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Flat-Roof-Installation

Flat Roof Installation

We specialize in the Installation of a Two-Ply Rubber Roofing System. This system comprises of 2 layers of Modified Bitumen Torch Down Rubber Membranes that are fused together. By adding a second layer, it makes this type of roofing superior to any other roofing system.

The Two Ply Modified Bitumen Torch Down Rubber membrane is a superior roofing system than that of a Single Ply EPDM or TPO Roofing System. This roofing system can be installed almost over any surface including stone and other roofing membranes making it a very cost-effective roof that will outlast any other roof.

A 40-year warranty comes with the Two-Ply Rubber Roofs we install.

We service all of Fairfield County, Connecticut, and Westchester County, New York.

 

Steps for Installing a Two Ply Roofing System

Step 1 – Preparing the Surface

  • Remove debris from the roof
  • Remove unnecessary obstacles like unused vent pipes, left behind A/C units.
  • Remove old roofing material off from existing flashing
  • Clean drain areas by removing roofing materials to expose drain flange
  • Clean scupper areas to expose copper
Preparing the surface for installing a new rubber roof. Use leave blower

Preparing the roof for new Installation

When it comes to Roof Installation, the fewer obstacles on a roof, the less labor, and materials used the less the cost of the roof. Remove old Air Conditioner units and old vent pipes as well as old roof vents.

 

Remove old a/c units prior to the Installation of a new roof

Roof Vents

Thes roof vents are designed to remove dampness from inside the rafters. They are not always beneficial and by removing them will do no harm.

Remove air-vents from roof

Step 2 a – Gravel Stone Surface

  • Rake the gravel rock around to level off the roof. Move loose rock to lower areas to build up the area
  • After raking the gravel making a smooth surface and removing clumps and larger rocks, install a fiber base paper by using long screws and anchor plates purchased from a roofing supply warehouse. Make sure the fiberglass paper is not wrinkled when anchored down spacing the anchors every 2 feet. Be careful not to cover the metal flashing and drip edges.
  • Install a Modified Bitumen Self-Adhering Base over the fiberglass base. Be careful not to include any metal parts.
  • Torch Down a Modified Bitumen Rubber Membrane with ceramic granules embedded to the self-adhering membrane fusing them together.
  • Use special adhesives to attach the Torch Down Rubber to the flashing and other metal areas.
Gravel Rock roof surface - Steps taken of installing over this surface

Installing a Two-Ply Rubber Roof over gravel

A Two-Ply Modified Bitumen Torch Down Rubber membrane was installed over this surface. As long as the big stones are removed and the gravel is raked evenly.

Gravel Rock Roof - Installing a 2 ply over this surface is fine

In the Process of installing a Two-Ply Rubber Roof over gravel

Once the Two-ply Modified Bitumen Torch Down Rubber membrane is installed over the gravel, no one can tell by walking on it. It is super tough and no foot traffic or any workman will be able to damage it.

In the process of Installing a Two Ply Rubber Roof over a gravel Rock roof

Step 2 b – Existing Modified Bitumen Rubber membrane

  • If the surface has a fresh coating of Aluminum Asphalt Coating (silver paint) then skip this step and follow Step 3
  • If the surface has a pretty worn down coat of silver paint and flaking off, then sweep brush any loose paint and debris off the surface. Use a leave blower to get the dust off.
  • Look for any wrinkles in the membrane and cut them away.
  • Remove the existing roofing membrane from existing flashing to expose the flashing around skylights, vents, walls and where necessary.
  • Fill areas where water would normally pond by installing ISO board over the existing roofing membrane.
  • Lower areas around a drain area by removing roofing material.
  • Install a self-adhering Modified Bitumen Base membrane in the areas where the surface had to be build up and where roofing material was removed to lower the roof.
  • Torch Down a Modified Bitumen Rubber Membrane with ceramic granules embedded in the self-adhering membrane fusing them together.
  • Use special adhesives to attach the RorchDown Rubber to the flashing and other metal areas.
Installing over an existing Modified Bitumen Rubber Membrane - Cut away the wrinkles

Aluminum Asphalt Coating (silver paint)

If the existing roof has a coating of Aluminum Asphalt (silver paint) but is mostly peeled off or 80% of the membrane is exposed, then it is advisable to install a membrane directly onto it with a torch fusing the new membrane with the existing rubber membrane.

A Modified Bitumen Torch Down Rubber Roof with Aluminum Asphalt coating (silver paint)

Existing Modified Bitumen Torch Down Roof

An Existing Modified Bitumen Torch Down Roof is ready for a new layer. Fusing the two together becomes an indestructible roof that will last beyond 40 years. If there is silver paint between the twp layers, then the two layers won’t be able to melt together.

A modified Bitumen Torch Down Rubber Roof ready for a new layer.

Step 2 c – EPDM Rubber Surface

  • If the EPDM Rubber roof is still firmly attached to the substrate and not wrinkled, then screw down more anchor over the top of the rubber.
  • Remove the EPDM rubber from all flashing detail as in A/C units, skylights, vent pipes, parapet walls, drains, and siding.
  • Clean and prepare the flashing and drip edges by removing adhesive with Laquer Thinners.
  • Install new flashing where necessary.
  • Cut away any wrinkled surfaces.
  • Install a Modified Bitumen Self-Adhering Base
  • Torch Down a Modified Bitumen Rubber Membrane with ceramic granules embedded to the self-adhering membrane fusing them together.
  • Use special adhesives to attach the RorchDown Rubber to the flashing and other metal areas.
Steps on how to Install over a EPDM Rubber Roof

EPDM on a Residential house

This EPDM Rubber Roof already had several patches. This is a perfect example of a roof that can be covered with a Two Ply Modified Bitumen Torch Down Rubber membrane.

This small EPDM roof already had several patches.

Step 2 d – Plywood Substrate or Decking

  • Install the necessary insulation with fasteners
  • Install Modified Bitumen Self-Adhering Base over the insulation
  • Install metal flashing where necessary.
  • Install drip edges
  • Torch Down a Modified Bitumen Rubber Membrane with ceramic granules embedded in the self-adhering membrane fusing them together.
  • Use special adhesives to attach the RorchDown Rubber to the flashing and other metal areas.
Steps on how to install a rubber roof over plywood or decking

Step 3  – Detailing

  • Once the Modified Bitumen Torch Down Rubber is fused to the Self Adhering base, it is time to take care of the details. On every corner of skylights and a/c unit curbs and around every vent pipe, particular attention must be given to make the necessary patches.
  • Use special adhesives to make necessary seals around skylights, A/C units, and vents, vent pipes, and pitch pockets.
  • Attach the rubber membrane to the drain or scupper with special adhesives.
After installing the final layer, details like corners of skylights and a/c units must be sealed

Step 4 – Cleaning up

  • Pick up all loose roofing materials
  • Use a leave blower to blow the roofing surface clean.
  • Walk around to make a final inspection to see if all detail is taken care off.
Walk around on the roof and inspect every detail and see if you missed anything

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