High performance precision solution to thermal

insulation and water drainage on flat roofs.

 The XtraFall Taper System provides the designer and contractor
with a precise, technically excellent solution to providing thermal
insulation and bespoke drainage on flat roofing that avoids water
retention and consequent damage in traditional flat roofs.

Features
• Highest Performance Rigid PIR Insulation
• Practical Solution: flat roof insulation and drainage in a Single
System
• A cost effective solution to creating drainage falls with excellent
U-values
• Factory bonded components manufactured to precision
tolerances
• Factory made quality assured single component system
• Quality Assurance of mechanical properties of component
bonding
• Pre-mitred, hips, valleys and extensive range of accessory
pieces
• Rigid, lightweight material accepting maintenance traffic
• Suitable for new and existing flat roofs
• Non-deleterious Material Manufactured without the use of
CFC’s/HCFC’s
• Zero ODP and Low GWP
• Potential Green Guide Rating A

2
 Icopal XtraFall

Total flat roof insulation

solutions
including the XtraFall range of tapered systems.

Icopal offer a comprehensive range of high performance PIR Flat

Roof insulation boards includeing the XtraFall range of tapered
insulation, providing comprehensive solutions for all flat roof
projects whatever the choice of Icopal waterproofing system, with
the highest environmental scoring within the ’BRE Green Guide’
and is available with Factory Mutual accreditation. Our extensive
range of high performance PIR foam insulation products with
unique performance characteristics has been engineered to meet
any project specification.

The XtraFall system is supported by a range of ancillary products,

designed to ensure continuous thermal insulation and complete
roof drainage. These products are exclusive to the XtraFall system.

Thermazone Foilboard Thermazone Torch On Thermazone Roofboard

Tapered Insulation for Mechanically Fixed Tapered Insulation for Partially Bonded Tapered Insulation for Bonded Single Ply,
Systems Torch On Systems Partially Bonded, Pour & Roll and Heat
Activated Systems.

Aluminium faced rigid PIR Bituminous faced rigid PIR Mineral glass tissue faced rigid PIR

Thermal Conductivity 0.022 W/mK Thermal Conductivity as Low Thermal Conductivity as Low
as 0.024 W/mK as 0.024 W/mK
LPC/FM Approved

3
 Survey and
Design Service
Icopal offer a free no obligation in-house design service for clients
looking to specify an Icopal flat roof system incorporating XtraFall
insulation.
Our area technical managers are trained to survey roof areas using
the latest and most accurate equipment available, including digital
inclinometers and laser levels.
Xtra-mitre boards are placed in the appropriate location on the
roof, then the XtraFall Tapered Insulation boards are placed to suit.
The XtraFall boards are laid away from the Xtra-mitre boards as
dictated by the XtraFall Layout drawing and the topography of the
roof. Xtra-mitre boards and XtraFall boards are always used in
conjunction with roof insulation layout drawings.

It should be noted that correct on-site setting out of the laying

pattern, of XtraFall boards, is essential to quick and efficient
placing of the insulation. The roofing contractor must ensure that
the information/drawing provided is relevant to the on-site works.

Cut to falls designs are produced by our tapered insulation design

team and can be tailored to the requirements of any project.
U-Value calculations and condensation risk analysis calculations
are available on request.

Insured guarantees are available for Icopal flat roof systems

incorporating XtraFall tapered insulation. For further details on
this please contact Icopal Technical Services.

Mitres
Hip/Valley Boards
Xtra-mitre Hip / Valley boards are prefabricated composite falls PIR
tapered insulation boards. Xtra-mitre boards are an integral part
of the XtraFall tapered roof insulation system. The construction of
the Xtra-mitre board is faced PIR insulation with in-built composite
falls. Xtra-mitre boards are made to suit the full range of XtraFall
board thicknesses. Mitred board size 1200 x 1200.

XtraFall system of tapered insulation boards, which due to 1/60 XtraFall board sections

graduated thicknesses, will cause positive drainage falls on flat

roofs. Xtra-mitres are prefabricated to allow changes in direction of
drainage falls, without on-site cutting of XtraFall insulation boards, 1/80 XtraFall board sections
with the associated labour and waste costs. Each Xtra-mitre board
is clearly identified by board type and the direction of fall.

4
 Icopal XtraFall

Drainage Design

Sump

Preformed crickets

Valley Board

Ridge Board

Features
• Creates multi-directional falls
• Exact dimensions
• Clear board identification
• Easily installed
• Suitable for all roof Specs
Benefits
• Good roof drainage
• Quick board laying
• Reduced on-site cutting
• Lower labour costs
• Versatile systems

5
 Foil Board
Tapered Insulation for Mechanically Fixed Systems

Thermazone Foil Board is a high performance Polyisocyanurate flat roof insulation with vapour-tight aluminium foil facings suitable for
use with Icopal single ply systems. Thermazone Foil Board is available in flat or tapered variants.

Thermazone Foil Board Roof Application

High Thermal Performance

Thermal Conductivity as low as 0.022W/mK 15/5253

Compatible with Icopal mechanically fixed single ply systems.

Loose laid ballasted systems

XtraFall Foil Board Sheet Sizes (mm) Typical R-values Maximum Span

Thickness R-value Thickness Trough Openings

Size (mm) (m2K/W) (mm) (mm)
1200 x 1200 80 3.63 25 ≤ 75
90 4.09 30 76-100
Thicknesses 100 4.54 35 101-125
1/60 30-410mm 110 5.00 40 126-150
Thicknesses 120 5.45 45 151-175
1/80 30-315mm 130 5.90 50 176-200
140 6.36
Thermazone Foil Board insulation boards laid over metal decks should
be in accordance with BS 4841: Part 3.

XtraFall Foil Board Tapered System

1/60 XtraFall board sections 1/80 XtraFall board sections

6
 Icopal XtraFall

Product Specification

Design Roof Loads

XtraFall Foil Board high performance PIR roof insulation,
manufactured to EN ISO 13165 and EN ISO 9001 2008 Quality
Management. For use as a tapered to falls roofing insulation board.
Waterproofing Membranes
XtraFall foil boards are for use with mechnically fixed single
ply waterproofing membranes. Thermazone foil boards are not
suitable for use with built up bitumen based roofing or mastic
asphalt systems.
XtraFall Insulation Installation
Thermazone foil board must be mechanically fixed in accordance
with the Icopal fixing calculation for the project.
XtraFall is designed for roofs with limited access subject to
pedestrian traffic for maintenance only, for roofs with regular
maintenance the designer should consider the provision of
walkways. Special provision for the roof top installation of
equipment/machinery will be necessary.
Fire Performance
The fire rating of any roof containing XtraFall product when tested
to BS 476 Part 3 will depend on the type of deck and the nature
of the waterproofing covering. Please contact Icopal Technical
Services for guidance.

Boards to be laid in accordance with the XtraFall Insulation layout

drawing. During laying, water must not ingress under the insulation
layer. Typical Physical Characteristics
Property Units
Day/night seals must be used during all interruptions to works. 3
Density (Foam Core) 32kg/m
Careful attention to roof details and setting out of laying pattern of
Compressive Strength >150kPa @ 10%Compression
XtraFall is required.
Water Vapour Resistivity >100MNs/gm
Thermal Conductivity 0.022 W/mK
XtraFall is designed to be installed by a competent contractor,
experienced with this type of product. Boards that have been
damaged or allowed to get wet should not be used.

Quality Management Systems

Environmental Management

7
 Roof Board
Tapered insulation for bonded single ply, partially bonded pour and roll and
heat activated systems.
Thermazone Roof Board is a high performance Polyisocyanurate insulation board with mineral coated glass facers suitable for use below
single ply , partially bonded pour and roll and heat activated fully adhered roof membranes, single ply waterproofing systems and
partially bonded built-up felt. Thermazone Roof Board is available in flat or tapered variants.

Thermazone Roof Board Roof Application

High Thermal Performance

15/5253
Thermal Conductivity as low as 0.024W/mK

Compatible with Icopal Adhesively Bonded

Single Ply Roofing Membranes and Partially Bonded
Bituminous Membranes

LPC/FM Approved

XtraFall Roof Board Sheet Sizes (mm) Typical R-values Maximum Span

Thickness R-value Thickness Trough Openings

Size (mm) (m2K/W) (mm) (mm)
1200 x 1200 80 3.20 25 ≤ 75
90 3.60 30 76-100
Thickness 100 4.00 35 101-125
1/60 30-410mm 120 5.00 40 126-150
Thickness 140 5.83 45 151-175
1/80 30-315mm 50 176-200

Thermazone Roof Board insulation boards laid over metal decks should
be in accordance with BS 4841: Part 3.

XtraFall Roof Board Tapered System

1/60 XtraFall board sections 1/80 XtraFall board sections

8
 Icopal XtraFall

Product Specification

Design Fixing
XtraFall Roof Board high performance PIR roof insulation, Insulation can be bonded /adhered or mechanically fixed to the
manufactured to EN ISO 13165 and EN ISO 9001 2008 Quality substrate. The location/quantity of fixings to be in accordance with
Management. For use as a tapered to falls roofing insulation board. the Icopal fixing calculation.

Waterproofing Membranes Roof Loads

XtraFall Roof Board Mineral-Glass tissue facings is a standard
product. Designed for use with partially bonded pour and roll, Icopal
T.A. and bonded single ply systems.
XtraFall Insulation Installation
Thermazone Roof Board must be bonded to VCL or mechanically
fixed in accordance with the Icopal project fixing calculation. Boards
to be laid in accordance with the XtraFall insulation layout drawing.
During laying, water must not ingress under the insulation layer.
Day/night seals must be used during all interruptions to works.
Careful attention to roof details and setting out of laying pattern of
XtraFall is required.
XtraFall is designed for roofs with limited access subject to
pedestrian traffic for maintenance only, for roofs with regular
maintenance the designer should consider the provision of
walkways. Special provision for the roof top installation of
equipment/machinery will be necessary.
Fire Performance
The fire rating of any roof containing XtraFall product when tested
to BS 476 Part 3 will depend on the type of deck and the nature
of the waterproofing covering. Please contact Icopal Technical
Services for guidance..

XtraFall is designed to be installed by a competent contractor, who

Typical Physical Characteristics
is experienced with this type of product. Boards that have been
damaged or allowed to get wet should never be used. Property Units
3
Density (Foam Core) 32kg/m
Compressive Strength >150kPa @ 10% Compression
Water Vapour Resistivity >100MNs/gm
Thermal Conductivity 0.024 - 0.026 W/mK

Quality Management Systems

Environmental Management

9
 Torch On
Tapered insulation for partially bonded torch on systems

Thermazone XtraFall Torch On is faced with a polypropylene fleece finished bitumen/glass fibre
working surface and a mineral glass facing to the under side.
Thermazone XtraFall Torch On is available in flat or tapered variants.

Thermazone Torch On Roof Application

High Thermal Performance

15/5253

Thermal Conductivity as low as 0.024W/mK

Compatible with Icopal torch applied partially bonded

bituminous based roofing systems

XtraFall Torch On Sheet Sizes (mm) Typical R-values Maximum Span

Thickness R-value Thickness Trough Openings

Size (mm) (m2K/W) (mm) (mm)
1200 x 1200 80 3.20 25 ≤ 75
Thicknesses 90 3.60 30 76-100
1/60 30-410mm 100 4.00 40 101-150
Thicknesses 120 5.00 50 151-200
1/80 30-315mm 140 5.83

Thermazone Torch On insulation boards laid over metal decks should

be in accordance with BS 4841: Part 3.

XtraFall Torch On Tapered System

1/60 XtraFall board sections 1/80 XtraFall board sections

10
 Icopal XtraFall

Product Specification

Design Fixing
XtraFall Torch On high performance PIR roof insulation, Insulation can be bonded /adhered or mechanically fixed to the
manufactured to EN ISO 13165 and EN ISO 9001 2008 Quality substrate.
Management. For use as a tapered to falls roofing insulation The location/quanitity of fixings to be in accordance with the
board. Icopal project fixing calculation.

Waterproofing Membranes Roof Loads

XtraFall Torch On Bitumen/mineral-Glass tissue facings is a XtraFall is designed for roofs with limited access subject to
standard product. Designed for use with Icopal partially bonded pedestrian traffic for maintenance only, for roofs with regular
torch on systems. maintenance the designer should consider the provision of
walkways. Special provision for the roof top installation of
XtraFall Insulation Installation equipment / machinery will be necessary.
Thermazone Torch On must be bonded to VCL or mechanically
fixed in accordance with the Icopal project fixing calculation. Fire Performance
Boards to be laid in accordance with the XtraFall insulation The fire rating of any roof containing XtraFall product when tested
layout drawing. During laying, water must not ingress under the to BS 476 Part 3 will depend on the type of deck and the nature
insulation layer. of the waterproofing covering. Please contact Icopal Technical
services for guidance.
Day/night seals must be used during all interruptions to works.
Typical Physical Characteristics
Careful attention to roof details and setting out of laying pattern
Property Units
of XtraFall is required.
3
Density (Foam Core) 32kg/m
Compressive Strength >150kPa @ 10% Compression
XtraFall is designed to be installed by a competent contractor, Water Vapour Resistivity >100MNs/gm
who is experienced with this type of product. Boards that have Thermal Conductivity* 0.024 - 0.026 W/mK

been damaged or allowed to get wet should never be used.

Quality Management Systems

Environmental Management

11
 Preformed Crickets
XtraCrickets Provide an efficient tool for the management of rainwater drainage on roofs, the pre-cut pyramidal piece allows for
directional drainage towards outlets in new or exisiting roofs where ponding may occur.

Definitions Features
XtraCrickets are constructed of modular tapered PIR insulation Multiple applications
panels, which solve localised drainage issues on roofs. Layout drawings
XtraCrickets provide drainage slopes to either direct rainwater Ease of installation
to a specific area such as RWOs or direct rainwater away from
obstructions to drainage such as roof lights and lift shafts.

XtraCrickets are a pre-engineered to customer requirements, they

are quickly and easily installed on top of the base roof insulation.
The XtraCricket system is designed to integrate with XtraFall
tapered insulation designs. The modular system facilitates simple
specifier/customer instruction and ordering. Quick and easy
installation on-site is supported by a layout drawings and each
module is clearly identified.
XtraCrickets can be made to suit most applications. The modular
construction allows for adjustment of length and width to suit
all roof types and applications. The on-site combination of roof
rainwater outlets and roof slope variations requires a flexible and
creative design approach. XtraCrickets meet this requirement. The
customer needs to advise only the roof slope and the distance
over which the XtraCricket is needed, our design team will do the
rest.
XtraCrickets are suitable for use with all roof insulations and
waterproofings. XtraCrickets design, as with all tapered insulation
systems, requires certain criteria, to ensure that correct drainage
falls are achieved. The drainage fall along the leading edge of the
XtraCricket is a function of the fall on the roof and the angle of
slope of the cricket. The greater the fall on the roof the lesser the
angle of slope requirement.
Whilst there is a convention that the slope / taper of the cricket
is twice the slope of the roof, increasing the taper or fall of the
XtraCricket will not enhance the ability of the XtraCricket to
assist roof drainage. So the less the fall in the roof, the wider the
XtraCricket. The critical factor is the degree of drainage fall on the
XtraCricket valley slope. This is why each unique roof slope should
have its own unique length to width ratio.

XtraCrickets can be made to suit most applications.

Lengths up to 2.40m are readily available. Larger XtraCrickets
can be made to order.

1/4 Diamond XtraCricket 1/4 Diamond

1/2 Diamond
XtraCricket
XtraCricket 1/2
1/4 Diamond
Diamond
Full Diamond
XtraCricket
XtraCricket
XtraCricket 1/2Full
Diamond
Diamond
XtraCricket
XtraCricket Full Diamond XtraCricket

12
 Icopal XtraFall

Sumps
Prefabricated insulated rainwater outlet sumps are available that can be adjusted to suit 4, 3 or 2 sided outlets. The pre-formed PIR
insulation tapers in thickness, from 50 to 30mm in 600 x 600mm modular panels. The sump can be placed at the RWO location, on the
roof deck or it can be laid directly on top of a base layer of insulation to give the appropriate insulation thickness.

Section A-A
Features
Suitable for use with RoofGard outlet range
A Assists drainage
Centred Sump Corner Sump Edge Sump
Continuous thermal insulation

Benefits
Roof Surface Slope
XtraCricket Valley Slope
No on-site cutting
n A-A
Quick installation
XtraCricket Angel
Labour saving
Torch on facing shown. Also available in Foil and Roof Board
Corner Sump Edge Sump

XtraCricket Parrell Slope

e
XtraCricket Valley Slope

Fillet
XtraCricket Parrell Slope

An insulated angle fillet, suitable for all applications where acute angle directional changes are required by bituminous roof
membranes, to avoid stress-nodes. Each fillet is 1200 long and 50mm in vertical depth. The facing of bituminous glass tissue allows
perfect bonding to the waterproof membrane.

Features
Torch on facing shown. Also available in Foil and Roof Board
Easily handled / fitted
Fits irregular gussets

Benefits
Cost effective
Labour saving

13
 Icopal Secure 5-Step Process
1. Consultation and Site Survey
We understand that each project is different and it is vital for us to understand your requirements
and expectations right from the outset. Refurbishment projects start with a comprehensive site
survey including detailed analysis of the existing roof build up and condition. This information is
critical to the correct specification and products being recommended.

Consultation Surveys
Our experienced team of Area Technical Managers are on hand to Surveys include a full roof condition report including where
offer professional advice on all aspects of your project including: appropriate:
• The appropriate design for roof build up and building use. • Roof measure & layout
• R  ecommendation of the correct waterproofing system & • Roof falls & drainage items
associated products such as drainage and daylighting. • Rooflight replacement program
• Interface detailing • Core samples to assess existing condition and roof build up.
• S  ystem performance and guarantee expectations • Moisture probe analysis
• E  nvironmental impact • Photographic records
• B  udget costing • Detailed assessment of roof failure mode and remedial options.
• P  lanned maintenance schedules • Roof details and interfaces.
• D  rawings and calculations • Thermographic imaging where appropriate.
• R  egular feedback and project updates

• S
 ite specific issues such as Occupancy, Schedules and Liaison.

2. Design and Specification

We provide a full design service including specifications, drawings and calculations, prepared in line
with the Building Regulations and Codes of Practice. The quality of our products and comprehensive
guarantees safeguard your project while our extensive knowledge and expertise means we can
advise you on the correct system for your project. As a multi material supplier we can specify the
most appropriate solution without bias, ensuring that it is the best fit for your specific project
requirements.

Design
• P roject Specific detail drawings showing critical elements such
as interfaces and terminations.
• W ind Uplift calculations in line with BS EN 1991-1-4/NA:2008.
• Insulation Drainage: Our in house design team will prepare
tapered insulation designs for effective roof drainage and
thermal values in compliance with BS EN ISO 6946 Annex C.
• U -Value & Condensation risk analysis. Icopal will recommend
a solution to combat any potential threat of interstitial
condensation.
• Vapour Control & Airtightness. We supply a wide range of
Vapour Control Layers & sealants to ensure the correct level of
protection for your project.
Specification
• T he sooner we can become involved in your project, the more
effective we can be in helping you to achieve your expected
outcomes of performance and cost.
• A fully detailed specification package is prepared based upon
your project criteria and our detailed analysis and submitted
for your consideration in either long form using Specmaster or
short form NBS format.

14
 Icopal XtraFall

3. Installation
Our approved specialist contractors carry out all installations and ensure that from the outset,
work is completed efficiently and to specific qualitative standards. All our accredited contractors
have undergone comprehensive and specific training at one of Icopal’s training centres. The
installation process includes a pre-commencement briefing with your contractor, a full overview
of the specific requirements and features of the roof detailing. Icopal can even arrange for unique
mock-up structures of key detailing elements to be created so that all involved can rehearse and
prepare beforehand.

4. Site Support and Project Monitoring

Our site technicians are regularly on site to closely monitor progress and ensure the project runs
smoothly, focusing on any potential drift from specification, quality of workmanship and aesthetic
condition. Through their expertise and practical approach they offer technical advice and support
throughout the project and beyond, with detailed site reports issued following each visit and a final
inspection to confirm your satisfaction and sign-off.

5. System Guarantee
Our guarantees are comprehensive and industry leading. We support our systems with single point
responsibility covering product, workmanship, design and consequential damage. We carry annual
product guarantee insurance which is arranged with first class security in the London Insurance
Market and are the only waterproofing manufacturer regulated by the Financial Conduct Authority
(FCA). This is our confirmation that we operate with integrity and provide the financial strength
of a global market leader. Most importantly that we have our customers best interests at heart.

E
CUR
SE

15
Icopal Ltd
Barton Dock Road
Stretford
Manchester
United Kingdom
M32 0YL

Tel: +44 (0) 161 865 4444

Fax: +44 (0) 161 864 2616
info.uk@icopal.com
www.icopal.co.uk

ICO3218
June 2016
Issue 01