Roofing contractors are always looking for ways to do their job more efficiently and to provide product choices that they feel improve the quality and durability of the installed roof. Asphalt felt underlayments, also referred to as “felt paper” or “tar paper,” have served the roofing industry well for decades. However, there have always been shortcomings with these products. As the monikers indicate, the most prevalent drawback of these products is that they are essentially paper saturated with asphalt. The organic paper core of these products is sensitive to changes in humidity and tears easily. Because the paper core isn’t 100 percent saturated, the paper can still absorb moisture, which can cause waviness when installed on the roof. Generally, the heavier the paper core, the more waviness potential. The other major drawback of these products is their propensity to tear easily. Tearing is a concern especially where it occurs around fasteners when the product is enduring foot traffic during roof covering installation. Tearing is also a major concern when it comes to the ability of the underlayment to remain in place during a high wind event, especially if the primary roof covering has blown off.
The above concerns were the primary drivers for the development of synthetic underlayments. Synthetic underlayments are designed to provide superior strength: resistance against both tensile (pulling) and tearing. However, the test standards for these products just hadn’t caught up to product development – until now.
Early synthetic underlayments were tested and qualified for use under ASTM Standards that were intended to be applied to asphalt-impregnated felt underlayments. For many years, the International Codes (IBC and IRC) and the Florida Building Code
have referenced ASTM D226, ASTM D4869 and ASTM D6757 – all standards that were intended to apply to asphaltic felt underlayments. The problem with that approach was that those standards are primarily composition driven. Since they were intended to be applied to asphaltic underlayments, there is very little testing that can be performed on synthetic underlayments. In fact, when a synthetic underlayment is tested under ASTM D226, for instance, the only tests that can be applied are the Unrolling, Breaking Strength and Pliability tests. Those that have installed underlayment know that those three tests alone demonstrate very little about a product’s suitability.
It didn’t take too long for the roofing industry to recognize the unsuitability of the existing felt standards for assessing synthetic underlayments. As a result, several synthetic underlayment manufacturers worked with the International Code Council Evaluation
Service (ICC-ES) to develop Acceptance Criteria for synthetic underlayments. Acceptance Criteria are similar to ASTM Standards, with a couple of distinct differences:
■ They are not consensus-based standards; the test requirements and conditions of acceptance are determined by the manufacturer and ICC-ES with very limited input from industry stakeholders.
■ The Acceptance Criteria cannot be referenced in the I-Codes as a Reference Standard.
Acceptance Criteria are deemed to be an alternative compliance path that applies to products for which the codes do not include prescriptive requirements. Additionally, they are limited to use exclusively for the purposes of obtaining an ICC-ES Evaluation Report. The two applicable Acceptance Criteria are:
■ AC 188 – Acceptance Criteria for Roof Underlayments
■ AC 207 – Acceptance Criteria for Polypropylene Roof Underlayments (limited to spun bond polypropylene underlayments)
After years of increasing numbers of synthetic underlayment products being introduced into the market, without a defined process for qualifying the underlayments, the roofing industry decided that it was finally time to develop a consensus standard for these products.
Over approximately an eight-year period, members of an ASTM Task Group worked to develop a standard that establishes appropriate and stringent performance requirements for synthetic underlayments. Task group members represent contractors,
roof consultants, product manufacturers, test labs, test equipment manufacturers and more. This diverse membership lends credibility to the process and the resulting standard.
The result of this hard work is ASTM D8257 – Standard Specification for Mechanically Attached Polymeric Roof Underlayment Used in Steep Slope Roofing. This standard establishes a high bar for synthetic underlayment performance and durability. It includes many test requirements that are unprecedented for underlayment standards. These tests include fastener pull-through, UV resistance and hydrostatic resistance among others.
To illustrate the benefits of synthetic products that are tested and approved in accordance with ASTM D8257, below is a table that compares the differences between the various felt-based ASTM Standards, the ICC-ES Acceptance Criteria and the new ASTM D8257 Standard.
The next step in this process is to propose inclusion of the new standard into the Florida Building Code. This work is currently underway and there are many industry stakeholders that are in support of this effort, including FRSA.
The underlayment technology available today provides a much more diverse array of products. Product innovation continues to improve existing products and provide an even wider variety of products to complete your next job.
Greg Keeler is the Technical Services Leader for Owens Corning Roofing and Asphalt, LLC. Greg has been with Owens Corning for 9 years and has 36 years of experience in architecture and spent 24 years as a building official. He serves on and chairs several task groups within ASTM D08, Committee on Roofing and Waterproofing, and the Asphalt Roofing Manufacturer’s Association. He also serves on the UL Standards Technical Panels for UL 790, UL 2218 and UL 580/1897 and on FRSA’s Codes Committee and Codes Subcommittee.
Previous Article
Next Article