icopal Monarplan Series User manual

Synthetic
Membranes
Monarplan®
Installation Manual

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Contents
1 Subject and range of application 3
2 Icopal Synthetic Membranes – Product range at a glance 4
2.1 System Components 4
3 Packaging, delivery, storage and disposal of materials 9
3.1 Packaging, delivery and storage of membranes
and accessory materials 9
3.2 Disposal of construction site waste and
packaging material 9
4 Roof types 10
4.1 General 10
4.2 Method of Attachment 10
4.3 Choosing of membrane 11
5 Installation principles 12
5.1 Seam overlap 12
5.2 Laying order 12
5.3 “Separation” of the roof sealing 12
5.4 Laying direction 12
5.5 Position of butt joints 13
5.6 Tips for installation 13
5.7 Formation of expansion joints 14
6 Membrane Application 15
6.1 Tools and Equipment 15
6.2 Hot-Air Welding 16
6.3 Welding of T-joints 17
6.4 Weld tests 19
6.5 Sealing of seams 20
6.6 Welding of aged (weathered) membranes 20
7 Methods of application 21
7.1 Introduction 21
7.2 Perimeter Fastening 21
7.3 Membrane Termination 24
7.4 Mechanically Fastened System 25
7.5 Ballasted System 27
7.6 Adhered System 29
7.7 General Information on Flashings and Trims 33
8 General Information on Substrates 35
8.1 Introduction 35
8.2 Acceptable Substrates 35
8.3 Fastener Withdrawal Resistance Criteria 36
9 Roofing Details 37
9.1 Parapets 37
9.2 Protection against wind uplift 37
9.3 Edge Protection 37
9.4 Corners 38
10 Materials from other manufacturers 40
11 Examples for System Components 41
11.1 Vapour Control Layers (vcl) 41
11.2 Insulation 42
11.3 Protection, Separation and Levelling Layers 42
12 Quality Assurance 43
Maintenance 44

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1 Subject and range
of application
This application manual contains basic rules and serves as a
guideline for roof waterproofing with Monarplan® waterproofing
membranes for new buildings and refurbishment. They are
the manufacturer’s instructions and guidelines for roofers and
construction site managers. They are the result of decades
of practical experience in the laying of Icopal waterproofing
membranes on millions of square metres of roof areas.
Adherence to the relevant technical rules, as published in
standards and regulations, as well as to the workers protection
and safety regulations is obligatory. The handling instructions and
notes on can labels and safety data sheets for Icopal adhesives
and accessory materials are to be observed. Drawings included in
these instructions are not true to scale and are schematic.
Please take notice of the local winduplift regulation. The way of
installing is also dependant on the specific construction of the
building.

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2 Icopal Synthetic Membranes
Product range at a glance
Monarplan® is a range of thermoplastic heat weldable water-
proofing membranes suitable for flat, curved and pitched roofs.
PVC membranes from Icopal have been in use for over 50 years,
covering roofs of all types and forms. Whether it’s domestic or
commercial, public or private; Monarplan® membranes offer a
flexible and lightweight waterproofing solution with a proven
track record. Monarplan® is a flexible PVC (polyvinyl chloride)
single ply membrane offering excellent characteristics of
strength, elongation and weathering, making it ideal for new build
or refurbishment projects
2.1 System Components
2.1.1 Monarplan® Membranes
All roofing materials are subjected to environmental conditions
that can alter the physical and chemical properties of the material.
These conditions include ozone, heat, solar radiation, thermal
cycling, freeze/thaw, pollution, biological growth and ponding
rainwater. Waterproofing properties must be maintained during
exposure to the roof environment or the roof will not perform
as expected. The inherent performance benefits of Monarplan®
ensure both the specifier and building owner of a versatile, durable
and stable roofing option.
• Monarplan® FM
is a polyester reinforced membrane designed specifically for
use within mechanically fastened applications. The polyester
fabric gives the membrane inherent tensile strength which
is required to facilitate the use of fasteners to restrain the
system against wind uplift. Mechanically fixed systems can
be cost effective solutions, and are ideal where lightweight
constructions are considered.
• Monarplan® G
incorporates a glass reinforcement encapsulated between two
layers of extruded PVC. The membrane is specifically designed
for use within ballasted inverted, ballasted warm roof or green
roof constructions where the membrane is buried.
• Monarplan® GF
is the same glass reinforced PVC membrane as Monarplan®
G, but incorporating a polyester fleece backing. The factory
laminated polyester backing allows the membrane to be
applied in a part mechanically fixed/part adhered system or
alternativly fully adhered to the underlying substrate using a
compatible cold applied adhesive and can be the ideal solution
on curved, steep or undulating roof designs that prove
challenging for other systems.
• Monarplan® D
unreinforced flashing is intended to be used in the formation
of internal/external corners, field fabricated pipe flashings,
sealant pockets and scuppers, when the use of injection
moulded accessories are not feasible.
Durability
Monarplan® provides exceptional weather resistance and
protection against usually expected temperatures. Monarplan®
is UV resistant and remains virtually unchanged throughout
its serviceable life. Accelerated age testing completed on the
Monarplan® membranes provide an anticipated life expectancy
in excess of 30 years in middle Europe demonstrating superior
durability and system service life performance.
Compatibility
Monarplan® roof membranes can be installed on all major roof
deck types such as plywood, timber boards, profiled metal,
concrete and cementitious screeds. However, PVC membranes
can be adversely affected by contact with bituminous or coal
tar products. In this situation or when used over polystyrene
and unfaced polyurethane insulations a separation layer will be
required.
Product range
Monarplan® waterproofing membranes are high-quality synthetic
membranes which come in 4 different types, complete with
preformed details, coated metal sheets and accessory materials.

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Type of membrane
Membranes Monarplan® FM Monarplan® G Monarplan® GF Monarplan® D
Type of reinforcing polyester reinforcing glass fleece
reinforcing
glass fleece
reinforcing and
polyester fleece
backing (250 g/m²)
unreinforced
(homogeneous)
Effective thickness [mm] 1.2/1.5/1.8/2.0 1.5/1.8/2.0 1.5/1.8/2.0 1.5
Membrane width [m] 1.06/1.50/1.60/2.12 3) 2.12 2.12 0.7/1.4
Standard length [m] 1) 20/15/15 20/15/15 20/15/15 15
Standard colour 2) grey, anthracite grey, anthracite grey, anthracite grey, anthracite
Accessories
Monarplan® internal/external/
universal corners
+ + + +
Monarplan® coated metal sheet + + + +
Adhesives & other liquids
Icopal Fleeceback Adhesive
Partly Bonded (TK 400)
+
Icopal Fleeceback Adhesive
Fully Bonded (TK 3958)
+
Monarplan® Contact Adhesive
(TK 914)
+ + +
Monarplan® liquid PVC + + + +
Monarplan® membrane cleaner + + + +
1) specified lengths on request
2) special colours on request
3) New widths soon available: ISM SK (SKS): 1,06 / 1,65 / 2,12
ISM NL (NLS): 1,09 / 1,54 / 2,18

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2.1.2 Accessories
All Monarplan® single ply roof systems are complimented by a
comprehensive range of ancilliary products to ensure maximum
compatibility and single source responsibility for the roofing
system.
1 Monarplan® Coated Metal sheet is a 0.6 mm hot dipped
galvanised steel sheet coated with a layer of 0.6 mm non-
reinforced PVC film for an overall thickness of 1.2 mm. The
sheet is cut into appropriate widths and used to fabricate
metal drip edges or other roof perimeter edging profiles. The
coated metal can also be used to provide mechanical restraint
at any changes in level, abutments or roof area perimeters.
2 Monarplan® D Unreinforced Flashing is intended to be used
in the formation of internal/external corners, field fabricated
pipe flashings, sealant pockets and scuppers, when the use
of pre-moulded accessories are not feasible. Monarplan®
D Strips are also used to achieve a watertight detail where
end laps of the Monarplan® GF membrane are butt jointed.
they are also used in conjunction with coated metal drips and
upstands.
3 Monarplan® W Walkway Membrane is a weather resistant
PVC membrane which is anthracite in colour and incorporates
an aggressive, non-slip, interlocking herringbone tread
pattern.
4 Monarplan® inside, outside & universal Corners aid speed of
installation on site.
5 Monarplan® Pipe Fittings are moulded preformed PVC
pipe flashings (pipe boots) designed to suit a range of pipe
diameters, achieving a watertight seal.
6 Monarplan® Standing Seam Profiles are used to replicate the
appearance of lead standing seam or metal profiles.
3
4
5 6
1 2

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7 Monarplan® Outlets are manufactured from rigid PVC
incorporating a Monarplan® flange for easy welding to the roof
membrane. Connection is made with the plumbing using a
rubber gasket. The Monarplan® Outlet rang is completed with
leaf guards where required. Outlets are available in standard
and refurbishment versions. Also available is a Monarplan®
Horizontal Outlet. Please consult product information sheet for
further information.
8 Icopal EPDM sealents can be combined with the Monarplan®
outlet to construct a waterproof solution.
9 Icopal fixation bar is a 3 m galvanised steel bar with pre-
drilled holes at specified centres to facilitate the mechanical
restraint of Monarplan® membranes at the base of upstands
or angle changes (Remark: Monarplan® Coated Metal sheet is
preferred). It should be fastened to the more stable substrate, ie
fixed vertically to the structural deck or horizontally to masonry
or concrete upstands.
10 Icopal universal leaf grate is a rigid plastic leaf grate with
expanding clamps.
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8
9
10

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2.1.3 Adhesives, Solutions and Compounds
Icopal Fleeceback Adhesive for fully bonded application:
Terokal TK 3958 is a high strength, single component moisture
curing polyurethane adhesive that has been formulated
for bonding fleece-backed single ply roofing membranes to
various substrates including suitable roof insulation panels.
The cured adhesive film has very good resistance to heat and
hydrolysis, and is blue/ green in appearance.
Icopal PVC Contact Adhesive: Terokal TK 914 is a high strength
solvent based contact adhesive that allows the bonding of
Monarplan® non-fleeceback membrane to various porous
and non-porous substrates. The adhesive provides instant
contact adhesion and is particularly useful at details such as
upstands and abutments.
Icopal Fleeceback Adhesive for partly bonded application:
Terokal TK 400 is specially developed I-component foam
adhesive for adhering of roofing membranes used for partly
bonded application. Can be applied until - 5ºC under normal
building moisture conditions.
Icopal Insulation Adhesive: Terokal TK 395 is a high strength
I-component foam adhesive for bonding thermal insulation
products on flat roofs.

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3 Packaging, delivery, storage and
disposal of materials
3.1 Packaging, delivery and storage of
membranes and accessory materials
Handle all materials to prevent damage. At the factory, the
waterproofing membrane rolls are individually wrapped and laid
horizontally on pallets for transportation. The pallets are covered
with PE foil.
Leave the material in its original packing until used and protect
from moisture. Unsealed packing units must be carefully closed,
if stored in the open for a longer period. After long-term storage,
small buckles may show at the roof sealing after laying.
The membrane rolls must be stored horizontally on a clean flat
and dry level surface. The rolls must be stored in a weather-
sheltered place avoided to direct sunlight, or covered with a clean
tarpaulin. Moisture on the membranes may impair weldability.
Pallets should not be stapled.
Temporary storage on roofs should be in rolls and with an even
spread over the roof deck, on lightweight steel decking only in
bearing areas.
The accessory materials are packed weatherproof in synthetic /
tin containers or cans.
Please note the storage conditions and shelf life indications on
the container labels!
Adhesives must be stored at temperatures around 20 °C
depending upon the product (consult the individual product
technical datasheet for specific storage instructions). All
flammable materials shall be stored in a cool, dry area away from
sources of heat, sparks and open flame. Follow the precautions
outlined on the label of the container.
Materials from open containers can be processed only for a short
time.
3.2 Disposal of construction site waste and
packaging material
The National Regulations must be noted.
Icopal supports the Pan-European ROOFCOLLECT® to collect and
recycle PVC roofing membranes.
The aim of ROOFCOLLECT®, a program set-up by the leading
manufacturers of plastic roofing and underlays, is the cost-
effective and environmentally compatible collection and recycling
of PVC roofing underlays. Icopal actively supports the pan-
European program.

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4 Roof types
4.1 General
There are generally three types of flat roof construction:
Warm Roof
The thermal insulation is positioned above the roof deck
immediately below the waterproofing, resulting in the structural
deck and ceiling being at a temperature close to that of the interior
of the building. A vapour control layer is placed between the roof
deck and the insulation to minimise the risk of condensation.
Ventilation of the roof void is not required. However due
consideration must be given to providing a minimum upstand
requirement of 150 mm above the finished roof level for all details.
Ventilated Roof (“cold roof”)
This type of roof must be carefully designed to avoid premature
failure and should be avoided wherever possible.
Thermal Insulation is positioned beneath the structural
deck resulting in the roof covering and structural deck being
substantially colder in winter than the interior of the building.
The structural deck therefore becomes a potential point for
condensation, and so it is important to provide a minimum 50
mm void between the top of the insulation and the roof deck. This
void must be ventilated and cross ventilation must be provided
with a minimum 25 mm continuous opening at eaves on opposing
sides of the roof. A suitable sealed air-leakage barrier, or vapour
control layer installed at ceiling level is good practice, as this will
help restrict the passage of warm moisture laden air into the roof
structure.
Inverted Roof
Sometimes referred to as an ‘upside down’ roof, the thermal
insulation is positioned above the roof covering, resulting in the
roof covering, structural deck and ceiling being at a temperature
close to that of the interior of the building.
Since the insulation is above the waterproofing system the
insulation must be water-resistant and it must be ballasted
to prevent floatation of the insulation boards and to protect
against wind uplift. Therefore, the roof deck must be capable of
withstanding the additional loading of a ballasted roof.
4.2 Method of Attachment
The roof system must be secured to the roof structure to protect
against wind uplift. The components of the roof system can be
secured in a number of ways.
Mechanically Fastened
The membranes and insulation are secured using screw fasteners
which are fixed directly to the structural deck.
Adhered
The layers can be adhered using adhesive compounds to attach
the membranes or insulation to the substrate beneath.
Ballasted
The membranes and insulation can be secured using a selected
material, such as river-washed pebble or concrete paving slabs to
weight the layers down to protect against wind uplift or floatation.
A separation layer (PE foil) is required and an additional protection
layer may be required beneath the ballast material to protect the
underlying layers from damage.
Depending on project requirements and scheduling it is possible
to use a combination of methods, eg mechanical fastening of
insulation, and adhering of the waterproofing layers.

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The following tables are intended to offer a simple summary. Please consult with Icopal Technical Services on project specific situations.
Type of membrane
Monarplan® FM Monarplan® G Monarplan® GF
Application of membrane to Insulation Substrates (warm roofs)
Method of Application Mechanically Fastened Ballasted Adhered Ballasted
Insulation Type
Mineral Wool
Plain/tissue Yes Yes Maybe 6) Yes
Bitumen faced Yes 2) Yes Maybe 6) Yes
Expanded PS
Bitumen faced Yes 2) Yes 5) Maybe 6) Yes
Glass Fleece Yes Yes 5) Maybe 6) Yes
PIR/PUR
Glass Tissue Face Yes Yes Yes 1) Yes
Foil Faced Yes Yes Maybe 5) Yes
Bitumen faced Yes 2) Yes 2) Yes 1) Yes
Naked Yes 2) Yes 2) Yes 1) Yes
Composite Board
Perlite Yes Yes Maybe 6) No
Cork Yes Yes Maybe 6) No
Application Direct to Common Substrates (cold or inverted roof situations)
Method of Application Mechanically Fastened Ballasted Adhered Ballasted
Substrate Type
Concrete
Cellular/Rough Yes Yes Maybe 6) Yes
Cast Yes Yes 2) Maybe 6) Yes
Ply/OSB Yes 2) 3) Yes 2) Yes 1) Yes
Profiled Metal Maybe 6) Maybe 6) Maybe 6) Maybe 6)
Timber Boards Yes 2) Yes 2) Yes 6) Yes
Asphalt/Bitumen Yes 2) Yes 2) No 4) Yes
Cold or inverted
roof situations
Warm roofs
1) Icopal Single-Ply Fleeceback Adhesive.
2) Requires separation/protection layer beneath.
3) Monarplan® Contact Adhesive. Please note, coverage rates are adversely affected,
to be used for upstands
4) Direct contact not possible. Use thickness of suitable insulation board, or similar.
5) For insulation boards, consult insulation manufacturer for guidance.
6) Consult Icopal Technical Services for guidance.
4.3 Choosing of membrane
The choice of membrane will depend on the application and substrate.
Step 1: Type of Roof Warm / Cold / Inverted / Refurbishment
Step 2: Type of Substrate Plywood / OSB / Metal / Concrete / Timber boards
Step 3: Method of Application Mechanically Fastened / partially or fully Adhered / Ballasted / Combination

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5.2 Laying order
Regardless of the type and the laying method of the
membranes, the seam laps can be arranged with or
against the “water flow”, due to the homogenous seam
welding without foreign matter. When arranging with
the “water flow”, water may ingress under already laid
membranes if it rains while waterproofing works are still
in progress.
5.3 “Separation” of the roof sealing
The field sealing is always “separated” from the sealing of
parapet and upstand flashings.
However, membranes of the field area are principally
raised approx. 5 cm to parapets and upstands. Timber or
insulation fillets are not required.
5.4 Laying direction
Generally, the Monarplan® waterproofing membranes
can be laid parallel or perpendicular to the roof slope.
If using mechanical seam fastening of the waterproofing
membranes on corrugated steel or timber decks, the
membranes have to be laid perpendicularly to the span
direction of the steel sheets or the boarding.
5 Installation principles
Minimum of 5 cm for bonding and loose laying
under ballast.
Minimum of 12 cm load distribution plates
Ø 50 mm (mechanical fastening)
Minimum of 11 cm for load distribution plates
40 x 82 mm (mechanical fastening)
And washers smaller than 50 mm.
5.1 Seam overlap
Monarplan® waterproofing membranes are marked with several dashed lines along one longitudinal edge. These markings can be used
as guiding lines for the corresponding lap width.
5 cm
11 cm
12 cm
5 cm
11 cm
12 cm
5 cm
11 cm
12 cm
waterflow
laying order
5 cm
laying direction of Monarplan®
span direction steel sheets

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5.5 Position of butt joints
At the end of the membrane, i. e. normally after 15 m, the backed
Monarplan® GF waterproofing membranes can be butt-jointed or
hot-air welded at an overlap of approx. 1 cm and covered with an
unbacked strip of at least 15 cm width.
Unbacked membranes, however, are laid, analogue to the
longitudinal edge, with an overlap of at least 5 cm at the end of
the membrane.
Double T-joints are forbidden!
Double T-joints are avoided by a staggered arrangement of the
membrane ends.
If membrane ends are arranged without stagger, the end joints
are to be covered with an unbacked tape of at least 15 cm width.
5.6 Tips for installation
In case of low ambient temperatures, small ripples may show
on the waterproofing membrane after laying (especially in warm
weather).
NOT ALLOWED
min. 5 cm
laying orderlaying order
min 150 mm
min. 20 mm
Approx. 15 mm overlap

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5.7 Formation of expansion joints
Expansion joints has especially to be planned by the architects
and are project specific. Contact the Icopal technical service for
guidance and advice.

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6 Membrane Application
6.1 Tools and Equipment
The following is intended as a basic list of tools and equipment
and their operation necessary to install a Monarplan® Roof
System. Depending on the project, other tools and equipment
may be required.
Additionally, these instructions are provided as recommended
guidelines to follow to ensure proper performance of the
equipment and successful installation of the Monarplan®
membrane. Icopal does not endorse or recommend any particular
brand of equipment.
Welding Machine
This is a self-propelled, electrically powered machine with attached
air blower and heating unit. There are several models available,
and proper operating instruction in the use of each model is the
responsibility of the manufacturer/supplier of the machine.
Always read and/or ask the manufacturer of the equipment for
the operating procedure. The following should be either checked
or the routine followed daily to ensure proper splicing.
Alignment - Check the machine set-up to ensure proper alignment
of the heating nozzle and pressure wheels or moving parts to see
they move properly or are free-spinning.
Air Intake - Make sure the air intake is open. Clean out the air
intake for the blower unit regularly.
Repair - Check the machine for worn or broken parts which need to
be replaced. Take care to protect the pressure wheel from notches
or cuts to prevent incomplete sealing of the welded splice.
Power-up - Before the machine is connected to the power source,
make sure it is switched off to prevent a power surge that could
damage the unit. Turn on the unit and allow the blower/heater
unit to reach the necessary welding temperature. Always carry
out a test weld on a sample piece of membrane each morning
prior to welding.
Cleaning - Occasionally clean the heat nozzle with a wire brush to
remove any build-up of membrane material.
Hand Welder
These tools are used for detailing and making welds not accessible
by welding machines. The hand welder should be set to the
appropriate welding temperature. Many of the care and operating
notes for the welding machines apply to the hand welders as well.
Tool Kit
A typical tool kit should include the following:
• A 40 mm seam roller
• A penny roller
• A seam probe
• Hot-air Handheld Welder
• A 40 mm flat nozzle
• A 20mm flat nozzle
• A 20mm angled nozzle
• A pair of scissors
• A wire brush

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6.2 Hot-Air Welding
6.2.1 General
Monarplan® roofing membranes are hot air welded to each other
and the compatible range of PVC ancillaries in a homogeneous
manner. The welding zone must be clean (free from dust) and
dry. All welds shall be a minimum continuous width of 20 mm.
Hot-air welding is possible without further measures at ambient
temperatures of at least +5 °C.
The roofing membrane must be unrolled without tension and free
of wrinkles. The endlap area between sheets is 50 mm minimum.
To achieve a good weld, the following criteria should be considered:
• The ambient temperature and possible wind
• The temperature of the substrate and
• The temperature of the roofing membranes
• Welding speed / traction of the welding machine
• Volume and temperature of hot-air
• Humidity (water absorption)
All joints in the Monarplan® Roofing System are hot air welded.
It is recommended that welding machines are used for all field
joints. Manual hand held welders should be used for details and
inaccessible areas only. The welding machines should be well
maintained and yearly calibrated.
Welding temperatures will vary dependent upon the weather
conditions of the day. Test welds should always be carried out
before commencing work, adjusting the temperature settings as
necessary to achieve the proper weld.
Deficiencies
Wrinkles, capillaries and fish-mouths are to be avoided. When
these deficiencies occur they shall be repaired immediately.
Notice
Complete all roofing work and flashing each day to prevent water
from getting under completed roof sections. Any areas where
water has penetrated the completed roof must have any moisture
and wet insulation removed. Temporary sealing of the edge of the
roofing membrane is the responsibility of the contractor. The tie-
off must be higher than the drain, and slope to the drain.
6.2.2 Hot-air welding with welding machines
Position the automatic hot air welding machine with the pressure
wheel approximately 3 mm over the weld edge to ensure a sealed
edge. Lift the overlapping membrane sheet and insert the blower
nozzle between the overlap. Immediately begin moving the
machine along the lap to prevent scorching of the membrane. The
seams are welded in one operation usually at a speed of 2.0 to 3.0
m/min. At the end of the run, remove the nozzle first and then
stop the machine’s forward motion.
When the welding machine moves over an insulation plate,
insulation step off, lap crossover, etc., these areas should
immediately be hand-rolled to ensure a complete weld.
Metal tracks may be used over the deck membrane and under the
welding machine to minimize or eliminate wrinkles.

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6.2.3 Manual Hot-air welding
Use a hand-held welder and silicone covered roller to complete
welds and details where the welding machine is inappropriate.
All hand-held welders, which produce the necessary hot air
temperature of approx. 400 - 450 °C and the necessary air
volume can be used. Hot-air tools with closed loop controlled
temperature (compensation of voltage fluctuations) with display
are recommended.
The hand-held welder is to be inserted at an angle of
• approx. 45° to the membrane edge and
• approx. 30° to the roof area
into the seam overlap.
When the welding parameters are adjusted correctly, there is a
certain development of smoke and the surface of the lower sheet
turns shiny-brilliant when heated correctly. A change of colour,
scorching or the formation of ashes on the nozzle or the welding
zone indicates that the welding temperature is too high.
Membranes are seal-welded in one operation by moving
backwards, whereas small tapes (up to 30 cm) are first tacked
and then seal-welded. When seal-welding, the nozzle must be
inserted between the membranes in a way that the top membrane
edge will also be heated and plastified.
The plastified lap areas will be fused by applying moderate
pressure with a silicone pressure roller, following parallel to the
opening of the nozzle. Due to the backwards movement, the
nozzle always blows against already seal-welded areas of the
seam. The weld must have a consistant width as possible and a
minimum width of 20 mm.
6.3 Welding of T-joints
T-joints are created when 3 membranes meet and must be
formed very carefully, in order to prevent capillary action. T-joints
must be thoroughly manual hot-air welded.
When planning the layout of the sheets cross-joints should be
avoided. When the roof is long or when this should prove to be
too arduous a membrane strip of min. 300 mm width shall be
centered and welded over the overlap. Treatment is similar to that
of T-joints.
1
2
3

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6.3.1 Butt joints of unbacked membranes
Unbacked membranes are laid, analogue to the longitudinal edge,
with an overlap of at least 5 cm at the end of the membrane.
The top corner of the membrane must be rounded off!
Before welding the T-joint, the respective inner (middle) membrane
end must be chamfered over the whole lap width (min. 4 cm)! This
can be done with the hot nozzle of a hand-held welder, if necessary,
with a metal plate serving as an underlay.
Note: Be aware that the temperature of the hot air welder is not too
high and overheat/burning the membrane!
min. 5 cm
min. 5 cm
min. 5 cm
round off
laying order
6.3.2Butt joints of backed membranes
Backed membranes (Monarplan® GF), at the end of the membrane,
are butt-jointed or, if appropriate, tacked with hot air with an
overlap of approx. 1 cm (advantageous at low temperatures) and
covered with an unbacked tape (15 cm tape width for mechanically
fastened waterproofing membranes, e. g. if fasteners are placed
at the butt joint) of at least 15 cm width.
The length of the tape: membrane width + approx. 5 cm.
At one end of the tape, both corners have to be rounded off.
Place the tape at the centre of the joint with the rounded-off end
extending approx. 5 cm onto the previously laid membrane, which
is through at the joint. The other side of the strip should end level

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with the membranes to be joined. Tack the strip in this position, in
the middle, with hot air and seal it all around the perimeter.
The longitudinal seam edges of the membranes to be joined, which
are under the rounded-off end of the tape, must be chamfered at
a width of approx. 5 cm or 10 cm each. As must the longitudinal
seam edges at the other end of the tape itself, at the width of the
lap. After chamfering, the strip will be welded at its longitudinal
edges and at the rounded-off end.
Be especially careful when welding the chamfered areas with hot
air.
The welding edge of the following membrane overlaps another
longitudinal edge of the joined mem branes and the tape in the
chamfered area by at least 5 cm.
Again, be especially careful when welding the chamfered areas
with hot air.
6.4 Weld tests
6.4.1 Non-destructive weld test
After the seam has cooled down to the ambient temperature, the
sealing layer from the seam edge (min. 2 cm) must be cohesive
without any foreign matter over the complete welding width, and
the seam has to be permanently waterproof and highly resistant.
The performance of the roof sealing depends to a great extent on
the quality of the seam.
In order to detect possible voids, the welding seams must be tested
over the complete length, paying special attention to the T-joints.
Seams welded with hot air can be tested immediately after cooling
down to the ambient temperature.
A non-destructive test along the seam edges can be done by
the roofer using a seam probe. The tool shall slide along the
seam with little pressure continuously. When a deficient weld is
detected (the seam probe penetrates into the overlap), it should
be immediately visibly marked and repaired as soon as possible.
min. 5 cm
chamfered areas
min. 15 cm
min. 15 cm
approx. 5 cm
laying order
Always use a patch of 150 x 150 mm minimum with rounded
edges. When the deficiencies are ‘long’, cut the patch to the size
of the problem zone plus a 50 mm perimeter overlap. Circular
patches shall have a minimum diameter of 150 mm.

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6.4.2 Destructive weld test (Peel test)
Before starting work on site (morning and afternoon) and
whenever there has been a change in the weather conditions, the
welding parameters have to be verified and adjusted accordingly
by carrying out a welding test. This is a site test and samples are
torn by hand in the absence of a calibrated peel tester in the lab.
Width of the sample: >20 mm
The requirement for a good weld is that the peel resistance is
greater than the required inter-laminar adhesion between the top
and bottom PVC layers.
The peel test (by hand) shall not be carried out before the sample
has cooled down to ambient temperature. Prior to performing
the peel test, cut the sample material into strips 20 mm wide.
The samples shall he torn by hand in lengthwise and crosswise
direction respectively. When there is a delamination of either the
top or bottom sheet the requirement is fulfilled and the welding
parameters are set correctly. The delamination means a controlled
destruction of the product.
When the seam peels off without a delamination of the
membrane layers, it is indicated that the welding parameters
were insufficient. A visual check can give a lead to whether:
• The air temperature was too low
• The traction of the machine was too great
• The pressure was not big enough
• The material itself was too cold or damp.
New tests must be carried on cooled samples until the correct
parameters can be set for the next period of work.
The peel test can also performed directly on the construction site
using an electrical tensiometer. The advantage is to determine
the welding strength and/or the peel force as well as the
corresponding elongation data.
6.5 Sealing of seams
Seam edges of Monarplan® waterproofing membranes, whether
backed, unbacked or reinforced, do not require sealing. The sealing
gives however additional protection for the seam edge. After
seam testing, the seam edges can be sealed with approx. 20 g (25
ml) Monarplan® liquid PVC per meter welded seam; i.e. approx.
100 m of seam edges with 2.5 l Monarplan® liquid PVC. The seam
edges have to be dry and clean.
6.6 Welding of aged (weathered) membranes
Generally, weathered membranes may be fused with new
material on site after years. Necessary technological changes
(closing of roof penetrations, flashing of new penetrations to
the existing roof sealing) and repairs of damage resulting from
inexpert handling, can be carried out with the same material.
Where it is to overlap with the new material, the weathered
surface must be thoroughly cleaned with low-surface-tension
water (water with dish- washing liquid), if necessary, after drying,
with Monarplan® cleaner for waterproofing membranes.
The overlapping surfaces must be absolutely dry and clean and
can be welded with hot air.
Test welds are obligatory!
Weathered unbacked membranes - if the underneath is clean -
can also be welded to underlying new material. Humidity and
moisture trapped under the membranes may impair weldability.
The described pretreatment, particularly the drying, is essential
for the welding area.