPO” or “PVC”; these markings are repeated several times to avoid misidentification
  • Shelf life: None
  • IMPORTANT: TPO and PVC are not interchangeable and will not weld to each other
Before you begin
It is essential that the material is clean. The flat sheet goes through a few processes at the contractor’s metal shop, including shearing and breaking. When the metal is formed, it picks up dirt and contaminants that can negatively affect its weldability. The most common error associated with hot-air welding coated metal is the lack of proper cleaning.
After the coated metal profiles are fastened into place on the roof and before you begin welding, clean with Weathered Membrane Cleaner (for TPO) or PVC and KEE HP Membrane Cleaner (for PVC and KEE HP). Pour the appropriate cleaner from a safety can onto an HP Splice Wipe or other natural fiber rag; then, wipe the metal with the wet cloth to make sure the entire area is clean. If there’s a heavy buildup of dirt, you may need to use a Primer Pad to remove it. When working with cleaners, remember to wear appropriate personal protective equipment, including safety glasses and permeation-resistant gloves that meet ANSI/ISEA 105-2005.
Make sure the underside of the membrane being welded to the coated metal is also cleaned. Allow at least 10 to 15 minutes for the solvents in the cleaner to flash off the surfaces you’ll be welding.

Heat welder setup
When setting up your heat welder, you must consider the thickness of the membrane you’re welding to the coated metal. An 80-mil membrane will require more heat than a 45- or 50-mil membrane. Start the process with the hand welder at the number 7 or 8 setting. Because the 35-mil TPO or PVC film is laminated to the metal, it remains robust during the welding process and will accept more heat without distortion.

Welding coated metal to membrane
Start the welding process by building an air dam parallel to the rear edge of the metal. This will trap the heat and ensure it isn’t lost under the membrane. Using a hand welder and a 2” neoprene roller, weld the membrane to the coated metal, then roll in a perpendicular motion.

Check your welds
To check for proper fusion, weld a strip of membrane to a scrap piece of coated metal. Once your weld has cooled, pull the membrane until failure. Proper fusion has occurred if the membrane delaminates from itself, leaving the bottom ply welded to the film, or if the membrane tears when you try to pull it off the coated metal.

For more information on securement requirements and instructions on how to address metal end joints, follow detail U-1B. Please contact Jim Gage with questions.

    Jim Gage
    Senior Technical Specialist
    Product Marketing
    james.gage@carlisleccm.com
February 25, 2020
Dual Tanks Cold Weather Application Tips

Proper material temperatures are imperative to ensure that adhesive products deliver the highest level of performance. When applying adhesive products below the manufacturer’s recommended application temperatures, application speed and performance can be drastically affected. To help address material temperature issues, Carlisle has recently announced the availability of heated blankets and temperature sensing nozzle technology. Flexible FAST reaches its maximum performance when the material temperature at the time of installation is 70°F or rising. When temperatures fall below 70°F, urethane adhesives can experience mixture ratio issues that could create application issues. To help address material temperatures during winter applications, the use of hot boxes and power blankets are recommended to ensure the adhesive remains at 70°F or above at the time of application. For more information regarding heated blankets, click here or visit the website for one of Carlisle equipment partners: PowerBlanket 4C's Spray Equipment Panther East In addition to heated blankets, Carlisle has also made advancements to delivery systems to help applicators identify when an adhesive product is too cold. In January 2020, Carlisle introduced Temperature Warning Tips for Flexible FAST Dual Tanks. These tips make it easy to apply polyurethane adhesives properly. Carlisle’s Temperature Warning Tips provide the applicator with a visual cue to easily identify if the material is too cold during application: Nozzle turns BLUE when adhesive temperature is below the required 70°F. Nozzle will be CLEAR when adhesive is spraying at optimal temperature. Compression seal added to create a tighter fit between the gun and tip. This helps eliminate adhesive leaks. For more information, please contact your manufacturer's representative.

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February 11, 2020
Code-Required Minimum R-Values

Over the past 10 years, there has been a shift in minimum required R-values. The 2015 International Energy Conservation Code (IECC) is the driving force behind this movement. More than 20 states have adopted the 2015 IECC, or a portion of its provisions, as their statewide energy code. See the chart below for minimum R-values per climate zone. Since 2009, the roofing industry has seen an R-10 increase in the majority of the states. The total minimum insulation thickness has increased from 3.5" (R-20) to 5.2" (R-30) in parts of over 40 states. The map below can help you identify climate zones within your state. Climate zones 4 through 8 have experienced an R-10 increase. Additional resources are provided below to help you determine the applicable energy code and its associated minimum R-value requirements in a given state or local jurisdiction.    1. Minimum Insulation R-value Requirements: Non-Residential, Above Roof Deck    2. The Building Codes Assistance Project For more information on R-value requirements, please contact Brandon Reynolds at brandon.reynolds@carlisleccm.com

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January 28, 2020
Polyiso Storage, Handling, and Application Guidelines

It is well known that moisture is detrimental to roof system performance. Wet insulation can lead to several issues including mold, reduced membrane adhesion, and ultimately roof system failure during wind events. Because wet polyiso must be removed and replaced, watertight tie-ins are essential every night. But let's take a step backwards and look at overall polyiso storage before and during installation. An appropriate understanding of storage, handling, and application will result in a properly constructed roof system. Material delivery should be carefully coordinated with the roof installation schedule to minimize outdoor storage. However, short-term outdoor storage can be necessary at times. When storing polyiso outdoors, bundles should not be stored directly on the ground. If possible, they should be stored over a finished surface rather than dirt or grass. Bundles should be covered with a waterproof cover and secured to prevent wind displacement. Exercise care when handling polyiso to prevent breaking or crushing the edges and surfaces. Polyiso should always be installed on dry roof decks and in dry conditions. Apply only as much polyiso as can be covered by completed roofing the same day. Roof surface protection (plywood) should be used in areas where storage and staging are planned to reduce direct, excessive traffic. Tips: Place bundles on pallets or included feet over a finished surface such as gravel, pavement, or concrete. Remove polyiso bundles from trucks with proper equipment. Do not push bundles off the edge of a truck or "roll" a pallet across the roof deck. Follow Carlisle’s requirements regarding product application to ensure adequate performance of the roofing system. For more information, please contact your manufacturer's representative.

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