icopal Monarplan Series User manual

Synthetic
Membranes
Monarplan®
Installation Manual

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
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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.