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

Laminated Cover Board Features Foam Insulation

ShieldBase 180 Laminated Cover Board provides a 2-in-1 composite layer cover board solution for commercial roofing applications.

ShieldBase 180 Laminated Cover Board provides a 2-in-1 composite layer cover board solution for commercial roofing applications.

IKO ShieldBase 180 Laminated Cover Board provides a 2-in-1 composite layer cover board solution offering versatility for commercial roofing applications.

ShieldBase 180 is a composite of 1/2-inch high compressive IKOTherm CoverShield polyiso insulation that is factory laminated to a 180-gram polyester reinforced SBS modified bitumen base sheet.

The CoverShield layer of the product features a foam insulation with thermal properties, which offers insulation protection and an R-value of 2.5.

The dual selvage, self-adhering edges of the product allow for easy joining of the base to the adjacent ShieldBase 180 boards.

It can be applied as a mechanically fastened system, offering a fastening pattern of 18-inch on-center to reduce material and labor. Additionally, ShieldBase 180 Cover Board may be adhered with IKO Millennium Adhesive or fully adhered with hot asphalt.

IKO provides a full suite of asphalt low slope roofing systems and accessories, including built-up roofing (BUR), cold applied, heat welded, self adhered and more. In addition, IKO offers building envelope and bridge deck and waterproofing membrane systems and accessories, along with wall insulation and air/vapor barrier systems.

For more information on ShieldBase 180 and details on IKO’s commercial roofing system solutions, visit the website.

Prefabricated Edge Metal Helps Shape Unique Roofs on a Georgia Hospital

To expand its services and make it easier for patients and visitors to navigate its facility, Gordon Hospital, Calhoun, Ga., underwent a $37 million expansion. The project added 59,000 square feet of hospital space, renovated 11,500 square feet of space, and created a new patient tower entrance to separate inpatient and outpatient service entrances. The various aspects of the project included 11 different roof areas, so the project’s general contractor, the Atlanta office of Birmingham, Ala.-based Brasfield & Gorrie, brought Atlanta’s Diamond Roofing Co. into the project during concept design.

The architects designed all the curves and unique walls to make the campus beyond ordinary and give the hospital a certain appeal.

The architects designed all the curves and unique walls to make the campus beyond ordinary and give the hospital a certain appeal.

“The hospital addition and renovation was still just a sketch and a narrative, and we worked together to understand the owner’s needs and architect’s intent,” says Dave Mossige, Diamond Roofing’s president. “Roofing systems have be- come very complex over the years and it really does take a roofing specialist to navigate the numerous options and decide the best roofing systems for the project.”

Having the roofing contractor onboard from inception also helped with staging. When it became apparent that two canopies between the new and existing buildings would pose significant challenges with materials’ access, the team was able to plan ahead and stock-pile materials near the area months pri- or to needing them.

GETTING THINGS LEVEL

Because this was a fast-track project, 10 to 15 crew members worked across multiple roof areas. “All the other trades come in behind us once we have the roof ready, so getting the roof area dried-in was key to the schedule,” Mossige says. “That’s why we chose a more durable two-ply modified bitumen rather than a single-ply system for the roofing. Disturbances that happened to the base while the trades were working off the roofs could be quickly and easily repaired before we applied the cap sheet.”

The roofing areas added up to 25,400 square feet of space, including the main roof, penthouse and various other canopies. The main roof on the new addition was unique because it was divided into two portions: one with a steel deck and another with a concrete deck for future vertical expansion. The concrete deck was 5-inches higher than the steel deck.

To make the steel deck meet the thickness of the adjacent concrete deck for a level roof, Diamond Roofing’s team mechanically fastened 5 inches of polyisocyanurate insulation on the steel and then installed a 1/4-inch-per-foot-total tapered ISO system. The team then applied a cover board to increase the system’s wind rating and provide better adhesion of the base ply. The tapered system and cover board were set in ribbons of low-rise foam adhesive. The next layer was an SBS modified bitumen as a cold-process adhesive and then a fire-rated granular cap sheet, also set in a cold-process adhesive.

Although Diamond Roofing has a sheet-metal shop in which team members fabricate edge metal, it worked with a supplier to source prefabricated edge metal that had been formally tested to meet or exceed the hospital's required FM 1-105 criterion.

Although Diamond Roofing has a sheet-metal shop in which team members fabricate edge metal, it worked with a supplier to source prefabricated edge metal that had been formally tested to meet or exceed the hospital’s required FM 1-105 criterion.

PRECISE EDGE METAL

Although Diamond Roofing has a sheet-metal shop in which team members fabricate edge metal, most of the roofing firm’s product is equivalent to a wind rating of FM 1-60 and FM 1-90. FM approval ratings apply to uplift pressures in pounds per square foot. Hospitals are constructed to stricter standards, however, and officials at Gordon Hospital wanted to ensure an FM 1-105 approval rating. Diamond Roofing worked with a supplier to source prefabricated edge metal that had been formally tested to meet or exceed the FM 1-105 criterion.

The ability to order the sheer volume of edge metal needed also saved time on the project. “We had over 2,500 lineal feet of edge metal on this project. That would’ve taken us three weeks to fabricate,” Mossige explains. “In addition, the highly unique specifications of the edge metal needed for the project made it more cost-effective for us to outsource it.”

The edge metal needed to be a heavy gauge of 0.063 prefinished aluminum with a protective Kynar 500 resin-based coating. The architects also wanted welded mitered corners. In certain places on the roofs, unusual radiuses and slopes—occasionally joining with straight coping at offset angles—meant some inside and outside miters had to be exactingly produced for odd angles like 104 and 140 degrees.

For example, on one parapet, two different elevations come together at a corner, making precision critical for the manufacturer and installer. “When you are dealing with preformed metal, you have to be precise,” Mossige notes, “but when you’re doing a raised, offset miter, you have to be perfect.”

PHOTOS: OMG EDGESYSTEMS

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Membrane Is Factory Laminated to Cover Board

SOPREMA Inc. has developed SOPRASMART Laminated Boards, which combine SOPRALENE SBS-modified bitumen membrane and cover board into one installation layer, resulting in application consistency and complete adhesion.

SOPREMA Inc. has developed SOPRASMART Laminated Boards, which combine SOPRALENE SBS-modified bitumen membrane and cover board into one installation layer, resulting in application consistency and complete adhesion.

SOPREMA Inc. has developed SOPRASMART Laminated Boards, which combine SOPRALENE SBS-modified bitumen membrane and cover board into one installation layer, resulting in application consistency and complete adhesion. SOPRASMART is manufactured in a controlled setting, utilizing heat-welding equipment to laminate the SBS-modified bitumen coating of the base ply to the desired cover board. This eliminates the risk of delamination or wrinkling, and the sealed overlap protects the assembly from open flame intrusion when torch welding. SOPRASMART is available in a variety of cover-board options, including SOPRABOARD, high-density polyisocyanurate foam board, gypsum panels and high-density rock wool. It can be mechanically fastened or adhered using the DUOTACK adhesive.

NRCA Releases Market Survey on Sales Volume Trends

The National Roofing Contractors Association (NRCA) has released its 2014-15 market survey providing information about overall sales volume trends in the roofing industry, roofing experiences, material usage and regional breakdowns. It is an important tool to measure the scope of the U.S. roofing industry, and the data provides a glimpse into which roof systems are trending in the low- and steep-slope roofing markets.

This year’s survey reports sales volumes for 2014 and 2015 projections averaged between $7 million and just more than $8 million, respectively, and revealed a near-steady ratio of low- to steep-slope sales of 72 percent to 28 percent.

For low-slope roofs, TPO remains the market leader with a 31 percent share of the new construction market and 26 percent of the reroofing market for 2014. Asphalt shingles continue to dominate the steep-slope roofing market with a 44 percent market share for new construction and a 58 percent share for reroofing.

Polyisocyanurate insulation continues to lead its sector of the market with 75 percent of new construction and 70 percent of reroofing work.

In addition, roof cover board installation for 2014 was reported as 24 percent in new construction, 46 percent in reroofing tear-offs and 30 percent in re-cover projects.

NRCA’s market survey enables roofing contractors to compare their material usage with contractors in other regions, and provides manufacturers and distributors with data to analyze, which can affect future business decisions.

Georgia-Pacific Gypsum’s Durable Cover Board Outperforms High-density ISO in Puncture and Hail Testing

Third-party testing results confirm that Georgia-Pacific Gypsum’s DensDeck Prime Roof Boards display puncture and impact resistance, protecting thermoplastic roofing membranes better than high-density polyisocyanurate (HD ISO) cover boards.

All types of commercial roofing membranes are susceptible to everyday punctures from a variety of sources. Rigid objects with sharp edges like dropped tools; heavy equipment; winds which blow branches and debris onto roofs; and frequent foot traffic for general maintenance and repair can cause punctures at any time, explains Todd Kuykendall, director of marketing and product management, Georgia-Pacific Gypsum. “DensDeck Prime cover boards support membranes so they can resist puncture damage, allowing them to do their job as the front-line protection of the roof assembly against water intrusion.”

Thermoplastic membranes tested in assemblies with 1/4-inch DensDeck Prime boards underneath were 83 percent more puncture resistant than membranes with 1/2-inch HD ISO or with no cover board at all, based on average calculations.

Thermoplastic membranes tested in assemblies with 1/4-inch DensDeck Prime boards underneath were 83 percent more puncture resistant than membranes with 1/2-inch HD ISO or with no cover board at all, based on average calculations.

The independent ASTM D5635 puncture test results indicate that thermoplastic membranes do not puncture as easily when 1/4-inch DensDeck Prime Roof Boards are used as a cover board, as compared with HD ISO boards. Puncture-resistance testing conducted by Jim Koontz & Associates, July 21 to August 1, 2014, in its Hobbs, N.M. laboratory, according to ASTM D5635 standards. Assemblies included a base layer of 2 inches, 20-psi polyisocyanurate insulation; and configurations were covered with 45-mil thermoplastic polyolefin (TPO) or 48-mil polyvinyl chloride (PVC) membranes. The test method evaluates the maximum puncture load the samples can withstand, without allowing the passage of water when subjected to impact from a rigid object with sharp edges. Thermoplastic membranes tested in assemblies with 1/4-inch DensDeck Prime boards underneath were 83 percent more puncture resistant, on average, than membranes with 1/2-inch HD ISO or no cover board at all.

Durable and versatile DensDeck Prime roof boards can potentially save money for roofing contractors, building owners and facility managers by eliminating or reducing the need for costly repairs due to punctures during and after completion of the roof installation, Kuykendall adds, “In these puncture tests, HD ISO performed similar to no cover board at all, allowing thermoplastic membranes to puncture more easily.”

Thermoplastic membranes tested in assemblies with 1/4-inch DensDeck Prime boards underneath were 83 percent more puncture resistant than membranes with 1/2-inch HD ISO or with no cover board at all, based on average calculations.

In addition to puncture resistance testing, the independent company also conducted tests simulating the impact of hail in a variety of roofing scenarios—and the results were similar.

Performance of 1/4-inch DensDeck Prime roof board versus HD ISO or no cover board at 1.5- to 2.5-inch hail ball impacts. Assemblies in these tests with thermoplastic membranes and high-density ISO cover boards demonstrated 25 to 30 percent greater indentation than similar tests with DensDeck Prime roof boards.

Performance of 1/4-inch DensDeck Prime roof board versus HD ISO or no cover board at 1.5- to 2.5-inch hail ball impacts. Assemblies in these tests with thermoplastic membranes and high-density ISO cover boards demonstrated 25 to 30 percent greater indentation than similar tests with DensDeck Prime roof boards.

FM 4473 (using NBS— National Bureau of Standards—23 standards) hail test results indicate that DensDeck Prime boards offer key benefits against hail damage versus HD ISO products. Hail testing (or impact resistance testing of rigid roofing materials by impacting with freezer ice balls) conducted by Jim Koontz & Associates July 21 to August 1, 2014, in its Hobbs, N.M. laboratory, according to FM 4473 (using NBS 23 standards). Based on average results using 1.5- to 2.5-inch freezer ice balls. Assemblies included a base layer of 2-inch 20-psi polyisocyanurate insulation; and configurations were covered with 45-mil thermoplastic polyolefin (TPO) or 48-mil polyvinyl chloride (PVC) membranes.

  • Less likelihood of membrane damage — Assemblies with DensDeck Prime panels exhibited less indentation that stressed the membrane and can potentially result in membrane failure;
  • More resilience during hail events — Assemblies with DensDeck Prime panels withstood larger hail sizes that may cause cover board fractures.

Performance of 1/4-inch DensDeck Prime roof board versus HD ISO or no cover board at 1.5- to 2.5-inch hail ball impacts. Assemblies in these tests with thermoplastic membranes and high-density ISO cover boards demonstrated 25 to 30 percent greater indentation than similar tests with DensDeck Prime roof boards.