1. Purpose:

INTRODUCTION
WHAT IS POLYURETHANE?
It is the first step in the Combo roof system which is providing thermal and moistures protection.
A chemical reaction will happen when two liquid components are combined at the tip of a gun. When the two parts are combined in the spray nozzle, they start a chemical reaction that creates the foam. Within seconds, the liquid is on the roof surface has expanded to 20 times its original mass, within minutes this foam can be walked on and cures to 90 percent of its full strength in about four hours.
 
The purpose of this quality system procedure is to ensure that: 

• All polyurethane application procedure documents are controlled, reviewed and approved prior execution.
• All records are available with evidence.
• Polyurethane process are matching with the required measurements and specification according to: BS EN 14315 1 2013
• Achieving polyurethane main purpose as an advanced waterproofing method. 
• Ensuring professionalism and consistently provide products that meet customer and applicable statutory and regulatory requirements, and aims to enhance customer satisfaction. By providing conforming product and continuous improvement and the prevention of nonconformity.

2. Scope

Installing waterproofing insulation system.
This type of insulation system forms a thermal and moisture protective system; it can be applied either on a concrete slab or any other surface with any shape or size.
This material has many properties which can be summered as follows:

• Seamless: Polyurethane foam is applied as a liquid, creating a single close celled monolithic membrane that covers the entire roof. 
• Flexible: The foam can be sprayed onto virtually any surface, irregularly shaped roofs. 
• Lightweight: Foam roofing typically weighs around 50 lbs. per square, moreover it is ideal for aluminum suffice. 
• After polyurethane application, the solid surface is now high water resistant. Its high insulation reduces heat penetration which boosts the buildings overall. POLYUERTHANE is designed to provide a high performance.
  

03. Responsibilities

TERMS & DEFINITIONS
MR Management Representative
GM General Manager
PE Project engineer
PUR Purchase head department
PS Project supervisor.
MP Manpower

Management Representative (MR):

• Is responsible for the document and data control. 
• Maintain and control all the related records. Uncontrolled documents will not be updated.

General Manager (GM):

• Responsible for the approval. 
• Responsible for reviewing the documents before issuance.

Project engineer (PE): 

• Prepares/reviews the site requisitions and materials specification. And officially communicate with head of purchase order regarding materials orders.
• Ensures that material submittal schedule is followed.
• Ensure that equipment meet the requirements and availability of manpower.
• Follow up application sequence.
• Follow up any non-conformity might be arising and determine the corrective action. 

Purchase head department (PUR):

• Issue the LPO based on project specification that had been previously communicated.
• Recording delivery based on our purchasing procedures.

Project supervisor (PS):

• Assesses completion of required prior work, to ensure the surface preparation is done.
• Verify field measurements.
• Verify receiving the required materials according to the LPO.
• Reporting / recording any non-conformity that might exist.

Manpower (Mp): 

• Crews must be aware about scope of work generally, and about requirements, specification and procedure classification especially.
• Crews are ready to start work, in order to ensure that work begins only when they verify that conditions conform to the project quality requirements.
• Crews must be aware about safety rules.

04 Procedure:

General Requirements 

         Determine the sequence:

ROOF PREPERATION: 

• Electrical conductors and water pipes should be sealed properly.
• Water rain pipes should be in place at specific height 
• Parapet should be plastered to the required height.
• The threshold either for door or staircase, as well as dome holes should be in place and at specific height (in case of existing).
• All electrical conductors or other pipes might be existing in the middle of roof slab, should be passing through sleeves. These sleeves will support replacement procedures in case of further maintenance for these conductors are required.
• Roof slab is well cleaned from all dust or debris.

Safety advice

• Protective clothing, safety goggles and impermeable gloves must be worn while implementation.
• Splashes in the eyes, must be thoroughly rinsed with plenty of water, parts must be washed then with soap and water.
• Contaminated clothing must be changed daily bases.
• One of the consequences of non-observance of the safety advice could be allergic reactions.

Storage and delivery

Products must be protected from moisture. Can be kept for at least six months at 15~30℃ in hermetically sealed drums.
Products should not store for long periods at temperatures below 10℃, because it may be able to lead to an excessive increase in viscosity, particularly if moisture has access to the product.
Products must be receiving according to purchase procedure and in good conditions.

All raw materials must be received either in site or warehouse should be attached with certificate of analysis and take into consideration this procedures must be fallen with any each delivery in order to ensure that the expiry date is matching with our requirements of 6 months.
In case the received materials were expired we have to start goods return procedures and making official complaint to the concern supplier, and send supplier evaluation form. 


Determine criteria and methods required to ensure the effective operation and control of these processes by:

• Ensure the availability of information necessary to support the operation and monitoring of these processes 
• Measure, monitor and analyze these processes 
• Implement actions necessary to achieve the planned results and continual improvement:
  
  
  

To ensure the above points we should follow the below instruction:

• Install all materials in strict accordance with all published safety, weather, and temperature precautions given by the manufacturer.
• Foam normally shall not be applied when the measured roof deck temperature is below 50°F (10℃), or above 120°F (48℃).
• Foam shall not be applied when the relative humidity is above 85%.
• Foam shall not be applied when wind velocities exceed 12 miles per hour, as measured by a wind velometer, as well as wind direction.
• Application of spray foam shall not commence during inclement weather or when precipitation.
• Foam shall not be applied to any surface where visible moisture is present or, when tested with a moisture meter, registers a reading greater than ten percent. 
  

Process conditions clarifications:

Environment conditions

Pre preparations

• Conduct a pre-job assessment so that health and safety risks can be identified and managed. Special hot or cold working conditions.
• Review environmental conditions, (air and surface temperature, relative humidity, surface moisture, and wind speed) to ensure that they are appropriate for polyurethane foam application.
• Establish a safe work zone around the polyurethane foam application.
• Providing a safety tools like eye wash or cleansing wipes if tap water is not accessible at the jobsite. As well as mask to prevent breathing chemicals, vapors, and/or dust. Also other safety requirements should be available like gloves, head coverings, and foot protection.
• Use equipment that is clean and well maintained.
• Ensure that chemical drums, hoses, and other equipment are warmed up to the proper temperature before use, as per manufacturer guidelines. Ensure that proper equipment settings (e.g., pressure, temperature,) are used.
• Perform a small test spray and check foam quality after five minutes. Make any necessary equipment adjustments.

Handling breakdown:
The storekeeper and the management representative should maintain maintenance and calibration register weekly basis, this procedure must be communicated to all concern crews before spraying, to avoid any breakdown.

Paying high attention to the control panel unit that will prevent exceeding pressure and temperature more than safety limits, in this case the observer should start breakdown process and communicating with authorized person.


ALARMS procedure:

• Check the electrical supply connections
• Check the product pressure.
• Check the heater heating system.

To avoid breakdown there are many precaution must be taking into consideration:

• To prevent all possible bodily harm, all applicator must follow safety procedures through wearing gloves, protective goggles, and safety footwear and face masks. Use breathing equipment when working with the machine in enclosed spaces.
• Handling of the raw materials should be very carefully.
• Disconnect the unit from the power supply before carrying out any operation inside the electrical console.
• The electrical maintenance of the machine must only be performed by a qualified electrician.
• To avoid damage caused by the impact of pressurized fluids, maintenance work should not be performed on components until the pressure has been completely eliminated.
• The unit includes components that reach temperatures that are liable to cause burns. The hot parts of the unit must not be handled until they have cooled.
• Fire extinguisher must be available for any moments as well as the first kit aid. 

Application following up and inspection:
Generally, polyurethane insulation inspections follow a multi-step process with each step documented through observation, photography and commentary as follows:

• General observations and visual surface inspection
• Thickness testing
• Physical sampling by: Qualitative analyses and testing in the lab.

Visual Observations:
Visual observations are those that can be seen with the naked eye such as: 
Cracks and shrinkage:
Are characterized as cohesive failure, the approximate size and numbers must be recorded.

Surface Appearance
Surface texture will fall under one of the following labels:
1) Smooth
2) Orange Peel
3) Coarse Orange Peel
4) Verge of Popcorn
5) Popcorn
6) Tree bark

Numbers 5-6 are not acceptable. They must be removed.

• Gaps: are unintentional openings in the thermal envelope which may permit excessive heat transfer
• Mechanical Damage
  Any vandalism should be considered as a defect and must be reported immediately.
• Color: exposure to Ultra-violet radiation (such as from sunlight) causing a change and darken the surface, whereas the interior mass is not affected. Then the surface tends to turn an orange color. The surface typically becomes dusty and friable.
  As a result, UV rays affect the adhesion and losing the foam thickness.
  That means the polyurethane is not acceptable.

Thickness Testing
By taking thickness measurements at a variety of high and low locations. 
BY USING CALLIPER Physical sampling: by providing samples 10cm*10cm to be testing in the lab. 

PREPARATOY SITR INSPECTION 

TASK-READY INSPECTIONS

WORK IN PROCESS QUALITY INSPECTIONS

WORK TASK COMPLETION QUALITY INSPECTIONS

MARKING OF NONCONFORMANCES AND OBSERVATIONS

CONTROL THE CONTINUATION OF WORK

RECORDING OF NONCONFORMANCES

COPMLETION