Repair Systems — Sheet Membranes
Hot melt rubberised asphalt systems — roofs and podiums
Technical product reference for hot-fluid-applied rubberised asphalt waterproofing systems. Covers system principles, inverted roof assembly, specialist equipment and applicator requirements, Australian market availability, and brand comparisons for podium slab, roof deck, and plaza deck applications.
What are hot melt rubberised asphalt systems — roofs and podiums?
Hot melt rubberised asphalt is a hot-fluid-applied waterproofing membrane system applied as a heated liquid directly to a prepared concrete deck or roof substrate. The material — a blend of refined bitumen or asphalt, synthetic rubber polymers, and mineral stabilisers — is heated in a specialised thermostatically controlled melting kettle to between 160°C and 190°C and poured or pumped onto the substrate, where it flows to conform to the deck surface before cooling and solidifying into a continuous, monolithic, fully bonded waterproofing layer. A reinforcing fabric (typically polyester fleece) is embedded into the hot material while it is still fluid, and a second pour is applied over the fabric to complete the system. The result is a seamless, joint-free membrane that fully bonds to the substrate — eliminating the risk of lateral water migration beneath the membrane that is possible with loose-laid or mechanically fixed sheet systems.
Hot melt rubberised asphalt is primarily specified on large concrete podium slabs, roof decks, plaza decks, and car park structures where the application area, loading conditions, and design life requirements justify the plant and specialist labour involved. Key advantages over torch-on modified bitumen sheet and single-ply sheet membranes include: full substrate adhesion preventing lateral water tracking, self-healing properties where the material can re-seal minor punctures under heat, zero-fall capability on inverted roof assemblies, and compatibility with heavy ballast, paver, and growing medium systems above the membrane. The system is applied in an inverted roof configuration — the membrane is applied first, protection board and insulation are placed above the membrane, and ballast or growing medium is placed above the insulation.
Hot melt rubberised asphalt is a niche product category in the Australian waterproofing market. The principal brands — Henry 790-11, Soprema Colphene H, and SikaShield Hot Melt — are well established in the UK, North American, and European markets but have limited documented distributor presence in Australia. Specifiers should confirm current Australian product availability, distributor access, and accredited applicator availability before specifying hot melt rubberised asphalt on any Australian project.
Product Reference
4 products — 3 brands — hot-fluid-applied rubberised asphalt membrane systems for podium slab, roof deck, and plaza deck waterproofing — specialist applicator and thermostatically controlled melting equipment required — confirm Australian availability before specifying
Henry 790-11 Hot Rubberised Asphalt
Hot-fluid-applied rubberised asphalt — confirm Australian distributor
Hot-fluid-applied rubberised asphalt waterproofing membrane — two-pour fabric-reinforced system — fully bonded monolithic membrane for podium slabs, roof decks, plaza decks, car parks, and below-grade applications — confirm Australian distributor availability before specifying
System Description
Henry 790-11 is one of the most widely specified hot-fluid-applied rubberised asphalt waterproofing membranes internationally, with a long track record on podium decks, plaza decks, parking structures, highway bridge decks, roof decks, tunnels, and planters. The product is a blend of refined asphalts, synthetic rubber, and mineral stabilisers, applied as a heated liquid and cured in-situ to form a continuous, seamless, fully bonded waterproofing layer. It is used in protected membrane roof assemblies — the membrane is applied to the structural slab, covered by protection course, insulation, drainage layer, and ballast or growing medium.
The system is applied in two pours with polyester reinforcing fabric embedded between pours. Total applied thickness is typically 5–6mm for the two-pour reinforced system. Henry 790-11 bridges non-working cracks in the substrate — the hot material flows into surface irregularities and cracks up to approximately 1.5mm width during application, providing a more forgiving application on imperfect concrete substrates than sheet membrane systems.
Henry 790-11 is a US product. Confirm current Australian distributor availability, local stock, and specialist applicator availability before specifying. The Henry 790-11 EV (Environmentally Responsible) variant contains up to 25% post-consumer recycled content from reclaimed rubber — confirm whether the EV variant is available in Australia.
Technical Properties
- Hot-fluid-applied rubberised asphalt — blend of refined asphalts, synthetic rubber, and mineral stabilisers
- Two-pour system with polyester fabric reinforcement embedded between pours
- Fully bonded to concrete substrate — no seams in field — monolithic membrane
- Applied thickness: typically 5–6mm for two-pour reinforced system
- Bridges non-working cracks up to approximately 1.5mm in substrate
- Self-healing properties — minor punctures can re-seal under heat
- Application temperature: 160°C–190°C — thermostatically controlled melting kettle required
- Suitable for: podium decks, plaza decks, roof decks, car parks, tunnels, planters, below-grade
- Inverted roof (protected membrane) assembly — membrane applied first, insulation and ballast above
Limitations
- Confirm Australian distributor availability before specifying — Henry is a US product with limited confirmed Australian distribution
- Specialist thermostatically controlled melting kettle required — not standard roofing equipment
- Specialist applicator required — confirm availability in the project location before specifying
- Structural engineer must confirm roof/podium loading capacity for melting plant before placement
- Not for exposed applications — must be covered by protection course, insulation, and ballast or growing medium
- Confirm current product specification, Australian availability, and pricing with Henry Company or Australian distributor before specifying
PROCUREMENT SOURCES
Confirm suitability with the current manufacturer TDS before specifying or applying.
Soprema Colphene H
Hot-applied rubberised asphalt — Soprema — confirm Australian distributor
Hot-applied rubberised asphalt waterproofing membrane — mineral filler reinforced — two-pour system with fabric — podium decks, plaza decks, inverted roofs, green roofs, planters, and below-grade applications — confirm Australian availability before specifying
System Description
Soprema Colphene H is a hot-applied rubberised asphalt waterproofing membrane composed of a select blend of refined asphalts, recycled rubber, and inert mineral extenders. It is used in horizontal and vertical waterproofing of podium slabs, plaza decks, planters, tunnels, underground vaults, bridges, foundation walls, garden roofs, and parking structures. Applied as a heated fluid and reinforced with polyester fabric between two pours, Colphene H cures to a continuous, seamless, fully bonded membrane.
Colphene H EV (Environmentally Responsible) contains up to 25% post-consumer recycled rubber content. Soprema also produces the Duoflex hot melt structural waterproofing system — an SBS polymer-modified rubberised bitumen formulation specifically developed for inverted flat roof and podium deck applications, BBA certified in the UK for lifetime-of-structure performance.
Soprema is an international manufacturer with a broad product range. Confirm current Australian distributor, product availability, and specialist applicator access before specifying any Soprema hot melt product on an Australian project.
Technical Properties
- Hot-applied rubberised asphalt — blend of refined asphalts, recycled rubber, and mineral extenders
- Two-pour system with polyester fabric reinforcement
- Fully bonded to concrete substrate — seamless monolithic membrane
- Colphene H EV contains up to 25% post-consumer recycled rubber content
- Suitable for: podium decks, plaza decks, inverted roofs, green roofs, planters, tunnels, below-grade
- Self-healing properties
- Application temperature: confirm with Soprema TDS — typically 160°C–190°C — thermostatically controlled kettle required
Limitations
- Confirm Australian distributor availability before specifying — Soprema hot melt products have limited confirmed Australian distribution
- Specialist thermostatically controlled melting kettle required
- Specialist applicator required — confirm availability before specifying
- Confirm whether Colphene H or Duoflex hot melt system is the appropriate Soprema product for the specific application — they are different formulations for different system configurations
- Confirm current product specification, Australian availability, and pricing with Soprema or Australian distributor before specifying
PROCUREMENT SOURCES
Confirm suitability with the current manufacturer TDS before specifying or applying.
SikaShield Hot Melt 50/70
Hot melt bitumen waterproofing — Sika Australia — confirm Australian availability
Hot melt bitumen waterproofing element for inverted roofs, ballasted roofs, podium decks, and terraces — SikaShield system — heated in thermostatically controlled melting kettle at 165°C–185°C — Sika-accredited applicator required — confirm Australian product availability with Sika Australia
System Description
SikaShield Hot Melt 50/70 is Sika's hot melt bitumen waterproofing product for inverted roof, ballasted roof, podium deck, and terrace applications. Part of the SikaShield hot melt structural waterproofing system, it is heated in a mechanically agitated, thermostatically controlled melting cooker at 165°C to 185°C and applied to the prepared concrete substrate. As with other hot melt rubberised asphalt systems, it is applied in conjunction with reinforcing fabric to form a two-pour reinforced membrane, and is used in protected membrane (inverted) roof assemblies.
Sika has a confirmed Australian presence through aus.sika.com — however, hot melt bitumen products are a specialist segment of the Sika roofing range and may not be stocked or supported by Sika Australia's standard trade distribution network. Confirm with Sika Australia directly whether SikaShield Hot Melt is currently available, whether specialist applicators are accessible, and whether the product is supported with technical backup in Australia before specifying.
The SikaShield system includes a full range of complementary components — primers, detail membranes, upstand systems — all specified within the Sika system. Confirm the complete system specification with Sika Australia technical before specifying individual components.
Technical Properties
- Hot melt bitumen — applied at 165°C–185°C — thermostatically controlled melting cooker required
- For inverted roofs, ballasted roofs, podium decks, and terraces
- Two-pour system with polyester fabric reinforcement — fully bonded to concrete substrate
- BBA certified — confirm Australian certification status with Sika Australia
- Full SikaShield system — primer, detail membrane, field membrane, and accessories
- Sika-accredited applicator required
Limitations
- Confirm Australian product availability with Sika Australia before specifying — SikaShield Hot Melt is a specialist product — confirm stocking, distributor access, and applicator availability directly
- Specialist thermostatically controlled melting cooker required — not standard trade equipment
- Sika-accredited specialist applicator required — confirm availability in the project location
- Confirm the complete SikaShield system specification with Sika Australia technical — do not specify individual components without the full system context
- Structural engineer must confirm loading capacity for plant on roof or podium deck before placement
- Confirm current product name, TDS, and pricing with Sika Australia before specifying
PROCUREMENT SOURCES
Confirm suitability with the current manufacturer TDS before specifying or applying.
Mastic Asphalt — Traditional Hot-Applied Bituminous System
Traditional hot-applied mastic asphalt — specialist contractor-applied
Traditional hot-applied mastic asphalt waterproofing — specialist contractor-applied — fully bonded seamless bituminous system — established in Australian podium and roof deck waterproofing — heavier and thicker than rubberised asphalt — specialist mastic asphalt contractor required
System Description
Mastic asphalt is a traditional hot-applied bituminous waterproofing system that predates modern rubberised asphalt systems. It is a mixture of bitumen, limestone aggregate, and mineral filler heated to approximately 200°C–220°C and applied by specialist mastic asphalt screeders using wooden floats and hand tools. Applied in multiple layers to a total thickness typically of 20mm or more, mastic asphalt is heavier than modern rubberised asphalt systems but provides excellent durability and a long track record of performance on podium slabs, roof decks, and balconies.
Mastic asphalt has a longer established track record in Australian strata building waterproofing than the more modern rubberised asphalt systems — it was widely used on podium slabs and roof decks in Australian strata buildings constructed from the 1960s through to the 1990s before the widespread adoption of torch-on modified bitumen sheet systems. Many existing Class 2 strata buildings in Australia have existing mastic asphalt waterproofing on their podium slabs — identifying and specifying the correct remediation approach for failing mastic asphalt is an important skill for waterproofing consultants on Australian strata projects.
Mastic asphalt remediation may involve: over-coating existing mastic asphalt with a compatible liquid-applied PU or hybrid membrane where the existing asphalt is structurally sound, replacing failing mastic asphalt with a torch-on sheet or single-ply sheet system, or applying new mastic asphalt over the prepared substrate where a specialist mastic asphalt contractor is available and the design life justifies the cost.
Technical Properties
- Traditional hot-applied bituminous system — bitumen, limestone aggregate, and mineral filler
- Applied at 200°C–220°C by specialist mastic asphalt screeders using wooden floats
- Total applied thickness typically 20mm+ — multiple layers
- Fully bonded to substrate — no seams — established durability record
- Established in Australian podium and roof deck waterproofing — specialist contractor required
- Heavier than rubberised asphalt and modern sheet membranes — confirm structural loading with engineer
Limitations
- Specialist mastic asphalt contractor required — mastic asphalt screeding is a separate trade from standard waterproofing — confirm contractor availability before specifying
- Heavier than modern systems — 20mm+ at approximately 20 kg/m² or more — confirm structural slab loading capacity with engineer before specifying
- Not a factory-manufactured membrane — quality depends on site mixing, temperature control, and application skill
- Traditional mastic asphalt is not the same product as modern rubberised asphalt — do not specify as equivalent
- Remediation of existing mastic asphalt: confirm compatibility of any over-coating membrane with the existing asphalt before applying — not all liquid-applied membranes bond reliably to mastic asphalt without specific primer or preparation
- Confirm contractor availability and current pricing — mastic asphalt contracting is a reducing trade in Australia
PROCUREMENT SOURCES
Confirm suitability with the current manufacturer TDS before specifying or applying.
Hot melt rubberised asphalt system comparison
Side-by-side comparison of hot melt rubberised asphalt and mastic asphalt systems. Confirm all product selections against the current manufacturer TDS and confirm Australian availability before specifying.
| Product | Brand | Material | Application temp | Applied thickness | Australian availability | Key restriction |
|---|---|---|---|---|---|---|
| Henry 790-11 | Henry Company | Refined asphalt / synthetic rubber / mineral stabilisers | 160°C–190°C | 5–6mm two-pour reinforced | Confirm with Henry — limited AU distribution confirmed | Specialist melting kettle and applicator required — confirm Australian availability before specifying |
| Soprema Colphene H | Soprema | Refined asphalt / recycled rubber / mineral extenders | 160°C–190°C — confirm with TDS | Confirm with Soprema TDS | Confirm with Soprema — limited AU distribution confirmed | Specialist melting kettle and applicator required — confirm Duoflex vs Colphene H for specific application — confirm AU availability |
| SikaShield Hot Melt 50/70 | Sika Australia | Hot melt bitumen | 165°C–185°C — thermostatically controlled | Confirm with Sika TDS | Confirm directly with Sika Australia — specialist product | Sika-accredited specialist applicator required — confirm Australian availability with Sika Australia directly before specifying |
| Mastic Asphalt | Various specialist contractors | Bitumen / limestone aggregate / mineral filler | 200°C–220°C — hand applied by specialist screeder | 20mm+ — multiple layers | Established in Australia — specialist contractor required — contractor availability reducing | Heavy system — confirm structural loading with engineer — specialist mastic asphalt trade — not interchangeable with rubberised asphalt |
CONFIRM AUSTRALIAN PRODUCT AVAILABILITY AND SPECIALIST APPLICATOR ACCESS BEFORE SPECIFYING ANY HOT MELT SYSTEM
Hot melt rubberised asphalt systems are an established waterproofing technology in the UK and North American markets, but have limited confirmed distributor presence and specialist applicator networks in Australia. The principal international products — Henry 790-11, Soprema Colphene H, and SikaShield Hot Melt — may not be currently stocked, distributed, or supported by specialist applicators in the project location. Specifying a product that cannot be sourced or installed by an available specialist applicator in Australia will delay the project and may result in an alternative product substitution that is not equivalent. Confirm product availability, distributor access, and specialist applicator availability in writing with each manufacturer before including any hot melt rubberised asphalt product in a project specification.
HOT MELT APPLICATION REQUIRES SPECIALIST THERMOSTATICALLY CONTROLLED MELTING EQUIPMENT — NOT STANDARD ROOFING PLANT
Hot melt rubberised asphalt must be heated in a mechanically agitated, thermostatically controlled melting cooker capable of maintaining a precise temperature range — typically 165°C to 185°C. Standard roofing torches, open flame kettles, and general heating equipment are not appropriate for hot melt rubberised asphalt application. Overheating above the maximum application temperature (typically 220°C) degrades the rubber polymer and permanently reduces membrane performance — overheated material must be discarded. Underheating produces a material that is too viscous to flow and bond correctly to the substrate. The melting cooker must be confirmed as available and in calibrated working order before the application programme is committed. Additionally, the structural loading of the melting kettle on the roof or podium deck must be confirmed with the structural engineer before plant is placed.
MASTIC ASPHALT IS NOT THE SAME PRODUCT AS MODERN RUBBERISED ASPHALT — DO NOT SPECIFY AS EQUIVALENT
Mastic asphalt and hot melt rubberised asphalt are related but distinct bituminous products. Mastic asphalt is a traditional hand-applied system using bitumen, limestone aggregate, and mineral filler, applied at 200°C+ to a typical total thickness of 20mm or more by specialist mastic asphalt screeders. Modern rubberised asphalt (Henry 790-11, Soprema Colphene H) is a rubber-polymer-modified system poured at lower temperatures to a thinner total thickness of 5–6mm. They have different mechanical properties, different application methods, different weights, and different structural loading implications. When specifying remediation of an existing mastic asphalt system, confirm with the waterproofing consultant whether new mastic asphalt, a compatible liquid-applied membrane, or a sheet membrane system is the correct remediation approach — do not assume they are interchangeable.
HOT MELT RUBBERISED ASPHALT IS AN INVERTED ROOF (PROTECTED MEMBRANE) SYSTEM — THE MEMBRANE IS NEVER EXPOSED
Hot melt rubberised asphalt is applied directly to the structural slab and immediately covered by a protection course, then insulation (XPS board), then drainage layer and filter fabric, then ballast, pavers, or growing medium. The cured membrane is never left exposed to UV, foot traffic, or the elements — it is permanently buried under the system build-up. This is the inverted (protected membrane) roof assembly. The hot melt membrane is not suitable for exposed applications and should not be specified as an exposed surface finish. If an exposed podium or roof deck finish is required, specify a PVC or FPO single-ply sheet membrane (see the Single-Ply Sheet Membranes page) or a liquid-applied PU membrane instead.
Disclaimer
This page provides general technical information only. Final product selection must be confirmed against the current manufacturer technical data sheet, project specification, substrate condition, structural loading capacity, drainage design, NCC requirements, and waterproofing consultant advice. Hot melt rubberised asphalt installation requires specialist thermostatically controlled melting equipment and specialist applicators — confirm Australian product availability, distributor access, and accredited applicator availability before specifying. Structural engineer confirmation of roof or podium slab loading capacity for melting plant is mandatory before application. Do not rely on this reference as a substitute for professional waterproofing consultant or structural engineer advice.