Silicone Coating Restores the Roof, Reduces Utility Costs at Mixed-Use Complex

At the Shoppes of Johnson’s Landing in Angier, North Carolina, ACC applied a high-solids silicone roof coating on the 20-year-old metal roof to seal penetrations, restore the roof, and provide a white reflective coating. Photos: All-County Contracting (ACC)

Glenn Wujcik, the owner of All-County Contracting (ACC), headquartered in Raleigh, North Carolina, has been fascinated with spray rigs since he and his brother first used one in 1979 to insulate a van with spray polyurethane foam (SPF). His company specializes in applying SPF and roof coatings on existing buildings. Lately, he’s found silicone roof coatings are making up an increasing share of his company’s workload.

“The coatings industry in general is booming right now,” Wujcik says. “A lot of the TPO and EPDM roofs are nearing the end of their service life, and instead of tearing them off, if you catch them in time, you can go over it with the silicone coating and get a new 10-year warranty. Silicones have a proven track record. When you put it on properly, it weathers really well. It has excellent elongation.”

Wujcik characterizes himself as a hands-on owner who strives to be on the site for every job. He believes there is an art as well as a science to operating a spray rig properly, and experience is crucial. “I love doing this,” he says. “I’ve been doing it for more than 30 years, my business partner’s been doing it more than 30 years, and our best sprayer has sprayed more than both of us combined. We know what we have to do, we know how long it’s going to take, and we have the right equipment. We are really good about the preparation and the application.”

Coatings and spray foam are excellent products, but only in the right situations, notes Wujcik. They should only be used on the proper substrates and applied in the right conditions. “In spraying, the most important thing is knowing when not to spray,” he says. “Right now, I’m working on a job, and for the last two days, there have been 10-20 mph winds, and I haven’t finished it yet. I told the owner, ‘I haven’t oversprayed anything yet, and I don’t want to.’ I’d rather do it right and not have any problems.”

Wujcik points to a recent project on a mixed-use building in Angier, North Carolina, to illustrate some of the benefits of a silicone roof coating. “It’s a U-shaped building with about 14,000 square feet of roof space,” Wujcik notes. “There’s a bakery, a restaurant, a pharmacy, and a doctor’s office, and there are a lot of penetrations on the roof.”

The penetrations were the site of multiple leaks. Wujcik decided to use a high-solids silicone coating, GE Enduris 3502, to prevent leaks and extend the life of the roof. The monolithic coating will seal the penetrations, and the white reflective surface will provide an additional benefit: reduced cooling bills in the summer. “Putting a white coating on it is going to reduce their energy load in the summer pretty substantially,” he says.

Applying the Coating

On this project, the first step was to pressure wash the existing roof. “That’s where most coating jobs fail — surface preparation,” Wujcik states. “Washing the roof properly is one of the most important steps.”

The high-solids silicone coating was applied to the existing standing seam metal roof. Care had to be taken to ensure all sides of the metal ribs were properly covered with the material. Photos: All-County Contracting (ACC)

The company uses 4,000 psi belt-drive power washers, so care has to be taken not to damage the roof or skylights, which are covered and marked for safety reasons. The company follows all OSHA regulations, which in most cases means setting up safety lines 6 feet from the edge, with stanchions 10 feet apart, to establish a safety perimeter.

“Safety is my number one thing,” Wujcik says, “I’ve been doing this a long time and I’ve never had a lost-time accident. I preach safety. That is absolutely the most important — and accidents are expensive.”

The next step is to apply the GE Seam Sealer at the penetrations. “When this roof was originally installed 20 years ago, they did it textbook perfect,” Wujcik notes. “Each 4-inch pipe coming though had at least 20 fasteners holding it down.”

However, over time, the rubber grommets on the fasteners can degrade, and expansion and contraction can take their toll. “We have really hot summers here, we’ve seen roofs where literally thousands of fasteners have backed out,” he says.

The seam sealer is typically applied with a brush. “Any horizontal seams, any termination bars, any penetration that goes through the roof that has a screw, we apply the seam sealer,” he says. “It goes on quite thick — at about 80 linear feet per gallon.”

After the seam sealer cures for one day, the coating is applied. Spraying flat roofs with EPDM, TPO, and PVC membranes is a fairly straightforward process, according to Wujcik. “You basically spray it just like you would spray paint a wall,” he says. “You overlap your spray pattern 50 percent. I’ve been doing it for so many years, and you get a feeling for how fast you can go.”

After the roof was power washed, the seam sealer as applied to the seams and penetrations. After it cured, two coats of the high-solids silicone product were sprayed on the roof. Photos: All-County Contracting (ACC)

A wet mil gauge is used to ensure the proper thickness. Wujcik notes the high-solids silicone formulation has very little shrinkage as it dries.  “As we’re spraying, we insert the gauge into the wet coating and it tells you how many mils you have sprayed down. In this case, we were applying to achieve 21 dry mils.”

The spray rig is set up on the ground and operated by one man, while the sprayer and the hose man are working on the roof. “It’s a minimum of a three-man crew per coating rig,” he notes. “You’re dealing with about 6,000-7,000 psi of pressure, so you need special hoses rated for at least 7,000 psi. You never want to kink them. If you busted a hose, by the time someone came down from the roof to the machine, you could pump out 20 gallons on the ground. That’s why you need a ground man.”

Flat roofs are sprayed perpendicular to the roof, but the standing seam metal roof on this project called for a different technique. “On metal roofs with high ridges, if you don’t angle your gun you’ll miss the sides of the ribs,” Wujcik points out. “You have to do it from one direction, working one way, and then turn around and do it from the other direction, working the other way. If you try to spray straight down on the roof, you’re going to miss the nooks and crannies in all of those ribs.”

The surface area of the ribs also has to be taken into account when calculating the amount of liquid that will be applied, notes Wujcik.

The final step in the process is to touch up the applications at the penetrations to ensure a clean look. On vertical surfaces including parapet walls, crews ensure the coating is applied to a uniform height. “On the last day, we take up brushes and rollers and cut in straight lines,” he says. “That really finishes the job. The detailing gives it that final touch.”

Open for Business

The active and open jobsite posed some challenges. “There were a lot of cars around the building, so we had to be very careful not to hit them with overspray,” Wujcik notes. “When you’re working on a plant, you might be able to move all of the cars to a different location, but at doctor’s offices and restaurants, you have traffic in and out of the parking lot all of the time. We can use car covers if there are a few cars there, but when they are in and out like that, it’s not practical, so you have to be very careful when you do the job.”

The job was completed in the winter, and bad weather resulted in some delays. “A job like this in the summertime would have been a weeklong project at most,” Wujcik notes. “This project took almost a month because we had an exceptionally cold winter with a lot of high winds. It took extra time, but that’s my philosophy: If it’s not the right conditions, I just won’t do it.”

The project qualified for a 10-year warranty, and when it expires ACC plans to be there to pressure wash and recoat the roof for another 10-year warranty.

“We inspect our jobs every year,” Wujcik says. He notes that annual roof inspections and routine maintenance are the simplest and most cost-effective ways to ensure the roof’s life span. Yet these steps are often neglected.

“It’s amazing that some of these multi-million-dollar companies don’t send their maintenance guys up on the roof for 10 minutes to check the drains,” he says. “If a roof has 2 inches of pine needles around the drain, the whole roof has to have 2 inches of water on it before it begins to drain. That puts tremendous, tremendous stress on a roof. Keeping your drains clear is really important.”

TEAM

Roofing Contractor: All-County Contracting (ACC), Raleigh, North Carolina

MATERIALS

Roof Coating: Enduris by GE 3502, GE Performance Coatings, www.GE.com/silicones
Seam Sealer: GE Seam Sealer, GE Performance Coatings

Standing Seam Metal Roof Crowns Jaindl Farms Office Addition

The Jaindl Farms office complex sits on an a 12,000-acre turkey farm complete with its own feed mill. Photo: Steve Wolfe Photography.

Jaindl Farms is a multigenerational family business that encompasses a land development company and a fully integrated turkey farm. Its headquarters sits on 12,000 acres of farmland in Orefield, Pennsylvania, where the company grows the crops to make the feed for its turkeys. When the owners contacted MKSD Architects in Allentown, Pennsylvania, about adding space to their offices, the goals were to provide room to expand and to honor the Jaindl family’s history and legacy.

“The owner has a deep appreciation for all things agrarian and for old barns,” recalls Todd Chambers, partner, MKSD Architects. “One day we were meeting about the project, and he said, ‘What do you think about reusing the timber frame of an old barn?’ A light bulb went off.”

A large barn in Northampton County was located and dismantled, and the frame was repurposed for the office addition. The new two-story stone structure connects to the existing one-story office building, which was roofed with natural cedar shakes. A standing seam metal roof was specified for the new structure in

The new two-story addition was constructed with wood repurposed from a barn built around 1900. It was topped with a new standing seam metal roof. Photo: Steve Wolfe Photography.

keeping with the traditional architecture of the area. “We were concerned about the aesthetics, so standing seam was an obvious choice,” Chambers says. “We tried to keep the penetrations to a minimum and keep them out of the view of the main facade.”

The roofing contractor on the project was The Gehringer Company, headquartered in Whitehall, Pennsylvania. The company was called in to handle the project by the general contractor, Allentown-based Bracy Contracting Inc. The Gehringer Company’s president, Tom Gehringer, recommended a Dutch Seam roof system manufactured by ATAS International because it had the durability and aesthetics the project required, but was also easy to install. “It’s less labor-intensive than other systems because it doesn’t require a mechanical seamer,” he notes.

A Turkey Shoot

The roofing installation went very smoothly, according to Gehringer and Chambers. The Gehringer Company crews installed 6,400 square feet of ATAS MRD-110 Dutch Seam panels on the roof. They also installed approximately 500 square feet of metal panels as siding on the dormers. “It’s a 12-inch-wide piece with a raised section at the lock,” notes Gehringer. “When it’s installed looks like board and batten siding.”

The roof features dormers to bring in natural light. The dormers are sided with metal panels to minimize roof maintenance. Photo: The Gehringer Corporation.

Installation began in January 2017, so the weather posed the biggest challenge. “We did it when the temperatures were pretty low. The highs were in the 20s,” Gehringer recalls. “The nice thing is you can install the system in almost any temperature.”

After ATA-Shield high temperature synthetic underlayment was applied to the entire surface of the plywood deck, the roof panels were installed. “We worked from our aerial lifts,” Gehringer explains. “We purchased two aerial lifts several years ago and now use them for almost all of our steep roofing installations.”

Details included SL-2 Snow Meister snow guards from Berger Brothers. “In this climate, one of the tricky pieces with standing seam is sliding snow, so we specified snow guards that clamp to the standing seams,” Chambers says. “The ones we used emulate the turkey tail feathers.”

Roofing crews also tied in a small section of new cedar shakes to extend the hallway of the existing structure and connect it to the new addition. “We installed the original cedar shakes on the adjacent section for Bracy Contracting almost 20 years ago,” notes Gehringer.

The project went off without a hitch. Gehringer credits his company’s experienced crews and field supervisors for its

The snow guards installed on the project were chosen in part because they reminded the business owners of a turkey’s tail feathers. Photo: The Gehringer Corporation.

excellent track record. “I believe we’re one of the larger architectural metal roofing installers in our area and have virtually no callbacks on roofs we install,” he says. “What it boils down to is having people that know how to do it right — and having people that are committed to doing it right. And with architectural metal work, you have to take your time and do it right. This metal roof is going to look exactly like it looks now for at least 30 years.”

Looking back, what strikes Chambers is how different this project was from his typical assignments. “We’re commercial architects. We do a lot of health care work,” he says. “The ability to design something that’s not done every day, and is different than your typical approach, is refreshing and fun.”

TEAM

Architect: MKSD Architects, Allentown, Pennsylvania, www.MKSDarchitects.com
General Contractor: Bracy Construction Inc., Allentown, Pennsylvania, www.BracyConstruction.com
Roofing Contractor: The Gehringer Corporation, Whitehall, Pennsylvania, www.GehringerRoofing.com

MATERIALS

Metal Roof Panels: ATAS Dutch Seam MRD110, .032 aluminum, Medium Bronze, ATAS International Inc., www.ATAS.com
Metal Siding Panels: ATAS Multi-Purpose Panels MPW120, .032 aluminum, Sierra Tan, ATAS International Inc.
Synthetic Underlayment: ATA-Shield, ATAS International Inc.
Snow Guards: SL-2 Snow Meister Snow Guards, Berger Building Products, www.bergerbp.com

Communication Is Crucial When You’re Working on Top of the Village Hall

Lincolnshire Village Hall houses city offices and a police station. The structure’s roof and gutter systems were recently replaced by All American Exterior Solutions. Photos: DaVinci Roofscapes

The Lincolnshire Village Hall, located in Lincolnshire, Illinois, houses city departments and the offices of elected officials, as well as the Lincolnshire Police Station. When its natural cedar shake roof and inlaid gutter system began to fail, city officials looked for a solution that would provide the desired aesthetics but last longer and require less maintenance.

Dale Pole of All American Exterior Solutions, a full-service union roofing contractor headquartered in Lake Zurich, Illinois, thought he had the answer. Pole, a 32-year industry veteran who is now the company’s vice president of operations, dropped off samples of a synthetic shake roofing tile manufactured by DaVinci Roofscapes and asked if city officials wanted to give it a try.

All American was awarded the job in 2016. The scope of work consisted of a complete re-roof of the complex, including the steep-slope roof system on the hall and tower. The project also included five sections of flat roofing and replacement of the copper gutter system. The job was complex, but All American was up to the challenge. The company worked in conjunction with Illinois Roof Consulting Associates, located in McHenry, Illinois.

The Steep-Slope System

The building’s signature feature is the observatory tower over the main entrance, which extends approximately 45 feet in the air. The main roof features a pitch change at the rear of the building, where the roof goes from 4:12 to 12:12. All

The complex is located right next to a large pond and bordered by mature trees, so the jobsite limited access to sections of the roof. Photos: DaVinci Roofscapes

American installed approximately 23,000 square feet of the DaVinci product, Bellaforté Shake in Tahoe, a blend of four colors. The company also fabricated the new gutter system out of 20-ounce lead-coated copper with soldered seams. Approximately 600 feet of new gutters were installed.

Work began in late spring, and the 23-year-old existing roof was torn off in sections. GAF Weather Watch Water & Ice Shield was applied as a leak barrier, followed by Proof Synthetic Underlayment from ABC Supply. “We couldn’t install the tiles until the inlaid gutter was in place, so we used a synthetic underlayment to keep everything watertight during the tear-off process,” says Pole.

Gutters were installed in an 8-inch-by-8-inch trough. “There was a course or two of the DaVinci, and then the inlaid gutters were set into the roof, and the roof starts again,” notes Pole. “The trough area was also layered with ice and water shield before the copper gutters were put in.”

Transitions and flashings were also made of copper. “Everything on this job was 20-ounce lead-coated copper,” notes Pole. “All of the valleys, transition flashing, and the gutters were all lead-coated copper.”

The DaVinci synthetic shake tiles were easy to install, according to Pole. “They are nailed in place,” he says. “You can use stainless steel nails or hot-dip galvanized nails. In this case, we used 1-1/2-inch stainless steel ring shank nails.”

Low-Slope Areas

The low-slope roofs were covered with a GAF two-ply modified bitumen system. Michael McCory, project manager, headed up the crews on the five low-slope sections, which totaled approximately 2,700 square feet.

The observatory tower over the main entrance features a walk-out area with a modified bitumen roof system. Photos: DaVinci Roofscapes

The low-slope sections had different substrates. Two balconies had concrete decks, while two canopies and an area over the garage had wooden decks. Some of the flat roofs had paver systems, which had to be removed and replaced after the new system was installed.

Half-inch DensDeck Prime cover board from Georgia-Pacific was installed over the wood and concrete decks. The GAF mod bit system consisted of a Ruberoid 20 base sheet and Ruberoid Granular FR cap sheet in white. “It was applied in a cold-process adhesive,” says McCory. “No torches were used. A manufacturer’s inspection was part of the process for a 20-year warranty.”

The upper level of the tower features a small walk-out balcony. “That was probably the most difficult area,” notes McCory. “It was covered with pavers and difficult to reach. We had to remove the pavers and store them in the stairwell during the installation.”

A Challenging Jobsite

Logistics at the jobsite posed a few problems. “The hardest part was the observatory tower by the front entry,” Pole recalls, noting an 80-foot man lift was used to remove the existing cedar and install the synthetic shake. “On the tower, it was all lift work. For other parts of the project, workers on both the steep-slope and the low-slope portions of the roof were tied off at all times.”

Crews installed 23,000 square feet of Bellaforte Shake by DaVinci Roofscapes on the building’s main roof. Photos: DaVinci Roofscapes

The building is bordered by mature trees and a large pond, limiting roof access. “On the west side of the structure, the pond comes right up against the building,” Pole says. “We had to use a lift that could stretch over that pond to get that end of the roof.”

An Equipter mechanized debris hauler was used to get around narrow grassy areas near the building. “We used an Equipter, which is like a gas-powered, mobile dumpster, to drive around the building and enter the courtyard for our debris,” Pole says. “We have two of those pieces of equipment, which we use on a lot of our jobs to get the shingles out. They don’t damage lawns and help protect the landscaping.”

The building was occupied during the installation, so care had to be taken to ensure business was not disrupted and passers-by would be safe. “The village offices were open for business while we were working, and the police station was open as well,” notes McCory. “The tower and front entryway had to be completed on the weekend, as that was the only walkway for the public to get in.”

The police station had several doors, so crews had to coordinate with officers while replacing the roof on that section and let them know where they were setting up the crane. The courtyard area was also restricted at times.

“We obviously had to keep everything neat and organized and make sure we cleaned up every day to make sure nothing would bother the people working in the building and the residents who came in to the village hall to get permits or whatever the case may be,” McCory says. “You don’t want police cars getting flat tires.”

Communication is the key to meeting customers’ needs, especially with an occupied building. “Whoever the building owner is, I give him my cell number and make sure I have his,” Pole notes. “I try to stay in contact with them and let them know if anything is changing. I ask them if they have any questions or issues, or if their schedule is changing. On this project, they said it was like we were never even there, and that’s what we like to hear.”

Feedback from the city has been positive, according to Pole. “They are very happy with it,” he says. “The system has the look they wanted. It looks like shake, they had a lot of colors to choose from, and they won’t have the maintenance issues that they did with the cedar. And it will last a lot longer. They will save a whole roof replacement phase in the life of the DaVinci product.”

Pole believes his company’s diverse portfolio gives it an edge. “We’re one of very few union companies that have their own shinglers, flat roofing crews, and sheet metal workers in house. We also do waterproofing, metal wall panels and insulation,” he says.

“This project shows our strength — we can do it all.”

TEAM

Roofing Contractor: All American Exterior Solutions, Lake Zurich, Illinois, www.aaexs.com
Roof Consultant: Illinois Roof Consulting Associates, McHenry, Illinois, www.irca.com

MATERIALS

Steep-Slope Roof System
Synthetic Shake: Bellaforté Shake in Tahoe, DaVinci Roofscapes, www.DaVinciRoofscapes.com
Underlayment: Proof Synthetic Underlayment, ABC Supply Co. Inc., www.ABCsupply.com
Leak Barrier: Weather Watch Water & Ice Shield, GAF, www.GAF.com

Low-Slope Roof System
Modified Bitumen Base Sheet: Ruberoid 20, GAF
Modified Bitumen Cap Sheet: Ruberoid Granular FR, GAF
Cover Board: DensDeck Prime, Georgia-Pacific, www.DensDeck.com

Challenging Wintertime Installation Completed on Tight Schedule

Roofing work on the 250,000-square-foot expansion of Chicago Premium Outlets was completed in five months under challenging weather conditions. Photos: Johns Manville

The Chicago Premium Outlets 250,000-square-foot expansion includes 30 new or expanded stores, two new restaurants, 2,200 additional parking spaces, public art, outdoor fireplaces and a large pond. According to Mike Reynolds, senior project manager for Olsson Roofing Company Inc., headquartered in Aurora, Illinois, “Chicago Premium Outlets is more of a pedestrian mall since the expansion.”

Located approximately 40 minutes from downtown Chicago, the complex now features more than 170 stores including Adidas, Coach, Nike, kate spade new york, Movado Company Store, Saks Fifth Avenue Off 5th, Tommy Hilfiger, Vera Bradley, and Restoration Hardware. The reflecting pond is an inviting rest stop for shoppers, and it includes a play area and a pier-like pavilion with tables, chairs and umbrellas. To support the expansion, Olsson Roofing Company, the roofing contractor on the project, selected a TPO roofing system manufactured by Johns Manville.

A Challenging Installation

The project team faced two pressing challenges: weather and an aggressive timeline. The roofing-installation time frame fell between January and May, so the majority of the work needed to be completed during the coldest time of year. “We had our work cut out for us,” Reynolds says.

Photos: Johns Manville

The second challenge was the schedule. “The Olsson Roofing team worked several Saturdays and overtime to get the project finished as quickly as possible,” notes Reynolds. “We even heated the inside of the buildings to melt the snow on the roof and shoveled areas to make room for the product on the roof.”

Olsson Roofing chose to install the roof system using the RhinoBond induction welding attachment system from OMG Roofing Products. “We knew that RhinoBond would contribute to a successful installation of the TPO since we were dealing with below-freezing temperatures for most of the first 90 days,” Reynolds says.

Photos: Johns Manville

The 60-mil TPO was installed over two layers of ENRGY 3 roof insulation (one layer was 2 inches thick and the 2.5 inches). The majority of the roof surface features white TPO, but some EPDM was also used. “Olsson Roofing also used JM EPDM for the parapet walls since rubber is more flexible and quicker to install in cold weather and on vertical surfaces. They appreciated the ability to mix the systems and keep the project moving forward during cold-weather installation,” says JM sales representative Jason Conley. “With such a tight deadline, it was great to have the versatility of two excellent products — the durable 60-mil JM TPO and the flexibility of the JM EPDM, which provided just the right solution for our customer.”

TEAM

Architect/Specifier: FRCH Design Worldwide, Cincinnati, Ohio, www.frch.com
General Contractor: Graycor Inc., Oakbrook Terrace, Illionis, www.graycor.com
Roofing Contractor: Olsson Roofing Company Inc., Aurora, Illinois, www.olssonroofing.com

MATERIALS

Insulation: ENRGY 3, Johns Manville, www.JM.com
Membrane: 60-mil TPO in White, Tan and Light Grey, Johns Manville
Attachment System: RhinoBond, OMG Roofing Products, www.OMGroofing.com

Offices & Warehouses

Workforce Essentials, Clarksville, Tenn.

Team

Roofing and Wall Panel Installer: Modern Heating Cooling Roofing, Clarksville, (931) 647-0815
Architect: Lyle Cook Martin Architects, Clarksville
Metal Panel Distributor: Commercial Roofing Specialties Inc., Nashville, Tenn.

Workforce Essentials is a private, non-profit organization providing workforce development services for the Tennessee Department of Labor in a nine-county area.

Workforce Essentials is a private, non-profit organization providing workforce development services for the Tennessee Department of Labor in a nine-county area.

Roof Materials

To meet design objectives, four different PAC-CLAD products were selected. The roof uses 20,500 square feet of 16-inch, 24-gauge Silver Metallic Tite-Loc Plus panels. The façade features 7,800 square feet of Precision Series wall panels finished in Sierra Tan and installed vertically. Complementing the façade is 4,000 square feet of 12-inch Almond Flush panels installed as soffit. In addition, 4,520 square feet of 24-gauge Medium Bronze flat sheet was used for fascia and trim.

“The Tite-Loc Plus panels were long—85 feet—and were rollformed onsite,” says Bill Kimbrough Jr., estimator and project manager for Modern Heating Cooling Roofing. “Getting them up to the high roof was a challenge. All other profiles were fabricated and delivered by Petersen. Currently, PAC-CLAD is about the only product we use.”

Metal Panel Manufacturer: Petersen Aluminum Corp.

The roof uses 20,500 square feet of 16-inch, 24-gauge Silver Metallic Tite-Loc Plus panels.

The roof uses 20,500 square feet of 16-inch, 24-gauge Silver Metallic Tite-Loc Plus panels.

Roof Report

Workforce Essentials is a private, non-profit organization providing workforce development services for the Tennessee Department of Labor in a nine-county area in the middle of the state. Located on a highly visible urban-infill site, the new Workforce Essentials headquarters and career training center is situated at a “gateway entry” intersection to the downtown district. The new 40,000-squarefoot facility consolidates services that had been provided at agency offices previously scattered around the city. After initially considering renovation of an aging building on the site, the organization’s board of directors determined that construction of a new, energy-efficient headquarters was a better course of action. Good visibility and an easily identifiable aesthetic were important to site selection and building design criteria.

Different departments within the building are visually and strategically defined in separate wings and entrances. The administrative office wing to the south is defined by a vertical brick corner tower and sloping metal roof planes and cladding. The larger career training center portion of the building is introduced by metal wall panels in a calming color palette of Sierra Tan. Thematic entry canopies, protruding aluminum sunshades and aligned horizontal fenestration tie together the architectural composition. The overriding idea is for the building to serve as a machine with different parts working together for a common purpose.

Brad Martin, principal/designer at Lyle Cook Martin Architects, explains: “Workforce Essentials has a variety of regional offices throughout the area it serves. All are different and very few are freestanding. The organization has never really had a corporate look or identity. Now, with this new building, we can incorporate its design features and architectural aesthetics into future new buildings and renovations and begin to develop an iconic look.”

Photos: Petersen Aluminum Corp.

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A Dynamic Rooftop Renovation Lures a New Type of Workforce

Commercial office properties have always had to contend for tenants as a part of doing business and, increasingly, existing buildings are facing stiffer competition from new office properties offering integrated amenities packages that go way beyond the lobby coffee shop. As a new generation of employees enters the workforce, employers are challenged to secure leases that provide more than simple office space, instead offering an attractive combination of recreation, retail and relaxation options that feel more akin to a resort than a workplace. In the case of Prudential Plaza, a 41-story structure in Chicago built in 1955, the challenge for the building owners was to offer new value in a building originally designed to respond to a workforce that no longer exists.

The rooftop transformation is highlighted by a fully wired amphitheater, fire-pit lounge and a small lawn accompanied by a new 12,000-square-foot fitness center and a 7,000-square-foot clubhouse located inside.

The rooftop transformation is highlighted by a fully wired amphitheater, fire-pit lounge and a small lawn accompanied by a new 12,000-square-foot fitness center and a 7,000-square-foot clubhouse located inside.


Investing more than $85 million into building renovations, Prudential Plaza’s owners envisioned a top-to-bottom rehabilitation, crowned by a 13,000-square-foot amenities deck on the 11th floor. The rooftop transformation is highlighted by a fully wired amphitheater, fire-pit lounge and a small lawn accompanied by a new 12,000-square-foot fitness center and a 7,000-square-foot clubhouse located inside. These amenities are exclusively for building tenants and their employees. Kyle Kamin, a Los Angeles-based CBRE Inc. executive vice president and tenant broker who has clients in Prudential Plaza called the roof deck “a game-changer with an unbeatable view.”

Engineering

Certainly the idea of a gorgeous tenant recreation and lounge area would appeal to most; however, few outside of the design and construction industry would appreciate the immense challenge of adding this type of space on top of a 60-year-old roof. When Wolff Landscape Architecture, Chicago, was asked to partner with Chicago-based architecture firm Solomon Cordwell Buenz for landscape design, project manager Ishmael Joya quickly understood the complexities of the situation. Joya is a landscape architect with 15 years’ experience, specializing in green-roof construction.

“Prudential Plaza is a classic figure in Chicago’s skyline and the first time we walked the project it was clear that the 4 1/2-inch-thick roof deck was going to present some design and construction challenges,” Joya remarks. Although the Wolff Landscape Architecture team has completed many green-roof projects, including renovations, Joya realized that adding what is essentially a mini-park to a very thin structural surface was going to require out-of-the-box thinking. “In any roof-deck renovation, it’s critical to reduce the weight of the building materials because the building is only designed to support a maximum amount of weight and that can’t be compromised,” he says.

Joya worked closely with the design team’s structural engineer, Wiss, Janney, Elstner Associates Inc., Chicago, to make sure the appropriate products were specified to support the expected weight of each area of the renovation

Demolition and Interim Roof

Like many large-scale occupied renovation projects, Prudential Plaza’s overall renovation was executed in multiple phases, allowing construction activities to take place while tenants maintained their typical routines. Romeoville, Ill.-based Preservation Services Inc., a commercial roofing company, was responsible for rehabilitating the original 11th-floor roofing structure. The original roof was a modified bitumen membrane that had been applied directly to a layer of lightweight concrete and covered by 2- by 2-foot pavers. Preservation Services carefully removed the pavers, old membrane and thin layer of concrete.

Investing more than $85 million into building renovations, Prudential Plaza’s owners envisioned a top-to-bottom rehabilitation, crowned by a 13,000-square-foot amenities deck on the 11th floor.

Investing more than $85 million into building renovations, Prudential Plaza’s owners envisioned a top-to-bottom rehabilitation, crowned by a 13,000-square-foot amenities deck on the 11th floor.

Because the building is located adjacent to a series of vaulted streets, the construction team was unable to use a high-reach crane because the weight of the crane would have required special provisions and necessitated street closures. Consequently, crews carried all removed debris down through the freight elevators during the night while the building was largely empty. At the end of each night, a single-ply EPDM membrane was rolled out, seamed and secured to protect the under structure from possible water penetration the next day.

Once demolition was complete, the EPDM was opened in select areas so repairs to the concrete slab could be made by other trades. When repairs were complete, a single layer of torch-applied modified bitumen membrane was applied to the deck along with additional structural steel required to support the added weight of trees, planters, patios and people. Finally, a white, granular-surfaced modified bitumen roof over tapered isocyanurate foam insulation was installed making the undersurface ready for the plaza deck renovation work.

Weight Considerations

Joya recommended a lightweight expanded polystyrene (EPS) material with high compressive strength that is used to reduce axial loading on structures. He has found the product very easy to work with, which saves time and money, ultimately allowing designers to put more of the client’s investment into tangible value users will see and feel rather than subsurface building materials.

On the Prudential Plaza roof-deck renovation, two types of EPS were used. EPS 15 was used in areas that would largely be filled with plants and wouldn’t bear much foot traffic. EPS 46, chosen for its high compressive strength, was used as a structural fill across the design’s many grade changes and in areas that would bear more weight of roof-deck occupants. For Joya, another advantage of using the EPS is being able to see the shape of the assembled product and make any required changes before the concrete is poured and work becomes significantly more complicated.

PHOTOS: Wolff Landscape Architecture

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Projects: Office and Warehouse

BMC ISSAQUAH, ISSAQUAH, WASH.

Because of the steep slope of this roof, the Columbia Roofing & Sheet Metal crew installed 60-mil Sureweld HS (High Slope) TPO.

Because of the steep slope of this roof, the Columbia Roofing & Sheet Metal crew installed 60-mil Sureweld HS (High Slope) TPO.

Team

Roofing Contractor: Columbia Roofing & Sheet Metal, Kent, Wash.
Project Foreman: Rudy Sanchez

Roof Materials

Because of the steep slope of this roof, the Columbia Roofing & Sheet Metal crew installed 60-mil Sureweld HS (High Slope) TPO. HS TPO contains more fire-retardant chemicals in the membrane to help decrease the spread of fire. In addition, 1/4-inch Securock Glass-Mat Roof Board was installed, which gave the building a Class A fire rating while helping protect against moisture and mold.

TPO Manufacturer: Carlisle Syntec Systems
Roof Board Manufacturer: USG

Roof Report

BMC Issaquah manufactures doors and high-end cabinetry. The industrial building features a 525-square barrel roof that was very wet and experienced dry rot. The crew replaced nearly 150 sheets of plywood throughout the project.

The main challenge during installation was safety because of the extreme slope. The barrel roof is nearly 60-feet tall from the bottom to the top of the barrel, making installation on the edges difficult because crewmembers had to hot-air weld rolled product on a nearly vertical surface. The HS TPO added another level of difficulty while welding along the edges.

The project was completed on May 1, 2015.

PHOTO: Columbia Roofing & Sheet Metal

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Projects: Office

DPR Construction, Phoenix

Eighty-two Daylighting Systems were installed in the renovated 16,533-square-foot building.

Eighty-two Daylighting Systems were installed in the renovated 16,533-square-foot building.

Team

Roofing contractor: Arithane Foam, Corona, Calif.
Architect/engineer: SmithGroupJJR, Phoenix
Daylighting systems distributor: Norcon Industries, Guadalupe, Ariz.

Roof Materials

Eighty-two Daylighting Systems were installed in the renovated 16,533-square-foot building, formerly an abandoned retail boutique at the corner of 44th Street and Van Buren in Phoenix.

“The use of the Daylighting Systems was an integral part of our sustainability and lighting energy savings plans for the renovated space,” says Dave Elrod, regional manager of DPR Construction, Phoenix. “The products are a cost-efficient solution to provide lighting since they nearly eliminate the need for artificial daytime lighting.”

In addition, the roof is composed of foam with an R-25 insulation value (approximately 4-inches thick) over plywood sheathing.

Daylighting systems manufacturer: Solatube International Inc.
Foam roofing manufacturer: Quik-Shield from SWD Urethane

Roof Report

DPR Construction is a national technical builder specializing in highly complex and sustainable projects. In less than 10 months, the design-build team researched, designed, permit-ted, and built a highly efficient and modern workplace with numerous innovative sustainability features.

In addition to natural daylighting, the office features an 87-foot zinc-clad solar chimney, which releases hot air from the building while drawing cooler air in; shower towers that act as evaporative coolers to regulate building temperatures; 87 operable windows designed to open and close automatically (based on indoor/outdoor temperatures); and two “vampire” shut-off switches to keep electrical devices (radios, cell-phone chargers, microwaves) from using plug energy when no one is in the office.

Access to the building was limited during construction. Spray foam roofing, which took about seven days to complete, had to be done in small quadrants because of the tight schedule as work was progressing in the other sections. The roofing workers were challenged by the barrel-shaped roof, which created footing difficulties, and the many penetrations that had to be flashed, including all PV support legs, Solatubes, skylights and HVAC penetrations. Work was completed in the middle of winter, so additional protections and efficiencies were required.

The circa-1972 building has been officially certified as a Net-Zero Energy Building by the Seattle-based International Living Future Institute through its Living Building Challenge program. It also has received LEED-NC Platinum certification from the U.S. Green Building Council, Washington, D.C.

PHOTOS: Ted Van Der Linden, DPR Construction

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A Standing-seam Roof Protects a Bank and Its Offices for the Long Term

Located on a high-traffic, signature intersection in Taylorville, Ill., Palmer Bank sought a timeless design that would visually represent its strength and stability to the community of just more than 11,000 people.

Design for the project was provided by The Redmond Co., Waukesha, Wis. The design team blended extensive detailing and profiling of the metal roof with a masonry façade to create an attractive prairie-style look.

Design for the project was provided by The Redmond Co., Waukesha, Wis. The design team blended extensive detailing and profiling of the metal roof with a masonry façade to create an attractive prairie-style look.

Design for the project was provided by The Redmond Co., Waukesha, Wis. The design team blended extensive detailing and profiling of the metal roof with a masonry façade to create an attractive prairie-style look.

“We clearly wanted to take advantage of the great location with a strong, timeless design,” says Andy Young, The Redmond Co.’s director of project development and construction manager on the project. “We presented two options to the bank regarding the roof … It was pretty unanimous that everyone liked the standing-seam profile look. We also liked the life-cycle cost of the roof since the bank plans to be the owner of this building for the long term.”

Installation of the standing-seam roof was completed by E.L. Pruitt Co., Springfield, Ill.

Installation of the standing-seam roof was completed by E.L. Pruitt Co., Springfield, Ill.

Installation of the standing-seam roof was completed by E.L. Pruitt Co., Springfield, Ill. The crew, which consisted of six tied-off workers, installed fascia, gutters, downspouts and soffit. Flashing components were custom-fabricated in E.L. Pruitt’s shop.

The metal is coated with ENERGY STAR-approved colors and is vented for optimal airflow, which greatly in-creases the roof’s longevity and energy efficiency. The metal was installed over roof-deck protection and a self-adhered underlayment.

The metal is coated with ENERGY STAR-approved colors and is vented for optimal airflow, which greatly in-creases the roof’s longevity and energy efficiency.

The metal is coated with ENERGY STAR-approved colors and is vented for optimal airflow, which greatly in-creases the roof’s longevity and energy efficiency.

According to Dallas Stephenson, E. L. Pruitt’s project manager, the roofing job took about six weeks to complete. He explains: “The most difficult part was doing all the seam layout because the product requires a progressive install, which means you can’t really start in the middle of the roof and work both directions. You have to start in a corner and work out of a corner and then work into a corner and then work back out of the corner.”

The metal was installed over roof-deck protection and a self-adhered underlayment.

The metal was installed over roof-deck protection and a self-adhered underlayment.

Stephenson notes symmetrically lining up seams on the bank’s dormers and then across the roof was challenging. “Once we got all that figured out—took all the measurements on the job site and confirmed them—it went fairly smoothly,” he says.

“We knew the many hips and valleys would be somewhat of an installation challenge, but the installer did a terrific job,” Young notes.

Stephenson is quick to return the compliment: “Scott Brooks, site superintendent, and Andy Young from The Redmond Co. did an excellent job of picking a good team to build Palmer Bank. Everything just worked out great!”

PHOTOS: Petersen Aluminum Corp.

Team

Roofing installer: E.L. Pruitt Co., Springfield, Ill.
Designer: The Redmond Co., Waukesha, Wis.

Roof Materials

Approximately 9,000 square feet of 24-gauge, 16-inch Snap-Clad panels and 2,200 square feet of PAC-850 Soffit Panels were utilized to meet the design objectives. The Snap-Clad panels were finished in Charcoal and the 0.032 PAC-850 Panels were finished in Slate Gray.
Panels’ manufacturer: Petersen Aluminum Corp.
Roof deck protection manufacturer: Deck-Armor from GAF
Underlayment manufacturer: Grace Ice and Water Shield

A Design Firm Trusts Its Regular Roofing Contractor to Install a New-to-him Insulated Metal Panel on its Office

David Miller, owner of Alpine Roofing LLC, Durham, N.C., has been in business since 2008. He specializes in what he calls the “complete roofing package”—making sure that all the areas of a roof are properly installed so the roof system lasts for 30 years or more without any problems. Miller and his crew’s attention to detail has made him the chosen roofing contractor of Durham-based BuildSense Inc., a residential design and construction firm that has a sustainability emphasis.

BuildSense Inc. is a Durham, N.C.-based residential design and construction firm that has a sustainability emphasis. PHOTO: Catherine Wilborne Photography

BuildSense Inc. is a Durham, N.C.-based residential design and construction firm that has a sustainability emphasis. PHOTO: Catherine Wilborne Photography

Miller knew he was doing good work for BuildSense, but he was assured of this fact when BuildSense’s owners—Randall Lanou, LEED AP, MCGP, and Erik Van Mehlman, AIA, CGP—asked him to reroof the existing building that would become the firm’s new office. Not only did they trust Miller enough to reroof their practice’s new home, but they also entrusted him with a roof cover he had never installed before.

“They knew I hadn’t worked with this insulated metal panel product before,” Miller recalls. “But they said I had always done them right and they wanted to give me the opportunity to look at this type of project. It seemed like it was up our alley. We handle things we haven’t done before with attention to detail and an understanding of how water causes problems. We try to do the best job we can.”

Sustainability Focus

BuildSense’s new office at 502 Rigsbee in Durham was built in 1945 as a farm-equipment-maintenance building. The structure had spent its last 30 years as various automotive service centers. The 1-story, 6,000-square-foot solid masonry building had optimal orientation to achieve Lanou and Mehlman’s daylighting and solarpower goals. By adding a second story in which BuildSense and tenants (occupied today by a marketing firm and a yoga studio) could operate, Clear-Vue Glass, BuildSense’s partner in the building’s purchase, could maintain an office, fabrication facility and showroom at pedestrian level.

To create the most energy-efficient building possible, Lanou and Mehlman opted to take the existing structure down to its skeleton, leaving only the masonry shell and primary steel columns and girders. Originally, they planned to maintain the existing roof and build the second story on top. However, the roof sloped from north to south about 3 inches for drainage. The partners decided to remove the wood framing, add more steel and a metal deck, and pour a new level composite concrete slab for the second story.

BuildSense pursued a tight, well-insulated building envelope. For the roof, Lanou and Mehlman specified an insulated metal panel featuring a 6-inch urethane core that boasts an R-value of 42. “It’s also painted white, which significantly helps us reduce our cooling loads in the summer—the predominant loads in a commercial building in our climate,” Lanou explains. “It’s very well air-sealed, very well insulated and it’s reflective.” In addition, the roof cover, insulation and finished ceiling are provided in one component.

Roof Install

A crane was required to lift all panels to the roof from one side of the building because power lines impeded the other sides. “The crane would grab the bundle of panels, which were staged on the high side of the building, and lift them up and over the building to place them on the low side,” Miller says. “It would’ve been so much easier if we had access completely around the building but we had to have a big crane come out there and do that lift.”

The roof cover, insulation and finished ceiling are provided in one component. PHOTO: Barrett Hahn

The roof cover, insulation and finished ceiling are provided in one component. PHOTO: Barrett Hahn

Once the panels were on the building near where they would be installed, manlifts further assisted with situating the panels on the roof. “The larger panel sections were 400 pounds each and 42-inches wide,” Miller explains. “They were awkward to handle. You also had to make sure when you were moving them around on top of the steel trusses that you didn’t scratch the finished paint on the underside of the panels, which would serve as the second-floor ceiling.”

Miller says safety was the biggest challenge on the project. His crew was tied to steel beams or apparatus that bolts onto the standing seam once they were past the leading edge. “We also made sure no one got hurt while we were moving the 400-pound panels. You don’t want a 400-pound panel on one man and he’s trying to hold the thing up without his knowledge. Honestly, a 400-pound panel once it is in motion may end up being 2,000 pounds of live load so we had to work in unison. We had one crew leader who would call out the play, saying ‘1, 2, 3, we’re going down’ or ‘1, 2, 3, we’re moving the panel over’.”

The coordination among the crew helped because the panels weren’t packaged exactly as they would be installed on the roof. “Some of them were upside down and we had to rotate,” Miller notes. “Without a lift there fulltime, it would’ve been even more challenging. Plus, we were working about 35 feet above the ground and 15 feet above the concrete floor of the building. We had to stay safe, stay tied off.”

Once the lifting and maneuvering were handled, Miller says the installation, which took about a week, was similar to any standing-seam roof, except each panel is 8-inches tall. “The top of the lock must be engaged while the panel is rotated so the tongue at the bottom of the panel engages with the lock,” he says. “Once you are engaged at the top and bottom, then you manually seam the locks together at the top. When you’re all finished you take a massive power seamer and run down the seam and it locks that joint together, so you have all kinds of wind-uplift value.” [Read more…]