FM Global Property Loss Prevention Data Sheets

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October 2012 Page 1 of 6

REPAIR OF WIND DAMAGED ROOF SYSTEMS

Table of Contents
Page 1.0 SCOPE ................................................................................................................................................... 2 1.1 Changes .......................................................................................................................................... 2 2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 2 2.1 Introduction ...................................................................................................................................... 2 2.2 Construction and Location ............................................................................................................... 2 2.2.1 Ballasted Single-Ply Membranes Repair Method ............................................................. 2 2.2.2 Nonballasted Roofs Repair Method ................................................................................. 3 2.3 Human Factor ................................................................................................................................... 5 3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 5 4.0 REFERENCES ....................................................................................................................................... 5 4.1 FM Global ........................................................................................................................................ 5 APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 5 APPENDIX B DOCUMENT REVISION HISTORY ....................................................................................... 5 APPENDIX C ADDITIONAL INFORMATION .............................................................................................. 5

2002-2012 Factory Mutual Insurance Company. All rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in whole or in part, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without written permission of Factory Mutual Insurance Company.

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Repair of Wind Damaged Roof Systems

FM Global Property Loss Prevention Data Sheets

1.0 SCOPE This data sheet provides recommendations for the repair of wind-damaged roof systems. The recommendations are intended for relatively small damaged areas. For information on new construction and planned (non-wind-damaged) recover/reroof installations, refer to Data Sheet 1-28, Design Wind Loads, and Data Sheet 1-29, Roof Deck Securement and Above-Deck Roof Components. Other data sheets with information on roofing include: Data Sheet 1-32, Existing PVC Roof Covers Data Sheet 1-33, Safeguarding Torch-Applied Roof Installations Data Sheet 1-49, Perimeter Flashing Data Sheet 1-52, Field Verification of Roof Uplift Resistance 1.1 Changes October 2012. Minor editorial changes were made. 2.0 LOSS PREVENTION RECOMMENDATIONS 2.1 Introduction 2.1.1 Use FM Approved (see Appendix A, for definition) components and systems for all applicable assemblies, whether or not specifically stated. 2.1.2 All FM Approved materials are required to have the Approval mark on the packaging or the material itself. Materials without proper labeling are not FM Approved and should not be accepted. 2.1.3 Provide thorough supervision by the building owners qualified representative during all roof repairs to ensure quality of workmanship and adherence to FM Approved standards and project specifications. 2.1.4 Remove all wet insulation and dry the deck prior to making permanent repairs. 2.1.5 During permanent repairs, remove only that portion of roof covering and insulation that can be replaced the same day. This will reduce additional wetting of the insulation and limit additional water damage. 2.1.6 Provide a minimum of two 10 lb (4.5 kg) ABC fire extinguishers on the roof during repairs. 2.2 Construction and Location 2.2.1 Ballasted Single-Ply Membranes Repair Method The following recommendations are intended to apply to damaged ballasted roofs not originally constructed per Data Sheet 1-29. Roofs installed per Data Sheet 1-29 are expected to experience only minor ballast scour, unless the damaging winds exceeded those listed in Data Sheet 1-28, or if the flashing becomes dislodged. Before making repairs, several items should be considered: The wind speed that caused the damage The size and weight of the in-place ballast Whether flashing damage initiated the roof cover damage. If this is the case, the roof could have been damaged even if the ballast was adequate per Data Sheet 1-29. 2.2.1.1 Excessive Ballast Scour No Roof Cover or Flashing Damage 2.2.1.1.1 Redistribute gravel or reset the pavers if the 3-sec gust wind speed was below, but within 20 mph (9 m/s) of, the recommended design (per Data Sheet 1-28). 2.2.1.1.2 If wind speeds were more than 20 mph (9 m/s) lower than the recommended design, the ballast was likely undersized and/or the weight was less than recommended. In this case, action beyond redistributing the ballast is necessary to prevent additional damage. Some alternatives are as follows:

2002-2012 Factory Mutual Insurance Company. All rights reserved.

Repair of Wind Damaged Roof Systems

FM Global Property Loss Prevention Data Sheets

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A. Provide ballast of the recommended size and weight per Data Sheet 1-29; roof structural capacity must be checked. If the in-place ballast is undersized, it may be acceptable to spread it into the roof field. Then, provide the proper size and weight of ballast at the roof perimeter and corners. B. Remove the ballast and fasten the membrane to the deck in a manner equivalent to the FM Approved mechanically fastened version of the particular membrane. Corner/perimeter fastening enhancements should be made per Data Sheet 1-29. C. If the field of the roof ballast is adequate, fasten the membrane in the roof corners and perimeter only, as outlined above. If the generic type of membrane is not known, fasten the corner/perimeter using batten bars placed 36 in. (914 mm) on-center with screws spaced 6 in. (152 mm) on-center for wind exposures 1 and 2 (see Data Sheet 1-28). Install a termination bar (batten) between the mechanically fastened and ballasted areas. Secure the termination bar with screws spaced 6 in. (152 mm) on-center. Seal the battens with a cover strip. Note: if the insulation has been displaced, it will be necessary to cut the membrane to reset the insulation. 2.2.1.2 Roof Cover Damaged Replace all wet insulation with insulation FM Approved for use on the particular deck. Repair and make the cover watertight. Repair any damaged flashing as described in Section 2.2.2.1 according to the manufacturers specifications. Undamaged flashing not fastened per Data Sheet 1-49 should also be properly fastened to limit potential future damage. Secure the roof covering as described in Section 2.2.1.1. 2.2.2 Nonballasted Roofs Repair Method 2.2.2.1 Flashing Damage If the perimeter flashing is bent outward from the face of the wall because a hook strip was not installed at the lower edge, but the metal is not severely damaged, it can be pushed back into place and secured with screws and rubber washers per Data Sheet 1-49. Nails should not be used. If more severe damage is evident, replace the flashing system with an FM Approved system or one installed per Data Sheet 1-49. 2.2.2.2 Roof Deck Damage If the existing roof deck shows signs of rotting or similar deterioration due to a damaged roof covering, remove the defective areas to the structural supports, and replace with properly secured FM Approved materials. If the roof deck is damaged due to the interior environment, such as gypsum or cementitious wood fiber decks over a high-humidity occupancy, replace the deck with a deck material tolerant of the occupancy. If the above-deck components have been removed, replace the securement of the deck for adequacy per Data Sheet 1-28. If additional deck securement is needed, it should be applied in all areas where necessary to reduce the potential for future damage. 2.2.2.3 Roof Cover Removed In some cases, only the roof cover is removed (delaminated) from the insulation. If the existing insulation is dry, in good condition, secure, and has not otherwise been damaged, it can remain in place. A new roof cover can be mechanically fastened through it. As an option, additional insulation (FM Approved for recover construction) can be mechanically secured through the existing insulation and a new roof cover then applied. If the delaminated roof cover is a single-ply membrane and it has not been severely damaged, it can be refastened through the insulation using mechanical fasteners. Ensure fastener type and spacing are per the listing in the Approval Guide, an online resource of FM Approvals, for the mechanically fastened version of the particular membrane. Provide corner/perimeter fastening enhancement per Data Sheet 1-29.

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Repair of Wind Damaged Roof Systems

FM Global Property Loss Prevention Data Sheets

2.2.2.4 Roof Cover and Insulation Facer Delaminated If the roof cover and the insulation facer have delaminated, replace the above-deck components or mechanically fasten the recover components (new roof cover and/or insulation) through the existing materials to the deck as outlined above. For single-ply covers, refastening per Section 2.2.2.3 may also be acceptable, depending on the membrane condition. 2.2.2.5 Roof Cover and Insulation Uplifted If the roof cover and insulation have been lifted from the deck, have a roof inspection conducted by a qualified roofing consultant and replace the roof cover and insulation if warranted. 2.2.2.6 Mechanically Fastened Base Sheet or Insulation Failure When a mechanically fastened base sheet or insulation is removed from a roof deck by wind, it may be due to one of the following deficiencies: A. fasteners were improper for the deck. B. fasteners were spaced too far apart. C. fastener head/plate was too small. D. insufficient fasteners at roof perimeter and corners. E. fasteners corroded. Deficiency A would be characterized by fasteners pulled out of the deck. Deficiency C would be characterized by the insulation or base sheet tearing over the fastener heads. Deficiencies B and D could be characterized by either or both types of damage. Corrosion, deficiency A, usually results in thinning of the fastener shank and/or broken fasteners. Except for E-type damage, replace fasteners in the damaged area with the appropriate type and adequate number (per Data Sheet 1-29), followed by installation of a new roof cover. Repair of the existing cover may be possible with certain single-ply membranes. Corroded fasteners are usually an indication of excessive moisture. If corroded fasteners are found, have a moisture survey conducted by a qualifed roof consultant to determine the extent of wet materials. Replace wet materials with proper materials. Wind damage can also be due to a base sheet or insulation of insufficient strength or thickness. Uplift forces are concentrated at fasteners, and a weak base sheet or insulation can fracture around the heads of the fasteners (see C above). Correct this deficiency by increasing the fastener density, using a stronger base sheet or insulation, or using a larger fastener head or plate. If the original roof system has been improperly secured, refasten the entire system, even if only a portion is damaged. This will minimize the possibility of further damage. If the existing construction is dry, the new fasteners can be driven through the existing built-up roof (BUR) into the deck, followed by application of a new roof cover. For information regarding refastening existing BUR covers, refer to Data Sheet 1-29. For single-ply membranes, refasten the roof cover as described in Section 2.2.2.3. After identifying the deck material, a suitable fastener can be determined from the Approval Guide or Data Sheet 1-29. If necessary, check fastener strength by performing actual pull-out tests on fasteners driven into the deck. Pull-out tests should be run on fasteners used with cementitious wood fiber, gypsum, or lightweight insulating concrete decks. Fastener density is then determined per Data Sheet 1-29. 2.2.2.7 Moisture Wind damage can occur to roof systems that have been exposed to moisture. Causes of moisture include leaking roof covering, exposure to moisture prior to application of roof cover, and a high-humidity atmosphere below the deck. Prolonged exposure to moisture can result in deterioration of the deck, insulation, and fasteners. These deficiencies may not be apparent until the roof is damaged by wind. If such exposure is suspected, have a moisture survey conducted by a qualified roofing consultant to determine the potential for problems. These deficiencies should be corrected by replacing the wet or deteriorated materials.

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Repair of Wind Damaged Roof Systems

FM Global Property Loss Prevention Data Sheets

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2.2.2.8 Non-Nailable Decks Winds occasionally cause adhered base sheets or insulation to delaminate from non-nailable decks (structural concrete, etc.). This has mainly occurred when the base sheets or insulation have been adhered with insufficient ribbons or strips of asphalt. These methods provide only partial contact area. Damage seldom occurs when the components are fully mopped to a primed substrate and adequate flashing is provided. Ensure full mopping for adequate insulation securement. Only use strip or spot mop base sheets within the limits of FM Approved systems. Repair to these deck types can be made by refastening through the existing construction with an appropriate fastener (see Approval Guide) and applying a new roof cover. A second method is to remove all above-deck materials and adhere or mechanically secure a new FM Approved roof cover system to the deck. 2.3 Human Factor 2.3.1 Manage hot work according to Data Sheet 1-33, Safeguarding Torch-Applied Roof Installations, and Data Sheet 10-3, Hot Work Management. 3.0 SUPPORT FOR RECOMMENDATIONS Wind can damage roofs in a number of ways. Types of damage include: perimeter flashing components removed or loosened. roof covering and/or insulation removed. roof covering and/or insulation delaminated. roof deck panels dislodged or lifted. roof covering damaged by impact from wind-blown objects. dislodged roof protrusions such as vents and skylights. Any or all of the various kinds of damage can occur in one windstorm. 4.0 REFERENCES 4.1 FM Global Data Data Data Data Data Data Data Sheet Sheet Sheet Sheet Sheet Sheet Sheet 1-28, 1-29, 1-32, 1-33, 1-49, 1-52, 10-3, Design Wind Loads Roof Deck Securement and Above-Deck Roof Components Existing PVC Roof Covers Safeguarding Torch-Applied Roof Installations Perimeter Flashing Field verification of Roof Uplift Resistance Hot Work Management

Approval Guide, a publication of FM Approvals APPENDIX A GLOSSARY OF TERMS FM Approved: References to FM Approved in this data sheet mean the products and services have satisfied the criteria for FM Approval. Refer to the Approval Guide, an online resource of FM Approvals, for a complete listing of products and services that are FM Approved. APPENDIX B DOCUMENT REVISION HISTORY October 2012. Minor editorial changes were made. May 2000. This revision of the document has been reorganized to provide a consistent format. APPENDIX C ADDITIONAL INFORMATION When the insulation or cover has been delaminated, field uplift tests (Data Sheet 1-52, Field Uplift Tests) or test cuts may be needed to determine the damaged area. The separation may or may not be noticed during the storm or be evident upon subsequent inspection.

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Repair of Wind Damaged Roof Systems

FM Global Property Loss Prevention Data Sheets

When wind damage occurs, primary consideration should be given to removing the damaged, wet, or deteriorated materials and making temporary or permanent repairs as quickly as possible. The permanence of repairs will depend on the nature and extent of damage. In a majority of losses, roof covering wind damage begins at the perimeter flashing. The roof cover edge is rolled back by the wind after the perimeter flashing assembly has failed. Because of this, it is extremely important that all flashing damage be repaired adequately and promptly. Wind damage to roof insulation and coverings usually begins at or near the windward edge, particularly at the corners, and progresses inward. The damage can take the form of direct uplift or peeling action of the wind working on the unprotected covering after initial damage occurs. In reroofing design, several factors should be considered in determining whether or not the existing roof system should be left in place. These factors include, but are not limited to: condition of the existing deck and insulation. dead load capacity of the deck. the need for additional insulation. the extent of damage. Prior to initiating permanent repair procedures, the extent of wet materials should be determined; see Data Sheet 1-29. Wet materials should be removed. There is some controversy within the roofing industry as to what amount of moisture is excessive within a roof system. One measure is any amount above the equilibrium moisture content. A second measure is the amount of moisture that reduces the thermal resistance of the insulation by 20%. Other measures are also used. For the purposes of this data sheet, wet insulation is defined as that which is weakened to the point where wind uplift resistance is deficient, or that which will cause or significantly increase the potential for corrosion of the deck or fasteners. There is full agreement, however, that materials that are obviously wet should be removed. A roofing qualified consultant should be engaged to evaluate the existing conditions. If existing materials are to be left in place, the dead load capacity of the deck should be investigated to ensure the deck will not be overstressed.

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