Soft, Diffused Natural Light Transforms Eagles Nest Outfitters’ Office

VMS Northlights bathe the design and sales work areas in diffused natural light. Photos: VELUX

For years the staff of Eagles Nest Outfitters (ENO) worked in cramped, dark offices in downtown Asheville, North Carolina. Their second office didn’t even have any windows, which isn’t ideal for an outdoor equipment company specializing in portable hammocks and camp chairs.

So, when it came time to move from downtown to a location that could accommodate both the office and a warehouse, the company’s leaders challenged architects to connect the new space to the outside.

“We’re an outdoor company, and we’d all rather be outdoors each and every day,” says Lane Nakaji, general manager with ENO. “No one wants to work in darkness.”

Challenge: Opening Up a 1970s Building

The new building was at first not very promising. Located in a business park with views of the Blue Ridge Mountains, it dated back to the 1970s with a red brick exterior and a cedar shake mansard roof.

“It was a rabbit warren of an office,” says Charles Krekelberg, the project manager on the ENO project for Samsel Architects. “They had perimeter windows behind arbor vitae trees, so it was oppressively dark.”

“They wanted to radically transform the space,” Krekelberg adds. “They wanted open spaces for people to collaborate, planters and natural light.”

The building was gutted down to the exterior walls and a new roof constructed. Inside, the maze of hallways and offices became open space. And to solve the lighting problem, architects turned to two VELUX products: VELUX Modular Skylights (VMS) – Northlight Configuration and Fixed Curb Mounted skylights.

The VELUX Modular Skylight system eliminates the need for on-site glazing and can be installed quickly in varying weather conditions, which for this project included freezing rain and snow.

Ridgelights 25-40° have the classic A-frame look: two rows of self-supporting skylights mounted on standard steel profiles. The skylight installer, JP Ross & Co., installed 320 Ridgelight modules on the Burkert building configured into four rows over the center of the manufacturing space.

“We only turn the lights on when it’s raining or very cloudy,” says Allison Ettinger, ENO’s credit manager. “Natural light is generally more relaxing. It’s definitely softer than turning on the electric lights.”

The skylight units are all fixed with dimensions of 39.4 inches in width by 47.2 inches in height and high-efficiency glazing. The LowE3, argon-filled dual paned glazing assembly consists of a high-strength outer tempered pane and an inner laminated pane. The system is equipped with electrically controlled shades, which employees say are only drawn on weekends to optimize the building’s energy efficiency.

The office also has nine VELUX Fixed Curb Mount skylights (FCM 2246) with LowE3, laminated glazing and solar-powered remote controlled shades installed over offices, hallways and conference rooms. The building is topped by a 24-gauge standing seam metal roof system manufactured by Englert Inc., which was installed by DLV Roofing.

Quick Installation

Like other VMS configurations, the Northlight system arrives on the jobsite palletized for easy staging. Its plug-and-play installation method takes less time than custom, site-glazed skylights. It took the crew from JP Ross & Co. one week to complete the installation.

“We focus only on skylight design, sales and installation and have over 20 years of experience,” notes Jason Peterson, project manager with JP Ross &Co. “The only difference with the Northlight was that the panels were installed vertically.”

A vapor barrier wraps around the skylight modules and lines the interior roof rough opening for an airtight seal between the skylight modules and the building, creating a very energy-efficient building envelope.

Natural light bathes the sales department and product development area throughout the day, and employees are happy to have it. “When we don’t have that glare from artificial lights, it creates a calm,” says Julia Schell, manager of e-commerce at ENO. “Things get hectic round here. Sometimes when we come in after the weekend and the blinds have been closed, we forget and turn the lights on and it’s like ‘What’s wrong?’”

The Northlights also give the building’s exterior a unique look. “The owner wanted the skylights to be as much of an exterior expression of the design as an interior lighting device,” Krekelberg says. “They truly liked the look of the skylights and wanted them on the roof.”

TEAM

Architecture/Design: Samsel Architects, Asheville, North Carolina, https://samselarchitects.com

General Contractor: Heritage Restoration & Construction, Asheville, North Carolina, www.heritage-restoration.com

Roofing Contractor: DLV Roofing, Asheville, North Carolina, www.dlvroofing.com

Skylight Installer: JP Ross & Co., Charlotte, North Carolina, www.jprossskylights.com

MATERIALS

Skylights: VELUX Modular Skylight system – Northlight Configuration and Fixed Curb Mounted skylights, VELUX, www.veluxusa.com

Metal Roof: 24-gauge mechanically fastened standing seam roof system in Charcoal Gray, Englert Inc., www.englertinc.com

New Roof and Building Upgrades Provide Security for Florida Day Care Center

The Joseph Caleb Center

The Joseph Caleb Center received a building envelope upgrade that included a new modified bitumen roof for the low-slope sections and a new standing seam metal roof on steep-slope sections at the perimeter. Photos: Polyglass USA Inc.

The Joseph Caleb Center in Miami caters to a very young clientele, but the building housing the early childhood education center was definitely showing its age. The existing roof was failing, the concrete walls were cracked, and the window seals were broken. The restoration project was a complicated one, with several roof and wall systems that had to be tied in together. Luckily, that’s just the type of project Errol Portuondo likes. Portuondo is the owner of Florida Building & Supply in Miami, which focuses primarily on commercial restoration and re-roofing projects. The company restored the building, topping it with a new self-adhered, modified bitumen roof system and crowning it with a standing seam metal roof around the perimeter.

“We handle the whole envelope,” Portuondo notes. “That’s what sets us apart. That’s our niche. We like to go into these projects that have four, five, six items—the kind of projects other companies avoid. Most people like to handle the easy stuff—get in and get out. We like to tackle the harder type projects that require a lot of thinking.”

Complicated Scope of Work

The project required a roof system that was Energy Star rated and would comply with South Florida’s requirements for high velocity hurricane zones. Furthermore, the building would remain open during the roofing installation process, so the roof system could not give off any fumes or volatile organic compounds (VOCs). A self-adhered modified bitumen roof system from Polyglass USA Inc. was chosen for the flat roof sections because of its high reflectivity, durability, and ease of installation, as well as the lack of any odor.

The existing roof consisted of a mechanically attached modified system surrounded by a standing seam metal roof. Florida Building & Supply first removed the metal roof system, as it partially covered the flat roof. After the steep-slope sections were dried in with 30-pound felt and Englert MetalMan HT self-adhered underlayment, crews began to tear off the old modified system. Everything was removed down to the lightweight insulating concrete (LWIC) that had been installed over the metal deck.

The day care center

The day care center was open during the restoration project, so the safety plan included moving the children’s playground during the roof installation. Photos: Polyglass USA Inc.

The specification called for adhering polyiso insulation directly to the lightweight with OlyBond 500 adhesive from OMG Roofing Products, so making sure the LWIC was in good shape was crucial. Core samples were taken of the roof and subjected to a series of adhesion and compression tests required by the county. “We passed all of the tests and got all of the approvals regarding the lightweight, and we installed the insulation and the Polyglass system on top of that,” Portuondo says. “We like using that system because it is easy to install and allows us to salvage the lightweight. It also gives you really great uplift resistance.”

Crews installed tapered polyiso insulation manufactured by Hunter Panels to a custom-designed layout provided by ABC Supply Co. Insulation ranged in thickness from more than 5 inches to a minimum of 1 ½ inches. After the existing roof system was removed, Portuondo realized that the deck could not be penetrated without potentially damaging the structure, affecting the placement of emergency overflows. “Some of the existing buildings weren’t designed like they are today, so you have to work with the existing drains and make sure you can take care of the water through emergency overflows if any drains should get clogged,” he says.

After the insulation was installed, the 20,000-square-foot low-slope section was ready for the Polyglass three-ply, self-adhered modified bitumen roof system. Elastoflex SA V, a self-adhered SBS modified bitumen membrane, was used for the base and interply sheets. The surface layer consisted of Polyfresko G SA, a white, self-adhered APP modified bitumen cap sheet manufactured with CURE Technology, a thin-film technology designed to improve the membrane’s durability, UV and stain resistance, and granule adhesion.

“What we like about the self-adhered system is that you can move on the roof quick and clean,” Portuondo says. “Sometimes the intake of the mechanical units is up on the roof, and with a hot asphalt application, you have to be careful with any fumes. That’s not a consideration with the self-adhered system. It’s very clean and very fast, especially if you are about to get a rainstorm. You can get a barrier installed very quickly on the roof as opposed to hot asphalt or a torch system.”

Details, Details

Once the new low-slope roof was installed, work began on the new standing seam metal roof manufactured by Englert. Tying in the metal roof with the modified roof was relatively easy, according to Portuondo, but other details were more problematic.

The last steps included perimeter metal trim and gutters. “We work closely with the manufacturers based on their inspection process and when there are certain details,” notes Portuondo. “In this specific project, there were a lot of details.”

Waterproofing the skylights

Waterproofing the skylights was tricky, as the glass extended under the metal roof and ended just a few inches from the new modified bitumen roof system. In these sections, Polyflash 2C, an odor free, fluid-applied flashing system from Polyglass, was used. Photos: Polyglass USA Inc.

Florida Building & Supply also handled repairing and painting the perimeter of the building. Hairline fractures in the concrete block walls were repaired with epoxy injections prior to painting. Crews also re-caulked and waterproofed all of the windows and skylights, including glass walls that extended under the metal roof at the top and ended at the bottom just a few inches from the modified roof system.

“That tie-in was very difficult because by the time you ended your base flashings for the modified, you were right at the glazing,” Portuondo says. “For those areas, the only solution was the Polyglass Polyflash 2C kit.” Polyflash 2C is an odor free, fluid-applied flashing system that is UV-stable.

Setting up the plan of attack in advance was crucial, notes Portuondo, but with any older building, you have to be ready to adapt as the job progresses. “You don’t really know structurally what you’re going to run into until you start to tear off,” he says. “Sometimes what you find under the roof turns out to be different than you expected, and you have to make changes in the field.”

Safety is always the top concern for both employees and members of the public, notes Portuondo. “We moved the playground area and set up a safety perimeter fence,” he explains. “We made sure the children would not be harmed while we were installing the roof, so that was a logistical problem.”

The company is used to overcoming logistical problems. “Our forte is re-roofing existing buildings, and so they are always active,” he says. “We strive to do quality work and stay on top of everything. We’ve just been doing this for so long that we know what we’re doing.”

MCA Announces Metal Roofing Championship Game Winners

The Metal Construction Association (MCA) has sponsored its 3rd annual Metal Roofing Championship Games at the Metalcon International tradeshow in Baltimore, Md. The event was sponsored by Triangle Fastener Corp., Roof Hugger LLC, D.I. Roof Seamers, S-5!, Drexel Metals Inc. and New Tech Machinery. Award sponsors were Akzo Nobel Coatings Inc., ATAS International Inc., Atlas Bolt & Screw Co., The Bradbury Group, Chicago Metal Supply and Fabrication Inc., Designandbuildwithmetal.com, Englert Inc., Modern Trade Communications Inc., Novagard Solutions, PAC-CLAD Petersen Aluminum Corp., SFS intec and Valspar.

Each day had five battles, inspired by this year’s theme ‘Battle Stars Over Baltimore’ in honor of the birthplace of our star-spangled banner. The battles were appropriately named the Triangle Fastener “Screwgun Challenge”, Roof Hugger’s “Hug-A-Roof”, New Tech Machinery/Drexel Metals’ “Install-A-SSR Roof”, D.I. Roof Seamers’ “Seam-it-Up” and the S-5! “Let-It-Snow”.

Ten teams of two contestants each pre-registered to compete during the two-day event. The contestants represented construction companies; Thomas Phoenix International of Easthampton, N.J.; DYMI Construction Inc. of Morrisville, Pa.; Hardin Construction LLC of Union Bridge, Md.; Intermountain Roof Advisors of Salt Lake City, Utah; Rosselli Roofing and Siding of Wantage, N.J.; William Molnar Roofing Inc. of Riverview, Mich.; ARCON of Vanceboro, N.C.; Mad Metal LLC of Arden, N.C.

A total of $5,800 was awarded to the battle winners this year. The top awards for each day were a grand prize and a best quality. The first winner for both the grand prize and best quality awards was Joe Allen and Paul Kulb of Thomas Phoenix International and on the second day the same was awarded to Dennis Duce and Gonzolo Tellez of Intermountain Roof Advisors. Dennis Duce states “It was an honor to be part of this event and we are looking forward to competing next year again”.

Next year, the event will be held in Las Vegas on Oct. 18-20. The MCA Roofing Games Committee plans to make this event a hallmark to the Metalcon International Tradeshow by awarding a National Metal Roofing Championship. To present this award, the overall winner of each of the two days will return on the third day of the show for a competition to compete for the title of National Metal Roofing Champion. Next year’s teams will be able to pre-register for the event beginning in February 2017.

Englert Inc. Acquires Roselle Tool and Die

Englert Inc. acquires Roselle Tool and Die, which was established in 1946 and served Englert as a vendor for over 40 years. Roselle Tool and Die has closed in Roselle, New Jersey, and is opening an expanded shop within Englert’s new manufacturing and office building at Two Amboy Avenue in Perth Amboy, New Jersey.

Owner George Kaminski, who has been with Roselle for 31 years, purchased the business 20 years ago from its founder. Kaminski was featured in the first edition of Tool and Die Design by McGraw Hill, which highlighted six of his strip layouts, and die designs.

He is bringing long-term employees Don Howe and Roman Fayngersh, with him. Ed Lovis, who has been Englert’s only in-house tool and die maker, will join the three men at the new location.

They are expecting delivery of new hi-tech equipment to make Englert’s tool and die making among the best in the industry. Kaminski estimates that 80% of the machine tools currently in use at Englert were designed and built by his team.

Kaminski is looking forward to the new assignments they are expecting. He said, “We have a whole list of new die parts to make, including a number of new gutter components. We are excited and ready to go.”

Event Details for MCA Metal Roofing Championship Games

Celebrating its 3rd Annual metal roofing challenges to be held at Metalcon October 26 and 27 in Baltimore, MD, the MCA Metal Roofing Championship Games Task Force finalizes event details.

This year, there will be five challenges each day under the appropriately named theme; “Battle Stars Over Baltimore” in recognition of our Star Spangled Banner birthplace. Each day, 5 teams with 2 contestants each will compete to split a $500 cash award in each of the challenges, or $2,500 total each day. In addition to these cash awards, there will be a Grand Prize each day of $500 to the team that has accumulated the most points collectively from the 5 challenges. This represents a total of $6,000 being awarded over the course of the two-day competition.

The Challenges with each of their sponsoring MCA Members are as follows:

1. The Triangle Fastener Corporation “Screw Gun Challenge”, where contestants install a series of self-drilling fasteners into a structural zee-shaped purlin member. Fastest time, alignment and properly seated fasteners will determine the winning team.

2. The Roof Hugger Inc. “Hug A Roof Challenge”, where contestants will install 40 lineal feet of factory-notched zee-shaped sub-purlins on a mock-up existing ribbed metal roof paneled frame. Fastest time, properly seated fasteners and sub-purlin alignment will determine the winning team.

3. The New Tech Machinery with Drexel Metals “Standing Seam Challenge”, where contestants will install 6 each 16-inch wide metal roof panels over the factory-notched sub-purlins. Fastest time, correct clip attachment and properly seated panel seams will determine the winning team.

4. The D.I. Roof Seamers “Seam It Up Challenge”, where contestants will operate a standing seam roof seamer over the 16-inch wide metal roof panel seams. Fastest time and properly seamed panels will determine the winning team.

5. The S-5! “Let it Snow Challenge”, where contestants will install S-5! ColorGard® snow retention onto the 16-inch metal roof panels. Fastest time, properly seated fasteners and ColorGard® alignment will determine the winning team.

Judging will be provided by: The Metal Building Contractors and Erectors Association (MBCEA).

$500 Game Challenge Award Sponsors are as follows:

AKZO Nobel
ATAS International
Atlas Bolt & Screw
Bradbury Co. Inc.
Chicago Metal Supply
Designbuildwithmetal.com
Englert Inc.
NovaFlex/Novagard Solutions Inc.
Petersen Aluminum/PAC Clad
SFS Intec
Valspar
If interested in signing up your team to compete in the competition, contact any of the Sponsoring MCA Members as follows:

1. Triangle Fastener Corp, Randy Allen at rallen@trianglefastener.com

2. Roof Hugger, Inc., Mark James at mjames@roofhugger.com

3. New Tech Machinery with Drexel Metal, John DeBerard at john@newtechmachinery.com

4. D.I. Roof Seamers, Jonathan Rider at jonathan@dimetalworks.com

5. S-5!, Shawn Haddock at shaddock@s-5.com

Other questions about the Games can be directed to Mark James at 214-213-1070

Englert Holds Customer Appreciation Days and Offers Special Promotions and Pricing

Field Service Centers at four Englert Inc. locations will be holding Customer Appreciation Days during April, offering special promotions and pricing on metal roofing accessories, gutter products, trim coil and the Englert brand gutter screens, MicroGuard and SureGuard.

The annual open houses kick off Tuesday, April 7, at the Englert Field Service Center in Manassas, Va. from 8 a.m. to 2 p.m. Englert’s Pittsburgh Field Service Center in Coraopolis, Pa. will hold its Customer Appreciation Day on Thursday, April 9 from 8 a.m. to 5 p.m.

Englert’s Field Service Center in Long Island, N.Y. will hold its day on Tuesday, April 14 from 8 a.m. to 5 p.m. and the New Jersey center in Perth Amboy, N.J. will stage its annual open house on Thursday, April 16 from 8 a.m. to 5 p.m.

Along with free refreshment and giveaways, each location will also have special pricing on sealant, 5- and 6-inch gutter hangers, and Series 1300 stainless steel floating clips, and Series 2000 UL rated clips along with complimentary roofing and gutter machine tuneups for customers by appointment only. Customers must call (800) 364-5378 to reserve time for a tuneup.

  • Virginia — Tuesday, April 7
  • Pittsburgh — Thursday, April 9
  • Long Island — Tuesday, April 14
  • New Jersey — Thursday, April 16
  • Florida — Wednesday, May 6
  • Massachusetts — Tuesday, May 12
  • Connecticut — Thursday, May 14
  • Knoxville, Tenn. — Wednesday, May 20