In flat roofing, safety begins at the point of design. Under the Construction (Design and Management) Regulations 2015 (CDM), designers and clients have a responsibility to reduce the risks operatives face during installation. Advances in roofing materials and systems are making it possible to limit or eliminate hot works, improving safety without compromising performance.
Torch-on bituminous systems have been a prominent component of flat roof construction for decades. Their reliability and longevity are widely recognised and, for many contractors, using a gas torch has been as routine as reaching for a trowel or roller. However, with each open flame comes risk; to operatives, the building itself and the client’s investment. Rising insurance premiums and tighter safety expectations are prompting a shift towards systems that retain the performance benefits of traditional membranes while limiting the hazards of torch-applied methods.
STRIKING OUT DANGER
Flame-free roofing systems address risk at source, removing the need for hot works controls or permits. By specifying materials that don’t require torches, designers eliminate one of the most common ignition sources before work begins. This proactive approach allows contractors to focus on quality and consistency, confident that a significant hazard has already been removed.
Building owners, contractors and specifiers understand the true value of this approach. Fires caused by hot works can have severe consequences, including injury, extensive repairs and, in some cases, irreparable damage to a building’s contents. Specifying a system that removes this hazard protects both people and assets, while supporting the client’s brand integrity and providing reassurance to insurers.
PUTTING FLAMES IN THE PAST
The NFRC’s Safe2Torch campaign highlights the risks of hot works and encourages designers and contractors to remove fire hazards. Recent guidance updates elaborate on the need to remove the risk of fire at design stage and the importance of risk assessment based on site conditions and high-risk areas, such as near combustible upstands or timber substrates. This makes it clear that many roofing accidents could be prevented through improved specification and awareness, and that where a fire risk is identified, or cannot be ruled out, specifications should default to safer flame-free approaches.
BMI Icopal’s TorchSafe TA system expands on this concept, applying the flame-free approach across the entire roof field area. Every layer, from the vapour control to the cap sheet, is either self-adhered or bonded with cold-applied adhesives, eliminating the need for torches entirely.
At the heart of this system is the Pyrobar Underlay, a bituminous membrane with a coated upper surface designed for adhesive bonding. Combined with Icopal SA Primer and insulation adhesive, it enables a complete, flame-free, multilayer bituminous system that retains the robustness, flexibility and waterproofing performance traditionally associated with torch-applied systems.
There are also practical and commercial benefits. Traditional torch-applied systems require a fire watch at the end of each working period to monitor for any signs of smouldering or ignition, adding time and cost to projects. Torch-free systems eliminate this, reducing associated costs.
DURABILITY MEETS SAFETY
As important as safety is on site, it cannot come at the expense of durability. Flat roofs must withstand UV exposure, water and occasional foot traffic for decades. Torch-applied systems have set the benchmark for longevity, so it’s critical that alternatives meet the same standards. Advances in self-adhesive and cold-bonding bitumen membranes now ensure that these expectations are fully met. The TorchSafe TA system has a guarantee of up to 25 years, is supported by BBA certification, and offers the thickness and resilience of traditional multi-layer systems.
Innovations in roofing now means safety, performance and confidence go hand-in-hand. By specifying systems that remove the need for hot works, designers can address risk earlier in the project, while maintaining the durability and resilience that flat roofs demand. For installers, it provides a safer way to work without sacrificing build quality, and for main contractors and clients, reassurance that the building is protected from the outset. The result is better outcomes across the board, with roofing systems that protect both the people working on them and the long-term performance of the building.
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