Thermosetting Insulation Fills
Thermosetting insulation fill is a nonstructural product made by mixing perlite aggregate with hot asphalt binder. It can provide insulation, fill irregularities in the underlying structural substrate, and provide slope for positive drainage. When thermosetting insulation fills are correctly designed and installed over a structural roof deck, they can provide an adequate substrate for the roof system as well as slope for positive drainage. The hot loose fill shall be installed on a surface primed with M400 RubrPrime and screeded to a thickness that will allow for correct compaction to the specified thickness and density. The fill shall be compacted with a roller or hand tamper to a density between 18 and 22 pounds per cubic foot.

Design Requirements: The manufacturer's specifications and instructions shall be consulted for information about the thermosetting insulation fill's design and installation requirements.

Install Thermosetting Fills over Rigid Substrate Decks: Thermosetting fill shall be applied over a rigid structural deck such as concrete. When applied over metal decking, the fill manufacturer shall specify the span and metal gauge parameters. Cracks or openings in the deck shall be taped or grouted prior to application of the thermosetting fill.

Venting: Edge venting of thermosetting insulation fills shall be provided if the fill has been subjected to water other than that applied to cool the top surface prior to compaction.

Weather & Temperature: Thermosetting fills shall be mixed and applied hot. Application of the fill is acceptable in subfreezing temperatures, however, the weather shall be suitable for installation of the Fields roof system as soon as the fill is surface dry so as to prevent the entry of water into the roof assembly. It is good practice to schedule fill applications according to weather and temperature conditions that are suitable for the entire project.

Curbs & Cants: Only wood or fiber cants shall be installed on thermosetting insulating fills. The fill shall not be installed as a cant or for dead load weight such as that for rooftop installed equipment. The weight for such loads shall be transferred directly to the structural deck by raised curbs because the fill is a non-supportive component.

Surface Conditions: The fill surface shall be correctly compacted, smooth, and free of humps or depressions prior to installation of the Fields roof system.

High Humidity Building: If the building's interior has a high relative humidity, a Fields vapor retarder shall be installed over the deck and under the thermosetting insulation fill. Computing the dew point and correctly designing the vapor retarder are important during the reroofing design phase for insulation fills.

Superimposed Loads: Thermosetting insulation is sensitive to damage from gouging and over compaction. Excessive roof traffic and wheel loaded construction equipment shall be prohibited so as to avoid damage and over compaction of the fill. Damaged fill shall be repaired or replaced prior to installation of the Fields roof system.

Moisture: Water applied during the fill application shall be limited to the amount required for cooling the fill. A correctly compacted, sloped thermosetting fill will shed some water from unexpected light rainfall. However, water may enter at cracks or through the fill due to hydrostatic pressure that occurs with heavy rainfall or plugged drains. The fill shall be surface dry prior to installation of the roof system.

If the fill is placed over a monolithic substrate or vapor retarder, the development of an internal water table can cause the fill to separate from the substrate, and can even float the fill. This factor shall be considered during design, as any significant rainwater must be removed by drilling holes in the substrate at low points and by pumping water prior to installation of the roof system.

Compaction: Thermosetting fills are usually roller compacted to about two-thirds of their applied thickness. Hand tamping may be required at perimeters, curbs and other horizontal roof to vertical intersections. The roof system shall not be installed over uncompacted fills. Correct compaction shall yield a density between 18 and 22 pounds per cubic foot.

Insulation Board Attachment: Insulation boards are prohibited over thermosetting fills.

BUR Membrane Attachment: The BUR membrane shall be adhered in asphalt directly to dry thermosetting fill primed with M400 RubrPrime.

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