Project Description
Continental Mabor is one of northern Portugal’s key industrial manufacturing sites. At a facility of this scale, effective roof waterproofing is essential to protect operational areas, minimise the risk of water ingress and support uninterrupted production. Roof joints, pipes, ducts and other penetrations are particularly critical, as they bring together different materials, geometries and movement conditions that must be sealed correctly to maintain long-term weatherproofing performance.
The project involved three distinct roof waterproofing applications:
- Sealing a joint between PVC and TPO substrates
- Sealing circular pipe and duct penetrations through metal roofing
- Waterproofing complex rectangular roof penetrations
Each detail required a system suited to its substrates, geometry, dimensions and exposure conditions. Effisus supported the project with technical assessment, product selection, practical validation and application training.
Three complementary Effisus systems were selected:
- Effisus Easyrepair for the PVC and TPO joint.
- Effisus Stopper MR in its black, standard-temperature version for circular roof penetrations.
- Effisus Bond FT as the main waterproofing system for complex rectangular penetrations, with Effisus 2Bond DS providing additional local protection.
The project shows how application-specific waterproofing systems, supported by practical technical guidance, can simplify installation and deliver reliable results in a demanding industrial environment.
Project Challenges
Sealing a Joint Between PVC and TPO
One part of the project involved sealing a construction joint between PVC and TPO. As the two materials have different adhesion characteristics, the selected system needed to bond effectively to both surfaces while creating a continuous, flexible and watertight seal. Effisus assessed the actual site conditions and carried out practical adhesion validation before the solution was applied more widely.
The system needed to:
- Adhere reliably to both PVC and TPO
- Reinforce the watertightness of the joint
- Remain flexible after installation
- Be practical and efficient to apply on site
- Support the long-term durability of the completed waterproofing detail
Sealing circular pipes and ducts through the metal roof
A second application involved circular pipes and ducts passing through metal roofing. To identify the most appropriate solution, Effisus reviewed the requirements for each penetration, including:
- The diameter of each pipe or duct
- The penetration and roof configuration
- Potential exposure to elevated temperatures
- Whether the penetration was connected to heat-generating equipment
- The number and dimensions of the required sealing collars
The penetrations were operating under standard temperature conditions. The challenge was therefore to provide a practical, accurately sized solution for circular openings while maintaining reliable weatherproofing performance.
Waterproofing complex rectangular roof penetrations
The project also included rectangular roof penetrations with more complex geometries than the circular pipe and duct openings. Corners, changes in direction and transitions between horizontal and vertical surfaces required a flexible system that could be formed around the complete penetration while maintaining a continuous watertight seal. Local sharp edges were also considered within the detailing, but the principal requirement was to adapt the waterproofing system to the rectangular geometry and apply it in a controlled sequence.
Effisus Solutions
Effisus Easyrepair Tape for PVC and TPO Joint Sealing
Effisus proposed Effisus Easyrepair Tape for the joint between the PVC and TPO substrates.
Practical validation confirmed effective adhesion to both materials under the actual site conditions. This was particularly important because the waterproofing detail had to remain continuous across two surfaces with different characteristics.
Effisus Easyrepair Tape created a flexible sealing layer designed to restore and reinforce the watertightness of the joint. By bonding across both PVC and TPO, the system established a continuous waterproof seal at the mixed-material interface.
Effisus Stopper MR for Metal Roof Penetrations
For the circular pipes and ducts, Effisus selected the black, standard-temperature version of Effisus Stopper MR after confirming the penetration dimensions and exposure conditions.
Effisus Stopper MR is a prefabricated system specifically suited to circular penetrations through metal roofs and cladding. Its flexible collar can be cut to the required diameter, formed around the pipe or duct and mechanically fixed as part of the complete sealing detail.
Stopper MR offers a practical approach for circular openings. In this application, it helped significantly reduce sheet-metal waste and the need for specialised sheet-metal labour.
Practical training was arranged for the application team and covered:
- Surface cleaning and preparation
- Selection of the correct collar size
- Cutting the collar to the required diameter
- Positioning the system around the circular penetration
- Installation and mechanical fixing with screws
- Organisation of the collars according to their dimensions
- Final application checks
The hands-on demonstration gave the applicators a clear understanding of the complete process and the importance of accurate sizing, careful preparation and secure mechanical fixing.
Effisus Bond FT for complex rectangular roof penetrations
For the rectangular roof penetrations, Effisus proposed Effisus Bond FT as the main waterproofing system. Its flexibility allowed the membrane to follow the more demanding geometry of the penetration, including corners, changes in direction and the transitions between the roof and the vertical surfaces. Following the initial site assessment, Effisus prepared a technical submittal documenting the recommended products and installation sequence.
Effisus 2Bond DS was applied locally as an additional protective layer where required, including over sharp edges, before the Bond FT membrane was installed. Its role was to support and protect the main Bond FT system rather than act as the primary waterproofing solution.
The Effisus Team Approach
Effisus worked closely with the project teams to assess each roof detail and select the most suitable system based on the materials, dimensions, geometry and operating conditions. This reflects the wider Effisus approach: understanding the specific application requirements, selecting the right solution and supporting the site team throughout the installation process.
Our Added Value
The project brought together three different industrial roof waterproofing requirements within one coordinated technical approach. Rather than relying on a generic solution, Effisus matched each system to the shape, material and performance requirements of the relevant detail:
- Reliable joint sealing across PVC and TPO using Effisus Easyrepair Tape
- A practical solution for circular metal roof penetrations that reduced sheet-metal waste and reliance on specialised labour
- A flexible Bond FT system capable of sealing complex rectangular penetrations, supported by additional local protection where required
Effisus also provided:
- Product selection tailored to each application
- Adhesion validation on the actual substrates
- Review of penetration dimensions, geometry and exposure conditions
- Clear technical documentation and application sequencing
- Practical installation guidance
- Hands-on training for the application teams
- Support with detailing and final application checks
- Training certification
The practical demonstrations explained both how each system should be installed and why preparation, accurate sizing, overlap direction, sequencing and local protection are important to the performance of the completed waterproofing detail. By combining suitable products with technical assessment and practical support, Effisus contributed to the consistent execution of the roof joints and penetrations across the facility.
The project highlighted the versatility of Effisus solutions for mixed-substrate joints, circular metal roof penetrations and complex rectangular waterproofing details.
To learn more about Effisus industrial roof waterproofing, penetration sealing and on-site technical support, contact our team at [email protected].
Project Details
Project Types:
Maintenance
Project Segment:
Industrial
Application Segment:
Roofing
Application Type:
