Orlando Airport Project Necessitates Custom Fabrication, Precise Installation

 

Work on the first phase of the Orlando International Airport expansion project includes the South Airport Intermodal Terminal Facility and APM Complex, which features a standing seam metal roof

Architectural Sheet Metal Inc. has been in servicing the Orlando area for more than 23 years, specializing in commercial metal roofs and wall systems, primarily new construction. When Matthew Leonard, the company’s vice president, found out that the Orlando International Airport was proposing a new terminal project with a metal roof, he jumped at the chance to submit a bid.

He wanted to land the job because it would be the largest project the company has ever tackled, and one of its most prominent. He also wanted it for another reason—he knew he’d see it every time he drove to the airport. “For many years now, we’ve specialized in standing seam metal roofs. It’s our bread and butter,” he says. “We’ve done lots of schools, government building, military bases. It’s just something we enjoy doing. When this project came around, right here in our backyard, we knew we wanted to take it on. It’s larger than anything we’ve ever done, but it’s our specialty.”

The South Airport Intermodal Terminal Facility and APM Complex is a new construction project that coordinates mass transit for the airport, including regional rail systems and the Automated People Mover (APM). It’s part of the first phase of an ambitious $2 billion plan to almost double the size of the airport.

Architectural Sheet Metal installed the Berridge standing seam metal roof system, as well as internal aluminum gutters and a custom-fabricated aluminum bullnose that runs along the perimeter of the roof

The building encompasses approximately 200,000 square feet, and the structure is primarily covered with a standing seam metal roof. The scope of work for Architectural Sheet Metal included installing the metal roof system and internal aluminum gutters. It also included custom fabrication and installation of an aluminum bullnose that runs along the perimeter of the roof. “Every roof is radiused, and some sections have compound double raiduses,” Leonard notes. “The trickiest part of the project is probably the bullnose because all of the gable ends of the roof are radiused, and the large bullnose has to be welded on in 30-foot sections.”

Another tricky thing about the project is that the work was divided into two different contracts with two different construction managers. On one side of the building, which houses the monorail and parking garage, the project is overseen by Hensel Phelps, and on the other side, which handles the train lines, the construction is overseen by a Turner-Kiewit joint venture. The dividing point is a building expansion joint that runs across the middle of the roof. “We’re one of very few subcontractors out here that has a contract with both of the construction managers,” Leonard says. “They both have their own agendas, their own timelines, and their own completion dates, and it was a delicate balancing act working with the two of them.”

Installing the Roof

The roof system was designed to unify the elements of the structure and tie the building together. Some sections of the roof cover the building, while others serve as canopies, so there are two types of metal deck on the building. “The area we call the spine has a 3-inch-thick acoustical deck,” Leonard explains. “That was interesting because before we could put our 6 inches of polyiso on, we had to install batten insulation in the flutes. The acoustical decking is perforated, so you can see through it. That’s a little different, when you’re so high up. It spooked the guys at first to be able to see right through it.”

Crews dried in the entire roof with a waterproofing underlayment from MFM Building Products specifically designed for high-temperature applications.

The other sections were comprised of standard type B metal deck. Sections covering the interior were insulated, while canopy sections were covered with 5/8-inch DensDeck from Georgia-Pacific.

Crews from Architectural Sheet Metal dried in the entire roof with a peel-and-stick waterproofing underlayment from MFM Building Products specifically designed for high-temperature applications, MFM Ultra-HT. “It’s easy to install,” notes Leonard. “That’s our go-to underlayment for metal projects.”

After the underlayment was applied, the welded aluminum gutters were installed. “The longest piece was 78 feet,” says Leonard. “We fabricated the sections, water-tested them and shipped them out. We used a crane to lift them to the roof.”

The roof system was supplied by Berridge Manufacturing, and the 24-gauge galvalume metal panels were roll formed at the site. “Berridge has a ZEE-Lock double-lock standing seam panel,” Leonard says. “We own one of their portable roll formers, and we have it on site here. We pick it up with a crane, and lift it up to the edge of the roof, and we actually roll form our largest panels straight out to the roof. The guys just catch the panels as they come out of the roll former.”

Metal roof panels were roll formed at the site. For most roof sections, the roll former was hoisted by a crane, to the edge of the roof, and crew members stacked the panels as they come out of the roll former.

Panels were stacked in piles of 10 for installation. There were 12 different roof surfaces, so as the roll forming crew moved along, other crews would start installing the panels. “Every stack was tied down with strapping to ensure that it wasn’t susceptible to wind,” Leonard points out. “With a hurricane in the forecast, we were very careful about that.”

The panels in the spine area had a tighter radius, so those panels were formed on the ground using separate curving machine. Lining up the panels perfectly was critical. “With a radiused roof, it’s sometimes harder to find things to measure off to ensure your panels are straight. This panel is a left-to-right system. It’s a male-female overlay with a continuous clip that Berridge manufactures. The panels are hand-crimped together, and then you do the first and second stage of the double-lock panels with an electric seamer. You just turn it on and it goes up and over.”

Details, Details

Fall protection posts were installed during the framing process, which helped with safety planning but posed problems when it came to detailing. “It’s nice to have permanent fall protection points to tie into, as everyone had to be 100 percent tied off, but there are close to 200 fall protection posts on the project that we had to cut around and flash,” Leonard says. “I’ve never seen so many posts on a roof like that.”

The aluminum bullnose was constructed after precise measurements were taken at the site. After they were custom painted to match the roof, the 30-foot sections were lifted into place and installed.

Because the posts were tied into the structural steel and couldn’t be moved, the company designed and manufactured a welded aluminum flashing detail to ensure they all looked the same no matter where they landed in the panel profile. “We set up a welded aluminum flashing that should last forever, and it’s welded, so it shouldn’t leak. We try to go above and beyond in our flashing details.”

Leonard points to his company’s fabrication experience as a key to its strength. “We try to be more than just a roofing company,” he says. “We try to be a custom metal fabrication company that fabricates the panels to precise specifications determined by the site. We custom fabricate metal and then, as roofers, we install it. We like to have that double whammy. Not many people have that ability to do both.”

The company’s expertise came in handy on the bullnose. “The bullnose was originally bid as 22-gauge metal,” he says. “We looked at it and we didn’t like it. It’s a large, 9-inch radius, and we felt the thin, light-gauge metal would shake in the wind. Every 10 feet would be a lap joint with caulk, which would be susceptible to wind damage. We came up with the idea of using a welded piece of .080 aluminum. Once it was approved, we purchased a 100-ton press brake with a custom die to fabricate this bullnose.”

The bullnose was constructed from precise measurements taken at the site. “We took the radius off of the building and created jigs in our warehouse,” Leonard explains. “We welded pieces together in 30-foot sections, and we shipped them to a local painter who coated them with baked-on Kynar to match the roof.”

The bullnose was designed to hook into the gutter strap and wrap around onto the fascia, where it is screwed into the framing. In areas where there is no gutter, sections of the bullnose are equipped with a larger flange with an S-hook built into it to attach it to the roof. Corner pieces tie it all together.

Watching Out for Irma

Dealing with two different GCs was challenging, in part due to changes in the schedule. “Originally, we were supposed to finish one side first and then start the other side, but both phases of the project ended up starting around the same time,” says Leonard. “This doubled the manpower we needed on the job.”

Photos: Aerial Innovations

For changes like the bullnose, Architectural Sheet Metal had to make sure RFIs were submitted and approved by both sides. “Sometimes it was hard to keep track of who we submitted it to, but it worked to our benefit at times. Once it was approved by one side, it was easily approved by the other.”

The schedule had the crews working in hurricane season, and precautions were taken to make sure the job site was prepared for high winds. “When Hurricane Irma was approaching, I checked every single weather update every day until it made landfall,” Leonard recalls. “It hit on a Monday, and a full week ahead of that we were cleaning the roofs and preparing the gutters. We removed all debris on the jobsite because any trash on the roof could clog the downspouts. We added more and more men to the process throughout the week, and we shut the jobsite down on Wednesday. We took all of the material we had, stacked it, bundled it together, and we were able to move it all inside the building. We were pretty well complete on the Hensel-Phelps side, and Turner Kiewit brought in 40-foot Conex boxes for us to put our material in and secure it. They tried really hard to make sure the jobsite was secure.”

As the storm progressed, it deviated from the projected path, and no one could be certain which direction the winds might be coming from. “We just had to start battening everything down,” Leonard recalls.

Photos: Architectural Sheet Metal Inc.

Stacks of panels on the roof that were not yet installed were strapped every 2 feet on center. The entire state was in emergency mode, making things difficult. “For four or five days before the storm even hit, we couldn’t find water, rope and extension cords. Grocery stores were running out of supplies. Gas stations were running out of gas.”

After the storm passed, Leonard breathed a sigh of relief. The roof wasn’t damaged. The panels that had already been installed were in great shape, and the uninstalled panels weren’t harmed.

Elements like the weather are beyond anyone’s control, and Leonard notes his company tries to control as many variables as it can. “We have full control over the actual fabrication of the material and the quality of it,” he says. “When I call something in, I talk to our guy who works with me. Our company oversees it. Every morning I stop by the shop and follow up on the process on the way to the job site. We install it. I can make sure everything is OK.”

The project is nearing completion, and Leonard can’t wait to finish a landmark project he’ll see every time he makes a trip to the airport. “You can’t miss it,” he says. “It’s huge.”

TEAM

Architect: HKS Architects, Orlando, Florida, HKSinc.com
General Contractors: Hensel Phelps, Greeley, Colorado, HenselPhelps.com; and a joint venture between Turner Construction, Orlando, Florida, Turnerconstruction.com, and Kiewit, Sunrise, Florida, Kiewit.com
Metal Roofing Contractor: Architectural Sheet Metal Inc., Orlando, Florida, ASMfl.com

MATERIALS

Standing Seam Metal Roof: Berridge Zee-Lock Double-Lock, Zinc-Cote, Berridge Manufacturing, Berridge.com
Underlayment: MFM Ultra-HT Wind & Water Seal, MFM Building Products, MFMbp.com
Cover Board: DensDeck, Georgia-Pacific, Buildgp.com

Ultra-Steep Slope Roof Poses Challenges in Historic Church Re-Roofing Project

Century Christian Church is a landmark building in Owensboro, Kentucky. Completed in 1963, the church is included on the Kentucky Historic Register and recognized for its unique architectural style.
Photos: Owens Corning

At Century Christian Church in Owensboro, Kentucky, it is not the steeple that points toward the heavens above, but rather the entire roof. The church’s 50/12 pitch roof has become one of the most distinguishing features in the local landscape.

Completed in 1963, Century Christian Church is included on the Kentucky Historic Register and recognized for its unique architectural style. In fact, the roof is so eye-catching that it has been incorporated into the church’s website message which reads, “Our roof reaches up; our hearts reach out.” The roof ascends 40 feet and is divided into four quarters or “bows,” with each symbolizing one of the four Gospels in the Bible.

In 2016, the church’s building committee realized it was time for a new roof. Located in an open field apart from other structures, the roof had been struck by lightning on several occasions. The protective cable that ran down the sides of the church as a conduit for lightning strikes had been eroded and just one section of cable was intact. The building’s location also presented airflow challenges. Storms and strong winds crossing the field had caused shingles to loosen and fly off the building.

According to Harold King, a member of the Century Christian Church building committee, the church considered several criteria when selecting All American Home Improvement, LLC in Evansville, Indiana, to complete the re-roofing project. “We wanted a reputable company who was experienced in doing steep slope work, had an excellent safety record, and had a workforce equipped to meet the needs of this labor-intensive job,” he says, adding that the

The roof ascends 40 feet and is divided into four quarters or “bows,” with each bow symbolizing one of the four Gospels in The Holy Bible. Photos: Owens Corning

company’s Owens Corning Roofing Platinum Contractor certification provided additional confidence. “Our Owens Corning area sales manager, John Sabbak, explained the warranty for the re-roofing project and that was very important for us in selecting the materials for the project,” King says, noting that Sabbak also stopped by at different times during the installation to check in on the progress.

A Daunting Task

What were the challenges the roofing contractor faced in tackling the project? “What wasn’t a challenge?” asked Josh Long, Western Kentucky Sales Manager at All American Home Improvement. The metal capping required to protect the building from lightening, and the scorching summer heat during the installation were just a few of the challenges. By far, however, the two most daunting challenges were the safety concerns associated with the pitch and the wind issues that challenged shingle adhesion.

To help foster safety on the steep slopes, teams were assigned to cover each of the four “bows” comprising the roof. The teams used a precisely calculated system of ladders and walkboards to safely navigate and scale the roof. “Roofers getting home to their families safely every night will always be a top priority at Owens Corning,” says Sabbak, noting that All American Home Improvement teams were outfitted with personal protection equipment and participated in advance walk-through processes to safely tackle the project.

Installation teams from All American Home Improvement participated in advance walk-throughs to ensure everyone was well versed in the safety plan. Photos: Owens Corning

The building committee at Century Christian Church also wanted to avoid the safety and aesthetic concerns associated with shingle fly-off. That’s where Owens Corning SureNail Technology and Duration Shingles came into play. Developed to provide exceptional wind resistance, the system can qualify for a 130-mph wind warranty. “The Duration shingle delivered both the performance and the warranty we needed for a job with this kind of pitch and exposure to airflow,” says Long. According to Long, the shingles were also hand sealed as required by Owens Corning for the building’s pitch. “The SureNail Technology made it easy for the teams to install the shingle correctly because the white strip in the middle of the shingle leaves no doubt as to where the nail should go and facilitated a smooth installation,” he says.

As the roofing project progressed, so did public interest. The local newspaper stopped by to capture photos of residents watching the re-roofing spectacle from lawn chairs on the church lawn. The combination of re-roofing a challenging structure, improving the aesthetics of a historic building and scaling a very steep roof made it a memorable project according to Long. “It was a very unusual project from our daily jobs, and the challenges were part of what made the project so fun,” he notes.

TEAM

Roofing Contractor: All American Home Improvement, LLC, Evansville, Indiana, 1shingleatatime.com

MATERIALS

Steep-Slope Roof System: Duration Shingles with SureNail Technology, Owens Corning
Underlayment: ProArmor, Owens Corning

North Carolina Legislative Building Restoration Poses Unique Challenges

The North Carolina State Legislative Building was the site of a renovation project that included asbestos abatement in the interior and a complete restoration of the building’s roof systems.

The North Carolina State Legislative Building was the site of a renovation project that included asbestos abatement in the interior and a complete restoration of the building’s roof systems. Photos: SkySite Images

Some of the variables that can make a project difficult include a variety of complex, interconnected systems, unique design elements, and a tight schedule. These challenges are heightened on a highly visible, historic building, where the goal of keeping the design historically accurate must be balanced with making improvements to the structure and functionality of the systems. All of these elements and more were in play during the restoration of the one-of-a-kind roof on the North Carolina State Legislative Building in Raleigh, North Carolina. It took a talented team of design, engineering, and roofing professionals to bring the project to a successful conclusion.

Originally designed by architect Edward Durell Stone, the building has been the home of the state legislature since 1963, but water intrusion under its copper pyramids and at windows and doors on the promenade level precipitated a complete restoration project. Renovation work conducted in 2016 and 2017 included asbestos abatement in the interior and a complete restoration of the building’s roof systems.

The roofing phase of the project included removing and replacing the metal roof systems on the five copper-clad pyramids, as well as re-roofing the low-slope sections adjacent to the pyramids with a two-ply modified bitumen system. A liquid-applied waterproofing system was installed in the planter areas and under the pavers in the promenade section. The project also involved the removal and replacement of windows, doors, and skylights, as well as repairing and coating the concrete surfaces at the perimeter of the roof.

The design of the quilted flat lock copper panel system involved 17 different panel profiles. A false batten was added after the panels were in place.

The design of the quilted flat lock copper panel system involved 17 different panel profiles. A false batten was added after the panels were in place. Photos: SkySite Images

Companies involved in the project included Raymond Engineering, headquartered in Raleigh, North Carolina, which provided engineering and architectural services; Owens Roofing Inc., also located in Raleigh, which served as the general contractor on the roofing phase of the project and installed the low-slope systems; and The Century Slate Company, headquartered in Durham, North Carolina, which removed and replaced the copper roofs on the five pyramids.

Some of the key players in the project shared their insights with Roofing, including John Willers, a senior engineer with Raymond Engineering; Bert Owens, president of Owens Roofing; and Mike Tenoever, president of Century Slate.

“This is an iconic state building with a unique roof system which the owner and designer required to be aesthetically replicated,” Tenoever notes. “At the same time, some functionality and technical improvements were incorporated. This is a very high-profile project with a lot of complexity, particularly given the schedule. There were a lot of details compressed into a very short period of time.”

Design and Pre-Construction

Raymond Engineering conducted testing on the existing roofs and specified systems designed to match the originals and provide some necessary improvements, including added insulation and ventilation under the pyramids. Willers worked closely with Jason Mobraten, the senior architect on the project. “We provided the engineering and architectural services, beginning with design and then assisting with bidding and managing the construction phase of this project,” says Willers. “We engineered the copper roof, all of the detailing for the modified asphalt roof, and the detailing for the drainage, the pavers, and the sealants for the promenade.”

Crews from Owens Roofing removed the existing plants, media and drainage system from four 42-foot-by-42-foot fixed planters with skylights. After the substrate was cleaned and primed, a liquid-applied waterproofing system was installed.

Crews from Owens Roofing removed the existing plants, media and drainage system from four 42-foot-by-42-foot fixed planters with skylights. After the substrate was cleaned and primed, a liquid-applied waterproofing system was installed. Photos: SkySite Images

The schedule was an obvious challenge, as the majority of the work had to be completed while the legislature was in recess, and there were substantial financial penalties that would come into play if the work was not completed on time. “The client also required that the asbestos abatement be completed before re-roofing the copper-clad pyramids to avoid the risk of dislodging the asbestos-containing textured ceiling finish. However, doing the work in two phases allowed the asbestos contractor to get started while the rest of the job was designed and bid,” Willers states.

The building houses legislators’ offices, and it was open and occupied during construction, with the exception of the areas undergoing asbestos abatement. The schedule had to be carefully adjusted as the job progressed. “In addition to our role in monitoring the technical aspects of the construction, we closely monitored the construction phasing and sequencing, as it was directly driven by the schedule of the state legislature,” Willers notes. “We had to take a lot of care in developing the schedule and monitoring it.”

Willers and Mobraten knew that the details on this project would be crucial. “There were previously some issues where the copper and the low-slope membrane roofs met,” Willers says. “We detailed that very carefully so that we had redundancy in keeping that watertight.”

Extensive mock-ups of the copper pyramids were constructed and tested to ensure the quilted pattern could be exactly replicated while avoiding the leaks that plagued the existing structure.

Photos: SkySite Images

Photos: SkySite Images

As designers looked for ways to improve construction, they explored the design and construction of the quilted panels. “From a design standpoint, we wondered why we had this odd diamond-shaped pattern,” Willers recalls. “After we played with the dimensions a bit, we realized that if you fly over the building, from above all of those diamond sections look like squares.”

The key was to replicate the design with its false battens while avoiding leaks. “We were concerned about how to detail out the joining of the copper sheets that formed the diamond-shaped panels,” Willers says. “What had been done was susceptible to windblown rain getting in. We did two things differently: the little clips that supported these battens were secured by forming the clips with hooks that would be integral with the single-locked seams and soldering the clips to the top surface of the copper panels. Previously they were held in place by pop rivets, which went through the copper.”

The Secrets of the Pyramids

Century Slate was well prepared to tackle the copper roofing on the project. The company has been in business more than 20 years, and it specializes in historic restoration projects including slate, tile, wood, copper and other historical metals.

Crews from Century Slate removed the existing copper panels. The copper was salvaged and recycled.

Crews from Century Slate removed the existing copper panels. The copper was salvaged and recycled. Photos: SkySite Images

Tenoever knew the design of the original quilted flat lock copper panel system needed to be replicated exactly. “There were 17 different panel profiles, each within a very particular location within the roof’s quilted pattern,” Tenoever notes. “Proper placement of each different profile was essential to the whole system working correctly and looking like the original.”

The first step was to remove the existing copper roofs. “We tore off the entire system down to the deck,” Tenoever explains. “We then installed a semi permeable a vapor barrier, insulation, and a vapor retarder.”

Along with added insulation and Carlisle WIP 300HT self-adhering underlayment, crews also installed a vented nail base from Hunter Panels. “The Hunter Cool-Vent is a vented nail base that gets screwed down,” Tenoever says. “The goal was to have a breathable air cavity. All of the hip caps are actually vented to allow the air to get out.”

With the addition of the insulation and nail base, the roof was built up approximately 6 inches from the previous configuration. This added height necessitated changes in the custom flashing at the base of the pyramids but did not change the configuration of the copper panels.

In all, 22,500 square feet of copper panels fabricated by K&M Sheet Metal in Durham were installed. Each of the 17 different panels was labeled with a letter code. “When they were out at the site, we could just grab an A panel or a B panel, as needed, and bring them to that layout,” Tenoever explains. “Four of the pyramids were the same, and the center one was different, as that was the one that had skylights built into it.”

The areas between the pyramids were covered with a two-ply modified bitumen roofing system. Photos: SkySite Images

The panels feature flat-lock clips that were screwed down to the nail base. “It’s a typical flat seam panel system, and the panels interlock together,” says Tenoever. “You can see the batten panel above it, which is an aesthetic feature. The battens and the clips that held them were amazingly intricate, for what they were. They were cut out with a CNC machine and soldered onto the copper panels prior to installation. Later we came back and installed the batten system over the top.”

Century Slate built new curbs in the center pyramid for the new skylights, which were manufactured by Wasco. “The skylights were one of the last things to go on,” says Tenoever. “They were custom made because even though they look square, there isn’t a square angle on them.”

Custom copper flashings were installed at the bases. “One of the trickier parts for us probably would have been the tie-in of the modified roof, because Owens Roofing had to do their bit, and we were also replacing all of the wood blocking and everything all along the bottom edge before we could put our flashing on,” Tenoever recalls. “It took a lot of coordination between the two trades, but it all worked out.”

The Low-Slope Roof Systems

Owens Roofing served as the general contractor on the project and installed the low-slope roof systems. The company was established in 1986 in Raleigh, and focuses on commercial and institutional buildings, almost exclusively re-roofing. Much of its work is on historic buildings, so Owens was confident he could execute the project and complete it on schedule.

A scaffolding system offered secure roof access, but material had to be loaded and removed from one access point, so logistics had to be carefully mapped out.

A scaffolding system offered secure roof access, but material had to be loaded and removed from one access point, so logistics had to be carefully mapped out. Photos: SkySite Images

Crews from Owens Roofing installed 18,900 square feet of modified bitumen roofing from Soprema over concrete decks, including the areas between the pyramids. Tapered polyiso and half-inch DEXcell cover board from National Gypsum were installed using Duotack adhesive, followed by the two plies of modified bitumen membrane.

A liquid waterproofing system from Sika was specified for the large planter areas. Crews from Owens Roofing removed the existing plants, media and drainage system from four 42-foot-by-42-foot fixed planters with skylights. After the substrate had been cleaned and primed, the Sika RoofPro system was installed.

“Once it’s cleaned and primed, it’s pretty simple,” says Owens. “The product is one part, and you don’t even have to mix it. We applied it with rollers on this project. You embed fabric sheets in the system and then topcoat it. It was a cold-weather job, but fortunately we caught a break last winter in that it wasn’t as cold as usual, and we didn’t miss as much time as we might have.”

The 30,000-square-foot promenade section was originally covered by white granite pavers native to North Carolina. The old pavers were removed and replaced over a new roof system, which was comprised of modified bitumen sheets beneath the liquid-applied waterproofing system. “The concrete deck was primed and a modified bitumen base ply heat welded to the deck,” Owens explains. “This surface was primed in preparation for the Roof Pro system, which was then installed.”

Innovative Roof Services of Raleigh was called in to conduct a high-voltage electrical testing to ensure there were no voids in the system before the pavers were re-installed. The pavers had originally been set in a bed of mortar, and they had to be removed and cleaned, which revealed a problem. “When we took the pavers up, we found out that they ranged between 1-1/8 and 1-3/4 inches thick,” Owens notes. “That wasn’t a problem when they were set in a bed of mortar, but over extruded polystyrene, they would have been all up and down. We put in a change order and had the pavers set in a bed of sand on top of one layer polystyrene.” The sand was adjusted by hand to ensure the pavers were level. New pavers were added to replace those broken over the years.

On the roof’s concrete eyebrows, damaged areas of concrete were repaired, joints were sealed, and a cold-applied waterproofing system from Sika Sarnafil was used to cover 8,800 square feet of concrete.

Numerous Challenges

Important considerations on the project included safety and logistics, as well as the tight schedule. Safety was paramount, and a third-party safety monitor was on the site to ensure the safety plan was designed and executed properly. During the time between when the original skylights were removed and when their replacements installed, the voids in the roof deck needed to be cordoned off and covered according to OSHA regulations. Personal fall arrest systems were used on the pyramids and outside of the safety perimeter, which was marked with flags. “With the promenade, you had a wide concrete eyebrow, so it made it easier to set up the safety lines and keep everyone safely away from the edge,” Owens notes.

This aerial photo taken before the restoration project shows the copper roofs with their green patina. Photos: SkySite Images

“Safety is a key concern as on all jobs, but this one in particular was highly visible out the windows of the nearby Department of Labor,” Owens continues. “We were paid a courtesy visit and agreed with them that an on-site safety meeting conducted by their personnel might be useful. The owner allowed us use of one of their auditoriums and we had a very productive half-day meeting for all trades. Every week we had a meeting with a state construction monitor.”

A scaffolding system was set up that offered secure roof access, but there was only one point for loading and unloading material, so logistics at the site were a concern. “We had to use wheelbarrows and roof carts to transport materials back and forth to the scaffolding tower,” Tenoever notes. “Between the removal of the original roof and the installation of the multiple layers of the new roof system, over 150,000 square feet of roofing materials were moved by hand over an average distance of approximately 200 feet.”

Loading and unloading added another wrinkle to the complicated schedule. “The schedule was based on when the legislature was scheduled to come back to town—not how long the job was supposed to take,” Owens says. “We were all concerned with the ambitious time frame and $1,000 a day liquidated damages included with this job.”

Willers cited excellent communication as one of the keys to completing the project on time. “Fortunately, the project managers for the general contractor and other trades were highly organized individuals,” Willers says. “Regular site meetings were detailed and thorough. Although setbacks did occur, communication kept the ball rolling.”

The roof system on the building’s iconic copper clad pyramids was removed and carefully recreated, matching the original design while adding a vented cavity and increasing the thermal insulation. Photos: SkySite Images

A Unique Experience

Copper removed from the existing roof was salvaged and recycled, notes Willers, with the exception of a few pieces that

were cut into the shape of the state of North Carolina to serve as mementos of the unique project. “We’re very proud of the design and the outcome—and the assistance we got from all of the contractors involved,” Willers says. “We had some pretty heavy rains after the project was completed, including some high winds, and there were no leaks.”

Tenoever also looks back on the project with pride. “A one-of-a-kind roof system was custom built and delivered on schedule and with the owner and designer’s praises,” he says. “Taking something so amazing and restoring it to the beauty it originally had—we all get a kick out of that.”

TEAM

Design and Engineering Services: Raymond Engineering, Raleigh, North Carolina, RaymondLLC.com
General Contractor: Owens Roofing Inc., Raleigh, North Carolina
Metal Roofing Contractor: The Century Slate Company, Durham, North Carolina, CenturySlate.com
Leak Testing: Innovative Roof Services, LLC, Raleigh, North Carolina, IRS-LLC.net

MATERIALS

Metal Roof System
Copper: 20-ounce copper sheet metal
Vented Nail Base: Hunter Cool-Vent, Hunter Panels, HunterPanels.com
Underlayment: Carlisle WIP 300HT, Carlisle, Carlislewipproducts.com
Skylights: Wasco Skylights, Wascoskylights.com

Modified Bitumen Membrane Roof System

Membrane: Sopralene Flam 180 and Sopralene Flam 180 FR GR, Soprema, Soprema.us
Adhesive: Duotack, Soprema
Insulation: Sopra-Iso, Soprema
Cover Board: DEXcell, National Gypsum, NationalGypsum.com

Waterproofing System

Liquid Applied Membrane: RoofPro 641, Sika Corp., USA.Sika.com
Reinforcing Fabric: Reemat, Sika Corp.
Primer: Sikalastic EP Primer/Sealer
Extruded Polystyrene Insulation: Foamular 604, Owens Corning, OwensCorning.com

Contractor Restores the Roof on the Museum Beneath St. Louis’ Historic Gateway Arch

Western Specialty Contractors restored the roof of the Museum of Westward Expansion located beneath the Gateway Arch in St. Louis. This photo shows the protection board being installed prior to adding the leak detection system.

Western Specialty Contractors restored the roof of the Museum of Westward Expansion located beneath the Gateway Arch in St. Louis. This shows the protection board installed prior to adding the leak detection system.

The St. Louis branch of Western Specialty Contractors recently completed a project to restore and waterproof the roof of the Museum of Westward Expansion located beneath the iconic Gateway Arch on the St. Louis Riverfront. The work is part of a multi-phase project, spearheaded by nonprofit organization CityArchRiver Foundation, to expand and renovate the underground museum, plus renovate the grounds surrounding the Arch. The Jefferson National Expansion Memorial, which includes the Gateway Arch, Museum of Westward Expansion and the surrounding park, is maintained by the National Park Service.

Opened to the public in 1976, the Museum of Westward Expansion has undergone very few changes since its grand opening. The size of a football field, the museum features rare Native American Indian artifacts and materials documenting the days of Lewis and Clark and the 19th century pioneers who shaped the history of the American West.

Work on the 100,000-square-foot museum roof project began with removing sod and sandy soil covering the top of the roof and 10-28 inches of Elastizell engineered fill using a bulldozer. Next, the existing waterproof membrane was removed from the structural concrete deck.

After two layers of modified bitumen sheet waterproofing were installed, crews apply a coat of adhesive to adhere the asphaltic protection board.

After two layers of modified bitumen sheet waterproofing were installed, crews apply a coat of adhesive to adhere the asphaltic protection board.

Once the deck was exposed, Western crews went to work identifying and repairing leaks in the existing museum lid that had been present for many years, as the existing waterproofing had exceeded its lifespan. Several methods were used to evaluate the condition of the structural concrete deck, which included a chain-drag sounding along with visually identifying delamination and cracks.

Western crews then installed a two-ply Laurenco modified bitumen sheet waterproofing system covered with WR Meadows PC2 protection board. An electronic leak detection system followed by a permanent leak detection grid system were installed over the protection board. Crews then installed a layer of 1-1/2 inch, 60-psi Dow extruded polystyrene with an additional layer of the protection board and a J-Drain 780 drainage mat.

The next phase of the project involved waterproofing the 42,000-square-foot horizontal lid and the 37,000-square-foot vertical walls of the museum addition. Western’s scope of work in this area included installing a two-ply modified bitumen sheet waterproofing and protection board, as well as an electronic leak detection system, along with two layers of extruded polystyrene. A layer of extruded polystyrene was also installed on the vertical walls, followed by the drainage mat on both the horizontal and vertical walls.

During portions of the project Western crews were working over occupied space, as the museum was largely operational during construction.

During portions of the project Western crews were working over occupied space, as the museum was largely operational during construction.

Additional waterproofing of the north and south museum entrances encompassed approximately 13,800 square feet, which included approximately 5,000 square feet of deck around each leg of the Arch.

The museum was largely operational during construction, and for much of the project Western crews were working over occupied space. The company sequenced the removal of existing roofing material so that they could remove, clean and install new roofing material daily to keep the museum dry during construction.

Testing was a daily requirement during the waterproofing installation. Western was required to complete a pull test for every 500 square feet and take moisture readings for every 100 square feet. Daily observation reports had to be completed during the waterproofing application, with all testing results and location tests documented along with the weather conditions. Additionally, Western crews took 50 photos daily to document the testing and work area.

Construction on the Arch grounds began in August 2013, while renovations to the museum and visitor center began in April 2015. The multi-phase project is still underway, and the improved underground Museum of Westward Expansion is expected to be finished by summer 2018.

TEAM

Roofing Contractor: Western Specialty Contractors, St. Louis, Westernspecialtycontractors.com

MATERIALS

Waterproofing System: Laurenco Waterproofing, Laurencowaterproofing.com
Protection Board: WR Meadows, WRmeadows.com
Extruded Polystyrene: Dow, Dow.com
Drainage Mat: J-Drain, J-Drain.com

Fans and Community Rally to Replace Barrel Roof at Roadside America

Crews from Bachman’s Roofing, Building & Remodeling battled winter weather to install a new fully adhered EPDM roofing system from Mule-Hide Products Co.

Crews from Bachman’s Roofing, Building & Remodeling battled winter weather to install a new fully adhered EPDM roofing system from Mule-Hide Products Co. Photos: Mule-Hide Products Co. Inc.

Lovingly and meticulously crafted over a period of more than 60 years, the 6,000-square-foot display of miniature villages at Roadside America in Shartlesville, Pennsylvania, has been featured on the HISTORY channel and in such books as “1,000 Places to See in the USA & Canada Before You Die” by Patricia Schultz and “Weird Pennsylvania” by Matt Lake. To area families, however, the museum is more than just a funky tourist attraction. It is a treasure that has been shared by four generations—one that must be passed on to future generations.

So, when the building’s nearly 65-year-old barrel roof began to fail, threatening to shutter the museum and put its gems in storage for good, the community and fans far and wide rallied. Nearly $80,000 was raised, roofing crews worked in between winter storms, and a new EPDM roofing system was installed to protect the masterpiece below.

A Life’s Work

Dubbed “The World’s Greatest Indoor Miniature Village,” the display at Roadside America is the life’s work of its sole creator, Laurence Gieringer. Fascinated by miniatures from an early age, he made the first piece in 1902 and continued expanding the collection until his death in 1963. The result is a breathtaking snapshot of American rural life spanning more than 200 years, from a frontier town with saloons and horse-drawn wagons and carriages to a 1950s Main Street with a movie theater and tail-finned Chevys. The collection includes 300 hand-built structures, 600 miniature light bulbs, 4,000 tiny figurines, 10,000 hand-made trees, working model railroads and trolleys, moving waterways, wall paintings, and replicas of such landmarks as Mount Rushmore, the San Francisco-Oakland Bay Bridge, and Henry Ford’s original shop in Dearborn, Mich. The twice-hourly patriotic “Night Pageant” features an illuminated Statue of Liberty and the playing of America’s national anthem and Kate Smith’s rendition of “God Bless America.”

Originally housed in the basement of Gieringer’s childhood home and later in the carousel building of an abandoned amusement park, Roadside America moved to its current home in 1953. Still a family business, it is now owned by Gieringer’s granddaughter Dolores Heinsohn, and operated by his great-granddaughter Bettina Heinsohn and her husband Brian Hilbert.

A Preservation Mission

A carpenter by trade, Gieringer fabricated the rafters for the museum’s 80-square-foot-by-123-square-foot barrel roof

Years of water penetration had damaged the existing roof, and a complete tear-off and replacement was in order. The original rafters and roof deck were sound.

Years of water penetration had damaged the existing roof, and a complete tear-off and replacement was in order. The original rafters and roof deck were sound. Photos: Mule-Hide Products Co. Inc.

himself. In 2016—63 years later—they and the original wood plank deck were still in place. According to Carl Rost, general manager of contractor Bachman’s Roofing, Building & Remodeling Inc. of Wernersville, Pennsylvania, the hot-mop-down tar roof had been coated “20 times more than it should have been.” Time and weather had taken their toll. A severe snowstorm in January 2016 brought wind and tree damage. Consistent rain would cause leaks into the attic, with water sometimes dripping to the show floor below.

An elaborate water collection and removal system was created to protect the priceless miniatures. Buckets were placed in the exhibit and items moved whenever water started dripping to the show floor. Tarps—22-feet-by-22-feet—were hung in the attic, zig-zagging through the space to catch water and funnel it into 55-gallon barrels, which were then emptied by pumps.

Supporters Rally

While the patches and stopgap measures had done their job, they clearly were not a permanent solution. A new roof—and a major fundraising effort to pay for it—were needed.

Even with Bachman’s Roofing and the teams at roofing system manufacturer Mule-Hide Products Co. Inc. and the Reading, Pennsylvania, branch of building materials distributor ABC Supply working to keep costs as low as possible, the new roof would cost $80,000. Roadside America launched a GoFundMe.com campaign, raising nearly $19,000. Two anonymous donors contributed the remaining $60,000.

For many supporters, including Bachman’s Roofing Owner and President Eric Bachman and ABC Supply Branch Manager Jeff Smith, helping Roadside America was a matter of ensuring that a family tradition spanning four generations lives on. Their parents had brought them to the museum as children. They, in turn, took their kids, who are now sharing it with their families.

There was no question about helping Roadside America, Rost says. “Eric met with Brian and, within minutes, told him ‘We have to make this work.’”

EPDM Roofing System Selected

A 60-mil EPDM roofing system was chosen for its ease of installation on a barrel roof, its durability and its cost-effectiveness.

After the original roof system was removed, fiberboard insulation boards were fastened to the existing deck with screws and plates. The EPDM membrane was fully adhered using a fast-drying, freeze-resistant, low-VOC bonding adhesive. Photos: Mule-Hide Products Co. Inc.

The original plan was to recover the existing roof, reducing costs and, with winter weather at hand, allowing the crew to get the job done as quickly as possible. Once work began, however, the damage caused by years of water penetration was evident and the job switched to a complete tear-off and replacement.

EPDM roofing systems are common in Berks County, where Shartlesville is located. The membrane’s ease of installation on a barrel roof reinforced the choice to use it on Roadside America’s building.

“We’ve done quite a few barrel roofs and have found that EPDM works best,” Rost says.

Roofing membranes have “memories,” he explains. Rolled tightly for shipping, they want to snap back to that state when laid out on the jobsite. They must be given sufficient time to flatten out prior to installation, or wrinkling can occur. EPDM membranes “relax” much more quickly than other membranes do, particularly in the cold temperatures that the Bachman’s Roofing crew would be working in. The membrane also remains flexible in hot and cold temperatures, enabling it to be easily curved over the barrel roof’s rafters.

“We knew that EPDM would give us a fast, wrinkle-free installation,” Rost says.

EPDM also is less slippery than other membranes, points out Rob Keating, territory manager with Mule-Hide Products, helping ensure that snow will not slide off the curved roof, potentially injuring a museum guest or employee walking below. A snow rail manufactured by Alpine Snow Guards was specified and installed to alleviate previous issues with snow and ice sliding down the roof and damaging an air conditioning compressor.

A black membrane was chosen for its lower cost and because, with eastern Pennsylvania having more heating days than cooling days, it could help the museum manage its heating costs, Rost says. A 60-mil membrane was selected for its durability and long expected lifecycle, he adds, helping the museum reduce its ongoing maintenance costs and prolong the day when re-roofing would again be required.

The rafters—made of one-by-twos, one-by-fours, one-by-sixes, one-by-eights, one-by-tens and one-by-twelves to create the roof’s barrel shape—were still sound.

Fiberboard insulation boards were fastened to the existing deck boards with screws and plates. To accommodate the roof’s irregular shape and the cold temperatures, the EPDM membrane was fully adhered using a fast-drying, freeze-resistant, low-VOC bonding adhesive.

In addition to the barrel roof, the crew replaced an existing 625-square-foot low-slope section of EPDM roofing on one side of the building’s front.

Working Around Winter Weather

January and February bring snow, sleet, ice and wind to Shartlesville—certainly not ideal conditions in which to undertake a re-roofing project. Despite unfavorable weather forecasts, the Bachman’s Roofing crew began work as soon as the necessary funds had been raised and Roadside America gave the green light.

Roadside America is dubbed “The World’s Greatest Indoor Miniature Village.” On display at the museum are more than 300 hand-built structures, 600 miniature light bulbs, 4,000 tiny figurines, and 10,000 hand-made trees, as well as working model railroads and trolleys. Photos: Mule-Hide Products Co. Inc.

“The displays inside are priceless, and if they were damaged by water they couldn’t be replaced,” Rost says. “So, we said we’d work through the bad weather, taking time off as necessary.”

Work began on January 9, 2017. Thanks to some interference by Mother Nature, what normally would have been a one- or two-week job took six weeks. A crew of 10 completed the tear-off and eight professionals installed the new roofing system.

“Our crew endured,” Rost says. “One morning they called to tell me that they wouldn’t be able to work that day. I said ‘The storm went through last night. What’s the deal?’ They said that the parking lot was a sheet of ice. I had to see for myself, so I drove out there. The moment I got out of the car, I fell onto the completely iced-over parking lot.”

Given the roof’s slope, extra attention was paid to safety. Crew members worked carefully, without rushing—particularly when working along the roof’s steep edges. Everyone was harnessed while on the roof and followed all other relevant safety regulations. Rost and the firm’s safety inspector spent extra time monitoring the jobsite.

Mission Accomplished

With the re-roofing project complete, the buckets, tarps, barrels and pumps that once kept Roadside America’s miniature villages dry have been put away. A spring, a summer and an early fall have come and gone, with no leaks. The museum has been saved.

Hilbert extended thanks to those who made it possible. “Without the generous support of so many donors, this project wouldn’t have happened,” he says. “Where do you find that these days?”

Rost adds, “Now future generations can come and enjoy what four generations of our families have already enjoyed.”

TEAM

Roofing Contractor: Bachman’s Roofing, Building & Remodeling Inc., Wernersville, Pennsylvania, Bachmansroofing.com
Local Distributor: ABC Supply Co. Inc., Reading, Pennsylvania, ABCsupply.com

ROOFING MATERIALS

EPDM Membrane: Mule-Hide Products Co. Inc., Mulehide.com
Low-VOC Bonding Adhesive: Mule-Hide Products Co. Inc.
Fiberboard Insulation: Continental Materials Inc., Continentalmaterials.com
Snow Guard: Alpine Snow Guards, Alpinesnowguards.com

Federal Agency Relies on Silicone Coating System to Protects its Roof

The coating forms a seamless membrane. DLA chose to cover the previous gray coating with a white coating finished with granules to minimize heat absorption. Photos: GE Performance Coatings

The coating forms a seamless membrane. DLA chose to cover the previous gray coating with a white coating finished with granules to minimize heat absorption. Photos: GE Performance Coatings

The cold, snowy winters and hot, wet summers in Scotia, New York, put immense stress on local buildings’ roofs. A damp climate with conditions that often involve standing water can take a toll on conventional roof coatings. That was the reason the federal Defense Logistics Agency (DLA) first chose a waterproof silicone roof coating for its Scotia facility in 1996.

“Most building owners in this area spend thousands, sometimes hundreds of thousands, each year keeping their roofs intact,” says Dave Landry, director of operations for DLA, adding, “After using Enduris by GE, we spend almost nothing in comparison.”

More than two decades later, the coating’s 15-year extended warranty had long run out and DLA was ready to reapply. As in 1996, the alternative to resealing would have been a costly and intrusive tear-off. “We had a terrific first experience with Enduris roof coating,” says Landry. “Twenty-two years later, there was no question about who we’d use.”

Efficient Installation

The GE Performance Coatings team inspected the roof for damage before the work began. After more than two decades of punishing conditions, on average less than five mils of the original 21.5-mil coating surface had worn away. Because silicone coatings are seamless, the roof was also protected from expansion and contraction cycles caused by temperature

More than 20 years after applying a silicone roof coating on the roof of the Defense Logistics Agency in Scotia, New York, PUFF Inc. returned to conduct another installation.

More than 20 years after applying a silicone roof coating on the roof of the Defense Logistics Agency in Scotia, New York, PUFF Inc. returned to conduct another installation. Photos: GE Performance Coatings

fluctuations, which can tear apart dissimilar materials where they overlap. In the end, only 5 percent of the 275,000-square-foot roof required repair—the rest just needed a few more mils of coating. DLA chose to cover the previous gray coating with white coating finished with granules, helping to lower the amount of heat absorbed by the roof and add further protection.

The applicator, PUFF Inc., also experienced the benefits of the silicone coating. “During the seven-week project, we lost only one day to rain,” says Bill Rush, operations manager at PUFF Inc. and an approved applicator for GE Performance Coatings. “If it had been an acrylic coating, we would have likely lost a week to predicted rain delay. Additionally, there were two days that rain came unexpectedly from over the mountains, when the forecast was a 10 percent chance of rain.”

A quicker installation meant savings for the PUFF Inc. team—hotel rooms, per-diem expenses, and the opportunity cost of missing other jobs add up fast. Rush also felt a personal connection to the DLA’s positive experience. “I led the installation 20 years ago,” he says. “It’s a matter of great pride to see how well the system held up.”

TEAM

Roofing Contractor: PUFF Inc., Charlottesville, Virginia, Puffinc.com

MATERIALS

Coating System: Enduris by GE, GE Performance Coatings, GE.com/silicones

Historic 1883 Barn Gets New Composite Slate Roof

This timber-framed Standard Pennsylvania-style barn was originally erected in 1883. When its slate roof deteriorated beyond repair, it was replaced with a synthetic slate roof manufactured by DaVinci Roofscapes and installed by Absolute Roofing.

This timber-framed Standard Pennsylvania-style barn was originally erected in 1883. When its slate roof deteriorated beyond repair, it was replaced with a synthetic slate roof manufactured by DaVinci Roofscapes and installed by Absolute Roofing. Photos: DaVinci Roofscapes

Back in 1883, a timber-framed Standard Pennsylvania-style barn was constructed with a real slate roof on the homestead of the Hartong family, located in the City of Green, Ohio. After more than a century of service, the worn-out slate roof—and the rotting wood structural support system beneath it—have finally received a facelift.

“The structure was deteriorated beyond repair and had been leaking enough to also adversely affect the wood batten nailers,” says architect Chas Schreckenberger, AIA and principal of Braun & Steidl Architects. “Because this was a historic structure, our first choice was to replicate the original slate. When costs wouldn’t allow that, we investigated more economical slate alternatives.

“After reviewing all our choices, it was easy to make the selection of a DaVinci Roofscapes Single-Width composite slate roof. The appearance of the synthetic slate, its lightweight composition, affordability and durability all made it the obvious choice for this project.”

The next step required gaining approval on the roofing choice by the City of Green, which owns the structure, and the Ohio Historic Preservation Office, which awarded a grant to finance the roof’s replacement. Once approval was received, the project started. Christian & Son Inc. was brought in to replace the rotting timbers, and Absolute Roofing and Construction Inc. started the roof installation.

“The DaVinci slate tiles we specified enabled us to retain the historic character of the barn, even to the point of recreating the large ‘1883’ date on the roof,” says Schreckenberger. “The final outcome exceeded our expectations and everyone involved is extremely happy with the results.”

Roofer’s Perspective

The challenge of recreating the 1883 date on the roof, plus detailing the entire roofing job for the Hartong barn, required a great deal of collaboration between the team at Absolute Roofing and Braun & Steidl Architects. Started in the spring of 2016, from start to finish, the roof frame reconstruction and tile installation took about six months.

The 45-foot by 90-foot timber-framed barn is part of the Levi J. Hartong homestead, which was placed on the National Register of Historic Places in 2007.

The 45-foot by 90-foot timber-framed barn is part of the Levi J. Hartong homestead, which was placed on the National Register of Historic Places in 2007. Photos: DaVinci Roofscapes

“There were two significant challenges in this project,” says Chris Kamis, president of Absolute Roofing. “First, we were working alongside the framing team to make sure the structure was secure and ready for the roof installation. Second, we had to configure the 1883 date carefully.”

Recreating the numerals was a challenging task. “The DaVinci product was slightly different in dimension from the original slate, so it took several layouts to accurately recreate the date,” Kamis notes. “The original date on the roof had been very faded, so we had some guidelines. In the end, the roof looks terrific with the 1883 date in Evergreen tile colors showing up beautifully against the Slate Black tile background.”

The completed roof project received the Contractor of the Year Award from the National Association of the Remodeling Industry in 2016 in the commercial specialty category.

Historic Homestead

Recreating the 1883 date on the roof was a challenge, and it took several layouts to achieve the original look. Photos: DaVinci Roofscapes

Recreating the 1883 date on the roof was a challenge, and it took several layouts to achieve the original look. Photos: DaVinci Roofscapes

Reflective of the Pennsylvania German heritage of the Hartong family and the community in the 1880s, the 45-foot by 90-foot timber-framed barn rests on a tooled sandstone foundation. Finished with vertical wood boards, the barn is part of the Levi J. Hartong homestead that includes a farmhouse, summer kitchen, milk house and other outbuildings.

“The city purchased the property more than a decade ago and it was placed on the National Register of Historic Places in 2007,” says Sarah Haring, community development administrator for the City of Green in Ohio. “It’s located in the City of Green’s Southgate Park and since that time, the Summit County Mounted Unit has stabled their horses at the barn.

“The farmstead represents patterns in agriculture and architecture from the 19th century in our area. We’re excited to have the new roof overhead that so perfectly replicates what we believe the original roof looked like in 1883. The finished product is stunning and everyone, including visitors to the farmstead, are impressed with the look of the roof.”

TEAM

Architects: Braun & Steidl Architects, Akron, Ohio, BSA-net.com
Framing Contractor: Christian & Son Inc., Burbank, Ohio, Planexus.com
Roofing Contractor: Absolute Roofing and Construction Inc., Absoluteroofing.com

MATERIALS

Composite Slate Roof System: DaVinci Roofscapes, Davinciroofscapes.com

Summer Means a Crash Course in School Re-Roofing Projects

Strober-Wright Roofing executed a completed a tear-off and re-roof of the entire complex of Montgomery Lower Middle School. Approximately 130,000 square feet of roofing was removed and replaced with a two-ply modified bitumen system.

Strober-Wright Roofing executed a completed a tear-off and re-roof of the entire complex of Montgomery Lower Middle School. Approximately 130,000 square feet of roofing was removed and replaced with a two-ply modified bitumen system.

Summertime is the busy season for school construction projects, and as students prepare for vacation, restoration work heats up. At Strober-Wright Roofing Inc., a full-service roofing contractor headquartered in Lambertville, N.J., going to school in the summer is a big part of the company’s business plan.

The company is owned by Mike Strober, Mark Wright and John Foy, who share more than 100 years of experience in new construction, additions and re-roofing projects. “We specialize in schools,” says Robert Shoemaker, an estimator with Strober-Wright, who points to attention to detail as the key to succeeding in the competitive bidding market. “You have to sharpen your pencil. You have to understand what your crews can do and how fast they can do it. You have to know what their skills are.”

Mark Wright has been with the company 26 years, and he points to a recently completed project at Montgomery Lower Middle School in Skillman, N.J., as an example of just what Strober-Wright can do when faced with large-scale projects and tight deadlines. “We have the men and equipment to get these types of jobs done on time with high-quality workmanship,” he says. “That’s our strength.”

Wright and Shoemaker believe building relationships is essential in this segment of the market. “We’ve done a lot of schools,” Shoemaker says. “When our bid is successful, people breathe a sigh of relief and tell us they are happy to have us on their projects.”

The Roof System

The Montgomery Lower Middle School project was a complete tear-off and re-roof of a school complex encompassing several connected roof sections totaling approximately 130,000 square feet. There were two types of existing roof systems: a fully-adhered EPDM system and a ballasted EPDM system. These were torn off and replaced with a two-ply, hot-mopped modified bitumen system.

Tapered polyiso was installed to ensure proper slope to the drains, which were surrounded by an 8-foot tapered sump.

Tapered polyiso was installed to ensure proper slope to the drains, which were surrounded by an 8-foot tapered sump.


The Strober-Wright team looked for ways to make the installation as efficient as possible in order to meet the deadline. The original specification called for removing and replacing more than 100 existing roof drains, but the company suggested using SpeedTite drains from OMG Roofing Products instead.

“My partner, Mike Strober, came up with the idea to use the OMG drains, and we submitted it to the architect,” Wright notes. “The architect approved them. The key with these drains is you don’t need another trade to install them. They install quickly and minimize disturbance in the building because the drains drop into the pipe, bypassing the bowl. You don’t have to take the old bowl out and put a new bowl in. You don’t have to take ceiling tiles out and create a mess inside the building.”

Show Your Work

On the ballasted roof sections, the stones were removed by Adler Vacuum. Then the existing EPDM roof was removed in sections. “We’d take a section out and replace it the same day so the building was watertight every night,” Wright explains.

At the end of each day, the old system was tied off to the new section. “With the existing rubber roof, we would leave a little extra material and flop it back,” Wright notes. “We’d adhere the flap using hot tar to the new system, and just peel it back the next day and go again.”

On sections of the roof with metal decking, the 4-inch base layer of flat polyiso insulation was mechanically attached with fasteners and plates. On the sections with concrete deck, the concrete was primed with a quick-drying asphalt primer and the base insulation was then adhered in hot asphalt. The tapered insulation was then adhered in hot asphalt to ensure proper drainage.

After the cover board was secured, the modified bitumen system was installed. The base ply and cap sheet were set in hot asphalt. Once the roof system had properly cured, it received two coats of an aluminum reflective coating.

Safety is always top of mind, but there were no unusual safety issues on the project, notes Wright. “We followed our standard safety protocols,” he says. “You have to make sure you’re wearing proper clothing and safety equipment with hot asphalt. We set up a safety perimeter warning with flags. If you were outside the perimeter, you had to wear a harness and be tied off at all times.”

Going With the Flow

More than 100 new drains were installed. The existing strainer domes, clamping rings and hardware were removed, but the drain bowls were left in place. The SpeedTite Drains were inserted, and the mechanical seal was tightened to provide a secure connection to the existing drain leader.

According to the manufacturer, the drains have a built-in vortex breaker to help improve water flow and a mechanical seal that meets the ANSI/SPRI/RD-1 standard (holding a 10-foot column of water for 24 hours without leaking).

More than 100 drains had to be replaced on the school. Strober-Wright suggested using OMG SpeedTite drains, as they could be installed more efficiently than conventional drain replacement and caused less disruption in the building.

More than 100 drains had to be replaced on the school. Strober-Wright suggested using OMG SpeedTite drains, as they could be installed more efficiently than conventional drain replacement and caused less disruption in the building.


After the drains were flashed in, the clamping ring and strainer dome were installed. “The drains are flashed with the base ply and then a piece of the cap sheet over that, so it’s a two-ply flashing system,” notes Wright. “The architect here specified an 8-foot tapered sump, and that’s a nice thing because you have an 8-foot area around the drain that’s really going to flow. It works really well.”

A Tough Schedule

Work on the project began in late June and was completed in late August, just in time for the school year to begin. Crews averaged 12 people and completed approximately 50 squares of roof per day.

According to Wright, the toughest part of the project was the tight schedule, which was made even more difficult due to inclement weather. “It was a wet summer,” he says. “It seemed like we were constantly battling rain, and we had to make sure we didn’t get behind the eight-ball on the schedule. You can’t work when it’s raining. You have to just batten down the hatches and prepare to get started the next day.”

After the drains were flashed in, the clamping ring and strainer dome were installed. The drains feature an internal vortex breaker.

After the drains were flashed in, the clamping ring and strainer dome were installed. The drains feature an internal vortex breaker.

The company followed the weather report closely to plan each day’s production. “We have a weather company out of Hackettstown we use called Weatherworks,” Wright says. “When it comes to the weather—up to the minute, 24 hours a day—they are on top of it. They deal with nothing but New Jersey weather. We pay for the service, but it’s well worth it. Saving one day’s worth of work can pay for the whole year’s subscription.”

Despite the weather, work was completed on time and on budget. The project achieved the priorities the school system wanted: a durable, energy-efficient roof system with a 25-year warranty. “It’s a great system,” Wright states. “We make our bread and butter on these jobs. We hit our deadline, and now it’s on to the next one.”

TEAM

Architect: Parette Somjen Architect LLC, Rockaway, N.J., Planetpsa.com
Roofing Contractor: Strober-Wright Roofing Inc., Lambertville, N.J., Stroberwright.com

Photos: OMG Roofing Products Inc.

Restoring Natural Slate Roof Takes Expert Craftsmanship

Photos: Charles F. Evans Company Inc.

When it came time to replace the roof on Howard W. Jones Hall, Youngstown State University wanted to closely re-create the original graduated natural slate roof. Photos: Charles F. Evans Company Inc.

Even slate roofs have to be replaced sometime.

Howard W. Jones Hall is one of the oldest buildings on the campus of Youngstown State University in Youngstown, Ohio. The limestone structure with its twin towers is an iconic structure, and when the original slate roof finally deteriorated, the university wanted to keep the stately look of natural slate on the building’s exterior.

Charles F. Evans Company Inc. of Elmira, N.Y., was awarded the Jones Hall restoration job in early 2017 and named 37-year veteran Ken Dennison as the project manager. “We seem to excel in doing difficult projects, including specialty systems of slate, tile, and architectural sheet metal,” Dennison says. “We emphasize quality workmanship and uncompromising customer satisfaction. We also emphasize safety, and currently we are the only roofing contractor to be an approved OSHA VPP mobile Mobile Workforce STAR contractor.”

The university wanted to replicate the existing 6,500-square-foot graduated slate roof with random widths, and slate roofing tiles in the same color and size range were chosen. The scope of work included repairing the existing masonry and installing copper gutters, valleys and flashings.

Going Old School

The first step was removing the old slates, which proved a tough task. “We had to remove them almost one by one,” recalls Dennison.

Copper details were custom fabricated for counterflashing and step flashing.

Copper details were custom fabricated for counterflashing and step flashing. Photos: Charles F. Evans Company Inc.

The existing wood plank deck was in very good shape, and Carlisle Water & Ice Protection self-adhering underlayment was installed at the eaves, valleys and rakes. It was also applied around all of the details. Then two layers of 30-pound felt were tacked into place with plastic-capped nails.

Natural hand-split roofing slate was delivered pre-cut and pre-punched by Evergreen Slate Co., located in upstate New York. The slates were mixed to ensure proper color distribution and arranged in piles for installation on the site. Once the underlayment was in place, the slate was installed just as it might have been a century ago. “We used copper nails,” Dennison notes. “Everything was nailed by hand—two nails per slate.”

The installation called for a 3-inch head lap. “With random slate, you don’t need to put any vertical lines in, because nothing is going to line up vertically,” Dennison explains. “Every side lap has to be at least 3 inches, but there is no set pattern for the widths—we just mix them up. That’s why they use the term ‘random.’”

Handcrafted copper details completed the distinctive, traditional look. Flat-seam copper panels from Revere Copper were installed in the valleys, using clips to allow for expansion and contraction. Copper counterflashing and step flashing were also custom fabricated. “We bend it to fit whatever we might need,” notes Dennison. “We have a talented sheet metal shop at our office where we fabricate the big stuff, but we also cut and shape panels on site.”

Photos: Charles F. Evans Company Inc.

Photos: Charles F. Evans Company Inc.

A detailed safety plan was set up for the building, which was open and active during the entire installation process. Scaffolds with decking were erected at the eaves, and temporary tunnels were engineered to protect pedestrians at the entryways.

The rake edges did not have scaffolding, so a safety perimeter was set up 6 feet from the roof edge. Workers outside the line had use a personal fall arrest system, which was secured to anchors screwed into the rafters. “All of our mechanics are extensively trained, and each year everyone goes through additional training sessions,” Dennison says. “We all know what we’re supposed to do. We have a very stringent plan on project safety.”

Slate itself can pose its own set of safety concerns. “Slate can be heavy and sharp,” Dennison says. “It’s rock. You have to be very careful, but the guys that do it love it. A lot of roofs these days are totally hidden. On a slate project, at the end of the day you can step back, see what you’ve done, and be proud your work.”

Charles F. Evans is just putting the finishing touches on the roof at Jones Hall. “When we’re done with a project and the customer is happy, that’s the best satisfaction you can get,” Dennison says. “When the client is happy and you look back and see a beautiful product that you know you had a hand in—that’s what I like about it. A slate roof is really a work of art that will stand the test of time.”

TEAM

Architect: eS Architecture and Development, Dublin, Ohio, esarchitecture.com
Roofing Contractor: Charles F. Evans Company Inc., Elmira, N.Y., Evans-roofing.com
Slate Supplier: Evergreen Slate Co. Inc., Grandville, N.Y., Evergreenslate.com
Copper Supplier: Revere Copper Products, Rome, N.Y., Reverecopper.com

Metal Barrel Roof Tops the Rebels’ New Basketball Arena

The Pavilion at Ole Miss seats 9,500 fans.

The Pavilion at Ole Miss seats 9,500 fans. The building’s signature is its standing seam metal roof, which was manufactured by ACI Building Systems. Photos: Professional Roofing Contractors Inc.

The Pavilion at Ole Miss is a multi-purpose facility that is most famous for hosting the University of Mississippi’s basketball team. The arena cost approximately $97 million to build and seats 9,500 fans. The building’s signature arched metal panel roof was designed to complement the curved entrance and blend in with other architectural features on the university’s campus in Oxford, Miss.

Professional Roofing Contractors of Shelbyville, Tenn., was originally called in to assist with estimating the cost of the structure’s main roof, as well as a membrane roof system on the lower level. Upon final bid results, the decision was made to proceed with a standing seam metal roof on the upper portion of the building and a PVC roof on the lower level. Professional Roofing was the successful low roof bidder and selected ACI Building Systems to provide the standing seam roof materials and Sika Sarnafil to provide the PVC membrane roof materials. Professional Roofing installed both systems, with Jose Martinez as the crew leader for the membrane roofing portion and Dale Jones in charge of the metal roofing crew.

Larry W. Price, president of Professional Roofing, and Jonathan Price, the company’s vice president and the production manager on the project, oversaw the installation of 79,500 square feet of standing seam metal roofing and 46,500 square feet of PVC. There wasn’t much room for staging material on the jobsite, which didn’t give the company much room to maneuver. For the main roof, bundles of pre-cut metal panels were trailered in by ACI and loaded to the roof by crane.

“Logistics were complicated,” notes Larry Price. “Just getting a big enough crane in there and lifting the panels was difficult. Once we got the panels on the roof and they were situated, the roofers could just move ahead.”

Photos: Professional Roofing Contractors Inc.

Photos: Professional Roofing Contractors Inc.

Panels were installed with a 2-inch-high, double-lock standing seam, which was completed using a self-propelled mechanical seamer from D.I. Roof Seamers. The metal panels were curved into place by crews on the roof, who installed them over the staggered metal deck after it was covered with two 2-inch layers of polyiso insulation and Carlisle’s WIP 300 HT self-adhered underlayment. “The metal deck was segmented,” notes Jonathan Price. “We had to bridge some of those sections to make a nice, smooth curve.”

The scope of work included a large gutter at the roof edge. The gutter was 3 feet high and 2 feet wide, and crews from Professional Roofing flashed the gutter and lined it with the same Sika Sarnafil PVC used on the lower roof.

On the mezzanine level, crews installed a vapor barrier and mechanically fastened two 2-inch layers of polyiso insulation, as well as some tapered insulation for drainage. Once that work was completed, the 60-mil PVC was applied.

“Everything went pretty smoothly,” says Jonathan Price. “Logistics are usually tight on a new construction project, but once we adjusted to that, we just had to cope with the weather.”

“We had a lot of hot days and some rainy days,” Larry Price remembers. “Mississippi in the summer can get hot, hot, hot—and when it’s not hot, it’s raining.”

TEAM

Architect: AECOM, Kansas City, Mo.
General Contractor: BL Harbert International, Birmingham, Ala., Blharbert.com
Roofing Contractor: Professional Roofing Contractors Inc., Shelbyville, Tenn., Professionalroofingcontractors.com
Metal Roof Panel Manufacturer: ACI Building Systems, LLC, ACIbuildingsystems.com
PVC Roof Manufacturer: Sika Sarnafil, USA.sarnafil.sika.com