Restoring Multiple Roof Systems on Historic Structure Is a Labor of Love

The Evans family restored the mill’s main roof as well as the flat roof over a retail space. Crews also re-roofed the large covered porch on the side of the mill and the one-story log cabin residence added to the back of the mill. Photo: Evans Candy

The first thing longtime roofer Dave Fisher will do is correct your pronunciation of Lancaster County, Pennsylvania — it’s traditionally pronounced “Lang-kiss-ter” for anyone wondering. And tradition is important where Fisher’s from.

Founded in 1729, Lancaster County is one of the oldest communities in America. The area is the heart of Pennsylvania Dutch country and has a strong farming and milling history. At the height of the milling industry, the area had more than 300 various types of mills operating.

The list of historical buildings in Lancaster County is long, so working on old structures is nothing new to Fisher, who runs I & D Contracting Ltd. in Lancaster. But re-roofing a 130-year-old mill to protect the interior while preserving its key historic characteristics presents unique challenges. Throw in local attachment to the building and a personal relationship with the owner and the stakes for doing the project right get even higher.

The mill had many names and many owners over its history before the Evans family purchased it in 1983. Photo: Evans Candy

This was the challenge presented to Fisher’s crew in re-roofing the Evans Candy Store in Lancaster County, done in stages over the last several years, with the most recent project being completed in 2018. The candy store is located inside a flour mill that serves as a recognizable piece of Lancaster’s history. The structure was originally built in the 1700s, but dust from grinding flour was a perpetual fire risk, and the mill burned twice over its history. The existing structure has been in place since 1889.

The mill has had many names and many owners over its history, but the Evans family purchased the mill in 1983 and has worked to bring it back to its former glory. Coming from a line of Lancaster milling families themselves, the Evans have used the historic structure to create a destination retail location that keeps people coming back for more — more chocolate, that is — oftentimes long after they have moved out of the area.

The flour mill is an iconic structure in Lancaster County. The existing structure dates back to 1889. Photo: Lancaster Historical Society, Lancaster, Pennsylvania

“I refer to us as a very large mom-and-pop store. We still get most of our business from word of mouth and know many of our customers by name or what they order, but we’ve grown and branched out into grocery stores and specialty shops,” says Steve Evans, second-generation owner of the Evans Candy Store located in the old mill. “Still, about half of the people who order through our website are people who moved out of the area, but still want their Evans chocolate.”

Fisher is no stranger to the area, the old mill or the Evans family either. “I was born and raised in Lancaster County, so I’ve been familiar with this building since I was a kid,” Fisher says. “I’ve been doing work for the Evans family for 20 years now — sisters, brothers, parents. I’ve been glad to get to work on it and be a part of its story.”

Franken-Roof

Affectionately referred to as “Franken-roof” by both Fisher and Evans, the roof on the 10,000-square-foot Evans Candy Store consists of four separate roofs — a three-story, steep-slope roof; a two-story, flat roof over a retail space; a large covered porch attached to the side of the mill; and a long, one-story log cabin residence attached to the back of the mill. Each of these roofs has a different type and color of roofing installed for various reasons, and each presented its own challenges.

At one point, an owner of the mill covered the siding with red asphalt shingles, visible in this photo at the upper right. Photo: Evans Candy

The “Franken-roof” extended to nearly every part of the mill’s exterior as a previous owner nailed red-colored asphalt shingles over all of the building’s original 1889 wood siding in an effort to protect the historic structure.

“I’ve lived in this area my whole life and I’ve never seen anything quite like it,” Evans says of the shingle-covered exterior. “When my family started restoring the mill — I was like 10 or 11 years old — I can’t tell you how many dumb asphalt shingles I picked up. That was my job. My brothers knocked them off the house and I picked them up and put them in the trash.”

Since then, the entire bottom floor of the building has been retrofitted to house to the candy store, while the upper floors have been converted into 3,000 square feet of residential space that a number of Evans family members have called home over the years.

The Steep-Slope Roof

It’s difficult to know for certain, but Fisher thinks the original roof over the main portion of the mill was slate. By the time the Evans bought the mill in 1983, the roof had been replaced with asphalt shingles. Evans hired Fisher and the I & D Contracting crew to re-roof this largest portion of the building — a 2,400-square-foot steep-slope roof — 10 years ago. To protect the historic building, Fisher wanted to start from scratch and make sure the job was done right. When he tore off the old roof, he found no real roof decking, just old barn wood in random sizes fitted together.

To preserve as much of the historical nature of the building, Fisher kept the original board decking, shoring it up where needed, and applied TAMKO Moisture Guard Ice and Rain Underlayment. To help create a more uniform surface for the shingles, Fisher chose a thick felt paper — TAMKO No. 30 Underlayment — to cover the barn wood roof deck and started laying the Heritage Premium asphalt shingles.

The shingle application required some extra care and an attentive ear due to the old barn wood deck. “There were gaps between the old barn wood pieces, so we had to listen to the sound each nail made as it went in — you could hear the difference when the nail hit one of the gaps and didn’t get any wood,” Fisher says. “In those cases, we had to move the nail and try again, because we wanted to know that it was really solid.”

Evans chose the very light-colored Olde English Pewter shingle in an attempt to reduce the heat coming in to the third story. Energy efficiency is always a concern in buildings of this age. When the Evans family purchased the building, it had no drywall or insulation, just open studded walls. Over the years, the family added spray foam insulation, insulation batting and roof vents to help address heat flow in and out of the massive historic building.

Fisher notes his crew took extra care around the 130-year-old brick chimney, which had been re-pointed in the past but needed some additional work. Fisher fabricated aluminum flashing and counter flashing out of coil stock on an aluminum brake to further protect the historic structure from potential damage.

The Flat Roof

Before Evans befriended Fisher and the two started their working relationship, Evans hired another roofer friend, Josh Miller of Miller’s Roofing in Wellsville, Pennsylvania, to update the flat roof portion of the old mill. The existing asphalt roll roofing installed in the early 1980s had reached the end of its life and Evans and Miller worked together to add foam sheeting over top of the existing rolled roofing and finished it by installing a Versico EPDM roofing system in the late 1990s.

The original roof deck over the flat roof portion of the mill was tongue and groove, and the men worked carefully to preserve the integrity of the original decking as they modernized the covering.

The Covered Porch

Fast-forward to 2018, and Evans contacted Fisher to replace and repair the roof over a large covered porch connected to the side of the building. The 450-square-foot cedar shake roof was added in an effort to blend with the rest of the historical structure, but after several decades, the moss-covered shakes succumbed to water damage and began to fail.

Fisher and his crew removed the cedar shakes and found part of the reason for the roof’s failure — zero flashing connecting the shake to the side of the building, just some old caulk. As part of the re-roofing project, Fisher added new flashing where the porch roof connected to the side of the mill.

“We had to get creative — flashing underneath the existing siding to try and prevent the same problems from recurring,” Fisher says.

Evans loved the old cedar shake roof and felt torn when choosing a replacement shingle. He ended up going with Heritage Premium asphalt shingles for their durability and selected the Rustic Slate color to differentiate the covered porch from the rest of the structure.

“It was a toss-up — would I match the new shingles to the other parts of the building?” Evans recalls. “But then I realized, I kind of liked the covered porch being a separate entity unto itself. It had always had a different shade of roofing, signifying a separate area of the building, and I liked that. I chose the Rustic Slate color because it still gave that rustic, historic feel that I loved about the cedar shake.”

The Log Cabin Residence

The other roof Fisher’s crew updated on the old mill in 2018 was on the long, log-cabin residence attached to the side of the three-story structure. Despite looking like an original part of the mill’s construction, the log cabin was added to the building in 1992, as a retirement home for Evans’ aging parents.

The log cabin addition was constructed in 1992. The roof was recently replaced with TAMKO Heritage Premium asphalt shingles in Rustic Cedar to help it blend in with the rest of the historic structure. Photo: Evans Candy

By the time Fisher got a good look at the log cabin roof in 2018, he realized the existing asphalt shingles were at the end of their service life, and one particular section of the roof had been patched multiple times and had additional layers of shingles stacked on the roof in an attempt to repel water.

Fisher took the 1,600-square-foot roof down to the decking, installed ice and water shield, new felt paper and installed TAMKO Heritage Premium asphalt shingles. Evans chose the Rustic Cedar color for the new roof as it was similar to the previous shingle color that added to the rustic, historic look that Evans hoped the log cabin would have in an effort to have it meld with the rest of the 130-year-old mill structure.

“I liked that Rustic Cedar look, pairing it with the log front,” Evans notes. “I think back to olden times with the cedar shake and wanted to emulate that. And I think we accomplished it. It is fun — it makes us smile when people ask us, ‘How old is that log home?’ and we get to tell them it’s only 26 years old.”

Fisher has grown to appreciate what he calls the “hodge-podge” of roof styles and colors on the old mill, and says the most important thing is that the building’s owner got exactly what he wanted and is a happy customer.

“Sometimes if people want to see installed examples of different colors of TAMKO shingles, I just send them to the mill because they can see a variety there,” Fisher says, laughing. “I jokingly asked Steve the other day if he had a shed that we could roof for him … just to see how many different colors we could do.”

About the author: Melissa Dunson is an award-winning journalist with more than a decade of experience writing about a wide variety of business sectors, including the construction industry, and as a technical and creative writer for TAMKO Building Products.

TEAM

Roofing Contractor: I & D Contracting Ltd., Lancaster, Pennsylvania

Roofing Contractor: Miller’s Roofing, Wellsville, Pennsylvania

MATERIALS

Underlayment: No. 30 Asphalt Saturated Organic Felt, TAMKO, www.tamko.com

Waterproofing: Moisture Guard Ice and Rain Underlayment, TAMKO

Asphalt Shingles: TAMKO Heritage Premium Laminated Asphalt Shingles in Olde English Pewter, Rustic Slate and Rustic Cedar

Low-Slope Roof: Versico EPDM Roofing System, www.versico.com

Contractor Overcomes Challenging Logistics to Re-Roof 16-Story Westin Savannah

The Westin Savannah site posed logistical challenges, as it is bordered by the Savannah River, a canal and the Savannah Convention Center. Photo: SOPREMA

Were you to visit Savannah, Georgia, the Westin Savannah Harbor Golf Resort and Spa would be tough to miss. This landmark property, known for its 18-hole PGA golf course, secluded beach access and on-site spa, is the tallest building in the city at 16 stories. The aura of luxury surrounding the building was threatened, however, when Hurricane Matthew moved through the region, inundating the city with rainwater and causing the aging Westin Savannah roof to fail. With leaks resulting in the closure of a major portion of the hotel’s upper floor, it was clear the building owners would need to move quickly to restore a waterproof seal atop their building.

The job would not be easy. The Westin Savannah is surrounded by the Savannah River on one side, a canal on another and the Savannah Convention Center on a third. The only feasible area left to stage and load the roofing material onto a crane was the front parking loop and valet area — an area that would typically be avoided with any other roofing project. “We only had one spot where we could set up, and that was the biggest challenge,” says Larry Hoffman, the superintendent who oversaw the installation of the roof at the Westin Savannah on behalf of Whitco Roofing, the Westin’s chosen contractor. “We were very limited with regard to any mobility around that hotel, not to mention the fact that we had to get materials onto a roof that was 270 feet from the ground.” 

Envisioning an Approach

The Whitco Roofing team also had to deal with challenging application conditions, given that the roof had many penetrations due to the presence of air conditioning units, towers, exhaust vents, lighting, walkways, ladders, staircases and other equipment. Special care would have to be given to the installation of the flashing to ensure no opportunities for leak formation remained after the roofing job was done. Recognizing that the use of a liquid flashing material was the best bet to keep the roofing layer monolithic despite all the penetrations, the Whitco Roofing team set about selecting the right compatible materials for the job.

SOPREMA’s SENTINEL P150 60-mil PVC-based roofing membrane was selected for the projectbecause we wanted a durable roofing product that was compatible with a liquid flashing material for difficult base flashings encountered during this project,” explains Henri Brickey, director of business development for Whitco Roofing. “We recommended the SOPREMA PVC membrane for several reasons, the first of which is the superior chemical and UV resistance PVC offers over TPO. Since we also intended to wrap the large quantity of concrete and metal support column bases with SOPREMA’s ALSAN RS 230 Flash polymethyl methacrylate (PMMA) liquid resin, we made sure the PVC membrane was compatible and that we could include those areas under the roof’s warranty.” 

The Installation Commences

The complex coordination required for a successful roofing installation began on the ground. One week’s worth of material was staged at a time, then a crane was brought in to upload materials to the roof on the same day trash was being downloaded from the old roof tear-off process. All debris had to be carefully bagged and secured with tarps to avoid pollution in the nearby Savannah River, and the delivery and removal of four dumpsters at a time had to be carefully coordinated so that no dumpster was left on the premises overnight, blocking entry to the building. “You had to be out of there by five o’clock with everything, and it had to be done in a particular sequence, further complicating matters,” explains Hoffman.

On the rooftop, existing asphalt-based roofing materials were stripped down to the concrete deck. SOPREMA SOPRA-ISO3.5-inch polyisocyanurate insulation was adhered using SOPREMA DUOTACK 365 foam adhesive to provide improved R-value to the building. Next, the PVC membrane was bonded onto the insulation, providing both a reliable waterproofing layer and a reflective white finish that would help diminish heat absorption compared to the older materials. The liquid resin coating was then applied to prevent water intrusion at all exposed concrete column bases — extending up and coating metal base plates — and at vertical flashing points where air handling units tied into the building’s walls. New tapered crickets were also installed between drains, improving the overall flow of water on the roof and reducing the opportunity for ponding water.

Safety and Communications Prioritized

Throughout the project, OSHA guidelines had to be followed carefully on the rooftop and on the ground to ensure both workers and bystanders entering and exiting the hotel were safe. Flagging and ground guides were used around the staging area, and strict adherence to timelines for deliveries and mobilizations were also critical to the safe execution of the project. The Whitco Roofing team worked closely with the hotel management throughout the process to prevent interference with hotel operations and to minimize risks to guests. 

The building now benefits from a superior roofing membrane that is Energy Star-compliant, upgraded insulation, a strong foam adhesive that helps resist uplift pressure during storms and a monolithic waterproofing layer thanks to the liquid flashing installed around all penetrations. “SOPREMA’s single-ply membranes have a reputation for strength and durability,” notes Brickey, “and especially with the inclusion of the liquid flashing system to deal with difficult flashing details, we were able to provide a long-lasting, warranted waterproofing solution for the Westin.”

In all, more than 14,000 square feet of roofing material was replaced over the course of roughly a month by a large team of installers. In part because the hotel staff was so pleased with the way the job was planned, managed and executed, Whitco Roofing was brought back to install a new roof on a lower section of the building as well. That project was recently completed, positioning the Westin Savannah to resist the elements while serving as a relaxing getaway for the foreseeable future.

TEAM

Roofing Contractor: Whitco Roofing, Atlanta, Georgia, www.whitcoroofing.com

MATERIALS

Roof Membrane: SENTINEL P150 PVC, SOPREMA, www.soprema.us

Insulation: SOPRA-ISO, SOPREMA

Adhesive: DUOTACK 365, SOPREMA

Liquid Flashing: ALSAN RS 230 Flash, SOPREMA

Building to Last With Asphalt-Based Roofing

The property owner of this building opted for a BUR/modified-bitumen hybrid system with reflective white coating. Photos: Johns Manville

The advantages of a built-up roofing (BUR), modified bitumen, or hybrid roofing assembly include long life, a variety of maintenance options, and outstanding puncture resistance. This durability means property owners will spend less time worrying about fixing leaking roofs and the associated hassles — lost productivity, disruption in operations, slips and falls, repair bills, and other liabilities.

Recommending clients install a roof system that gives them the best chance of eliminating unproductive distractions is a good business decision for design/construction professionals. A more durable roof will enable property owners to focus on making profits instead of dealing with the aftermath of a roof leak.

“I have no problem endorsing asphalt-based roofing,” says Luther Mock, RRC, FRCI and founder of building envelope consultants Foursquare Solutions Inc. “The redundancy created by multiple plies of roofing is really what sets systems like BUR and modified bitumen apart.”

One can argue BUR’s closest cousin — the modified bitumen (mod bit) assembly — is actually a built-up roof made on a manufacturing line. The reality is the plies of a BUR create a redundancy that can help mitigate any potential oversights in rooftop workmanship.

BUR systems are offered in a variety of attractive and reflective options with a proven track record of performance. Photos: Johns Manville

“I’ve replaced BURs for clients I worked with 30 years ago,” says Mock. “We recently replaced [a BUR] specified in the early 1980s. And the only reason was because some of the tectum deck panels had fallen out of the assembly. Meanwhile, the roof was still performing well after 30 years.”

According to the Quality Commercial Asphalt Roofing Council of the Asphalt Roofing Manufacturers Association (ARMA), one of the main drivers of the demand for BUR systems is the desire of building owners for long life cycles for their roofs.

“A solid core of building owners and roofing professionals in North America continue to advocate asphalt-based roofing systems because of their long lives,” says Reed Hitchcock, ARMA’s executive director.

Benefits of Asphalt-Based Roofing

Over the years, asphalt-based roofing assemblies have earned a reputation for reliability with building owners, roofing consultants, architects, engineers, and commercial roofing contractors. The original price tag tends to be greater than other low-slope roofing options, but these assemblies offer competitive life-cycle costs. BUR enjoys a track record spanning more than 150 years; it provides a thick, durable roof covering and can be used in a broad range of building waterproofing applications.

An aerial view of a reflective roof membrane. Photos: Johns Manville

Available as part of fire-, wind-, and/or hail-rated systems, BUR and modified bitumen assemblies offer proven waterproofing capabilities, high tensile strength, long-term warranties, and a wide choice of top surfacings (including ‘cool’ options). Their components include the deck, vapor retarder, insulation, membrane, flashings, and surfacing material. The roofing membrane can be made up of a variety of components, including up to four high-strength roofing felts, modified bitumen membranes (hybrid systems) and standard or modified asphalt. Hot-applied asphalt typically serves as the waterproofing agent and adhesive for the system.

The roofing membrane is protected from the elements by a surfacing layer — either a cap sheet, gravel embedded in bitumen, or a coating material. Surfacings can also enhance the roofing system’s fire performance and reflectivity ratings.

Another surfacing option is gravel, commonly used in Canadian applications where the existing roof structure can handle the extra weight. There are also several smooth-surface coating options, the most popular of which are aluminum or clay emulsion products offering greater reflectivity than a smooth, black, non-gravel-surfaced roof. These reflective roof coating options are typically used in warmer regions when required by code. Reflective white roof coatings are also becoming more popular.

Cold-Process BUR

Cold application of BUR has provided an alternative to traditional hot-applied systems for more than 48 years. The term ‘cold-applied’ means the BUR roofing system is assembled using multiple plies of reinforcement applied with a liquid adhesive instead of hot asphalt. These cold adhesives are used between reinforced base/ply sheets to provide a weatherproof membrane.

The owner of this shopping mall chose BUR primarily due to its redundancy. Multiple plies of roofing can provide extra insurance against water intrusion. Photos: Johns Manville

In BUR cold-process roof systems, manufacturers typically require that only fully coated, non-porous felts (such as standard base sheets) are used as base and ply sheets. Generally, an aggregate surfacing or a coating is then applied over the completed membrane to provide surface protection and a fire rating for the roof system.

“In the re-roofing market, we’re definitely seeing more cold-applied systems being specified, particularly with modified bitumen,” says Mock. “It’s a natural alternative when a building may be occupied during the reroofing process and hot asphalt is not an option.”

Adhesives can be manually applied with a squeegee, brush, or spray application equipment. When numerous roof penetrations or rooftop access become issues, manual application of adhesives is usually the best option. Proper coverage rates are vital to a successful, long-term, cold-applied roof system. Both spray and manual application methods require the proper amount of adhesive material be installed. If too little adhesive is applied, there is a potential for an improper bond to be formed between the felts. If too much is applied, then the potential for longer setup times and membrane slippage is increased. Additionally, ambient temperatures must be 40 degrees Fahrenheit (5°C) and rising before installation. This limits, but does not preclude, use of cold-process BUR in much of the northern United States and Canada.

“I’m also comfortable specifying BUR, because I’m confident I will have a seasoned contractor on the job,” says Mock. “The commitment in terms of skilled labor and equipment is simply too great for these contractors to be first-timers.”

Flashings are another critical component of every roofing system, particularly in cold-weather applications. Four-ply BURs use modified bitumen flashings almost exclusively. These membranes are predominantly styrene butadiene styrene (SBS)-modified and offer greater elongation in frigid climates where it counts most — at the interface of the roof system with other building components.

Use of a modified-bitumen base ply is one way of handling general flashing requirements, although modified bitumen cap sheets are more common.

BUR Repair and Maintenance

Like all roof systems to some extent, the life expectancy of a BUR system depends on the property owner’s commitment to routine maintenance. All roof systems can benefit from an owner willing to undertake a proactive management plan. BUR installed over an insulation package lends itself well to non-destructive testing in the future (e.g., infrared) as a means to maximize service life.

“Asphalt roofing systems have the potential for a very long life, and preventive maintenance is the key to realizing that potential,” says Hitchcock.

Non-gravel BUR surfacing options include aggregate, a mineral surface cap sheet, or a smooth, surface-coated membrane. Photos: Johns Manville

The goal is for problem areas to be detected and fixed before they develop into leaks. Inspections can reveal potentially troublesome situations, such as a loss of gravel surfacing, which could lead to felt erosion or brittleness. Less commonly, punctures and cuts to the membrane can occur, so it is wise to remove sharp objects and debris from the roof. Clogged drains or poorly sealed flashings also present problems that are repaired easily. The effects of chemical exhausts on roofing materials should also be monitored.

Preventive maintenance actions can help catch problems before they damage larger areas of the roof system. Inspections should be performed not only on aging roofs, but also on newly-installed roofs to guard against errors in installation, design, or specifications.

BUR and modified bitumen also have a long history of proven performance in the northern United States and Canada, where snow and ice buildup are common. Perhaps more than any other roof membrane, the BUR system shrugs off minor abuse.

BUR has proven to be a low-maintenance roofing system, and it can also be effectively repaired when needed. This means property owners can usually get more life out of a BUR. The ability to enhance the performance of existing BUR membranes with coatings, mod bit cap sheets, or flood coats of asphalt explain the long service lives of these systems in demanding applications.

“Property owners rarely have to replace a four-ply BUR until it is absolutely, positively worn out,” says one roofing contractor who asked to remain anonymous. “Based on experience, these asphalt-based systems ‘hang in there’ longer than less-robust roof options.”

When BUR Is Not the Best Option

There is no roofing product solution that will fit every building specification, and that certainly holds true for BUR. Probably more than any other roofing system (except spray polyurethane foam), the built-up roofing application is more of a skill than a science. As alternative systems have been introduced into the market, the job of finding experienced BUR contractors has become more difficult. This is especially true for the hot mopping of multi-ply BUR systems.

BURs are labor intensive and their installed cost will fluctuate with crude oil prices. However, as oil prices have continued to fall, BUR manufacturers have enjoyed the lowest asphalt pricing since the 2008-09 recession. (The price of oil peaked at about $117 a barrel in September 2012 and is $50 a barrel at this writing.) Typically BUR manufacturers will pass on a portion of these savings to their customers.

BUR has always held up well in life-cycle cost analyses. However, if a roof is not expected to last 20 years or more, it usually does not make sense to specify a premium four-ply BUR.

On larger projects, gravel-surfaced BURs are typically not practical from a cost standpoint unless a source of gravel is available locally. Projects where roof access is difficult often present challenges when roofing kettles are used. And despite the preponderance of low-fuming asphalts and kettles, re-roofing occupied buildings is often unacceptable to neighbors and/or the property owner.

Built-up roofing systems have sufficient strength to resist normal expansion and contraction forces that are exerted on a roof; however, they typically have a low ability to accommodate excessive building or substrate movement. Rephrased, if the roof must be used to “hold the walls” together or if the use of “loose-laid insulation” has a benefit, then a traditional three- or four-ply built-up roofing system is not a good choice.

A built-up roof typically provides high tensile strength with low elongation. Guidelines about where expansion joints should be installed in the roofing system should not be ignored by the designer. These guidelines include installing expansion joints where the deck changes direction, approximately every 200 feet (61 meters), although many consider that this dimension can be expanded for single-ply roofing membranes; where there is a change in deck material; and, anywhere there is a structural expansion joint, etc. Based on these requirements, on some projects it simply isn’t practical to use a BUR.

BUR materials must be kept dry before and during installation to prevent blistering in the roof system. Proper storage is the key: Do not overstock the roof; use breathable tarps to cover material on the roof; store material on pallets to minimize the possibility of material sitting in water; and store rolls on-end to prevent crushing. In general, polymeric single-ply membranes like TPO (thermoplastic polyolefin) are less susceptible to storage issues.

Many roof consultants and product manufacturers clearly state that there should be no phased construction of a built-up roof. If phasing is required, then a BUR should not be specified. This is a clean and simple rule to understand; if the roof being constructed is a four-ply BUR, then only as much insulation should be installed as can be covered the same day with all four of the plies in the built-up roofing membrane. Phased construction of a built-up roof greatly increases the potential for blistering of the membrane and does not allow for the total number of plies to be installed in a shingled fashion. Phased application contains other perils, such as roofing over a small amount of overnight precipitation or dew that, even with the best of intentions, can cause harm.

As stated above, costlier modified bitumen materials should be specified for flashings and to strip in metal. Stripping in two plies of felt will most likely result in splitting at the joints in a gravel stop because the two-ply application cannot accommodate the movement in the edge metal. On new or existing buildings where significant expansion/contraction is expected, a TPO, PVC or EPDM roof membrane can save the property owners money and eliminate premature roof failure due to roof splitting.

Conclusion

Manufacturers across North America are making asphalt roofing systems like BUR better and more versatile for architects, builders, contractors, roofing consultants, and building owner/managers. Thanks especially to the addition of polymers that add stretch and strength, architects can now specify a commercial, low-slope roof as part of a multi-ply BUR system any way they want it — hot, cold, torch, or self-adhered (hybrid BUR) — to meet the individual low-slope roofing project’s needs.

Most importantly, asphalt-based roofing products offer exceptional life-cycle cost performance. They have proven to be reliable, easy to maintain, and are trusted to perform exceptionally well in extreme weather conditions.

ARMA Honors Top Asphalt Projects With QARC Awards

The QARC Gold award was presented at the International Roofing Expo in New Orleans, where Imbus Roofing received a $2,000. Pictured are Bob Gardiner, CertainTeed; Steve Sutton, Imbus Roofing; Andrew Imbus, Imbus Roofing; Tom Smith, CertainTeed and Ron Gumucio, ARMA.

The Asphalt Roofing Manufacturers Association (ARMA) recognized a historic music hall, a home with a roof built to withstand high-wind events, and a museum dedicated to the United States’ fight for independence as 2017’s top asphalt roofing installations. ARMA’s annual Quality Asphalt Roofing Case-Study (QARC) Awards Program awarded the projects that exemplify the most beautiful, affordable and reliable asphalt roofing systems in North America.

Imbus Roofing Co. Inc. received the Gold QARC Award for its new roof installation on the 225,000 square-foot, 139-year-old Cincinnati Music Hall. The Kentucky-based contractor installed designer asphalt shingles to replicate the Music Hall’s slate tile roof, while also providing crucial durability against Cincinnati’s tough climate.

Reliant Roofing Inc. was honored with the Silver QARC Award for its completion of Topsail Residence, a 10,600-square-foot asphalt shingle roofing system designed to endure high-wind events in Ponte Vedra, Florida. This high-performance roofing system not only provided the homeowners with a durable option, but also a visually stunning roof for years to come.

The Bronze QARC Award was given to Thomas Company Inc. of Egg Harbor Township, New Jersey, for its low-

slope installation on Philadelphia’s Museum of the American Revolution. Designed to achieve LEED Gold certification, the project featured a high-quality modified bitumen roof membrane to prevent water penetration and create a more stable surface for the facility’s vegetative roof.

According to ARMA, the 2018 QARC Award program received some of the most impressive and innovative submissions of asphalt roofing installments to date. “This year’s submissions demonstrated asphalt’s ability to provide a durable and reliable roofing system against harsh weather while simultaneously offering an array of beautiful colors, designs and installation options,” said Ralph Vasami, ARMA’s acting executive vice president. “These projects are true examples of what asphalt roofing can offer commercial businesses and private homeowners alike.”

The 2018 QARC Award recipients are:

Gold
Project Name: The Cincinnati Music Hall
Company: Imbus Roofing Co. Inc.
Project Description: This steep-slope roof was installed with CertainTeed’s Grand Manor luxury asphalt shingles in the colors Stonegate Gray and Brownstone, as well as DiamondDeck and WinterGuard underlayments. The size, complexity and steepness of the project presented a great challenge to the contractor, who managed to install a durable asphalt roofing system that was also visually stunning.

Imbus Roofing received top honors for its work on 139-year-old Cincinnati Music Hall. Photo: CertainTeed

Silver
Project Name: Topsail Residence
Company: Reliant Roofing Inc.
Project Description: GAF Grand Canyon Lifetime Designer Shingles in the color Stone Wood was selected not only for its beauty, but its superior high-wind protection. Hand sealed Timbertex Premium Ridge Cap Shingles and GAF self-adhering Leak Barrier were also installed for added leak prevention.

Reliant Roofing received the Silver QARC Award for its completion of Topsail Residence in Ponte Vedra, Florida. Photo: Justin Alley and Kyle Brumbley

Bronze
Project Name: Museum of the American Revolution
Company: The Thomas Company Inc.
Project Description: The historic project required a high-quality roofing membrane that offered an aesthetic appeal to the building. Thomas Company chose SOPREMA’s SBS Modified Base Ply – ELASTOPHENE Flam with the SBS Modified Bitumen Flashing Base Ply – SOPRALENE Flam 180 to keep the roof water-resistant year-round, protect the roof membrane from foot traffic and add a beautiful appearance to the museum.

The Bronze QARC Award was given to Thomas Company Inc. of Egg Harbor Township, New Jersey, for its work on Philadelphia’s Museum of the American Revolution. Photo: Soprema

Honorable Mentions:
Big House Castle Rock
Jireh 7 Enterprises
Castle Rock, Colorado
Malarkey Roofing Products

Closson Chase Winery Church Roof
AI Anthony Roofing LTD
Hillier, Ontario
IKO Production Inc.

Tiny House & Top Shop
M & J Construction
Erhard, Minnesota
CertainTeed Corporation

West Loch Village Senior Apartments
M & R Roofing
Ewa Beach, Hawaii
PABCO Roofing Products

For more information about this year’s winners or to submit an asphalt roofing project, visit www.asphaltroofing.org.

Perforated Starter Shingle Designed to Save Time and Reduce Waste

TAMKO Building Products, Inc. introduces the Perforated Starter shingle to its roofing product line. Made from fiberglass mat coated with asphalt and surfaced with ceramic granules, the Perforated Starter course shingle is the answer to roofing contractors need for an easy to install starter strip prior to shingle application. The perforation ensures that contractors no longer lose time field cutting shingles to the appropriate size while reducing related waste.

“Roofing contractors need more ways to make their jobs hassle-free,” said Vice President of Sales and Marketing for TAMKO, Stephen McNally.  “With TAMKO’s Perforated Starter shingle, you remove the tedious time-consuming job of field cutting shingles for the starter course so roofing contractors can finish a job quicker with less waste.”

TAMKO’s Perforated Starter shingle is intended for application to the eave or rake edge of a roof to assist with proper alignment of the shingle course. The starter strip also fills in the spaces under the shingle joints and helps the first course of shingles to seal. Perforated Starter comes in a bundle of 16 full-size (13 ¼ inches) perforated shingles to be separated into 32 starter strip shingles (6 ⅝ inches).

Available now to customers nationwide, the Perforated Starter shingle is being produced at TAMKO’s Frederick, Maryland manufacturing facility. The Perforated Starter shingle can be used with TAMKO’s full line of asphalt shingles including the Heritage series laminated asphalt shingles and Elite Glass-Seal 3-Tab shingles.

For more information, visit TAMKO.com.

Asphalt Shingles Offer Algae Resistance Warranty

PABCO Algae DefenderPABCO Roofing Products announces its new premium asphalt shingles featuring Algae Defender with an algae resistance warranty. Many areas of the United States are susceptible to black streaks on rooftops caused by algae – especially coastal regions or those that experience high humidity. Preventing those black streaks helps preserve your home’s curb appeal.

PABCO shingles and accessories featuring Algae Defender prevent black streaks caused by algae from forming on your roof, according to the company. “We have a precise target blend of copper containing granules in the manufacturing process and our results are closely monitored during every production run,” explains Rebecca Newman, Plant Operations Manager, “When moisture contacts your Algae Defender protected roof in the form of dew or rain, copper ions are gradually released over time to provide reliable protection from black streaks caused by blue-green algae.”

With more than two decades of experience in producing algae resistant shingles, PABCO has seen proven results from our manufacturing techniques. Newman adds, “We are constantly monitoring our algae resistant shingles in actual field installations to ensure they are performing to our high standards.”

PABCO shingles with Algae Defender are available in most markets where PABCO is sold. “We are excited about the Algae Defender warranty – which is Limited Lifetime for many products – and are confident in the performance.” States Gerry Kilian, General Sales Manager. “It is such a benefit to the homeowner to have that kind of protection.”

For more information, visit pabcoroofing.com.

Ventco Makes New Technical Catalog Available Online

Ventco Inc. has published its 2018 Technical Catalog and made it available for download on a revamped website.

“We’re excited about our new website and being able to offer our new Technical Catalog as a download there,” says Marty Rotter, owner of Ventco. “If you have a question about the compatibility of ProfileVent with 47 metal roofing panels or how to install ProfileVent, the information is available in the Technical Catalog.”

The new Technical Catalog and other Ventco brochures can be downloaded at: http://profilevent.com/brochure.html.

The 54-page catalog, which can be downloaded and printed, also includes information on Hip&RidgeVent, Contractors’ Choice, The RidgeVent and Mongoose ridge vent for asphalt, slate and cedar shingle roofs. The catalog features testing information and proper installation instructions for all Ventco products.

For more information, visit www.profilevent.com

Shingle Starter Material Is Non-porous

SBS Shingle Starter is a SBS modified starter strip coated on both sides with SBS rubberized asphalt compound and surfaced with black ceramic granules.

SBS Shingle Starter is a SBS modified starter strip coated on both sides with SBS rubberized asphalt compound and surfaced with black ceramic granules.

MB Technology’s SBS Shingle Starter is a premium SBS modified starter strip completely coated on both sides with SBS rubberized asphalt compound and surfaced with black ceramic granules. The SBS rubberized membrane provides a flexible starter roll and, because it’s non-porous, it provides a watertight membrane by itself. The fiberglass-reinforced product is used for eave and rake starter material for composition roofing. It is used with minimum 3/8-inch head roofing nails, fastened 12 inches on center and at 4 to 6 inches above the edge of the roof or as required by the shingle manufacturer.

Enter ARMA’s Quality Asphalt Roofing Case-study Awards Program

The Asphalt Roofing Manufacturers Association (ARMA) is searching for the top asphalt roofing projects in North America. Roofing contractors, architects, consultants and specifiers are invited to submit commercial and residential roofing projects to the association’s Quality Asphalt Roofing Case-study (QARC) Awards program, now and through the end of the year.

Each year a Gold, Silver and Bronze winner are chosen. These roofing professionals receive cash prizes and gain national recognition. Winners and their projects receive media coverage and are featured in top trade publications. This year, ARMA has redesigned its submission process to make it easier than ever. Simply upload photos of your project along with a description and details about why asphalt roofing materials were chosen. High-resolution photos of the completed project are strongly encouraged for submission. Both new construction and renovation projects are eligible for the program.

Submissions for the 2016 Quality Asphalt Roofing Case-study Awards Program are currently being accepted through Saturday, Dec. 31. Roofing professionals can submit as many projects as they want without any cost to enter.

“The QARC program helps ARMA recognize the most beautiful and innovative asphalt roofing projects being built or restored today,” says Reed Hitchcock, executive vice president of ARMA. “By celebrating the use of asphalt materials in these low- and steep-slope projects, we shine a light on skilled roofing contractors who demonstrate the benefits of asphalt roofing.”

For more information on the Quality Asphalt Roofing Case Study Awards Program, visit ARMA’s website.

Asphalt and Polyurethane Create Durable Membrane

The Garland Co. Inc.’s OptiMax polyurethane-modified asphalt-based roof membrane is developed with a process that combines asphalt with polyurethane to create a durable and long-lasting modified membrane.

The Garland Co. Inc.’s OptiMax polyurethane-modified asphalt-based roof membrane is developed with a process that combines asphalt with polyurethane to create a durable and long-lasting modified membrane.

The Garland Co. Inc.’s OptiMax polyurethane-modified asphalt-based roof membrane is developed with a process that combines asphalt with polyurethane to create a durable and long-lasting modified membrane. OptiMax becomes increasingly resilient as it ages because, with time, polyurethane molecules are chemically linked with one another. The process was first used in Europe in the paving industry.

When traditional SBS-modified membranes age, the oils within the membrane heat up and “cook out”, causing cracking and eventually leaking. OptiMax utilizes an “active modification” process, which involves chemically reacting the polyurethane modifier to specific molecules within the asphalt. This modification provides enhanced long-term performance characteristics and weatherability.

Its performance is further improved by the fact that minerals are more strongly attracted to the polyurethane in the OptiMax membrane. The result is improved adhesion thus providing UV protection, preventing the likelihood of cracking and leaking issues common in traditional membranes. During advanced surface testing, OptiMax had fewer cracks when compared to traditional asphalt-modified membranes and retained its tensile strength in the face of damaging UV radiation.

“OptiMax has the ability to literally change the face of the roofing industry. This new technology will revolutionize the market and redefine expectations of building owners in terms of performance and protection. OptiMax has been engineered to outperform other commercial roofing products in the industry,” explains Melissa Rus, Garland’s director of research and development.

PHOTO: The Garland Co. Inc.