Heraeus infra-red ensures polymer-polymer bonding in roofing manufacture

IKO designs, manufactures and installs roofing and waterproofing systems. It offers product solutions for flat and pitched roofing and DIY roofing mastic asphalt systems, as well as structural waterproofing and external protection systems for both commercial and residential projects. It is also a leader in the manufacture of roofing shingles and has a firm commitment to continued investment in new products and new manufacturing facilities.

A major product at Clay Cross is a range of single and multi-layered systems for flat roofing. Here, a first layer polymer material is joined with a textile base scrim and this assembly can then be completed with the addition of one or more further layers of polymer. The addition of additional polymer layers is carried out in a continuous process where the web of scrim-backed polymer, at speeds up to 10m/min, is brought into contact with a further polymer web on a drum. The surface of the scrim-backed polymer is heated to allow fusion to take place.

Heating is carried out by an infrared system contained in a specially constructed reflector which follows the curvature of the drum to ensure homogenous heat transfer. The infrared system uses six, 11kW fast response medium wave (FRMW) emitters and two 11kW carbon infrared (CIR) emitters. The CIR emitters ensure that all moisture is driven from the polymer while the shorter wavelength of the FRMW emitters is more penetrative.

The new system, designed and built by Heraeus, replaces a previous IR system, supplied by an Italian company, which had proved unreliable in operation. However, as Andrew McArthur, production engineer at IKO, points out, “ The retro-fit of the new system proved quite easy, even though we had little space for manoeuvre. And we are now obtaining more reliable and better quality polymer adhesion at this important stage of production.”

 Heraeus specialises in the production and application of high quality energy sources covering the electro-magnetic spectrum from ultraviolet to infrared. It has over 40 years experience in infrared technology and offers the expertise, products and systems to provide efficient and effective solutions to drying, heating and curing problems throughout industry.