Air Conditioner Curb Installation- Flat Roof – Watch Video

 Air Conditioner Curb Installation 

Installing a A/C curb on a flat roof

The Bow Tie Royale 6 Cinema Theater contracted Commercial Roof USA to install an air conditioning unit on an EPDM flat roof at 542 Westport Ave., Norwalk, CT.  Heating and Cooling Company located in Norwalk, CT.  Mike Tavolacci marked precisely where the curb would be positioned on the roof. We installed the air conditioner curb with vibration dampers minimizing noise.

A/C Curb Installation – Process:

The a/c curb installation process required us to cut through the EPDM rubber at the markings. Then, we removed a 3″ Insulation ISO board. Under the insulation was a 5/8″ gypsum board. After removing the EPDM rubber, insulation, and gypsum board, we had to cut through the metal sub-roof, which is the opening of the intake duct to the A/C unit.

"Locating the leak is harder than fixing it"

    1. Find the object or place where the roof is leaking
      • Get reference points inside the building or take measurements from two walls to get an approximate idea where the leak is on the roof
      • Check the flashing, skylights, door-pans, vent pipes for possible clues that could cause the leak
    2. Tools and Materials needed
      • Disposable Brush
      • Rags
      • Scissors
      • Steel brush
      • Scraper
      • Turbo Poly Seal or Super Silicone Seal from https://bergstromm.com/
    3. Prepare the Surface:
      • Use the wire brush and brush away any loose paint, debris
      • Wipe the surface clean from any dust
      • Remove any old caulking with a scraper
      • Remove old Tar
    4. Start the repair:
      • Open the can of Turbo Poly Seal or Super Silicone Seal.
      • Stir the contents well
      • Apply a thick coat of sealant over the leaky area covering at least 2 inches on each side of the leak
      • Measure and cut a piece of Polyester Fleece that will be big enough to cover the leak area
      • Apply the fleece over the sealant and dab it into the sealant with the brush
      • Apply a final coat of Sealant over the fleece ensuring that the entire Polyester cloth is covered
    5. Curing Time:
      • Make sure there is at least 1 hour time after fixing the leak and before it rains
      • It takes about 24 hours to cure at 65° F
      • If there is any  sealant left in the container, make sure to seal it very tightly

Pitch Pockets that are located next to Airconditioner units are common to cause leaks.

If your commercial roof is leaking, inspect the following:

  1. Locate the "Pitch Pocket" - this is where all the electrical wires and conduit pipes come through the roof
  2. Make sure the "Tar" is filled to the brim. If the tar is forming a pocket where water can accumulate, it will cause a leak
  3. Make sure the foam insulation around the condenser pip;e is intact. If the foam insulation is corroded or broken, when it rains, water will leak in between the foam and the pipe into the building
  4. Make sure that the Tar seals tightly around the condenser pipe and wires
  5. Check the transition from the Pitch Pocket to the rubber roof - the flashing may need repair

No matter what causes a leak, if you have Turbo Poly Seal or Super Silicone Seal, you can repair any leak

How to repair a leak:

  1. After locating the leaky area, prepare the surface by cleaning it removing loose paint and debris
  2. Wipe the area clean with a rag
  3. Apply one coat of sealant covering two inches on each side of the leak area
  4. Install a precut Polyester Fleece over the sealant embedding it
  5. Apply  a final coat of Sealant over the Polyester Fleece
  6. Make sure to close the container securely so no air can get in

Images of A/C Curb Installation Steps:

  1. Make sure all the measurements are correct and the location is properly marked.
  2. Prep surface area by removing all debris and water.

Placing the Curb into Position

After making the opening for the duct work, we put the curb into position. Because the roof is slightly slanted, one side of the curb had to be lifted to be level. After leveling the curb, we anchored it down with 4″ screws to the metal sub-roof.

After anchoring the curb, we vulcanized the entire curb with EPDM cover tape, and carefully added the flashing, as well, to tie it into the existing rubber roof.

Air Conditioner Curb Installation - Preparing where the roof will be cut for the A/C curb
The spot is marked where the A/C curb will be installed

Removing the rubber and insulation

Cut the rubber and insulation away to expose the metal sub-roof.

A/C Curb Installation - Removing Insulation
Cutting the EPDM Rubber and insulation away

4. Below is the metal sub-roof after the EPDM and insulation were removed. Use a metal reciprocating saw to cut this section out.

Caution!

Extreme caution must be taken during steps 3 and 4 because there could be electrical wires on the underside of the metal roof. In this case, a drop ceiling hanger wire was attached to the metal so we were fortunate enough to remove it without disturbing the drop ceiling.

Metal roof exposed under the rubber membrane and insulation
The metal deck must be cut

The metal roof had to be cut with a reciprocating saw.

5. Placing curb into position and ensuring it is level:

Important!

Since the roof was slightly slanted, we had to lift the curb by 5/8″ on one side to get it level. It is important to have it absolutely level; if it is not level, the bearings will wear off faster on the A/C unit.

Placing the curb in position to be flashed
The metal curb is placed into position

After removing the roofing material and cutting open the intake access area, we could place the curb in place.

6. Leveling the curb.

Important!

The roof is slightly slanted and it was necessary to level the curb before we started to install the flashing.  We used 5/8″ wood strips under the one end of the curb. After getting it level we secured the curb to the roof with 4″ screws that held it into place.

Air conditioner curb leveling
The curb must be leveled

This air conditioner curb had to be leveled before we could flash it.

7. Vulcanizing and flashing the air conditioner curb.

Important!

Once the curb was leveled we covered the entire outside of the curb with EPDM cover tape. To flash the curb, it is necessary to clean the existing roofing surface very well. We used lacquer thinners and rags to remove all the oxidation from the surface where we needed to adhere to the new EPDM cover tape.

After the cleaning, we brushed primer to the surface and waited for it to dry. After a touch dry test, we installed the cover tape and flashed the entire unit.

Curb-flashing-installation
Cover tape is used for the flashing

It is essential to clean the surface from old oxidation before installing the flashing.

8. Installing the flashing.

In the case of an EPDM roof, it is necessary to use the compatible material to do the flashing. In this case, we used EPDM cover tape. It is very important to use a roller to roll the cover tape so it can properly adhere to the EPDM rubber.

Cover tape being rolled out.

It is important to roll out every inch of the cover tape to get a secure bond to the EPDM rubber roof.

9. Cover the curb with a tarp.

Noteworthy

It is difficult to coordinate two different trade crews to complete an A/C unit installment on the same day, but if the A/C contractor marks out where the curb will be installed and leaves the curb on the roof, we can then notify them when the curbing has been completely installed and is ready for the A/C installation.

Covering a A/C curb with a tarp awaiting for unit installation
After installing the curb, we covered the curb with a Tarp

After installing the curb we cover it with a tarp. The A/C contractor can schedule a time to install the unit.

10. The proper material for the right job

IMPORTANT!

Whenever there is a curb to be installed or flashing that needs to be done, it is important to use compatible materials. On an EPDM roof, only EPDM materials must be used. The same principle applies to a Modified Bitumen Torch Down Roof; only Modified Bitumen materials should be used. Sometimes, we find that this principle is not practiced by other roofing contractors. In the images below we are flashing a curb with Modified Bitumen Membrane Torch Down material.

Flashin curb with Modified Bitumen Membrane
Flashing a A/C curb with a torch

Flashing the curb with a Modified Bitumen Membrane

The image below is also a Modified Bitumen Membrane curb installation. It is essential that a special tar is used to try and seal any flashing, but it should be used very sparingly. Installing a curb is very important and should only be done by professionals.

Curb-flashing-Modified-bitumen
More flashing repair on a A/C Curb

When the curb is installed on a Modified Bitumen roof, it’s important to use the same material to do the flashing.

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Review Peeper

Flashing

5.0 rating
May 30, 2020

Very informative and friendly we appreciate thank you.

Margarita salinas

very cool

5.0 rating
May 28, 2020

very friendly and good product.

Silvia

Drain leaking

5.0 rating
May 28, 2020

That information is very helpful for me because we have a leak in my flat roof.
Thank you very much

Adelaida Solis

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