System Stack

An overview of the roof breaking down the different layers required. Before starting any construction work, it may be necessary to obtain core samples. These samples will help identify the precise construction and its condition, ensuring that the roof design adheres to current building regulations.


Aluminium Surface

Inspected for defects and repaired where needed.

PU Activator

Applied using a brush or short pile roller to give an even coating across the substrate.

Porosity Primer

Again apply with a brush or short pile roller to give an even coating across the substrate.

Fibrecoat Resin

The first layer of Fibrecoat resin is applied at 1kg per square metre depending on surface condition.

Fibremat Reinforcement

150gm Fibremat reinforcement is embedded into first layer of resin with more Fibrecoat resin.

Fibrecoat Resin

Final layer of Fibrcoat resin is applied at 1kg per square metre

Preparation

Proper preparation is a crucial step in any project and ensures the success and longevity of the product, as well as the safety of those involved in the application process.


Inspection

Inspect the existing Aluminium surface to identify potential defects and rectify them accordingly. It's crucial to allow wet or excessively damp surfaces to completely dry before applying the Fibrecoat system. It's also necessary to temporarily remove any lightning conductors before work begins. The lightning conductors should never be attached through the Fibrecoat membrane.

Surface

The surfaces to be coated, including any existing coatings, repairs, or test sections, must be inspected and properly repaired to ensure a solid base for the new Fibrecoat system. Any large cracks or gaps can be v-cut with a concrete crack chaser and filled with suitable material.

Ensure that all areas to be treated are thoroughly cleaned by removing dirt, debris, water, mould and moss. Use an anti-fungal wash to treat any areas ensuring all spores are destroyed and power wash to remove any left-over residue.

Any loose concrete or brickwork should be removed and repaired using a suitable mortar. Large non-structural cracks should be cleaned and filled using a structural repair mortar. For any freshly laid concrete, you must allow the roofing surface to fully cure before applying Fibrecoat. Please follow the manufacturer's guidelines for exact curing times.

Weather and Working Temperatures

The standard Fibrecoat system should only be applied if the temperature is between 3°C and 30°C. The product can be applied in temperatures as low as 1°C but special product accelerators will be required. The system must not be applied in damp, wet or conditions which could cause surface moisture.

5°C

Min temperature

30°C

Max temperature

Application

Once the surface is prepped and ready the focus can then shift to system application. In this section, we take a look at the different primers needed for the substrate and how to apply them along with the main system.


Primers

Fibrecoat Primers cover a wide range of substrates and encapsulate the roof surface providing the perfect foundation to apply the Fibrecoat system. Two primers are required for application to Aluminium. The first is a PU Activator that coats the existing surface in a fine layer of particles to provide extra adhesion. The second is the Porosity Sealer which when cured provides the perfect base for the main system to bond to.

The PU Activator is a single-component, low-viscosity primer designed for non-porous surfaces. The product can be applied with a roller or bush up to 200g/m² depending on the surface condition. Once applied the product will evaporate leaving a matrix of molecules activating the surface of the substrate.

Coverage rates

Typical coverage rates

Smooth surface 100 g/m²
Rough surface 200 g/m²

Application qty's will vary depending on surface condition

Curing times

Typical curing timestaken at 15ºc

Times may vary due to changing temperatures

Touch dry

Min overcoating

Max overcoating

Porosity Sealer is a single-component, solvent-based, low-viscosity primer designed for use as a general-purpose primer for most well-dry porous substrates. This product can be applied with a roller or bush up to 300gm/m² depending on the surface condition.

Coverage rates

Typical coverage rates

Smooth surface 200 g/m²
Rough surface 300 g/m²

Application qty's will vary depending on surface condition

Curing times

Typical curing timestaken at 15ºc

Times may vary due to changing temperatures

Touch dry

Min overcoating

Max overcoating

Applying the Fibrecoat base layer.

Cut the Fibremat reinforcement to the required length and width for the proposed detail to be completed. Take into account the wind when cutting the fibreglass so as not to leave unmanageable sections.

Once everything has been prepared open a can of Fibrecoat and thoroughly mix using a paddle mixer at a low rpm. Ensure the product is completely homogenous and then leave it to rest to let excess air disperse before application. This can be checked by waiting until surface bubbles disappear in the drum. This will reduce the likelihood of pinhole formation in the membrane.

Apply Fibrecoat to the detail area ensuring works are progressed to the point of egress. Immediately lay the Fibreglass Matting into the wet coating and begin to embed it with a suitable roller. Use a loaded roller to ensure full saturation of the reinforcement. Coverage rates are governed by the substrate. Refer to the specification and/or Allbase technical department for more details.

Overlaps between strips of Fibremat reinforcement must be at least 50mm with feathered edges. Ensure there is sufficient material to saturate these overlap areas.

Keeping the container warm at room temperature will assist with the application and coverage rates of the embedment coat. Cold containers will make the product thicker and more difficult to apply and therefore a reduction in coverage rate will occur.

Once the detail areas are complete, begin installation on the main roof area. Ensure overlaps onto the existing reinforced Fibrecoat sections are by at least 50mm. Apply a layer of Fibrecoat and embed it into the Fibremat Reinforcement. Apply additional material where required. Insufficient coverage of the Fibrecoat material may make it difficult to embed the fibreglass. Flooding of the area may cause the Fibreglass to tent.

Monitor application and check for wicked fibres or pin holing and apply more product where required. Allow curing in accordance with Allbase Technical Services recommendations prior to application of the second layer. Once the membrane has cured, check for pinholes and any surface defects. Wicked fibres should be trimmed back and lightly abraded to provide an even surface prior to the application of the second layer.

Curing times

Curing times are given as a guide and will depend on site temperature.

Waterproof

Touch dry

Second layer

Full cure

Coverage rates

Coverage will depend on the surface condition.

Smooth surface - 1kg per square metre
Rough surface - 1.2kg per square metre

Applying the second layer of Fibrecoat.

After application of the base coat, ensure full coverage and encapsulation of the reinforcement in accordance with Allbase Technical Services and the specification for that project. Any defective or loose areas should be cut out and replaced with new material to ensure the coating is fully bonded to a sound substrate.

Prepare the specified Fibrecoat and apply it to the detail areas first before the main area. Ensure upstands are a minimum of 150mm above the finished roof level.

Apply Fibrecoat at the coverage rate specified by Allbase; run a spike roller slowly over the freshly laid Fibrecoat to burst any bubbles and release any trapped gas before the Fibrecoat skins over. Use volume-to-area calculations to work out the coverage per drum prior to application. This will ensure the correct coverage rate is achieved. Wet thickness readings will also achieve the same result but are limited to the area chosen to test.

Check all details and main roof areas for snags and treat them accordingly. Any pinholes should be treated with extra product leaving a smooth homogenous finish. Allow curing in accordance with Allbase Technical Services recommendations.

Designated walkways should be marked out and installed only after the top coat has cured. Ensure the membrane has reached full cure before reinstating any proprietary components or plant work on the roof.

All liquid details must be suitably terminated with suitable materials such as termination bars, flashings, trims etc. Refer to the specification or Allbase Technical Services for details.

Health and safety

Proper preparation is a crucial step in any project and ensures the success and longevity of the product, as well as the safety of those involved in the application process.


Handling

Use Fibrecoat in well-ventilated areas and store away from direct sunlight. Avoid inhalation and contact with eyes, skin, and clothing by wearing appropriate personal protective equipment as outlined below.

Ground and bond all containers when transferring the material, empty containers may still retain product and product vapour. Do not expose to heat, flame, sparks or other ignition sources such as cutting, welding, drilling, grinding or static electricity. Do not pressurise and provide adequate safety showers and eyewashes in the area of use.

Protective overalls

Always wear protective clothing when using Fibrecoat materials, the disposable coveralls available in the store are the best way to protect your clothing and uncovered areas.

Eyewear

Make sure you have on a pair of wrap-around safety glasses before handling or mixing any Fibrecoat resins, primers or cleaning solutions. Always have two bottles of sterile eyewash on site – one for the active site area and one for backup.

Gloves

Never let the Fibrecoat base resin, primers or solvents come into contact with the skin. Always wear either heavy-duty latex disposable gloves or heavy-duty reusables.


Storage

Along with keeping you safe, storing Fibrecoat roofing materials in the correct way will also maintain the life of the system allowing for optimum performance.

Fibrecoat resin

Materials must be stored undercover and storage areas must be kept between 5°C and 25°C. Materials should never be exposed to freezing conditions or excessive temperature changes. Once opened, containers should be used completely. The typical due date for Fibrecoat is one year after its manufacturing date.

Primers

Fibrecoat Primers should be stored in the original containers at temperatures between 5°C - 30°C. Product shelf life: 1 year, from the date of manufacture.

Fibremat Reinforcement

The 150gm Fibremat reinforcement must be stored under cover and in the dry. The rolls are supplied in a plastic film and then in a cardboard box. Do not get the fibreglass wet prior to or during installation.


Disposal

Any remaining Fibrecoat materials need to be disposed of in the correct way, without causing harm to the environment.

All remaining materials can be disposed of at special waste collection points. Containers or internal liners coming from a container, having contained the Fibrecoat resins and primers are also considered hazardous wastes. Dispose of in a safe manner in accordance with local/national regulations.

Recycling Programme

The Allbase recycling programme lets you return any remaining materials to us to ensure the waste product is disposed of responsibly or given a chance to be used again.