Expert Case Study: Analysis of Roof Components at Condominiums

Page 1 of 4

SEARCH our site

Home Page | About Us | Download Brochure | Client List | WINNER - Blue Chip Award
Speak to a world-class expert now.
1-800-FOR-KKAI (1-800-367-5524)
info@kkai.com

Analysis of Roof Components at

Condominiums

pending PrimeTrack
Rapid Response

Consultant
DAD is a Metallurgical Engineer, Metallurgist, Corrosion Engineering
Consultant, Research Scientist, Component Corrosion Failure Consultant with
world-class expertise in corrosion performance of materials, metal fatigue,
failure analysis, high temperature corrosion, aqueous corrosion, corrosion

Expert Testimony Services

Patent Infringement Expert Services

CENTER FOR RAPID RESPONSE

ENGINEERING SOLUTIONS

Case Studies

find

proprietary and patent-

PrimeTrack Project Management

LITIGATION SUPPORT SERVICES

Resumes Only

Our innovative,

PrimeTrack Instant Conferencing

System (patent pending)

Search Entire Site

protection and control, physical, chemical, mechanical properties of metals

and alloys, cyclic deformation behavior, stress corrosion cracking, high
strength aluminum alloys, aircraft structural materials, and fatigue crack

capabilities can help you

quickly find the experts
you are looking for.
Search here to examine
any of the more than
500 resumes for KKAI
lead consultants and
associated experts from
our global organization.

initiation.
Simply enter the type of

Speak to this experienced, world-class expert now.

Forensic Investigation
In-Depth Failure Analysis

Call (317) 735-7221

Root Cause Determination

E-mail dad@rapid-response-consulting.com

expertise you seek, and

then choose to search
the entire Rapid
Response site, to just
read resumes only, or to
read any of KKAI's more
than 400 case studies. A

ENGINEERING AND SCIENTIFIC

For additional or different expertise, browse other top-level expert resumes

CONSULTING SERVICES

in Expert Testimony, Failure Analysis, Manufacturing Optimization,

organization, KKAI adds

KKAI's Center for Rapid Response Engineering Solutions and a host of

more than 20 expert

Manufacturing Optimization
Product & Systems Engineering
Commercial & Industrial
Construction Technology
Materials Technology
Medical Device & Life Science Technology
Military & Defense
Computer and Information Systems

other Engineering and Scientific Consulting services.

Learn how KKAI assembles expert teams of any size or skill set combination

EMPLOYMENT
KKAI HEADQUARTERS
Kevin Kennedy & Associates, Inc.
Rapid Response Engineering Solutions
3905 Vincennes Road, Suite 320
Indianapolis, Indiana 46268
(317) 536-7000 voice
(317) 536-7220 fax
info@kkai.com
Email Now for Rapid Response

resumes and 40 expert

case studies to its Web
site each month, so
check back often.

to meet our clients' needs on a rapid-response basis - no matter how

complex the challenge.
Or, peruse our 400 case studies or 500 other expert resumes.

CALL US TODAY
Call KKAI with an urgent
need. Experts are paged

Environmental, Meteorological & Resource

Technology

SITE MAP

rapidly growing

instantaneously and can

Search Entire Rapid-Response Site

Search Resumes Only
Case Studies

Search

be made available in a
virtual conference room.
To experience this
unique capability, please
call us at 1-800-FORKKAI (1-800-3675524) from the United

Background and Site Investigation

On 1 and 2 May 2002 this consultant visited a Condominium project to
inspect alleged corrosion problems on a section of roof, labeled CU-33 and

States or 317-5367000 if calling

internationally.

CU-34, on the roof plan diagram, dated 22 May 2002. This consultant was
informed that the roof was originally constructed in 1965, and that a
phenolic-containing roof system was installed in 1987-1988. As indicated in
the report, the roof insulation was 1.2" thick, mopped, with a four ply coal
tar membrane with organic felts, with a top pour and gravel. The metal form
was hot dipped galvanized carbon steel. A layer of light weight concrete
(LWC) was placed directly on the metal form, with phenolic foam placed on
top of the LWC. A bituminous material separated the phenolic foam from the
LWC.
The roof was initially inspected from within the living spaces in the ceiling of
a ballroom, in a closet adjacent to the ballroom, in a corridor between the
ballroom area and the no longer used kitchen area, and in the kitchen area.
Severe corrosion, including full penetration by corrosion reactions, was
identified in each of the areas inspected. The corrosion product was primarily
red in color (hematite), although there were several indications of black
corrosion product (magnetite) where the metal was in direct contact with the
LWC. Three samples of corrosion product were collected from inside the 1
building. These were labeled Samples 1, 2 and 3. Sample 1 was taken from
an area in the ceiling of the closet next to the ballroom. This area is under a
partially enclosed patio, and no phenolic foam had been applied over the
LWC. Sample 2 was taken from the ceiling of the ballroom in an area near a
roof drain. This sample was taken from an area of the roof where the
phenolic foam had been removed in 2001. It was also identified as an area
where a workman had partially fallen through the roof. Sample 3 was
collected from an area of roof near the parapet. These areas are identified on
the roof plan in the report of 22 May 2002.
The external roof sections were also examined, and two sections of roof were
removed. These were "sandwich" sections wherein the composite roof
consisting of the membrane, the foam, the LWC and the metal sections were
connected with roofing screws and a section approximately 2' by 2' were

http://www.rapid-response-consulting.com/article091107b.html

26/03/2009

Expert Case Study: Analysis of Roof Components at Condominiums

Page 2 of 4

connected with roofing screws and a section, approximately 2 by 2 were

cut, bagged and sent to this consultant's laboratory. Sample 4 was collected
from an area adjacent to the enclosed living space, near the flashing joining
the building to the roof. Sample 5 was a section of metal form and LWC
collected from approximately the middle of the roof area where the phenolic
foam had been removed in 2001. This sample was also forwarded to this
consultant's laboratory. This consultant's samples 1, 2 and 3 were handcarried back to thelaboratory.
Laboratory Investigation
Specimens from each of the components of the roofing system were
immersed in water for a period of 24 hours, after which the water samples
were measured for leachable chloride content and pH. The protocol for these
tests and the resultant pH and chloride concentrations are shown in the
following table:

Upon opening the bagged samples of 4 and 5, it was noted that a significant
amount of moisture had been released from the samples and the insides of
the plastic bags were coated with water. Additionally the LWC samples were
exceptionally heavy and friable for a product of this type. Accordingly, an
LWC sample from each of the "sandwiches" was weighed and exposed to a
drying furnace at 150 degrees F for 24 hours. After the exposure the
samples were re-weighed with the following results:

Samples of each of the corroded area and associated roof components were
sent to Quantitative Technologies, Inc. (QTI) for a determination of formate
and sulfonate concentrations. The samples that were provided to QTI
included: (a) corrosion product samples from areas 1, 2, 3, 4 and 5, (b) a
sample of LWC from area 1, which was under the patio (inside the closet),
where no phenolic had been installed, (c) samples of the tops of the LWC at
areas 4 and 5, and (c) samples from the bottoms of the LWC at areas 4 and
5. The results of those analyses are appended to this report. To summarize
those results, no detectable formate or sulfonate was identified in any
sample except for the corrosion sample at area 2, where a workman had
partially fallen through the roof. Even in this area the formate level was at
only 202 ppm, judged to be a trace amount.
Discussion and Conclusions
It is obvious that the corrosion problems observed in the roof of the
Condominium project are not related to the chemical composition of the
phenolic foam that had been used for insulating purposes. Having examined
dozens of roofs where phenolic foam did play a role in accelerating corrosion
reactions, the damage to the roof bears none of the similarities observed in
previous studies. When phenolic foams are associated with corrosion
processes, formate is always observed in the corrosion product. Sulfonate is
observed when the roofing system has been exposed to significant amounts
of liquid phase water, and the phenolic foam is in direct contact with the
metal form. With the exception of one sample, none of the corrosion product
samples, or the light weight concrete samples showed measurable
indications of formate, and none of the samples showed any measurable
indications of sulfonate (note that the detectable limit is less than 50 ppm).
The one sample of corrosion product that showed trace amounts of formate
was in an area where a workman had penetrated the roof, and where the
phenolic foam had been removed prior to this inspection. The disturbance of
the roofing system, both by damage caused by the roof penetration, and by
the high probability that removal of the phenolic foam contaminated the
underlying roof and corrosion product with trace amounts of formate,
explains the presence of the formate. It should be noted that, in prior
investigations, corrosion induced by phenolic foams resulted in thousands of

http://www.rapid-response-consulting.com/article091107b.html

26/03/2009

Expert Case Study: Analysis of Roof Components at Condominiums

Page 3 of 4

parts per million formate in the corrosion product, in contrast to the 202 ppm
reported here. Even 3 the upper surfaces of LWC, closest to the phenolic
foam, were devoid of either formate or sulfonate, in each of the areas
examined, including where the roof had been damaged.
The observation that the LWC was virtually saturated with water explains the
corrosion damage to the metal form. It is likely that the LWC has been wet
for a considerable period of time, and that conventional corrosion by aerated
water is the cause of penetration of the metal form. Once the LWC was
saturated, the construction of the roof inhibited drying out of the materials,
causing it to act as a wet poultice against the steel metal form, in much the
same manner as a sponge retains water. It is significant that the pH of the
LWC was well below that expected for cementitious products (11 and 7
respectively). Cementitious products based on portland cement usually have
pH values higher than 12-13. These results indicate that the soluble
hydroxides usually found in these products have either oxidized by the
aerated water, or have leached out of the LWC, causing the product to
approach a neutral pH. Either of these possibilities takes a considerable
amount of time. The levels of chloride observed in the LWC are nominal, and
to be expected for a seacoast environment. Note that no chloride was
detected in the corrosion product, indicating that chloride is not a factor in
the corrosion of this metal form. While galvanizing can protect steel from
corrosion, by acting as a sacrificial material, its does so by preferentially
corroding the zinc. When the thin galvanizing layer is compromised,
corrosion of the steel metal form occurs.
To conclude, there is no evidence whatever that the phenolic foam played
any role in the corrosion damage observed in the metal form.
Read other articles by this KKAI Associate:
Water Leaks (Weeping) Staining Investigation
Materials Review for Seawater Cooled Heat Exchangers
Metallurgical Engineer, Metallurgist, Corrosion Engineering
Consultant, Research Scientist, Component Corrosion Failure
Consultant, corrosion performance of materials, metal fatigue,
failure analysis, high temperature corrosion, aqueous corrosion,
corrosion protection and control, physical, chemical, mechanical
properties of metals and alloys, cyclic deformation behavior, stress
corrosion cracking, high strength aluminum alloys, aircraft structural
materials, and fatigue crack initiation.
Resume of JUN
Resume of RMI
Resume of TEY
Resume of SVC

nuclear power steam corrosion, expert consultant

high temperature materials performance, expert
consultant
metallurgist, component corrosion failure expert
consultant
component corrosion failure expert consultant

To search for specific expertise, enter your search query (type of expertise
you are seeking) in the box below, choose to search the entire RapidResponse site or just resumes and brochures, then click the search button.
Please note that the list of resumes available online is a select subset of our
vast database. If your search of our site does not reveal the expertise you
are seeking, please call us toll-free (in the U.S.) at 1-800-367-5524 or
contact us for more information and we will gladly assist you in locating
the specific expertise you require.

Search Entire Rapid-Response Site

Search Resumes Only
Case Studies

Search

Have an urgent litigation support or engineering and scientific consulting

need? Contact KKAI now for world-class, expert rapid response.
1-800-FOR-KKAI (1-800-367-5524)
info@kkai.com
BACK TO THE TOP OF THIS PAGE
Kevin Kennedy & Associates, Inc.
Rapid Response Engineering Solutions
3905 Vincennes Road, Suite 320

http://www.rapid-response-consulting.com/article091107b.html

26/03/2009

Expert Case Study: Analysis of Roof Components at Condominiums

Page 4 of 4

Indianapolis, Indiana 46268

(317) 536-7000 voice
(317) 536-7220 fax

http://www.rapid-response-consulting.com/article091107b.html

26/03/2009