F l a t R o o f Te c h n o l o g y f o r t h e F u t u r e

Polyfin and O.C.-Plan

Installation Guide
for Waterproofing Membranes

Table of Contents

1. Products

2. Required tools and machinery

3. Substrate

4. Application

5. Seam connections

6. Junctions and borders

7. Separating layers

8. Important notice
9. Range of Accessories

1.0
1.1
1.2
1.3
1.4
1.5
2.0
2.1
2.2
2.3
2.4
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
5.0
5.1
5.2
5.3
5.4
6.0
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
7.0
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9

Product properties and product range for Polyfin (FPO)

Product properties and product range for O.C.-Plan (ECB)
Application methods
Industry standards, regulations and guidelines
Approvals, Test Certificates and third party monitoring
European Standards
Hand welding machine
Automatic welding machine
Checking the welding temperature
Screw drivers for mechanical fixing
Tools
General substrate conditions
Profiled metal deck substrate
Concrete roofs
Pre-cast concrete elements
Wooden structures and shells
Old roofs
Renovation of existing roofing membranes
Vapour barriers
Thermal insulation materials
General guidelines
Loose lay with ballast new construction
Loose lay with ballast renovation
Loose lay with ballast Reversed roof
Loose lay underneath roof gardens
Loose lay with mechanical fastening
General fixing
Mechanical fastening
Application variations
Laying on profiled metal deck
Number of fasteners
Application with adhesive fixing
Strip bonding with PU-adhesive
Full surface bonding with bitumen (hot bitumen)
Full surface bonding using O.C.-Plan 5028 SK
General information
Welding
Welding seam control
Connection of new membranes with already applicated membranes
Connection to other materials
General information
Non-moving wall detail
Moving wall detail
Rigid parapet detail
High parapet detail
Parapet detail on roofs using ballast
Moving parapet detail
Moving parapet detail under wall cladding
Internal and external corners
Edge termination
Butt joining membranes
Roof ridge sealing
Connection to dome lights
Connecting water drains
Connecting and sealing of gutters
Connecting roof penetrations
Structural joints / Expansion joints
General information
Thermal protection
Protective layers
Friction layers
Corrosion protection
Industrial safety
Dangerous Goods Classification
Fire classification
Fire protection layers
Storage

1. Products Polyfin (FPO)

1.0

Polyfin Roofing and Waterproofing membrane (FPO)

Polyfin is a synthetic membrane made of flexible polyolefines (FPO). More specific it is
a thermoplastic raw material. Polyfin is easy to apply and is particularly suitable for use
in new construction but is also used widely for renovation works. Because Polyfin is
available in many variations; with or without glass fibre reinforcement, with or without
polyester fleece backing in different thicknesses making it extremely versatile with applications in all areas. The standard thickness of our membranes is 2.0 mm, which is very
important as thickness not only is directly related to the lifetime of the membrane but
also to the quality of the welding.

Product

>

Area of use

>

Loose lay with ballast and

under roof gardens

Loose lay and mechanical

fastening
Stripe adhesive bonding

>

** Thickness in mm
**Width in mm

**Length per roll

>

Technical Data,
DIN Standard

with central glass fibre

reinforcement

Polyfin 4230

with central glass fibre reinforcement, polyester fleece backing and

one-sided selfedge

Polyfin 5028 SK***

Full adhesive bonding

*Colours

Polyfin 3020

with central glass fibre reinforcement, with self-adhesive backing

with release paper

light-grey, grey and black

light-grey

Material of the above-listed products:

Flexible Polyolefin (FPO)
2

2.8

20 m

20 m

15 m

2100/1500 /1050
750/525/350/250

* Special colours available upon request

** Standard range; Special sizes available upon request
*** Also available with double-sided selfedge

2100/1050/525

1050

The advantage with our Polyfin products is the enormous flexibility. They are very easy
to adapt to local conditions and are thus easy to install. Because they have a good elongation, they will adapt to all weather conditions optimally. The long life-time is the basis
of the good price performance ratio of our products.

Product properties

Proven suitability confirmed by

independent test institutes
PVC-free
Licensed construction material
Quality approved in accordance to
DIN ISO 9001:2000
Tested resistance against flying sparks
and radiated heat for roof constructions
Hail resistant
Ozone resistant

Suitable for use in potable water

Bitumen and polystyrene compatible
Root resistant in accordance to FLL
guidelines
Easy installation and processing
The hot air welding with a large welding
temperature window ensures homogeneous
joints and does not require any further joint
sealing measures

1. Products O.C.-Plan (ECB)

1.1

Roof and Sealing membrane (ECB)

O.C.-Plan is a synthetic roof and waterproofing membrane made from the material
ECB (Ethylene Copolymer Bitumen). This thermoplastic can be welded and reshaped
by thermal heat.
O.C.-Plan is available in different thicknesses with central glass fibre reinforcement,
with or without polyester fleece backing, one or double-sided selfedge. Depending on
your choice, you will be able to cover any type of application and detail, from loose lay
with ballast, adhesive bonding or by mechanical fastening with O.C.-Plan you will
always have the right membrane for your project.

Product

>
>

Area of use
Loose lay with ballast
and under roof gardens

Loose lay and mechanical

fixing
Stripe adhesive bonding

>

** Thickness in mm
** Width in mm

**Length per roll

O.C.-Plan 4230*

with central glass fibre

reinforcement, polyester
fleece backing and onesided selfedge

O.C.-Plan 4125*

with central glass fibre

reinforcement, with selfadhesive backing with
release paper

O.C.-Plan 5028 SK*

2,5

2,8

20 m

20 m

15 m

Full adhesive bonding

Technical Data,
DIN Standard

with central glass fibre with central glass fibre

reinforcement
reinforcement, polyester
fleece backing and onesided selfedge

O.C.-Plan 3020

Material of the above-listed products:

Ethylene-Copolymer-Bitumen (ECB)
2

2100/1500 /1050
750/525/350/250

20 m

* also available with double-sided selfedge

** Standard range; Special sizes available upon request

2100/1050/525

1050

1050

O.C.-Plan has a standard thickness of 2.0 mm, which is very important as thickness
not only is directly related to the lifetime of the membrane but also to the quality of the
welding. Independent tests have shown clearly that correctly applied O.C.-Plan membranes have a minimum life expectancy of 30 years.

Product properties

Tested reliability by a track record of more

than 50 million square meters over the past
35 years
Quality approved in accordance to
DIN ISO 9001:2000
Approved fire protection
Hail resistant
Ozone resistant
Radon gas resistant
PVC-free

Bitumen and polystyrene compatible

Root resistant in accordance to FLL
guidelines
Easy installation and processing
The hot air welding with a large welding
window ensures homogeneous joints and
does not require any further joint sealing
measures

1. Products

1.2 Application Methods

a) Loose lay with ballast such as gravel,
pavement tiles or as a roof garden
Polyfin/O.C.-Plan 3020
Polyfin/O.C.-Plan 4230
O.C.-Plan 4125

b) Loose lay and

mechanical fixed
Polyfin/O.C.-Plan 3020
Polyfin/O.C.-Plan 4230
O.C.-Plan 4125

c) Stripe or full adhesive

bonding
Polyfin/O.C.-Plan 4230
O.C.-Plan 4125 *
Polyfin/O.C.-Plan 5028 SK
* only fully bonded

1.3 Industry Standards,

regulations and guidelines

1.4 Approvals, Test Certificates and third

party monitoring

DIN 18531 (Roof waterproofing)

DIN 16729 (Raw material standard)

DIN 18336 (Waterproofing) = VOB

DIN 16726 (Test standard)

DIN 18338 (Roof waterproofing) = VOB

DIN 4102 part 7 (Fire behaviour for roofs)

DIN 1055, part 4 (Wind loads)

DIN 1055 part 4, (Wind loads)

DIN 18195, part 1 to 10 (Building waterproofing)

DIN 18897, part 1 to 3
(Trapezoidal steel sheet waterproofing)

1.5 European Standards

DIN 4102 (Fire resistance)

DIN EN 13956 (Roof waterproofing)

DIN 4108 (Heat resistance)

DIN EN 13967 (Building waterproofing)

Energy saving in accordance with EnEV

DIN V ENV 1187 (Fire behaviour for roofs)

5

2. Required tools and machinery

2.0 Hand welding machine

Hot air welding machine
VDE-tested, 230 Volt with variable
temperature control
Up to + 600C with a wide flat nozzle,
width 40 mm
Heat capacity 1400 Watt

2.1 Automatic welding machine

Self moving hot air welding machine
230 V/3500 Watt or 400 V / 5200 Watt
VDE-tested with variable temperature control up to + 600C
and infinite variable movement speed.
Nozzle width and width of pressure roller is 45 mm
We recommend using edge welding machines

Warning: At cable length 50 m at 230 V and

100 m at 400 V the use of mobile power aggregates is recommended to avoid power loss

2.2 Checking the welding temperature

The

welding temperature should have a temperature of approx.

+ 600C at the nozzle exit of the hand welding machine
A suitable measuring tool must be available at all times to
control the welding temperature

2.3 Screw drivers for mechanical fixing

For the correct execution of straight line fixing we recommend:
Suitable electric screwdriver/drill with locked guide rails
Aiming guide as well as magazines for screws and washers
for optimal productivity

2.4 Tools
Following tools are required to apply Polyfin/O.C.-Plan:
Hand welding machine / Automatic welding machine
Siliconised pressure roller, 40 mm wide
Cutting knife with hooked blade
Pair of scissors
Steel wire brush
Measuring tape
Measuring tool

3. Substrate

3.0

General substrate conditions

It is the duty of the applicator to check the substrate in particular the surface for
suitability. Recognized deficiencies of previous applications can be complained provided that they could affect the own installation work.
The load bearing construction must comply with all local technical regulations, especially in regards to loadability, flexibility, anchoring, water drainage etc. Expansion joints
must also be correctly designed and installed (see 6.16).
Roof areas should in accordance to flat roof regulations have a continuous slope
towards the water outlet. We recommend a slope of at least 2%. Roofs without slope
are also possible but only as a special construction. Water outlets should always be
placed at the lowest areas.

3.1

Profiled metal deck substrate

In accordance to DIN 18807 only galvanized sheets with factory-made corrosion protection should be used. The thickness should be minimum 0.88 mm. The wickets of
the profile must have the same height in accordance with flat roof regulations.
In the center, the deflection must not exceed L/300. When transporting the material it
is therefore important to ensure an even load distribution.
Shear panels are structural functioning disks from which the structural integrity of the
entire building depends on. On these, changes which might affect adversely the structural functionality must not take place. Likewise, it must be ensured that components
added underneath the profiled metal deck have no influence on the statics of the
whole construction.
Roof penetrations such as vents, drains etc, are to be reinforced through the use of
coated metal sheets. For dome lights, chimneys, A/C equipment it must be confirmed
and documented that there are no structural changes.

3.2

Concrete roofs
Concrete roofs as well as slope areas have to be sufficiently cured and dry on the surface in accordance with flat roof regulations. The surface has to be abraded, plain and
free of gravel, cracks and ridges.
Slope layers of light concrete etc. are not to be installed under the vapour barrier.

3.3

Pre-cast concrete elements

The applied concrete elements have to provide a plain surface. Construction joints
must be sealed and closed. The supporting joints (butt ends) should be covered with
protective stripes and fastened mechanically against movement

3. Substrate

3.4

Wooden structures and shells

The wooden construction must be protected against moisture. When laying wooden
construction materials, the thermal co-efficiency should be observed. The thickness
of the boards must be able to withstand the expected load and the distance of the
supports should be calculated accordingly, the boards should be at least 24 mm when
using wood and 22 mm when using derived timber products. The boards should not
be wider than 16 cm. The chip wood boards must all be with tongue and groove and
always be jointed together. The maximum board length should not be longer than
2.5 m. The requests for wood protection should be observed. Used impregnation or
other protection should not have any damaging effect on the roof construction.

3.5

Old roofs
Before any renovation can take place, several openings in the existing roof down to the
load bearing layer should be made to ensure its integrity (Vapour barrier condition,
thermal insulation thickness, moisture condition of the thermal insulation and possibility of drying out the roof construction if moisture is present).
Bitumen substrate
Waves, blisters and other factors causing unevenness should be mechanically removed
and levelled. In some cases a protective layer may be required.
Melting water protection
Before commencing a planned roof renovation it is vital to ensure that the structure is
sound and capable of retaining its function.

3.6

Renovation of a roof with existing synthetic membranes

We recommend to contact POLYFIN for individual assessment and recommendation.

3.7

Vapour barriers
Because of unexpected change of use of the building, we always recommend to use a
vapour barrier on thermal insulated roofs. We recommend using products made of PEfilm or bitumen such as POLYFIN PE-vapour barrier, water vapour diffusion resistance
of approx. 690000 (Sd >200 m). The vapour barrier should be fixed at all terminations
and brought up to the edge of the thermal insulation. Vapour barriers should also be
professionally connected to all drains and penetrations.
The vapour barriers should be laid loose with overlaps of approx. 10 cm and sealed
absolutely tight with a suitable double-sided adhesive tape. At all junctions PE-vapour
barriers have to be sealed absolutely tight using double-sided butyl adhesive tape.
Above air-conditioned rooms all junctions and covered seams have to be sealed with
butyl adhesive tape.
For concrete substrates and above air-conditioned rooms, we recommend using a
bitumen vapour barrier with an aluminium layer. When the vapour barrier also serves
as an air barrier it is vital to ensure that all overlaps and terminations are tightly sealed.

3.8

Thermal insulation materials

Only materials which are temperature and dimension stable and which are suitable and
firm enough to be walked on when installed underneath the waterproofing should be
used. Foam boards should be with tongue and groove - or installed in two layers with
staggered joints.

4. Application

4.0 General guidelines

Polyfin / O.C.-Plan are waterproofing membranes which are plasticized and welded
through heat.
Polyfin / O.C.-Plan can be laid exposed to weathering.
The waterproofing membrane on the roof should always be mechanically fixed on terminations, penetrations, dome lights and at parapet details before the termination details
are made over the fixed membrane in accordance to the flat roof guidelines. Membrane
edges should always be fixed with individual fixings (but min. 4 pc. per running meter) or
Polyfin / O.C.-Plan covered metal sheet corners (every 20 cm mech. fixed) (linear parapet fixing).
Polyfin / O.C.-Plan membranes are bitumen and polystyrene compatible and can be
used ideally for the renovation of bitumen sealed roofs.

4.1 Loose lay with ballast new construction

Roll out Polyfin / O.C.-Plan membranes and place the next
membrane with an overlapping of 5 cm and then weld. Lay
the next roll with an overlapping of 5 cm, weld and so on.
When laying loose on polystyrene insulation boards, PE-foam
etc., then the overlapping should be increased so that melting
and subsequent damage of the polystyrene is avoided.
Immediately after the application, the ballast to protect
against wind loads should be placed!

Gravel
Polyfin / O.C.-Plan
Thermal insulation
Vapour barrier
Concrete

A protection layer has to be applicated in accordance to the

flat roof guidelines.
The ballast placed should be in accordance to the flat roof
guidelines DIN 1055 part 4 (wind loads).

New construction

4.2 Loose lay with ballast - renovation

As Polyfin / O.C.-Plan are fully bitumen compatible, they are
particularly suitable for renovation of such. Therefore the normally used separation layer can be avoided. When renovating
using ballast then the membranes can be laid as described in
4.1. Before commencing it is however important to verify
whether an additional thermal insulation layer and/or a protection layer is required. Immediately, after the application, the
ballast to protect against wind loads should be placed.

Gravel
New thermal insulation

Polyfin / O.C.-Plan
Old sealing

Old thermal insulation

Vapour barrier
Concrete

The ballast placed should be in accordance to the flat roof

guidelines DIN 1055 part 4 (wind loads).
Renovation

4. Application

4.3 Loose lay with ballast Reversed roof

Gravel
Protection layer

Thermal insulation
Polyfin / O.C.-Plan
Concrete

Reversed Roof

Verify whether a protection layer in accordance to the flat roof

guidelines is required. The application of Polyfin/O.C.-Plan
should be done as described in 4.1. On the waterproofing, a
layer of thermal insulation made from extruded polystyrene is
placed. The boards should be with tongue and groove and be
placed tightly. On top of the insulation a layer of polyester
fleece is placed as a filtering layer. Immediately after placing
the fleece, the ballast should be placed to protect against
wind loads.
The ballast placed should be in accordance to the flat roof
guidelines and DIN 1055 part 4 (wind loads).
It is recommended to make the roof in segments and verify
these through an application plan or photo.

4.4 Loose lay underneath roof gardens

Planting

Drainage / filter- /
protection layer
Polyfin / O.C.-Plan
Thermal insulation
Vapour barrier
Concrete

Polyfin/O.C.-Plan are root resistant (FLL test). The application

of Polyfin/O.C.-Plan should be done as described in 4.1.
After completion of the waterproofing works, the protective
layers are to be placed.
Immediately after that the ballast should be placed to protect
against wind loads.
The ballast placed should be in accordance to the flat roof
guidelines and DIN 1055 part 4 (wind loads).
It is recommended to make the roof in segments and verify
these through an application plan or photo.

Green Roof

4.5 Loose lay with mechanical fastening

Polyfin / O.C.-Plan
Thermal insulation
Vapour barrier

Profiled metal deck

Light Weight Roof

With this application method, all the layers are fixed firmly to
the load bearing structure in one single operation.
On profiled metal decks, the thermal insulation boards should
be placed in cross direction to the profile direction, the waterproofing membranes as well. The minimum thickness of the
insulation should be in accordance to flat roof guidelines to
avoid damage caused by stepping on areas between the profiled metal deck.
The compressive strength of the insulation material must be
sufficient for the mechanical fastening and be permanent to
withstand damage.
The waterproofing sheet overlapping should be made in accordance to fastener width, welding width and 1 cm safety
distance to the fastener (see table 4.8)

Note: when using small sized insulation boards, the

flat roof guidelines should be followed.

10

4.6 General fixing

Only fasteners which have been tested for this specific purpose should be used (selftapping screws, wood screws or anchor systems with the corresponding load spreading
washers).
The systems must be corrosion protected, made of non-ferrous metal or of form-stable,
weathering and temperature resistant plastics.
Only screws which do not through self induced movements or vibrations screw themselves out should be used.
The pull-off strength of each of the fasteners to the load bearing structure should be
minimum 0.4 KN per piece.

4.7 Mechanical fastenings

Asymmetric fastening systems
The fixing is done at the membrane edge.
The fasteners are placed in the same
distance and parallel to the membrane edge.
The overlapping of the membrane is determined by the type of fasteners, the type of
welding machine and the safety distance of
both sides of the fasteners.

11cm
cm
11

Symmetric fastening
a) Both membrane sheets are overlapped
with 6 cm and not welded.
The fasteners are placed in the middle of the
overlapping.
The required waterproofing in the overlapping
and fixing zone is done by welding stripes of
Polyfin/O.C.-Plan 3020 in a width of approx.
25 cm directly onto the existing waterproofing
membrane.

25cm
cm
approx.
20 bis 25

66 cm
cm

b) This system is also used in light constructions such as edge and corner fastenings.
Here, the fastenings are placed as per
instructions and the overlapping stripes of
Polyfin/O.C.-Plan 3020 in approx. 25 cm
widths are made.

approx.
20 bis 2525
cmcm

11

4. Application

4.8 Application variations

In praxis, there are two variations commonly
used, described in the following examples:
Example 1: Asymmetric fastening

Example 2: Symmetric fastening

Polyfin / O.C.-Plan mechanically fixed

Polyfin / O.C.-Plan mechanically fixed

Homogeneous hot air welding

Seam
overlapping
6 cm

Seam overlapping
11 cm

10
4c
m

Homogeneous hot air welding

Covering stripes
25 cm

104 cm

Thermal
insulation

Thermal insulation

Vapour barrier

Vapour barrier

5 cm

Profiled metal deck

1 cm

4 cm

1 cm

5 cm

Profiled metal deck

1 cm

4 cm

1 cm

5 cm

The seam overlapping consists of 1 cm edge

distance, 4 cm fastener width, 1 cm safety
distance and 5 cm overlapping welding.

Examples for the application of Polyfin /O.C.-Plan the surface area

Usable
width*
0.94 m

2.00 m

Edge area
*= membrane width less overlapping

12

1.00 m

approx.

approx.
Usable
width*
0.94 m

Width = 1.05 m

0.42 m

0.50 m

stripes width = 0.25 m

Width = 1.05 m

0.42 m

Width = 0.52 m

Width = 0.52 m

stripes width = 0.25 m

Edge area

0.50 m

approx.

Direction of corrugations

4.9 Laying on profiled metal deck

When applying on profiled metal decks, the
membranes are in general laid cross to the
profile direction.
For edge and corner areas it is often an
advantage to use narrower sheets to facilitate a higher number of fasteners placed
uniformly to the membranes.
The middle area is normally done using wide
sheets.
Edge and corner areas are laid in longitudinal
direction of the corrugations by using additional fasteners in the membrane middle and
covering with stripes as described in 4.7 b.

4.10 Number of fasteners

Example for the application in corner and edge areas

(Excerpt from Flat roof guidelines Sept. 2003):

The calculation of the wind load is done using DIN 1055, part 4,
which distinguishes between middle, edge and corner areas.

Ground plan of the roof

For practical use, the tables 1.5 to 1.10 in the flat roof guideline
of Sept. 2003 can be used. This is for closed structures not
exposed to winds.
POLYFIN offers to calculate and optimise the mechanical
fasteners (acc. to DIN 1055, part 4 of March 2005) for each
individual project to reduce costs and optimise application.
Please provide roof dimensions, height, slope, termination
detail and description of structure.
In case of renovation it has to be tested if the pull-off strength
of each fastener is min. 0.4 kN per piece (see 4.6)
a
b

Building Width
Building Length
Edge Area
Corner Area

4.11 Application with adhesive fixing

Bonding is done if loose laying with ballast or loose laying
and mechanical fixing is not possible. When bonding all layers
of the roof construction are to be bonded with each other.
Suitable adhesives are polyurethane adhesives and conventional hot bitumen mastic. Please follow the instructions for
use of the adhesive manufacturer. Adhesive quantities acc. to
technical department of POLYFIN AG. Use only Polyfin and
O.C.-Plan fleece-backed membranes. Ensure that the fleece
layer is dry during application. The overlapping should be at
least 4 cm. Please observe 4.1 . Since the membranes are hot
air welded, one should ensure that the welding edges are free
of adhesive and other contaminants which will impair welding
quality.
The adhesive fixing method should only be used when the
substrate is round, firm and free of contaminants this is particularly important when renovating existing roofs where old
roofing layers might have insufficient strength to serve as a
suitable substrate.

13

4. Application

4.12 Strip bonding with polyurethane adhesive

The PU adhesive must be solvent free and approved for use in roof constructions. The
adhesive is applied in stripes on a suitable substrate. Adhesive manufacturers guidelines must be strictly observed (Adhesive quantities acc. to recommendation of the
technical department of POLYFIN AG)
Regarding the substrate please observe point 3. Polyfin / O.C.-Plan 4230 are placed
onto the liquid adhesive and pressed firmly to the substrate. Please observe the
instructions from the adhesive manufacturers carefully. Do not prepare an area larger
than can be covered within the reaction time of the adhesive. Corrections of already
laid sheets can be made within 20 minutes depending on adhesive and climatic conditions. At edges and terminations, all sheets should be mechanically fixed to the substrate. To avoid that the adhesive stripes can be seen on the surface, the applicated
membranes have to be rolled with a suitable weight. The adhesive has to be applicated stripewise and not in sinuous lines.

Note: As PU adhesives have limited or no early adhesive strength, it is

important to secure the sheets using ballast against winds during
adhesive curing. Small marks on the sheets, where adhesive stripes are
placed underneath, are possible.
4.13 Full surface bonding with bitumen (hot bitumen)
Polyfin 4230 / O.C.-Plan 4230/4125 are fully bitumen compatible and can be bonded
to the substrate using hot bitumen. Please select bitumen type according to roof
slope. Polymer modified and solvent-free bitumen can also be used. When bonding
coloured FPO membranes with bitumen slight discolourations could arise on the surface. These discolourations do not have any influence on the technical features, the
function or the life-time of the membranes.
a) Flame melting method
The bitumen mastic is poured to the substrate and spread evenly using a rake. After
cooling down, the waterproofing sheets are rolled out and aligned correctly, then rolled
back halfway. The bitumen (not the sheets) is then heated and melted using conventional gas flamers in the entire sheet width, the sheet is then pressed firmly and homogeneously into the melted bitumen. After completion, the second half of the sheet is
rolled back up and the procedure is repeated.
b) Brush application method
Use only Polyfin 4230/ O.C.-Plan 4230/4125 for hot bitumen application. The sheets
are rolled out, aligned and rolled back halfway. The brush is then dipped into the hot
bitumen mastic and then placed directly on the substrate directly in front of the rolledup sheet. The sheet is then rolled and pressed firmly so that a layer of bitumen always
is pushed in front of the roll.

4.14 Full surface bonding using Polyfin/O.C.-Plan 5028 SK

The substrate must be dry, firm, clean, free of oil, grease and other contaminants
which may affect the bonding adversely. The surface should be smooth, even and
without depressions and protrusions. If such are present they should be removed
beforehand. Pouring joints and tie holes should be filled with suitable mortar beforehand. Depending on substrate, a bitumen primer might be required. Roll out the
Polyfin/O.C.-Plan 5028 SK membrane, align correctly with 5 cm overlapping, remove
the release film while pressing the sheet to the substrate using a roller or broom. Roll
out the next membrane and align in that way that the 5 cm adhesive-free edge overlaps the previous membrane. Remove the release film while pressing the sheet to the
substrate. The seam connection is done by hot air welding. Butt endings of rolls need
to be sealed with an overlapping strip of Polyfin/O.C.-Plan 3020.
14

Notice: Please observe special storage requirements.

5. Seam connections

5.0

General information
Our roofing sheets are thermally welded together using hot air welding machines. The
overlapping sheets are homogeneously plasticized and joined together under pressure.
Temperature, roller pressure and speed while welding are important parameters and
must always be adjusted to the ambient working temperature.
The welding of Polyfin / O.C.-Plan is a homogeneous and environmentally stable
joining method without using plasticizers and other foreign compounds which may
deteriorate over time. A correctly welded joint is absolutely weathering stable and does
not require any further treatment.
Before commencing work, test welding should be completed to ensure welding quality.
The overlapping distance for both manual and automatic welding is 5 cm in which the
edge must be kept clean before welding to ensure a complete bond. All membranes
with a polyester fleece or self-adhesive backing have a fleece or self-adhesive free
edge of approx. 4 cm. Butt joints of the sheets have to be covered with a strip of
Polyfin / O.C.-Plan 3020. Width min. 12 cm.

5.1

Welding

Sketch 1: Pre-welding

a) Manual welding
Set the temperature to approx. + 600 C.
The welding is normally done in 2 steps:
1. The upper sheet in the overlapping is
fixed, approx. 5 cm from the edge, by pressing the silicone roller (see 1.) at the edge of
the underneath sheet to create a thin yet
homogeneous welding line. This thin line
ensures that during the main welding process no hot air escapes and the necessary
welding temperature is maintained which
ensures homogeneous seams.This additionally ensures a proper laying of the membranes.
2. The main welding is then done on the
remaining width of approx. 4 cm. In this
case, the welding unit and the silicone roller
are moved in a slow continuous movement
along the seam (see 2.)
After welding, turn down the temperature of
the welding machine, but keep the blower
on until the air is no longer hot (preserves
the heating elements).
3. When using polystyrene insulation sheets
the overlapping area has to be increased in
order to avoid damages caused by hot air.

app
r
4 cmox.

Pre-welding

approx. 4 cm
5 cm

app
rox
2c
m

Overlapping 5 cm
Pre-welding

approx. 4 cm welding

Sketch 2: Seam connection by homogeneous hot air welding

15

5. Seam connections

b) Automatic welding
Switch on the machine and adjust the temperature to approx. + 600 C. The welding is
done in one continuous operation. It is not necessary to make the pre-welding line as
when using manual hand welders as the automatic welders have a special ballast
system which ensures that the sheets are pressed together and no hot air can escape.
The welding speed is adjustable and will be determined by the ambient temperature.
The welding seam is approx. 5 cm.

5.2

Welding seam control

Before commencing work test welding should be completed to ensure welding quality.
A physical control (with a suitable hook) of the welding can only be done after min. 6
hours of cooling down. The membrane temperature should then be < 20C.

5.3

Connection of new membranes with already applicated membranes

New membranes may be joined together with already applicated membranes.
The surface of the already applicated membrane only has to be cleaned using a onehand angle grinder with a rotating wire brush to remove all accumulated dirt and patina
layers. Welding of the new material can be done as described in 5.1.

5.4

Connecting and welding to other materials

Please consult with POLYFIN AG.

6. Junctions and borders

6.0

General information
Connections to roof waterproofing is done using stripes of Polyfin / O.C.-Plan 3020.
According to Flat Roof guidelines, all connections and terminations must be structurally fastened to prevent horizontal forces from damaging the membranes. The sheets
must be fastened with singular fasteners (but min. 4 pc. per running meter) or Polyfin /
O.C.-Plan metal sheet corners (every 20 cm mech. fixed).
Rigid connections of two structurally separated structures should be avoided. Damages caused by shear and tensile loads can be avoided by installing sensible details
designed to cope with these movements. All these connections should be wind proof.
All details must be constructed in such a manner that no water can run behind or
underneath the sheets. At junctions individual seams facing the direction of water flow
cannot be avoided. This does not constitute a disadvantage for hot air welding.

16

6. Junctions and borders

All following sketches are not drawn to scale

6.1

Non-moving wall detail

Example

The Polyfin / O.C.-Plan 3020 sheets must be mechanically

fastened in the wall terminations and roof edges. Connecting
strips are fixed to the parapet using a suitable profile of steel
or aluminum. They are then welded to the roofing sheets
and the existing edge fastening (single fasteners or Polyfin /
O.C.-Plan metal sheet corners) will be overlapped.
The connection to the roofing sheets should not be more that
20 cm from the wall. To seal the profile, suitable sealants or
mastics can be used.

Wall connection profile

Polyfin /O.C.-Plan
Thermal insulation
Vapour barrier

Profiled metal deck

Edge fastening
Connection of the vapour barrier

6.2

Moving wall detail

Example

Contrary to the rigid detail, the Polyfin / O.C.-Plan 3020

connecting strip is not connected to the wall directly but to an
extra supportive detail, ie. a corner made of galvanised metal.
The connecting strip is then welded to the roofing sheets
and the existing edge fastening (single fasteners or Polyfin /
O.C.-Plan metal sheet corners) will be overlapped.

Overhang profile

Wall connection profile

Polyfin /O.C.-Plan
Thermal insulation
Vapour barrier

Profiled metal deck

Edge fastening
Connection of the vapour barrier

6.3 Rigid parapet detail

The detail is made similar to the non-moving wall detail, but
instead of terminating on the vertical wall, the waterproofing is
extended up over the parapet. Then a suitable cover profile is
placed on the parapet crown.

Example

Wall capping
Polyfin /O.C.-Plan
Thermal insulation
Vapour barrier

Profiled metal deck

Edge fastening
Connection of the vapour barrier

17

6. Junctions and borders

Example

6.4 High parapet detail

Wall capping
h > 50 cm

Intermediate fastening
covered
Polyfin/
O.C.-Plan

At parapet heights more than 50 cm, it is necessary to fasten

the sheet vertically and then continue over the parapet with a
new waterproofing sheet. The sheet terminating vertically
should ideally be fastened using a suitable profile which will
prevent damages caused by winds. This profile can be applicated as a 2-part covered connection. Then a suitable cover profile is placed on the parapet crown.

Thermal insulation
Vapour barrier

Profiled metal deck

Edge fastening
Connection of the vapour barrier

Example

6.5 Parapet detail on roofs using ballast

Wall capping
Ballast / planting

Polyfin /O.C.-Plan
Thermal insulation
Vapour barrier

Strong wind often results in travelling of the ballast gravel. To

avoid damages it is important to have mechanical fastening
(single fasteners min. 4 pc. per running meter or Polyfin /
O.C.-Plan metal sheet corners every 20 cm fixed on all termination details). We also recommend using concrete plates in
the edge and corner areas when using this design in high rises
and/or windexposed building locations. Then a suitable cover
profile is placed windproof on the parapet crown. The ballast
quantities are to be used acc. to the Flat Roof guidelines and
DIN 1055, part 4 (windload).

Profiled metal deck

Edge fastening
Connection of the vapour barrier

Example

6.6 Moving parapet detail

The application has to be done as described in 6.2 (Moving
wall detail). A wall capping profile should be mounted directly
on top of the parapet.
Wall capping

h 15 cm

Wall connection profile

Polyfin /O.C.-Plan
Thermal insulation
Vapour barrier
Profiled metal deck

Edge fastening
Connection of the vapour barrier

18

6.7 Moving parapet detail

under wall cladding

Example
Wall capping

Here the wall cladding will cover the sheet termination. The
cladding must be installed so that rain water can not run
behind the water proofing sheet. The parapet crown is then
covered with a suitable profile.

Wall cladding

h 15 cm

Wall connection
profile
Polyfin/
O.C.-Plan

Thermal insulation
Vapour barrier
Profiled metal
deck

Edge fastening
Connection of the vapour barrier

6.8 Internal and external corners

For corners, Polyfin / O.C.-Plan 3020 strips are used around
the corners and welded. They are then reinforced using prefabricated external and internal corners also supplied by
POLYFIN AG. External corners can also be used for sealing
straight angled or square roof penetrations such as ventilators
or dome lights.

Example
External corner

Internal corner

10 cm

10 cm

External corner

15 cm

15 cm

15 cm

Internal corner

19

6. Junctions and borders

Example

6.9 Edge termination

Min. 100 mm at roof slope 5

Min. 50 mm at roof slope > 5

Multipart edge termination profile

At edge terminations it is imperial to follow Flat Roof guidelines for correct terminations. For this special one-piece or
multipart profiles as well as profiles made of POLYFIN metal
sheets which allow proper connection to the waterproofing
membranes for this purpose are needed.

Sealing mask

Flange profile

Polyfin/
O.C.-Plan

Thermal
insulation
Vapour
barrier

Profiled
metal deck

Metal sheet for edge reinforcement

Timber deal board

6.10

Butt joining membranes (only for fleece backed

and self-adhesive backed membranes)
Butt joints should be mechanically fastened every 25 cm
over the entire roll width. The joint should be covered with a
25 cm wide strip of Polyfin / O.C.-Plan 3020 and welded on
all sides.

Example

6.11

Roof cover
Polyfin/O.C.-Plan

Separate cover stripe

Polyfin/O.C.-Plan
Fastening on left and right side
of the top ridge

20

Roof ridge sealing

Both roofing sheets should be mechanically fixed every
25 cm in the ridge direction. Finally they should be covered
with an approx. 25 cm wide Polyfin / O.C.-Plan 3020 stripe
which should cover the mechanical fasteners and then
welded on both sides.

6.12

Connection to dome lights, sky light strips and

rainwater removal installations
The Polyfin / O.C.-Plan sheets are laid whole way up to the
frame and fastened mechanically to the (wooden) raft as per
flat roof regulations. The overlapping stripe of Polyfin /
O.C.-Plan 3020 should be laid loose around the frame covering both the frame and the mechanical fasteners. The stripe
is then fastened to the frame using special clamping profiles.
The stripe is fastened as per drawing 2.
The strip has to be welded max. 20 cm from the vertical
frame. The intersection point at the corner between roof
surface and frame covering has to be fixed with corner
protection (made of homogeneous material Polyfin 1020 /
O.C.-Plan 1025 without reinforcement) from our range of
accessories.

Example 1

h 15cm

20cm

Connecting
bar
Polyfin /
O.C.-Plan

Connecting
vapour barrier

Example 2

Clamping strip

Corner protection with

Polyfin/O.C.-Plan,
approx. 8 cm
Surface sealing

8 cm
15 - 20 cm
15 cm

6.13

Connecting water drains

Internal drainage
For this detail, pre-fabricated self-clamping drains with
mechanical fastening are primarily used. The connecting
flange (approx. 50 x 50 cm) has to be carried out with homogeneous material Polyfin 1020 / O.C.-Plan 1025 without
reinforcement. The drain has to be fixed mechanically into
the underconstruction. Flat Roof guidelines state that drains
must be placed min. 50 cm from walls, parapets, joints and
other separating objects. Structures separated by expansion
joints must all have individual drains. For renovation, several
accessories from POLYFIN range can be used.

Example

Polyfin/
O.C.-Plan

Connecting flange
Surface sealing
Thermal insulation
Connecting vapour
barrier
Replace profiled
metal deck
Drain fixing

21

6. Junctions and borders

Example New Construction

6.14
direct welding

Polyfin/O.C.-Plan

Surface
sealing

For sealing roof gutters there are different options:

POLYFIN metal
sheet

Gutter

Example Renovation
Surface
sealing
Polyfin/
O.C.-Plan

New construction
The Polyfin / O.C.-Plan laminated metal sheets are to be
cut and shaped to fit the termination detail in such a manner
that they can be fixed firmly to the edge of the roof construction and then extend down into the gutter (see drawing). The metal sheets are then being fastened with a
distance of min. 0.5 cm. The roofing membrane should then
overlap the fixings of the metal sheets and then be welded
to the metal sheets.

Connecting profile
mechanically fixed

Renovation
The waterproofing sheets should be extended into the gutter
and then fastened using a suitable profile to the existing
profile.

Cover metal sheet

Thermal
insulation

Gutter

Strip
D - 6 cm = d

Polyfin/O.C.-Plan

h 15 cm
above top
layer
collar

Polyfin/O.C.-Plan

6.15

Connecting roof penetrations

Pipe penetrations are normally sealed using standard parts
from our accessories range or from a flange approx.
50 x 50 cm and a collar made from Polyfin 1020 /
O.C.-Plan 1025. In the middle of the flange a hole should be
cut. The hole should be approx. 6 cm smaller than the pipe
diameter. Using a hand welder, the flange is heated to make
it pliable and plastic so that it easily can be slotted onto the
protruding pipe. In some cases it is easier to make this
shape adjustment on a loose pipe with the same diameter.

Polyfin/O.C.-Plan

22

External drainage

Cover metal
sheet

Thermal
insulation

Connecting and sealing of gutters

connecting
flange

By making the hole in the flange smaller than the actual diameter and slotting it onto the pipe you will get a tight collar
(min. 10 mm) which fits on the pipe and the collar piece can
be welded onto this for a tight fit. The flange should then be
welded to the roofing sheets and the upper part of the collar
piece fixed using a suitable clamp. Straight faced penetrations such as vents, chimneys, access doors etc. should be
treated as wall connections and sealed in a similar manner.

6.16

Structural joints / Expansion joints

The layer structure of the roof must have joints whereever
there are joints in the underlying structure of the building.
Their nature depends on the anticipated settlement. Structural and expansion joints should normally be designed as
high points. They must not run through openings for projections through the roof and must not approach closer than
50 cm to such points.

Example
Tension Band

h 15 cm above
top layer

Example

Foam profile

Wall cover fixed

on one side only

Edge fastening

Polyfin/
O.C.-Plan
Thermal insulation
Connect vapour
barrier
Reinforced
concrete

Example

Edge fastening

Soft foam
Polyfin/
O.C.-Plan
Thermal insulation
Connect vapour
barrier
Reinforced
concrete

23

7. Separating layers

7.0

General information
Our roofing membranes are plasticiser- and softener-free and do not require any separating layers when in contact with e.g. bitumen and polystyrene as they are fully compatible. Wood preservation chemicals are not to influence the roof construction in a
dangerous way. Suitable separating layers are eg. raw glass fleece, plastic fleece,
PE-films etc. (see also our range of accessories).

7.1

Thermal protection
When using Polyfin / O.C.-Plan for waterproofing in civil construction underneath e.g.
asphalt (road and bridge construction) please contact the technical department of
POLYFIN AG.

7.2

Protective layers
Rough and uneven surfaces can eventually damage the waterproofing and therefore
often require a protective layer beforehand. Suitable protective layers are polyester
fleece or polyethylene foam sheets. Bituminous surface may also require a protective
layer. When Polyfin / O.C.-Plan 4230 is used, the protective layer can eventually be
omitted. One layer thermal insulation could also serve as protection layer. If heavy and
or pointed objects are to be placed above the waterproofing sheets, suitable protection is required. Rubber granulate mats are commonly used for this purpose.

7.3

Friction layers
When concrete is applicated directly on the waterproofing sheets as per German Standard DIN 18195, part 10 2 layers of 0.25 mm PE-film each have to be used as friction
layers. Other kinds of friction layers acc. to recommendation of the technical department of POLYFIN AG.

7.4

Corrosion protection
Through intensive UV light and humidity organic residues can be formed on the surface of the waterproofing sheet. These residues combined with bituminous materials
can lower the pH value of the surface water and can under adverse situations cause
an corrosion acceleration. We recommend using gutters and drains of plastics, cupric
or stainless steel or to coat all metal parts which may come in contact with the surface
rain water. Please observe local regulations for corrosion protection. Protection
coatings are maintenance coatings.

24

7.5 Industrial safety

Always observe local safety regulations. When welding membranes in small closed
rooms, ensure adequate ventilation.

7.6 Dangerous Goods Classification

Polyfin / O.C.-Plan products are not dangerous goods (see also Material Safety Data
Sheet). Polyfin / O.C.-Plan are environmentally friendly and are not hazardous to
waters (no detrimental effect on ground water or for animals). When welding or burning
POLYFIN membranes no dioxins, furans or corrosive gases are released.

7.7 Fire classification

Polyfin/O.C.-Plan have been tested in accordance with all common roofing regulations to conform with the class of Hard Roofings = resistance against fly ashes,
sparks and radiant heat in accordance with DIN 4102, Part 7 and European norm
DIN ENV 1187. As a construction material, Polyfin/O.C.-Plan are classified under
group B2 (DIN 4102, Part 1).
Test certificates are available upon request.

7.8 Fire protection layers

Raw glass fleece 120 g/m2, A2, are suitable as fire protection layer on polystyrene thermal insulations.

7.9 Storage
Polyfin/O.C.-Plan can be stored on construction sites, rolls must be standing if lying
then only one layer. They must be stored on an even and clean substrate. Polyfin /
O.C.-Plan 5028 SK must be stored standing on pallets and protected against UV light
as the adhesive mastic cannot be exposed to long term UV light, the rolls should be
used within 6 months from the production date.

25

8. Important notice

Always comply with all relevant regulations such as Flat Roof guidelines, Plumbing regulations, Safety Regulations and all manufacturer instructions for accessories, parts and tools.
Information given herein is based on present knowledge and more than 35 years experience
with these materials. A liability claim for a specific item used under a specific situation or
confirmation on suitability for a specific application can only be honored if this has been
given in writing by POLYFIN AG. The wide range of applications for these kind of products
always requires experience and competence of the user of these.
As our material warranty only can be applied when the above mentioned regulations have
been strictly adhered to, we strongly recommend to contact POLYFIN AG and request separate confirmation for situations where regulations can not be adhered to or are non existing.
This is particular important for situations where conditions deviate from the instructions and
regulations given and mentioned within this manual.
This installation guide loses its validity with the publication of a new version of this installation guide.

26

9. Range of Accessories

>

Flat Roof Accessories

External corner
Internal corner

Dome light corner protection

Roof ventilator
Outlet

Sealing sleeve
for round pipes

Sealing sleeve for lightning

arrester - tapered

Sealing sleeve for lightning

arrester - graded
Water outlet

Laminated metal sheet

PE vapour barrier film
PU Adhesive

Bitumen Primer
Maintenance Way Plates

Roof ventilator

Technical Data

Packing size

90, Edge length 100 mm

25 pc / box

Dia. 80 mm,
Thickness 2.0 mm / 2.5 mm

100 pc / box

Dia. 70 / 100 / 125 mm, Length 250 mm

5 pc / box

Dia. 40-160 mm

5 pc / box

90, Edge length 100 mm

Dia. 70 / 100 mm, Height 225 / 270 mm

25 pc / box

5 pc / box

Dia. 15-30 mm

10 pc / box

Dia. 10, 20, 30 mm

10 pc / box

1mx2m

30 metal sheets / pallet

2.0 kg metal can

6 cans / box

90, Length 425 mm, 100x65 mm

45 on request

Thickness 0.25, 0.32, 0.40 mm, Width 4 m

10 l metal can

Thickness 30 mm,
Width 500 mm, Length 500 mm

Sealing sleeve

1 pc / box

25 m per roll

10 l can

4 pieces / 1 m2

Outlet

27

POLYFIN AG
Ziegelhuser Strae 25
DE-69250 Schnau

www.polyfin.com

VAE 001/1206

Phone: +49 (0) 62 28 / 92 49 - 0

+49 (0) 62 28 / 92 49 - 50
Fax:
e-mail: info@polyfin.de