Synthetic Shake Roof Helps Hotel Fit in Mixed-Use Area of Biltmore Estate

Village Hotel, Biltmore Estate: Asheville, N.C.

The four-story, 130,000-square-foot hotel was designed to ensure it fit comfortably within the Antler Hill Village and Winery area of the Biltmore Estate.

The four-story, 130,000-square-foot hotel was designed to ensure it fit comfortably within the Antler Hill Village and Winery area of the Biltmore Estate.

Nestled on 8,000 acres of pristine land in the mountains of western North Carolina, Biltmore welcomes more than a million visitors each year. Facing increased demand for additional on-site lodging, the new Village Hotel on Biltmore Estate was commissioned.

“The task of designing the four-story, 130,000 square foot hotel to ensure it fit comfortably within the Antler Hill Village and Winery area of the estate fell to PGAV Destinations. Antler Hill Village was intended to look like a series of buildings that belonged together but maintain an individual identity through the use of different roofing materials and trim treatments,” says Emily Pelcak, director of practice and innovation for PGAV Destinations. “With the Village Hotel, we wanted to continue that story. We specified DaVinci Roofscapes synthetic shake roofing to complement the general aesthetics of the area but also to create a distinctive personality for the hotel.”

The sprawling 209-room hotel is tucked next to restaurants, shops and a winery that all have real or simulated shake roofing. Each of the structures has a natural, rustic feeling, inspired by the eclectic mix of cottages and farm homes original to the estate that opened in 1895 belonging to George Vanderbilt.

“The look of the DaVinci shake roofing is convincing as a shake shingle, which is a traditional building material in western North Carolina,” says Pelcak. “Their ability to create unique blends so the hotel could have subtle color shifts across the building roof was a key reason the DaVinci shake roofing was specified.”

To ensure a distinctive look to the roof, Pelcak and her team worked with DaVinci to gain samples of multiple color blends of Bellaforté Shake tiles. The final decision was to create and install three unique color blends with the predominant colors including a range of Tahoe colors (Light, Medium Light, Medium and Dark), plus Dark Chesapeake.

“The color selection was an arduous process since we wanted a subtle variation across the roof to blend with the adjacent existing structures and complement the main exterior facade treatment,” says Pelcak. “We’re proud of this project and pleased that The Biltmore Company is happy with the look and performance of the DaVinci product. Based on their feedback, we may specify these tiles again on future projects throughout the estate.”

The sprawling 209-room hotel is in a complex with restaurants, shops and a winery. Each of the structures has a natural, rustic feeling, complemented by a real or synthetic shake roof.

The sprawling 209-room hotel is in a complex with restaurants, shops and a winery. Each of the structures has a natural, rustic feeling, complemented by a real or synthetic shake roof.

Roof Report

With the design work complete, the installation task for the massive roof system fell to Benton Roofing. From start to finish, the project took nine months to complete, with 45 days dedicated to installation of the synthetic Bellaforté Shake roof.

“The multiple roof lines on the project give the hotel an appealing look,” says Caleb Benton, president and owner of Benton Roofing. “The project went smoothly and the roofing material was easy to install.”

“These roofing tiles are the perfect fit for this hotel since they’re impact- and fire-resistant, plus they’re basically maintenance-free. This was our first time installing DaVinci products and we were impressed.”

Although the Asheville area is not known for large amounts of snowfalls, the hotel designers took extra caution to specify snow guards be installed on the roof in key public areas. Manufactured by Rocky Mountain Snow Guards, the snow guards on the Village Hotel help prevent any collected snow from sliding off the roof in large pieces onto walkways.

Now open for more than a year, the Village Hotel provides easy access for visitors to the estate’s gardens, 10 shops, 15 dining venues, winery, equestrian center and outdoor activities. The main feature of the estate, Biltmore House, has 250 rooms with tours available daily.

Photos: The Biltmore Company

Medical Research Facility Showcases Eco-Social Construction

Kemper System Belfer Medical Research Building

The rooftop on the Belfer Medical Research Building not only houses HVAC equipment but serves as a rainwater detention system. The reinforced membrane waterproofing system by Kemper System was applied to the roof deck before the pavers were put in place on a pedestal system.

The Belfer Medical Research Building on the campus of New York’s Weill Cornell Medical College was designed to be a 19-story model of eco-social construction. Designed by Todd Schliemann of Ennead Architects, the building showcases a number of sustainability features, including a storm water detention system on the roof.

Built for a cost of more than $630 million, the tower includes 13 stories of research laboratories. The tower has three roof levels at the 17th, 18th and 19th floors. The rainwater detention system, known as a “blue roof,” not only helps regulate storm water discharge, but it feeds a water fountain and irrigates planters on the second-floor terrace.

In general, rainwater detention systems can either collect water in holding tanks and then meter it to the public sewer system, or retain it on a waterproofed roof expanse. The blue roof on the Belfer Research Building uses the latter strategy. It complies with New York City requirements and can hold up to 3 inches of water.

Roof Materials

Proper waterproofing on the project is essential. The solvent-free and odor-free KEMPEROL 2K-PUR cold, liquid-applied membrane system was used for waterproofing the blue roof. It was also used on the terrace and fountains on the lower level. The reinforced membrane system is designed for long service life and backed by an extended-wear warranty.

Eagle One Roofing Contractors Inc. of Astoria, N.Y., a certified applicator of the Kemper System, applied the waterproofing system. The two-part resin system is designed to fully adhere to the substrate, and is fully reinforced with fleece. The resulting membrane is completely seamless and unaffected by ponding water and ice. According to the manufacturer, it resists exposure to UV light, chemicals, oils and solvents. It is impervious to bio-deterioration and is both root- and rot-resistant, so it is also ideal for green roofs and landscaped areas.

Roof Report

The supporting structure below the roof was designed to carry the water load, with an allowance for heavy snow or ice buildup. The roof deck is concrete slab and includes a layer of rigid insulation below the waterproofing membrane for added energy efficiency. The gravity-fed drainage system was carefully sized to control the speed of drainage without the use of pumps, sometimes required for rainwater detention systems that use holding tanks. On the roof sections, the waterproofing sections were topped with concrete pavers on a pedestal system.

Construction at the Weill Cornell Medical College, both interior renovations and new construction, is designed to meet a minimum LEED Silver status. This project was designed to achieve Gold certification, the nationally accepted benchmark for the design, construction and operation of high-performance green buildings.

This illustration shows the assembly used for the blue roof on this project. The cold, liquid-applied reinforced membrane system was topped by concrete pavers. Image: Kemper System America Inc.

This illustration shows the assembly used for the blue roof on this project. The cold, liquid-applied reinforced membrane system was topped by concrete pavers. Image: Kemper System America Inc.

On the south side of the building, Ennead created a double-skinned, fritted glass curtain wall with openings and sun-shading devices that absorb the sun’s heat before it gets trapped inside, which would require the HVAC system to pump out more cold air. Continuous ribbon windows flood the building with natural light, and energy-efficient HVAC, lighting controls and water-conservation systems save on power and resources. The building’s green infrastructure is expected to shrink Weill Cornell’s energy bill for it by about 30 percent and reduce carbon dioxide emissions by about 26 percent compared to a building complying with the minimum requirements set by typical industry guidelines and standards.

The building includes a high-tech, multi-zoned HVAC control system to manage the indoor environment within different spaces. Biomedical laboratories, for example, generally require special air filtration systems supported by high-volume air circulation. Each of the laboratory levels includes four fume vents to the outside, except for the chemistry laboratory on the top floor, which uses 40 vents. In addition to thermostats and humidity sensors, indoor spaces utilize occupancy sensors to assist in regulating the ambient indoor environment and lighting to improve energy efficiency.

Photo: Kemper System America Inc.

TEAM

ARCHITECTS
Todd Schliemann, Ennead Architects, LLC, New York
William Cunningham, Weill Cornell Medical College, New York

ROOFING CONTRACTOR
Eagle One Roofing Contractors, Inc., Astoria, N.Y.

ROOF AND WATERPROOFING SYSTEM MANUFACTURER:
Kemper System America Inc., West Seneca, N.Y.

Insulated Metal Panels Save Time and Labor in Construction of Inmate Hospital

An insulated metal panel system from All Weather Insulated Panels was chosen for the project because of its durability, energy efficiency and ease of installation.

An insulated metal panel system from All Weather Insulated Panels was chosen for the project because of its durability, energy efficiency and ease of installation.

Under pressure from the federal government, the state of California had to build a new health care facility for its prison inmates—and do it fast. The logistics were daunting.

Planning for the 144-acre construction site that became the California Health Care Facility inmate hospital in Stockton, Calif., had to account for 1,700 personnel on the site at any one time. Physically, it was an imposing project: 23 buildings adding up to 1.2 million square feet, with 792,000 square feet of roofing.

Since there was very little space to store roofing material on site, it became clear in the planning stages that production had to be paced with installation, and a choreographed dance of trucks, forklifts, and installation crews had to be executed well in extremely compact areas.

That’s when using an insulated metal panel (IMP) system from All Weather Insulated Panels (AWIP) of Vacaville, Calif., dawned on the team at Roland Construction in Stockton.

The team realized using IMPs could save in both onsite manpower and installation time. “This being the largest project Roland has ever completed, as well as the demand for over 50 of our workers on site, plus personnel from other companies, the challenges were formidable,” said Jim Hoagland, the owner of Roland Construction.

Roof Materials

Representatives of Roland and the general contractor firm of Clark/McCarthy worked with the California Department of Corrections and Rehabilitation (CDCR) prior to the bid date to make sure that the IMP roof system would be acceptable to the state. Not only was it deemed acceptable, the state considered IMPs an upgraded component in the final design-build package submitted for consideration. The specification was amended to include insulated metal panels for the architectural roofing before sub-contractors submitted bids.

After the bids were opened, Roland Construction and AWIP earned the opportunity. In January 2012, work began immediately on the design of the 23 buildings. AWIP’s 4-inch thick SR-2 standing seam insulated roof panel with a 22-gage outer skin coated in Natural Green Kynar paint became the choice. The excellent insulating properties of the sandwich-style panel with an R-value equal to 32 in the darker color complied with the project’s LEED Silver Certification.

Roof Report

In May 2012, three five-man crews began work on adding the insulated metal panels to the roof. It soon became apparent that each crew could install panels quickly, safely and efficiently.

Over the course of six months, each crew using a small crane could install up to 7,650 square feet of roofing, meaning 15 workers added a total of nearly 23,000 square feet of roofing per day. Following behind the roof paneling crews were several other crews installing AWIP 2-and-half-inch DM40 wall panels, flashings, and trim to encapsulate the 192 fixtures that allowed natural light into the buildings.

The California Health Care Facility in Stockton is comprised of 23 buildings on 144 acres. A total of 792,000 square feet of roofing was installed on the project.

The California Health Care Facility in Stockton is comprised of 23 buildings on 144 acres. A total of 792,000 square feet of roofing was installed on the project.


The use of a vacuum lifter provided by Automatic Panel Lifting System (APLS) of Auburn, Calif., proved essential in the installation of the panels. The APLS lifters are designed to be hung from a crane or forklift. With the proper attachment setup, they are capable of raising panels up to 60 feet long weighing approximately 600 pounds each.

With the panels being able to be lifted and released in a matter of seconds, production was increased dramatically to meet the project’s breakneck schedule.

With a total cost of $906 million, the project was California’s largest public works project in 2012. Hoagland points out that the reduction in installation man-hours not only saved schedule time, but more than made up for the additional material cost over a more traditional built-up insulation and metal roof system.

“With all the pre-planning with our supplier, AWIP, and their going the extra mile for us, we could not have accomplished this project in such an efficient and timely manner,” notes Hoagland. “The use of AWIP’s insulated metal roof panels for this project proved to be the decision that made this job feasible.”

Photos: All Weather Insulated Metal Panels

TEAM

GENERAL CONTRACTORS:
Clark/McCarthy—a joint venture of Clark Construction Co. and McCarthy Building Cos., in conjunction with Roland Construction, Stockton, Calif.

INSULATED METAL PANEL MANUFACTURER:
All Weather Insulated Panels, Vacaville, Calif.

AWIP Ready for 2020 Regulations in 2017

Insulated metal panels consist of closed-cell foam composite encased by two pieces of galvanized steel. AWIP’s SR2 roof panel has a trapezoidal design to increase the panel’s overall rigidity.

Insulated metal panels consist of closed-cell foam composite encased by two pieces of galvanized steel. AWIP’s SR2 roof panel has a trapezoidal design to increase the panel’s overall rigidity.

By 2020, as regulated by the California (CPUC) Public Utilities Commission, all new residential construction in California will have to meet Zero Net Energy (ZNE) requirements. In essence, the regulation stipulates that the amount of energy a residential building takes off the power grid must be balanced by energy the residence generates and returns to the grid.

William Lowery, the president of All Weather Insulated Metal Panels in Vacaville, California, says his company “is ready for 2020 in 2017.”

Lowery believes that insulated metal panels (IMPs)—the “sandwich-style” roofing component consisting of closed-cell foam composite encased by two pieces of galvanized steel—can propel the North American construction industry into a new era.

“Insulated metal panels are better, faster and cheaper, and we’re at the forefront of changing construction in the United States,” says Lowery.

As an example, AWIP’s SR2 roof panel has a trapezoidal design that increases the panel’s overall rigidity, making it safe for longer spans and foot traffic despite using a lighter-than-usual 26-gauge steel, which reduces overall weight.

Furthermore, according to Lowery, insulated metal panels require far less specialized equipment to install than traditional building materials and, due to their self-aligning, tongue-in-groove joinery, they are a snap to fit together. Once assembled, they provide insulating values above R-50, securing the building’s thermal envelope.

William Lowery, the president of All Weather Insulated Metal Panels, believes insulated metal panel systems can help California homeowners meet strict upcoming residential building regulations.

William Lowery, the president of All Weather Insulated Metal Panels, believes insulated metal panel systems can help California homeowners meet strict upcoming residential building regulations.

“The SR2, to name one, not only meets the new CPUC energy needs, its means a savings in needing fewer solar panels,” says Kim Harrell, vice president of sales for AWIP. “Roof panels reduce the cost of materials and construction time. They will play comply with the CPUC’s aspirations for California and have significant role in helping new and existing construction projects all over the country.”

Finally, AWIP’s SR2 roof panel with the S-5! Clips makes attaching solar panels quick and easy without piercing the underlying substrate, thereby preventing and air, vapor or water leakage.

Green Roof Brightens the View for Patients at VA Hospital

At the Ralph H. Johnson VA Medical Center in Charleston, a modular green roof system was installed to improve the quality of life for patients in the extended care wing.

At the Ralph H. Johnson VA Medical Center in Charleston, a modular green roof system was installed to improve the quality of life for patients in the extended care wing.

Michael Whitfield was fascinated by the concept of green roofs, but he didn’t encounter many of them near his home in Charleston, S.C. He knew green roofs benefitted the environment, extended the life of roof systems and were aesthetically pleasing, so he was sure he could tap into the market in the Southeast as a green roof installer. When he couldn’t find a modular green roof system he liked, he designed his own. Whitfield is now the president and CEO of Green Roof Outfitters. Founded in 2009, the company manufactures components for green roofs installed all over the country. The company also installs green roofs itself, as was the case with a nearby hospital project.

After reading research studies that showed hospital patients recovered more quickly and needed less pain medication when they had a natural setting to look out on, Whitfield was inspired. He checked with local hospitals to see if there were areas that would be good candidates for green roofs. When the PR person at the Ralph H. Johnson VA Medical Center expressed an interest, Whitfield passed along the research material.

Months later he got a call asking him to submit a bid. While the hospital’s budget did not allow for a green roof to be installed on the entire building, there was a section of the roof that could be worked on right away. It was a 3,000-square-foot area on a wing for extended care patients, who looked out on a white TPO roof. “We put a green roof on that whole strip outside their windows so the patients would have something nice to look at,” Whitfield says.

Roof Materials

Construction took place on a weekend, when traffic would be lighter. A crane was used to load the material on the roof, including 4-inch-deep trays for the extensive modular green roof system and 2-inch-thick rubber pavers to go around the perimeter. Plants in the pre-grown mats included different varieties of sedum. Chives, prickly-pear cactus and other perennials were added later.

Green Roof Outfitters partners with growers around the country to provide pre-grown mats. Different varieties of plants are used in different parts of the country, but in most markets the company has had success with a blend using approximately 14 different varieties of sedum.

Whitfield believes the proper combination of plants is essential. “Two buildings that are right next to each other could have different microclimates, so you don’t know exactly what is going to work perfectly there and what is not,” he says. “We mix these plants with a variety—some do better in shade, some do better in sun. With the different tolerances they have, the strongest will survive, so we will always have something there. Many people make the mistake of planting one species they like with a certain pattern or color. But if you plant one species—a monoculture—and it doesn’t like it there, you’ll have a totally dead roof.”

Roof Report

The system does not require slip sheets for installation, but some roof manufacturers require them to maintain the warranty on the existing roof. In this project, a layer of 40-mil EPDM was placed on top the existing TPO roof. “We laid the modules on top of that,” says Whitfield. “We have rubber paver walk pads, which have feet on the bottom for drainage. We put those around the outside so we could have a nice-looking barrier and a walking area for the maintenance guys.”

Michael Whitfield was on hand to oversee the project at the VA medical center.

Michael Whitfield was on hand to oversee the project at the VA medical center.

“Many people don’t know this, but a green roof can help the roof last 200 percent to 400 percent longer by preventing UV degradation,” Whitfield says. “It shades the roof and protects it. During the day, exposed roofs get superheated in the sun, and cool at night, so they are constantly expanding and contracting. A green roof system keeps it at a constant temperature.”

Another benefit can come from creating functional space on the roof. “We wholesale a lot of systems that combine a green roof with pavers to add usable space,” he says, “We can supply ipe wood pavers or other pavers in different configurations on our pedestal system to make walkways and patios.”

Depending on the environment, an irrigations system is a common option. “Green roof are a low-maintenance systems, not a no-maintenance systems,” notes Whitfield. “We incorporated irrigation channels into the new design of our modules, so you can put in irrigation during the installation or after it is completed.”

Another change is a smaller module. “Our modules used to be 2-feet-by-2-feet, but they were really heavy for the roofers,” he explains. “Our new modules are half the size—one-by-two—so they are much easier to handle and put in place.”

As they become more comfortable with green roof systems, roofing contractors are finding out they can be a valuable add-on with roofing projects. “Once roofers are on the site with all of the equipment and labor, why not make double the money by installing roofing and a green roof?”

No special training is needed to install this tray system. “It’s easy to install,” Whitfield notes. “The modules come fully vegetated, 40 to a pallet. You just pick one up, put it down, and repeat. It’s like laying down dominoes, honestly.”

The modular system is also easy to move if roof maintenance is necessary. “Our system is so flexible,” he says. “If you need roof maintenance, you can just pick up a couple of trays, move them and move them back. This is such an easy, modern way to do it—and it’s very affordable.”

Team

Green Roof Manufacturer and Installer: Green Roof Outfitters

Photos: Green Roof Outfitters

Composite Slate Roof Offers Curb Appeal

 A composite slate roof was chosen to help the facility fit in with the surrounding area.

A composite slate roof was chosen to help the facility fit in with the surrounding area.

Jack Lucks has an “architectural eye.” His dedication to creating attention-grabbing projects has served him well during the past 43 years as he makes design and product decisions related to a variety of projects with different architectural styles.

In recent years Lucks and his group, Continental Real Estate Companies, have focused on the creation of senior/assisted living facilities. A recently opened facility in Granville, Ohio, has been well received, and Lucks, a founding partner with the group, credits the distinctive look of the building’s composite slate roof as a key to its curb appeal.

Roof Materials

The design goals included integrating the building with the surrounding area. “Granville is an older town, founded in the early 1800s,” Lucks notes. “There are lots of slate roofs in town that complement the Greek Revival style of this area. Having a composite slate roof on our facility that so perfectly replicates real slate was a smart decision.”

A composite slate roof from DaVinci Roofscapes was chosen for the project. “The black Bellaforté Slate roof has the aesthetic look we wanted without the weight of real slate,” says Lucks.

Lucks points out that the Middleton project is a single-story building with a roof that’s highly visible from the street. “When you look at this building, half of what you see is the roof,” he says. “That made the roofing decision especially important for us.”

According to Lucks he has been “enormously pleased” with the authentic look of the composite slate roof. “It’s not an exaggeration to say that the DaVinci roof has helped us gain tenants,” he says. “People look at the structure, see the brick and ‘slate’ exterior. It makes them take that crucial step to walk in our door.”

With 94 rooms, Middleton offers six levels of support for residents at the 92,000-square-foot structure. The facility provides restaurant-style dining, daily activities, an on-site theatre and nature paths, as well as laundry and housekeeping services, 24-hour licensed nurses and a beauty salon. “America’s population is aging,” says Lucks. “Our facilities help Americans age gracefully in beautiful settings that cater to their changing needs.”

Team

Roof System Manufacturer: DaVinci Roofscapes

Photo: DaVinci Roofscapes

Re-Roofing Project Protects Medical Center’s Critical Interior Space

The medical center is pleased with the decision to use FiberTite to protect their facility and trusts the roof system will be durable and reliable for many years to come.

The medical center is pleased with the decision to use FiberTite to protect their facility and trusts the roof system will be durable and reliable for many years to come.

Maintaining the building envelope is essential to the success of a facility with critical interior space. This is especially true with hospitals and medical centers, where facility managers need to be on top of the building envelope integrity so patients and valuable assets are protected.

When the staff at an acute care medical facility in Florida realized the building’s existing roof was reaching the end of its service life, they knew they had to take action right away. The medical center offers a 24-hour emergency department, surgical services and various other outpatient services, and avoiding interruptions caused by roof leaks was critical. Hospital officials sought out a roofing consultant to offer a recommendation for the best roofing system to protect the facility.

McEnany Roofing, located in Tampa, Fla., has been providing commercial and industrial roofing solutions for more than 27 years. “We worked on the medical facility’s behalf to recommend a roofing system for this environment,” says Mark Sloat, vice president and senior estimator at McEnany Roofing. “We used the services of an engineer to conduct an uplift test to help us determine the best roof to suit their needs.”

Roof Materials

After all the testing and research was complete, McEnany Roofing concluded that a FiberTite Roofing System was the best choice. The proven performance advantages in puncture resistance, durability, wind uplift and severe weather protection supported McEnany Roofing’s recommendation and after careful review of the data, the medical facility agreed. In 2016, McEnany Roofing installed more than 130,000 square feet of Elvaloy KEE membrane on the main hospital and two adjacent medical buildings.

Roof Report

The sensitive environment of the hospital setting also had to be taken into account. The water-based adhesive used to adhere the 45-mil FiberTite Fleeceback membrane on the upper roof of the main hospital helped mitigate odor. Other areas of the hospital had 45-mil FiberTite-SM installed using the mechanically attached securement. Both processes minimized disruption and allowed the medical center to maintain strict standards of patient care during installation. The medical center is pleased with the decision to use FiberTite to protect their facility and trusts the roof system will be durable and reliable for many years to come.

Team

ROOFING CONTRACTOR: McEnany Roofing, Tampa, Fla.
ROOF SYSTEM MANUFACTURER: FiberTite Roofing Systems, Seaman Corp., Wooster, Ohio

Photo: FiberTite Roofing Systems

TPO System Delivers Energy Efficiency for Company Headquarters

TurnKey Corrections constructed a new 115,000-square-foot in facility in River Falls, Wis.

TurnKey Corrections constructed a new 115,000-square-foot in facility in River Falls, Wis.

If you want it done right, do it yourself. Company owners Todd Westby and Tim Westby take a hands-on approach to running TurnKey Corrections, the River Falls, Wisconsin-based company that provides commissary and jail management services to county corrections facilities nationwide. The Westby brothers also take pride in the fact that TurnKey manufactures the kiosks it provides to its clients and develops and owns the proprietary software used to run them.

So, it’s perhaps not surprising that, when building the company’s new headquarters, Todd Westby, the company’s CEO, founder and general manager, served as the general contractor. Or that he had definite ideas regarding the roofing system that would be installed. Or that he was more than willing to get his hands dirty during the installation process.

Founded in 1998, TurnKey Corrections helps corrections facilities streamline and lower the cost of delivering a variety services to inmates, including commissary, email and email-to-text communication, video visitation, law library access, and paperless intra-facility communication and documentation. Following several years of robust growth, the company had outgrown its three existing buildings. So, it constructed a new 115,000-square-foot facility to bring all operations, including 50,000 square feet of office space and a 65,000 square-foot warehouse where commissary items are stored prior to shipment to corrections facilities, under a single roof and accommodate future success.

“We wanted to be involved in the project from beginning to end so we knew what we were getting and how it was built,” Todd Westby says of the decision to keep construction management in-house. “We wanted to know about anything and everything that was being built for the company in this building.”

In planning the project, Westby initially set two key criteria for the roofing system: that the building would be made watertight as quickly as possible so concrete slab pours and other interior work could be completed, and that the roof would be covered by a warranty of at least 20 years. The design-build firm’s initial plans called for a ballasted EPDM roofing system, but Rex Greenwald, president of roofing contractor TEREX Roofing & Sheet Metal LLC of Minneapolis, suggested a white TPO system, noting that it would meet the quick installation and warranty goals while also enhancing the building’s energy efficiency. Westby was intrigued and, after some research, agreed to the recommendation. In addition to helping reduce cooling costs during summer months, the reflective surface would allow a blanket of snow to remain on the roof during winter months to provide additional insulation.

The TPO roofing system was constructed over a 22-gauge metal fabricated roof deck.

The TPO roofing system was constructed over a 22-gauge metal fabricated roof deck.

The Roof System

The TPO roofing system included a 22-gauge metal fabricated roof deck; two 2.5-inch-thick layers of Poly ISO insulation from Mule-Hide Products Co., with tapered insulation saddles and crickets to aid drainage; and 811 squares of 60-mil white TPO membrane from Mule-Hide Products Co. The insulation and membrane were mechanically attached using the RhinoBond System from OMG Roofing Products. Cast iron roof drains, designed and installed by a plumber, were used rather than scuppers and downspouts—a practice that the TEREX team strongly recommends to prevent freezing during the cold Upper Midwest winters. Walkways lead to the mechanical units, protecting the membrane from damage when maintenance personnel need to access the equipment.

The TEREX team finds the RhinoBond System to be the most efficient and economical attachment method for TPO systems. Specially coated metal plates are used to fasten the insulation to the roof deck and then an electromagnetic welder is used to attach the membrane to the plates. The membrane is not penetrated, eliminating a potential entry point for moisture. And while other mechanical attachment methods require the crew to seam as they go, the RhinoBond System allows them to lay the entire membrane (a task which must be completed in good weather conditions) at once and go back later to induction weld the seams and plates, which can be done when Mother Nature is slightly less cooperative.

Greenwald estimates that the switch from the originally specified ballasted EPDM system to the TPO roofing system and RhinoBond System shaved at least 10 percent off the installation time and reduced the roof weight by 10 pounds per square foot.

Having Westby on-site as the general contractor also sped up the project considerably, Greenwald notes. “He was a huge asset to all of the subcontractors,” he explains. “We could get construction questions answered quickly and could talk through issues and procedures on a timely basis.”

And the most memorable moment in the project for Greenwald was seeing Westby working side-by-side with his crew. “One day we had a delivery truck show up, and Todd jumped on the forklift and helped us unload the truck.”

As sought from the project’s outset, the roofing system is backed by a 20-year, no-dollar-limit labor and material warranty.

With one winter of use in the rearview mirror, the roofing system has exceeded Westby’s expectations. Warehouse space was doubled, but heating costs have been cut in half. The 10-unit heating system also is able to keep the warehouse a uniform temperature, without the cold spots that were common in the old building.

“It really is a beautiful, very efficient and organized-looking roof,” Greenwald says.

Stanford Hospital Project Demands Versatility and Surgical Precision

The new Stanford Hospital is currently under construction in Palo Alto, Calif. The 824,000-square-foot facility connects to the existing hospital by a bridge and tunnel. The project includes a multi-level parking garage and with additional office buildings. Photo: Stanford Health Center.

The new Stanford Hospital is currently under construction in Palo Alto, Calif. The 824,000-square-foot facility connects to the existing hospital by a bridge and tunnel. The project includes a multi-level parking garage and with additional office buildings. Photo: Stanford Health Center.

Dennis Olson is used to dealing with large health care projects with multiple scopes of work, but the new Stanford Hospital project he’s currently working on might be the most challenging job he’s ever faced.

“I’ve never been involved with a project that’s been this complex and this difficult to roof and manage,” says Olson, the owner of Letner Roofing in Orange, Calif. “There are 16 different types of roofing and waterproofing systems, and each one is a little bit different at each location around the building.”

Located in Palo Alto, Calif., the new Stanford Hospital is an 824,000-square-foot facility that connects to the existing hospital by a bridge and tunnel. Olson is convinced his company is perfect for the job. He has been in the roofing industry for almost four decades, and he’s worked at Letner for more than 30 years. Olson worked his way up through the company as a foreman, project manager, and estimator before becoming the president and owner 15 years ago. “I have been estimating and managing health care projects for more than 25 years,” he says. “This job is right up our alley.”

The Company

Located in Orange, Calif., Letner Roofing specializes in commercial work including all types of roofing and below-grade waterproofing systems. “We are licensed with all of the major manufacturers to install their products,” Olson says. “We install basically every roofing and waterproofing system that’s available to the market. We have a sheet metal division that produces metal wall panels, roofing and general sheet metal.”

The new hospital features green roofs on the main hospital, central plant and parking structure. The garden roof section on level three of the main hospital building is shown here. Photo: Stanford Health Center.

The new hospital features green roofs on the main hospital, central plant and parking structure. The garden roof section on level three of the main hospital building is shown here. Photo: Stanford Health Center.

Olson believes the company’s success begins with its great alliances with top general contractors and owners. “Our strengths are our customer service and quality control, and our ability to get projects done efficiently and on time,” he says. “I think that’s why general contractors choose us. We do what we say we’re going to do, we do it efficiently, and we take a lot of pride in the finished product.”

Communication is the key, according to Olson. “We have weekly sales meetings where all of the project managers and sales staff get together,” Olson says. “We share information, which allows us to learn from our failures and successes. It’s a team atmosphere. There is no real competition between the sales guys other than the innate competition that you each have to be better. We don’t compete against each other; we all work together for the common goal.”

Keeping the lines of communication open with industry partners is a key part of the puzzle. “As far as communication with the general contractor, that’s pretty simple, but a lot of people miss that,” he says. “You have to return phone calls. You have to return emails. If you have an issue on a project, handle the issue efficiently. Bring scheduling problems or details issues to the attention of the general contractor early. Nobody like to be surprised. People like to be informed.”

Due to their expertise in design-build situations, members of the Letner team are often called in by general contractors at the design and budgeting stage to offer advice on the right materials and methods for a project.

That was the case with the new Stanford Hospital project and general contractor Clark/McCarthy—a joint venture of Clark Construction Co. and McCarthy Building Cos. “McCarthy is a contractor I’ve been dealing with for more than 25 years. I’ve done a lot of health care projects with them, so when Stanford came out, they certainly wanted our input and help developing the budgets,” notes Olson.

Underground, Overhead

For Letner, the project involved several scopes of work including roofing on the main hospital and below-grade and underslab waterproofing.

Below-grade work included a pre-applied blind-side waterproofing application by Cetco. Letner also waterproofed underground tanks for domestic water, fire suppression, and sewage with a hot rubber system by Gaco Western. “The hospital was built for the worst-case scenario,” Olson notes. “If there is a big earthquake, and services are interrupted, the hospital can sustain itself for a while.”

This aerial photo shows the new Stanford Hospital, which is currently under construction. When completed in 2018, the complex will showcase 16 different roofing systems on 12 different elevations. Photo: Stanford Health Center.

This aerial photo shows the new Stanford Hospital, which is currently under construction. When completed in 2018, the complex will showcase 16 different roofing systems on 12 different elevations. Photo: Stanford Health Center.

As the superstructure was being completed, the roofing work began. “As I said, there are 16 different roofing systems on this project. There are 12 different elevations,” notes Olson.

Systems range from urethane and urethane and polymethyl methacrylate (PMMA) coatings to split-slab and inverted hot rubber systems, PVC roof systems and hybrid dual waterproofing system. The largest roofing systems include a Sarnafil PVC roof on the main hospital and a hot rubber system by Cetco for use under the garden roofs. Letner is installing garden roofs on the third floor of the main hospital and another on the central plant building.

Both of these garden roofs were constructed over flat concrete decks. The first step was to provide positive slope for drainage. Cell-Crete Corporation of Hayward, Calif., provided lightweight insulating concrete (LWIC), which was used to create positive slope. After the LWIC cured, crews from Cell-Crete installed quarter-inch cement board over the LWIC.

The hospital’s surgery rooms are directly beneath the garden roof on the main hospital, so the system has to be bulletproof. “This roof area requires intricate detailing along with a Cetco hybrid dual waterproofing system,” Olson states. “After the lightweight concrete and cover board are in place, Letner will install 60 mils of Hydrofix urethane membrane, followed by Cetco Corflex, a unique combination of a re-enforced KEE membrane bonded to an active polymer core membrane. Both garden roof areas will be protected with an in-place leak detection system by Internal Leak Detection.”

The overburden at the hospital garden roofs will include insulation, drainage mats, various types of plants and trees and pedestal paver systems.

Letner installed PVC roof systems from Sika Sarnafil level three of the hospital and on the main roof of the hospital. The 60-mil PVC membrane was installed over insulation and DensDeck cover board. Insulation was a minimum of R-20 near the drains. Some sections of the PVC were topped by ballast rock.

On the adjoining multi-level parking deck, Letner installed PVC roofs on two office buildings. The rest of the roofing and waterproofing work on the parking structure, including another garden roof, was completed by Courtney Waterproofing and Roofing of Irvine, Calif.

Safety Precautions

Letner and the general contractor help ensure safety is always top of mind at the site. “On this project, like any other, the safety issues were extremely important,” notes Olson. “We have our crews stretch and flex daily, and everyone must wear the personal protective equipment required for each task. Fall protection is a concern at every elevation, and hot rubber is extremely hazardous activity that requires additional protection and monitoring.”

Elastizell lightweight insulating concrete from Cell-Crete was used to provide slope for drainage on the flat structural concrete decks. It was later topped with cement board. Photo: Cell-Crete

Elastizell lightweight insulating concrete from Cell-Crete was used to provide slope for drainage on the flat structural concrete decks. It was later topped with cement board. Photo: Cell-Crete

The perimeter walls were being constructed during the project, so extra precautions had to be taken at the roof edge. “We had to wear harnesses and be tied off at all times,” Olson says. “We are very concerned about safety. We have a safety manager, and he does a very good job of identifying possible hazards on each job. We identify those per deck and apply the proper safety measures required for each elevation.”

Waterproofing the tanks also required special care. “The domestic water, waste and fire tanks and are in the ground, so you have to have people certified to do that work with specialized equipment,” Olson states.

Challenging Schedule

Construction of the hospital is still underway. Work is expected to be completed in 2018. The sheer size and multiple scopes of work were obvious challenges on the project, but the schedule was also tight—and subject to change. Some roof details were changed and others were developed as the job progressed, so Letner’s crews had to make some adjustments on the fly. Letner continues to work with the consultant on the project, ABB, to iron out the details.

“Sometimes you have to adjust the schedule when you are coordinating the work with other trades,” Olson notes. “The schedule, coordinating with other trades and the number of changes on the job have been the biggest issues we’ve faced. It’s is still a challenge, as the work is ongoing.”

When it came time to stage equipment and materials, the large job site suddenly seemed small. “The site was kind of tight, so of course logistics came into play with loading and off-loading each different area,” he says. “Some areas were hard to get to, and sometimes we had to wheel the product through corridors to get to the decks. Not everything was easy to get to. Logistics were difficult, but we were able to overcome those problems. Clark/McCarthy helped out quite a bit with logistics and loading.”

Despite the complexity of the job, the installation work has gone smoothly, according to Olson. “As far as the application for our field crews, there’s not that much difficulty for them. They are all very talented at what they do,” he says. “It’s just a very difficult building, and there are a lot of details that are not typical.”

The key to overcoming difficulties? “It’s constant communication,” Olson says. “Our strengths are our management teams, from the field operations to office staff. We’re honest with our customers. They understand the level of customer service and quality we deliver. Our success is a testament to the service we provide to our customers. We are often praised for our service and workmanship, and we are very proud of our quality installations as well.”

On the adjoining multi-level parking deck, Letner Roofing installed PVC roofs on two office buildings. The rest of the roofing and waterproofing work on the parking structure, including another garden roof, was completed by Courtney Waterproofing and Roofing. Photo: Stanford Health Center.

On the adjoining multi-level parking deck, Letner Roofing installed PVC roofs on two office buildings. The rest of the roofing and waterproofing work on the parking structure, including another garden roof, was completed by Courtney Waterproofing and Roofing. Photo: Stanford Health Center.

TEAM

Architect:
Rafael Viñoly Architects in association with Lee, Burkhart, Liu Inc.

General Contractor:
Clark/McCarthy—a joint venture of Clark Construction Co. and McCarthy Building Cos.

Roofing and Waterproofing Contractors:
Main hospital building and offices: Letner Roofing, Orange, Calif.
Adjoining parking structure: Courtney Waterproofing and Roofing, Irvine, Calif.

LWIC Provider and Installer:
Cell-Crete Corp., Hayward, Calif.

Composite Shake Roofing Tiles Replace Cedar Shingles

The Schwabs chose DaVinci Roofscapes composite shake roofing tiles for their re-roofing project.

The Schwabs chose DaVinci Roofscapes composite shake roofing tiles for their re-roofing project.

It can be tiring to own real cedar shake roofing. There are cedar roof shingles that need replacing from time to time due to popping or warping, and insect infestations need to be dealt with regularly.

For Dave and Jeanne Schwab, the effort of cleaning and applying shake oil to their massive cedar shake roof every five years or so eventually wore them down. They loved the look of shake on their home in Mt. Vernon, Wash., but hated the maintenance aspects.

“Our home was built in 1993, and there’s a lot of roofing involved in its design,” says Dave Schwab. “Eventually the roof really needed to be replaced. We liked how the natural cedar roofing looked on the house, but when we went shopping for a new roof we wanted a cedar shake alternative.”

THE RE-ROOFING PROJECT

The Schwabs discovered DaVinci Roofscapes composite shake roofing tiles and were sold. “The authentic appearance of the DaVinci fake cedar shake sold us right away,” says Schwab.

“Then you add in the Class A Fire Rating, the impact resistance and the lifetime limited warranty and it was easy to make our decision.”

The large roof on the Schwab home is broken up visually by seven skylights and the addition of decorative European-designed ridge vents. The DaVinci Multi-Width roof, in the Mountain blend, now covers the home and attached three-car garage.

The house was re-roofed in 2015. “Every time I pull up to the house I still get a ‘wow’ experience,” says Schwab. “The color is perfect for our home. It looks so natural, yet we know we’ll never again have to spend another hour maintaining this roof. That’s the real joy of selecting synthetic shake shingles.”

The DaVinci Multi-Width roof, in Mountain Blend, covers the home and attached three-car garage.

The DaVinci Multi-Width roof, in Mountain Blend, covers the home and attached three-car garage.

THE SEQUEL

The Schwabs were inspired to build an outdoor shed by the cover of an old issue of Country Living magazine. “When we saw this potting shed on the magazine cover in 2002, we knew the style matched our home perfectly,” says Dave Schwab. “We purchased the plans from the magazine and constructed it in 2004 to hold our snow blower, bicycles, lawn mower and gardening tools.”

In 2016, the real shake shingles on the shed needed replacing, and the Schwabs knew exactly what they wanted to do.

“It was very exciting to complete this DIY project a decade ago,” Jeanne Schwab says. “We wired it with electricity, and added insulation and pine tongue and groove. For the floor, we put in a black and white checkered vinyl. Now, up on the roof we’ve replaced the shake and added DaVinci simulated shake roofing that matches our home. We even used it on top of the cupola.”

“Now we have two structures on our property with unified looks,” says Dave Schwab. “Having the potting shed completed gives us a great deal of satisfaction … and we’re sure the new DaVinci roof will serve us well for many years to come.”

Roof Materials

Roof System Manufacturer: DaVinci Roofscapes

Roof Restoration Project Keeps Rehab Facility Operating

Skyline Roof Restoration

Bill Steeves (left) and Steve Broda launched Skyline Roof Restoration, a company that specializes in restoring roofs with coatings.

Rehabilitation facilities help their patients stay healthy. Keeping roofs healthy is another matter.

When the roof at a rehabilitation center in Colorado was reaching the end of its service life, roofing contractor Bill Steeves recognized it was the perfect candidate for roof restoration project. Steeves is the president of Skyline Roof Restoration Inc., based in Frederick, Colo. The company specializes in roof coatings. It was launched last year by Steeves and his partner, Steve Broda. Broda is the founder of Skyline Roofing Inc., a full-service commercial roof contracting firm, also located in Frederick, where both men have worked since 2006.

“We formed Skyline Roof Restoration as a vehicle to promote restoring roofs with coatings,” Steeves says. “We have both been involved with various coating projects in the past and wanted to offer our expertise to clients where restoration is their most prudent option.”

In the Denver area, the coatings market is booming in part due to changes in local energy codes, notes Broda. Several municipalities have mandated with that a roof tear-off and replacement, the R-values in the roof have to be brought up to those for new construction. “It was becoming unaffordable for some people to do total roof replacement and upgrade to R-30 or R-38,” Broda says. “We needed another tool to provide them with a roofing option that was economical and did not force them to add the extra R-value to their roof systems.”

In many cases, coating an existing membrane roof can be an excellent option. “It can save the customers a lot of money compared to a roof replacement, and depending on the system and the thickness, we can offer a 20-year NDL warranty,” Broda notes.

Skyline Roof Restoration

The Centre Avenue Health & Rehab project encompassed 21,863 square feet of low-slope roof on 10 separate roof levels. The low-slope sections were surrounded by a standing seam metal roof.

According to Steeves and Broda, the key to the success of a roof restoration is making sure the underlying substrate is a good candidate for the coating. Skyline Roof Restoration will only authorize a coating project if it is the best option for the facility. “Steve and I have a combined 77 years of experience in commercial roofing, and there are very few scenarios we have not run across,” Steeves says. “We have both built very strong commercial companies based on return customers and referrals. We both really care about the final product, value to our customers, and the relationships we have developed over the years.”

The Diagnosis

Steeves had a hunch that the roof at the Centre Avenue Health & Rehab facility in Fort Collins might be reaching the end of its life span. “We have been doing all of the roofing work for Columbine Health Systems, the owner of Centre Avenue Health & Rehab, for more than seven years and have developed a great working relationship with the owner,” he says. “We had never been called to Centre Avenue for any leaks, but I knew the building was about 18 years old.”

This aerial photo shows the Centre Avenue Heath & Rehab roof after the restoration process was completed.

This aerial photo shows the Centre Avenue Heath & Rehab roof after the restoration process was completed.

Steeves suggested it was time to conduct a roof inspection at Centre Avenue but was told to wait. Sure enough, the next time it rained, a leak was detected. When Steeves met his repair crew on the site, he noticed that the fully adhered EPDM roof system on the flat roof sections was just beginning to exhibit signs of oxidation. A few stress fractures were visible in the membrane. “It was a perfect candidate for a roof restoration,” he says.

In a meeting with the owner, Steeves suggested the application of a high-solids silicone restoration system from GE Momentive. “I explained that the restoration process would, in effect, freeze the aging process of the EPDM by protecting it from further UV degradation,” Steeves says. “I had also, prior to our meeting, completed some research and found out that the local power company was offering a rebate for any Energy Star-qualified roof covering, which further reduced his total capital outlay.”

When Steeves detailed the costs involved with the coating project as opposed to a tear-off and replacement, the owner gave him the go ahead on the roof restoration plan and opted for a 15-year NDL warranty.

Broda and Steeves note that there are cases in which the existing roof is too far degraded to work well with a coating, and in those cases, the only viable option is a roof replacement. The silicone coating can be used on membranes including EPDM, TPO, PVC, modified bitumen and smooth built-up roofs, as well as metal. “It works with all types of membranes, but you have to catch these roofs before the end of their serviceable life,” says Broda. “They have to have some life left in them to coat them. If we are not comfortable putting a coating on a roof, we won’t do it.”

Often all that is needed is minor repair of wall flashings, curb flashings and penetrations. Wet insulation is another problem to look out for. “We’ll do an infrared scan of the roof before we coat it to make sure we don’t have any wet insulation in there.”

Every proposal is also contingent on a successful adhesion test. A sample area is set up and a pullout test is conducted to determine if the product will adhere well.

Photos: Skyline Roof Restoration Inc.

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