Methodology of OVER Deck insulation with INSUboard- XPS
Extruded Polystyrene Thermal Insulation Boards

INSUboard – Extruded Polystyrene (XPS) Thermal Insulation Board is a rigid foam Board, free from CFC and HCFC Blowing agents, having closed cell structure and is produced in a fully automated continuous extrusion process in accordance with international specification and standards.

INSUboard – XPS is a Special and High performance insulation material with High Compressive strength, Higher Thermal Resistance ( R Value) and Low Water absorption makes it an ideal insulating material for Over deck and Inverted Roof system.

Description of Item - INSUboard

Providing and laying INSUboard – ( XPS) Extruded Polystyrene Thermal Insulation Boards of desired thickness manufactured by Supreme Petrochem Ltd having thermal conductivity as per ASTM C 518 of 0.0289 W/MK , the compressive strength at 10% deflection as per ASTM C 1621 should be more than 350 Kpa , Density should be minimum 34kg/cum as per ASTM D 1622, Water absorption % by volume as per ASTM C 272 should be < 1%, Flammability as per DIN 4102, Part-1 of class B2. Which comply with ASTM C 578 Class Vi Standard requirements.

Advantages of INSUboard (XPS)

1) Free from CFC and HCFC.
2) INSUboard - XPS is a rigid foam board having closed cell structure
3) Negligible water absorption – No loss in Thermal Conductivity.
4) Very High Compressive Strength.
5) Light-weight & easy-to-handle.
6) Long term durability.
7) No capillarity, high moisture resistance.
8) High Insulation Value long term..
9) Lower Global Warming Potential
10) Resistance to growth of bacteria & micro-organism.

R & U Value Calculation of different thickness of INSUboard -XPS

Methodology of Waterproofing and Overdeck Thermal insulation (Inverted Roof System)

Providing Roof Waterproofing Treatment as recommended by the Architects/ Consultants/ Engineer In charge to make the roof watertight.

Providing a separation layer of 150-200 GSM Polypropylene/ Polyester Based Geo- textile Fabric with an overlap of 75 mm and 100 mm on the longitudinal and transverse directions above the waterproofing system.

Providing and installation of Thermal insulation system with 50mm/ 75 mm/ 100mm thick INSUboard- XPS - Extruded Polystyrene Board for achieving desired R or U Value with minimum density of 34 kg/ Cum by staggered pattern above the separation layer of geotextile.

Providing and laying separation Layer of 150-200 GSM Polypropylene/ Polyester Based Geo-textile Fabric with an overlap of 75 mm and 100 mm on the longitudinal and transverse directions above INSUboard – XPS Boards, followed by 300 microns of HDPE sheet and final finishing with Cement Screed/ Tiling.

Alternatively, Loosely laid Paver Blocks/ Precast Cement Tiles with adjustable/ non- adjustable supports as directed by the Engineer In Charge to form an accessible roof as per the details below:

Application Methodology

The RCC Roof surface to be provided with proper slope. Normally 1: 100.

Surface preparation including cleaning the surface, removal of dust, dirt and any other badly adhered material on the roof already laid to the desired slope.

Providing and applying Waterproofing System as recommended by Architects/ Consultants/ Engineer In charge to make the roof completely Water tight.

Providing a separation layer of 150-200 GSM Polypropylene/ Polyester Based Geo-textile Fabric with an overlap of 75 mm and 100 mm on the longitudinal and transverse directions above the waterproofing system.

Providing and installation of INSUboard – XPS of desired thickness above the waterproofing layer. Installation of INSUboard – Thermal insulation boards in a staggered Pattern with proper ship lap joints for continuity of Thermal insulation or to avoid Thermal bridges.

Providing and laying on the insulation board, Polypropylene/ Polyester based geo-textile fabric of 150 to 200 GSM with 75 mm to 100 mm minimum overlap on the longitudinal and transverse directions as a separation layer.

Incase of Protecting the waterproofing and Insulation System with Cement Screed, then providing and laying Screed receiving layer of 300 Microns HDPE Sheet except Black HDPE sheet above the separation layer of Geotextile with 75 to 100 mm overlaps on the longitudinal and transverse directions.

Protection Layer : Cement Screed – Minimum Average of 50mm thick. - Providing and laying above the 300 Microns HDPE Sheet, Screed receiving layer, a Cement Screed of Average Minimum thickness of 50 mm with M20 Grade of cement mixed with Construction fibre with suitable joints and sealing all construction joints with Polyurethane sealant as per the details mentioned below:

Option : 1
 
Protection Screed:
Over the HDPE of 300 microns layer, providing and laying Cement Screed of Average Minimum thickness of 50 mm and finishing the same as per below specifications with desired slope:
 
a) Thorough cleaning the surface.
 
b) Providing and laying Average Minimum 50mm thick Cement Screed with M-20 grade concrete mixed with Recron Polypropylene fibre @ 125 gms per bag of cement with Latex .
 
c) On green screed concrete, Cutting the construction joints of size 6mm x 15 mm (within 12 to 36 hours after laying the concrete) by making the panel size of 2 mtr x 2 mtr.
 
d) Filling the construction joints by using Polyurethane sealant. Complete as per specification.
 
e) Final finishing with desired Tiling by using Tile adhesive as required. ( Optional).
 
Option : 2
 
Loosely laid Paver Blocks/ Precast Tiles:
Alternatively, Waterproofing and Insulation System shall be protected with Precast Tiles/ Paver Blocks by loosely laid System instead of Cement Screed as a Protection and Final Finish. Paver Blocks/ Precast Tiles shall be loosely laid by interlocking system with adjustable or Non- adjustable supports as per the requirements.