Re-Roofing a Busy Hospital Poses Logistical Challenges

At Holmes Regional Medical Center, Advanced Roofing replaced 32,000 square feet of roofing on four different levels. Photos: Smith Aerial Photos

When leaks on the existing roof on the Holmes Regional Medical Center in Melbourne, Florida, became too much to bear, the need for a new roof on four levels of the building was obvious. But so were the numerous difficulties posed by removing and replacing the roof on an active hospital. To make matters more complicated, the areas affected were directly over the hospital’s main entrance and the neonatal intensive care unit (NICU), which cares for premature infants.

It would take a talented team of roofing professionals using the right products to install a durable roof system without disrupting patient care. Advanced Roofing Inc. was up to the challenge.

Advanced Roofing is a full-service commercial roofing contractor based in Florida. The company’s corporate headquarters is in Fort Lauderdale, with offices in Sanford, Tampa, Miami, Jupiter, Fort Myers and Jacksonville. According to Jason Carruth, branch manager of the Sanford location, the company installs almost every type of low-slope and steep-slope roof system. “We do production, service, maintenance — anything to do with commercial roofing,” he says. “Our specialty is re-roofing occupied buildings.”

For Holmes Regional Medical Center, a two-ply modified system with a reflective coating from Tremco was specified. This was an ideal fit for the re-roofing application at the hospital, notes Carruth, as it was a cold-applied system with low VOCs. “As a certified Tremco applicator, we were invited to bid on the project, and we were successful with the contract,” says Carruth.

High Degree of Difficulty

The project involved the complete tear-off and replacement of the roofs on the four lowest levels of the hospital, totaling approximately 32,000 square feet. These included two of the most sensitive areas on the building. “We did the whole section over the main entrance where everyone drops people off,” notes Carruth. “Another section was directly over the NICU center. We did the staging and handled personnel coming in and out on four roof levels over that area. The entire roof section also surrounds an open-air atrium below, so we had to roof around not only the main entrance, but an atrium as well.”

No torches could be used on the project, so cold-applied modified system from Tremco was specified. It was topped with a reflective coating. Photos: Advanced Roofing Inc.

Safety was the top priority, both on the roof and on the ground. “We had to have full-time supervision on the ground,” Carruth says. “We had ground safety monitors that worked for us, and they had to coordinate traffic at the drive-through and the turnaround, as well as the pedestrian walkway, which was right at the edge of our staging area.”

The site posed numerous challenges, as the lone staging area was limited and the schedule was subject to change at a moment’s notice due to emergency surgeries. “Work over the NICU unit was a little more involved due to the fact that we were almost continually on call,” Carruth explains. “On days we were able to work, we had to be ready to stop if there was anything critical going on.”

Work began in the areas with the most problems. “We started in different sections based on the priorities of the hospital,” Carruth notes. “We initially focused on the areas where the leaks were the worst.”

After the problem areas were fixed, work proceeded in sections, working from the back to the front to minimize traffic on completed areas. The process involved tearing off the existing built-up roof down to the concrete deck and installing a temporary roof to keep everything watertight. Then tapered insulation was applied in cold adhesive, followed by a cover board and the two-ply smooth modified system. The last step was the application of the Alpha-Guard MT coating, which was set in a polyester mat.

Logistics, loading and disposal of debris was a complicated process, as crews could only load the roof at one point accessible to a telehandler — a 10K Lull. This meant much of the material had to be moved a long way across the roof. “We had to haul all of the material and all of the debris from the old roofs across a level, down a level, and up a level to one spot,” Carruth explains. “Mobilization was a little bit difficult on it because we were only allocated one staging area.”

Tear-Off and Installation

Advanced used a 10-man crew on the project, doing most of the demolition work at night and installation work during the day. The fall protection plan included Raptor tie-off carts and anchor points at higher levels of the building.

Photos: Advanced Roofing Inc.

Mechanical roof cutters were used to tear off the existing built-up roof. In some sections, lightweight concrete also had to be removed. Debris was placed in a custom-fabricated trash box with a lid that had special forks for use with the telehandler. “We cut the old roof into small sections and just used hard elbow grease to pop them off the bottom,” Carruth says. “We utilized a Lull and a trash box to dispose of the that debris, driving it over to the dumpster, which was in the parking lot.”

After the temporary roof was installed, tapered insulation was set in a low-rise foam adhesive. This was topped with half-inch Securock cover board and the modified sheets. The two-ply Tremco system consisted of a PowerPly HD base sheet and Composite Ply HT top sheet, both set in PowerPly adhesive. Before the coating was applied, all of the edge metal and trim were installed. “We put all of flashings in, put all of the sheet metal on, we put the counterflashing in,” notes Carruth. “All metals were installed on this project were stainless steel, as it was in Melbourne and pretty close to the coast.”

The Alpha-Guard MT base coat and Alpha-Guard MT top coat were set in Permafab polyester fabric. The coating was applied using a squeegee.

The system supplies the benefits of solar reflectance, which include lowering the roof temperature and minimizing utility costs, but the roofs also had to be aesthetically pleasing. “There are patient rooms that look down in this roof, so that’s why we went with the light gray coating, which still supplies the necessary SRI [Solar Reflectance Index] value,” Carruth points out.

Minimizing Disruptions

The work areas also necessitated other considerations for patients and staff. “We had guest rooms where we had to hang tarps up so people couldn’t see us working at the time,” notes Carruth. “There were passive air louvers that we had to cover to keep debris from the tear-off from getting inside the building. We also had to put charcoal filters in all of the air intakes.”

The work schedule could change on a moment’s notice, so the roofing crews kept in almost constant contact with facility managers. “We’d provide them with a weekly schedule and every day we let them know where we would be working and what we’d be doing. If anything changed, we’d hear about it from their facility people and adjust on the fly.”

The project was completed on time, despite numerous weather delays and interruptions because of surgeries in the NICU. “The communication between the manufacturer’s rep, the owners and ourselves was excellent,” Carruth says. “Pre-planning is everything. When the key players on a job are all on the same page, that’s when a project ends up being successful.”

Success on this project meant protecting the patients and pleasing the owner with a top-quality system. The roof system was designed for high-priority, high-sensitivity projects, and there are few areas that are more sensitive than a neonatal intensive care unit. But these types of projects are familiar territory for Advanced Roofing.

“This is what we do. We re-roof occupied buildings,” Carruth says. “Not only are we putting on a roof system, we’re dealing with customers, we’re watching the weather forecast and making sure the roof is always watertight. The experience Advanced has roofing occupied building is why Tremco and Holmes selected us for the project. We know how to handle those situations and keep the roofs watertight on a daily basis.”

TEAM

Roofing Contractor: Advanced Roofing Inc., headquartered in Fort Lauderdale, Florida. www.advancedroofing.com

MATERIALS

Cold-Applied Modified System: PowerPly HD and Composite Ply HT, Tremco, www.tremcoinc.com

Roof Coating: Alpha-Guard MT in Light Gray, Tremco

Cover Board: Securock, USG, www.usg.com

Advanced Roofing Rides to Help Fight Multiple Sclerosis for 15th Consecutive Year

The bicycling team from Advanced Roofing Inc. participated in the Multiple Sclerosis (MS) Bike Ride for the 15th consecutive year, completing the trip from Miami to Key Largo and back March 3-4, 2018.

According to Advanced Roofing CEO and President Rob Kornahrens, this year’s team raised $25,160.50 for the Multiple Sclerosis Society, bringing the combined total for all 15 years to $590,525. “It was another great year,” Kornahrens said. “The weather was great and the event was well organized from start to finish. The Bacardi rum tent was great as always for those that go extra mile in raising funds. I thank everyone for their support and look forward to our 16th year next year.”

Kornahrens was first motivated to participate when his friend, Mark Speedy, was diagnosed with the disease. “He has gone through quite a struggle. However, I am happy to say after visiting with him recently his health has improved greatly due to the new medicines available through the M.S. research,” he said. “Additionally, since starting our MS Bike Ride team, my two nieces have been diagnosed with M.S., and due to all of your help, I was able to get them in treatment with some excellent doctors.”

Kornahrens urges others to help raise money to find a cure for Multiple Sclerosis, noting, “We will continue to ride until M.S. stands for ‘Mystery Solved.’”

For more information regarding Advanced Roofing’s next M.S. Bike Ride, contact Rob Kornahrens’ Executive Assistant Kim Campanile by calling (954) 522-6868 or emailing her at kimc@advancedroofing.com.

For more information or to make a donation to the Multiple Sclerosis Society, visit www.nationalmssociety.org.

For more information about Advanced Roofing, visit www.advancedroofing.com.

The bicycling team from Advanced Roofing Inc. participated in the Multiple Sclerosis (MS) Bike Ride for the 15th consecutive year

Re-Roofing of Shopping Center Poses Logistical Challenges

Southgate Shopping Center: Sebring, Florida

The re-roofing project of the shopping center totaled 79,556 square feet.

The re-roofing project of the shopping center totaled 79,556 square feet.

Roofing contractors often find themselves tackling re-roofs at shopping centers in piece-meal fashion, doing sections over the years as the budget allows. When property manager Southern Management and Development decided to remodel the entire Southgate Shopping Center in Sebring, Fla., in conjunction with Publix Markets’ replacement of their existing store at the location, they looked to Advanced Roofing to get the job done.

The scope of work included re-roofing three large sections of the retail plaza and a drugstore on the property. The roofing portions totaled 79,556 square feet.

Roof System

The roof specified was a two-ply modified bitumen system from Johns Manville. In the three large sections of the plaza, the existing built-up roof was completely torn off, while the drugstore was a re-cover project, notes Andrew Vik, estimator and project manager with Advanced Roofing’s Tampa branch, which operates under branch manager Michael Landolfi.

Roofing work started in November 2016 and was completed in February 2017. After the existing roof was removed, crews installed 2-inch polyiso to the steel deck. “We mechanically fastened that with a half-inch USG SecuRock cover board through the steel deck,” notes Vik. “The two plies of modified bitumen were then torch applied, a smooth base sheet and a white granulated cap sheet.”

On the drugstore, the roof was vacuumed, and the cover board and two plies were installed over the top of the old roof system.

In addition to the roofing scope, Advanced Roofing’s HVAC division installed and removed heating and air conditioning units and replaced some obstructive ductwork. “We had our own HVAC people working with our roofing crews, so it was easy to coordinate everything,” notes Vik. “We had HVAC installations on three of the buildings, and we remounted existing units on two of the buildings. There was also a lot of demolition on the south building, as there were several derelict units that
had been sitting there for quite some time. Those had to be hoisted off there and taken out.”

A Challenging Project

In addition to the roofing scope, Advanced Roofing’s HVAC division installed and removed heating and air conditioning units and replaced some obstructive ductwork.

In addition to the roofing scope, Advanced Roofing’s HVAC division installed and removed heating and air conditioning units and replaced some obstructive ductwork.


Logistics are often a challenge with a shopping center that remains open to the public, notes Vik. “You have to load and unload multiple levels of the roof at different times,” he says. “Customer relations is also a challenge; you have to keep everyone happy and ask a lot of questions. The construction manager has to do a lot of P.R. when he’s there.”

Demolition portions of the project were done at night and application during the day, so business at the mall was never disrupted. Traffic in the parking area was also a key concern.

“Setup areas had to be barricaded and marked off while we were loading and unloading,” Vik says. “There was even a drive under bridge connecting two buildings that had to be re-roofed, so we always had to be mindful of people below.”

Parapet walls did not surround all portions of the roof, so safety precautions included a safety perimeter; employees outside the perimeter had to be harnessed and tied off to a portable fall protection anchor system by Raptor.

The project went off without a hitch, according to Vik. “The mall was 100 percent open during the entire project,” he says. “Things went very smoothly— especially for everything that was involved. One of our mottoes is, ‘The harder the job, the better.’ We like a challenge. We take on a lot of projects other companies shy away from.”

The keys to his company’s success are coordination and versatility, states Vik. “We do it all,” he says. “We didn’t have to get anybody from outside the company to work on the project. We did all the roofing, all of the HVAC, and all of the hoisting was done in-house. We’ve also got lightning protection inhouse, and we have a solar division. We have a great team. Everyone does their part to get the bids out and get the jobs done. It’s the best team I’ve ever worked with.”

Team

Roofing Contractor: Advanced Roofing Inc., Tampa, Fla.
Consultant: CBA Roof Consulting LLC, Lake Worth, Fla.
Roof System Manufacturer and Technical Support: Johns Manville, Denver

Antis Roofing & Waterproofing Receives Community Involvement Award

In recognition of its continuous efforts to help the people of Orange County by keeping roofs over their heads and helping dozens of local charitable organizations, Antis Roofing & Waterproofing, Irvine, Calif., has been presented with the fifth annual CNA/NRCA Community Involvement Award co-sponsored by the National Roofing Contractors Association (NRCA) and CNA.

The award honors charitable works performed by NRCA contractor members.

Antis Roofing & Waterproofing was selected for its nonprofit organization The Antis Foundation. Founded in 2016, the Antis Foundation actively supports many local charities, including Habitat for Humanity, Orange County Ronald McDonald House, Pediatric Cancer Research Foundation and Alzheimer’s Orange County.

The Antis Foundation helps these organizations through its employee volunteer program, charitable grants, corporate and nonprofit collaborations, and pro-bono roofing work.

CNA awarded Antis Roofing & Waterproofing with $7,500 to be used in support of The Antis Foundation.

Additionally, second-place winner Advanced Roofing Inc., Fort Lauderdale, Fla., will receive $5,000 for its ongoing support of the Sonrise Mission, a faith-based rehabilitation program for adults with life-controlling dependency issues.

Third-place winner, Academy Roofing, Aurora, Colo., will receive $2,500 for its work with the Rose Andom Center, which assists victims of domestic violence.

The awards were presented March 2 during NRCA’s Awards Ceremony and Cocktail Reception held during NRCA’s 130th Annual Convention in Las Vegas.

To view CNA’s video featuring Antis Roofing & Waterproofing and its work with its nonprofit organization The Antis Foundation, click here.

ARMA Names Winners of 2017 QARC Awards Program

The Washington, D.C.-based Asphalt Roofing Manufacturers Association (ARMA) has named three winners of its annual Quality Asphalt Roofing Case-Study (QARC) Awards Program. The program seeks contractors who choose asphalt roofing and install beautiful and high-performing systems. This year, a stunning home in North Carolina, a commercial building in Florida and a firehouse in Washington state have been chosen as winners.

Chapel Hill Roofing Co. received the Gold QARC Award for its residential project titled The Triangle Home. The North Carolina-based contractor installed a full asphalt roofing system to fit the home’s complex architecture and the homeowner’s desire for a range of color options, protection from the elements and algae resistance at an affordable price.

The Silver Award was given to Advanced Roofing Inc., Fort Lauderdale, Fla., for the second year in a row. Its completion of a 49,955-square-foot roof on the Broward County Addiction Recovery Center’s Stephen R. Booher Building impressed judges with its intricacy. The new high-performance roof system provides weatherproof protection for the building’s residents.

Cascade Roofing Co., Burlington, Wash., was honored with the Bronze QARC Award for its steep-slope installation on the Burlington Fire Department firehouse. The building needed a new roof and required a product that had visual appeal, wind resistance and algae resistance. Cascade Roofing installed a full asphalt roofing system, including a synthetic underlayment and an ice and water shield on the leading edges.

ARMA received a record 40 submissions this year. These projects demonstrated the range of colors and designs that asphalt roofing can achieve, its ability to meet challenging project requirements and to provide reliability in tough climates. Each year, these projects are judged by a panel of roofing industry experts from trade associations, architecture firms and the media. Judges score projects based on their use of asphalt roofing technology to provide curb appeal, durability and value.

“As the QARC Awards Program has expanded over the last seven years, it has grown increasingly challenging for our judges to choose from the numerous excellent projects we receive,” notes Reed Hitchcock, ARMA’s executive vice president. “This year, it came down to identifying which projects demonstrated how contractors use asphalt roofing to solve key challenges for building owners and to provide peace of mind with a protective roof system.”

For more information about the QARC awards projects, visit the web page.

Project Profiles: Retail

Sierra Nevada Brewery, Mills River, N.C.

About 58,000 pounds of copper were installed on the brewery.

About 58,000 pounds of copper were installed on the brewery.

TEAM

Roofing Contractor: The Century Slate Roofing Co., Durham, N.C.
Architect: Matthew Galloway of Russell Gallaway Associates Inc., Chico, Calif.

ROOF MATERIALS

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project. This was close to 750,000 pounds of slate, or 375 tons.

About 3,000 feet of custom copper gutters and downspouts, conductor heads and 100 squares of painted standing-seam panels were fabricated, and pre-built copper clad dormers and decorative copper cornices were installed.

The project also included 35 squares of copper standing-seam roofing, 25 squares of soldered copper flat-seam roofing and 115 squares of copper wall cladding. About 58,000 pounds of copper were installed on the brewery.

Everything on the building is oversized and that meant everything had to be built to support the heavy structural loads and live loads from wind and mountain snow. The large roof faces called for 10-inch custom copper gutters. When you have gutters that large in the mountains of North Carolina you have to consider the extraordinary weight of the annual snow.

In addition to snow guards being installed on the slate roof, custom 1/4-inch-thick copper gutter brackets fastened the gutter to the fascia. It is typical on steel-framed construction, particularly on this scale, that the framing is out of square and there is widely varying fascia and rake dimensions.

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project.

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project.

However, these items should not appear out of square or have varying dimensions. Great care had to be taken to measure and custom bend onsite all the detail flashings so everything appeared perfect. This took many skilled craftsmen, a great deal of time and the absolute drive to provide the highest quality work.

Slate Manufacturer: Evergreen Slate Co. Inc.
Copper Fabricator: K&M Sheet Metal LLC
Supplier of Underlayment, Copper Sheets and Coil, Insulation and Nailbase Sheathing: ABC Supply Co. Inc.

ROOF REPORT

The new-construction project began in November 2013 and was completed in September 2015.
The team completed the slate installation so well that The Century Slate Co. was awarded the 2015 Excellence in Craftsmanship Award by Evergreen Slate for the project.

PHOTOS: The Century Slate Roofing Co.

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ARMA Selects Top Installations in North America

The Washington, D.C.-based Asphalt Roofing Manufacturers Association selected the winners of its Quality Asphalt Roofing Case Study (QARC) Awards, an annual program that recognizes exceptional roofing projects in the U.S. and Canada.

The Gold Award honored John Foster, a general contractor in Esparto, Calif., for his company’s installation on a star-shaped home. The homeowners required a roofing system with a style that wouldn’t get lost in the bold architecture. PABCO Roofing Products Premier Advantage Granite shingles provided the necessary aesthetic to complement the home while protecting it from the windy, damp coastal environment to which it is subjected.

The Silver Award was given to Advanced Roofing Inc., Fort Lauderdale, Fla., which was called upon to install a new low-slope asphalt roofing system on two buildings at the PGA National Resort and Spa in Palm Beach Gardens, Fla. The contractor chose a SOPREMA three-ply SBS-modified bitumen roofing system with a base sheet and cap sheet that delivered a pristine appearance while protecting the roof from harsh weather and heavy foot traffic.

Precision Roofing, Hialeah, Fla., received the Bronze Award for the roof it installed on Northeast Regional Library, Aventura, Fla. A GAF hybrid built-up/SBS-modified bitumen roofing system using three plies of GAFGLAS Ply 4 Ply Sheet and a Ruberoid EnergyCap 30 Granule FR membrane was chosen because the contracting company knew the system would meet the project’s durability requirements and budget restrictions.

“Each of the submissions we received this year illustrated the beauty and curb appeal that asphalt roofing can provide,” says Reed Hitchcock, ARMA’s executive vice president. “These winning projects were singled out for successfully using the unique qualities of their roofing materials to deliver superior protection for a building, whether from salty storms, high winds, or other wear and tear.”

The following received Honorable Mentions:

  • Rust Road Project, Grace Construction, New Boston, Mich.
  • Anacortes Home, Old School Roofing, Anacortes, Wash.
  • Mukilteo House, Chris Howard Roofing LLC, Mukilteo, Wash.
  • Mukilteo House, Chris Howard Roofing LLC, Mukilteo, Wash.

The 2016 awards were judged by a panel of roofing industry experts, including leaders from trade associations, architects and members of the media. The judges look for projects that use asphalt roofing technology to provide durability, value and curb appeal.