Proper Storage and Handling of Polyiso Insulation

Photo: SOPREMA

Punxsutawney Phil certainly got it right this year; we have had six more weeks of winter — and then some — particularly in the Northeast. As winter turns to spring, building and repair projects which frequently involve the roof get underway. As you commence these new and re-roofing initiatives, here are a few key considerations about the storage and handling of polyiso roof insulation on a jobsite.

Storage

Polyiso insulation is typically shipped protected by a plastic wrap, plastic bag or both. This factory packaging is intended for handling the polyiso in the manufacturing plant and during transit; it should not be relied upon as protection at jobsites or other outdoor storage locations unless specified otherwise by the manufacturer.

Material delivery should be carefully coordinated with the roof application schedule to minimize outdoor storage. When short-term outdoor storage is necessary, whether at grade or on the roof deck, the following precautions should be observed:

  • Bundles should be stored flat above the ground utilizing included feet or on raised pallets. If possible, the bundles should be placed on a finished surface such as gravel, pavement, or concrete rather than on dirt or grass.
  • Unless specified otherwise by the manufacturer, cover the package and pallet with a waterproof cover, and secure to prevent wind displacement.

Note: Polyiso insulation is fully cured and fit for installation upon delivery. No additional storage time is required.

Handling

Photo: Johns Manville

Exercise care during handling of polyiso insulation to prevent breaking or crushing of the square edges and surfaces. Remove the polyiso bundles from trucks with proper equipment. Other means of mishandling, such as pushing pallets off the edge of the truck or “rolling” the pallet across the roof deck, must be avoided.

Product Application

Polyiso should always be installed on dry, clean roof decks in dry conditions. Follow the manufacturer’s recommendations regarding product application to ensure performance to the intended design life of the roofing system. Apply only as much polyiso roof insulation as can be covered by completed roofing the same day.

Construction Traffic

Avoid excessive traffic during roof construction of or on a completed roof surface. Although polyiso has been designed to withstand limited foot traffic, protection from damage by construction traffic and/or abuse is extremely important. Roof surface protection such as plywood should be used in areas where storage and staging are planned and heavy or repeated traffic is anticipated during or after installation.

Photo: Johns Manville

Some designers and membrane manufacturers specify the use of cover boards as a means of protecting the insulation. If specified, installers should ensure the cover board used is compatible with all components of the roofing system, is acceptable to the membrane manufacturer, and meets specified fire, wind, and code requirements.

Polyiso roof insulation, like other roofing materials, requires a proper understanding of storage, handling, and application to result in a properly constructed roof system. To find additional information about the proper storage and handling of polyiso insulation and for more technical information on polyiso roof and wall insulation, please visit www.polyiso.org.

Reinforced EPDM Membrane Offers Tape-to-Tape Technology

JM EPDMJohns Manville unveils a new reinforced EPDM membrane sheet with tape-to-tape technology, JM EPDM R FIT. According to the manufacturer, the product is field tested and proven to speed up installation by as much as four times, leading to lower labor costs. The expense and time involved when using other membranes that require primer is also eliminated since no primer is needed, leading to lower installed costs. The initial bond between tape-to-tape membrane sheets has been measured to be up to 20 percent stronger compared to field-fabricated seams. The watertight seam is never exposed on the rooftop, so the risk of contamination during installation and post installation is minimal.

John Petruzzi, president of FPS Roofing, installed the new product and was impressed with how quickly the crew learned techniques to apply it. “We were sold when we saw for ourselves how fast the seam went together. We were hands-on with the product, the whole crew liked it, and I will continue to use it,” said Petruzzi.

JM EPDM R FIT enables a longer window of application time since the 10-foot-by-100-foot rolls are completely pre-taped. This means there is no waiting on primer to flash off to get to the next step. “Our field tests demonstrate that this product will go down up to four times faster than anything already on the market,” said John Quante, JM EPDM Product Manager, Roofing Systems. “The tape-to-tape creates a stronger initial bond, making the installation more robust from day one. This product evolution will allow roofers to bid more aggressively and no doubt architects and specifiers will see the benefits too.”

For more information, visit www.jm.com/roofing.

Challenging Wintertime Installation Completed on Tight Schedule

Roofing work on the 250,000-square-foot expansion of Chicago Premium Outlets was completed in five months under challenging weather conditions. Photos: Johns Manville

The Chicago Premium Outlets 250,000-square-foot expansion includes 30 new or expanded stores, two new restaurants, 2,200 additional parking spaces, public art, outdoor fireplaces and a large pond. According to Mike Reynolds, senior project manager for Olsson Roofing Company Inc., headquartered in Aurora, Illinois, “Chicago Premium Outlets is more of a pedestrian mall since the expansion.”

Located approximately 40 minutes from downtown Chicago, the complex now features more than 170 stores including Adidas, Coach, Nike, kate spade new york, Movado Company Store, Saks Fifth Avenue Off 5th, Tommy Hilfiger, Vera Bradley, and Restoration Hardware. The reflecting pond is an inviting rest stop for shoppers, and it includes a play area and a pier-like pavilion with tables, chairs and umbrellas. To support the expansion, Olsson Roofing Company, the roofing contractor on the project, selected a TPO roofing system manufactured by Johns Manville.

A Challenging Installation

The project team faced two pressing challenges: weather and an aggressive timeline. The roofing-installation time frame fell between January and May, so the majority of the work needed to be completed during the coldest time of year. “We had our work cut out for us,” Reynolds says.

Photos: Johns Manville

The second challenge was the schedule. “The Olsson Roofing team worked several Saturdays and overtime to get the project finished as quickly as possible,” notes Reynolds. “We even heated the inside of the buildings to melt the snow on the roof and shoveled areas to make room for the product on the roof.”

Olsson Roofing chose to install the roof system using the RhinoBond induction welding attachment system from OMG Roofing Products. “We knew that RhinoBond would contribute to a successful installation of the TPO since we were dealing with below-freezing temperatures for most of the first 90 days,” Reynolds says.

Photos: Johns Manville

The 60-mil TPO was installed over two layers of ENRGY 3 roof insulation (one layer was 2 inches thick and the 2.5 inches). The majority of the roof surface features white TPO, but some EPDM was also used. “Olsson Roofing also used JM EPDM for the parapet walls since rubber is more flexible and quicker to install in cold weather and on vertical surfaces. They appreciated the ability to mix the systems and keep the project moving forward during cold-weather installation,” says JM sales representative Jason Conley. “With such a tight deadline, it was great to have the versatility of two excellent products — the durable 60-mil JM TPO and the flexibility of the JM EPDM, which provided just the right solution for our customer.”

TEAM

Architect/Specifier: FRCH Design Worldwide, Cincinnati, Ohio, www.frch.com
General Contractor: Graycor Inc., Oakbrook Terrace, Illionis, www.graycor.com
Roofing Contractor: Olsson Roofing Company Inc., Aurora, Illinois, www.olssonroofing.com

MATERIALS

Insulation: ENRGY 3, Johns Manville, www.JM.com
Membrane: 60-mil TPO in White, Tan and Light Grey, Johns Manville
Attachment System: RhinoBond, OMG Roofing Products, www.OMGroofing.com

PVC System Is the Answer for U.S. Bank Stadium Roof

U.S. Bank Stadium is topped with a PVC roof system that display’s the company’s logo. Photo: Johns Manville

When discussions began about the new U.S. Bank Stadium in Minneapolis, Minnesota, there was a request for an outdoor stadium. However, state and local government provided funding specifically for an indoor stadium that would be able to host major events like the professional football championship game and the college basketball championship game. As a result, a translucent roof and mobile front windows were designed to allow natural light to enter the stadium and to give fans a view of downtown Minneapolis. The mobile windows also allow fans to experience outdoor elements while providing protection from snow, rain and cold winter weather. The roof design was developed taking into consideration the budget and the region’s weather; it would be costly to make it retractable, and a sloped roof lends to a more secure option for snowy weather.

Challenging Task

Berwald Roofing Company Inc., headquartered in North St. Paul, Minnesota, installed an adhered PVC roof system manufactured by Johns Manville over the structure’s metal deck. In all, 280,000 square feet of grey 60-mil PVC were installed. The system also included a vapor barrier and two layers of 1.6-inch ENRGY 3, a rigid roof insulation board composed of a closed-cell polyisocyanurate foam core with fiberglass reinforced facers. Half-inch DensDeck Prime cover board from Georgia-Pacific was also installed.

The roofing portion of the project began in April 2015, with an aggressive completion deadline of November 1, 2015. The schedule and logistics on the project posed major hurdles. “Getting material 300 feet up to the roof was our biggest challenge,” says Berwald Roofing Senior Project Manager Steven Hegge. “A big part of that was scheduling time to share the cranes with the iron workers and general contractor.”

Another challenge was storing material during the installation due to the limited amount of space on the roof. “All the decking had to be installed as we went along, just before roof installation,” Hegge states. “We were on a very tight time schedule in this multiple-phase construction project.”

“The general contractor and Berwald Roofing have worked with Johns Manville on numerous stadium projects in the past and preferred to use JM PVC on this complicated stadium project,” notes Johns Manville sales rep Bob Deans. “This application is on a 3.75-inch to 12-inch slope on the north side of the building, which adds to the difficulty of installing a fully adhered PVC roof assembly.”

The Solution

Due to restricted loading space at the jobsite, materials arrived to Berwald’s yard directly from the manufacturer. They were then loaded on Berwald Roofing semi-trucks each day for delivery. Once they arrived at the site, they were immediately lifted to the roof via tower cranes and installed in the most efficient time frame, to meet the owners expected installation timeline.

The stadium seats approximately 65,000 people for most games. However, this space is built to be expandable to hold up to 73,000 attendees for special events such as the professional football championship game, which the stadium is scheduled to host on February 4, 2018, and for events like the college basketball championship game, which will be held there in 2019. U.S. Bank’s logo is prominently displayed on the rooftop. Charcoal grey 60-mil PVC membrane was cut to specification using a computerized cutter to create an exact replica of the U.S. Bank logo. Berwald Roofing then adhered the charcoal grey PVC on top of the grey 60 mil PVC membrane using JM PVC low-VOC membrane adhesive and then heat-welded the edges of material to finish the application of the logo.

TEAM

Architects: HKS Inc., www.hksinc.com; Studio Hive, www.studiohive.com; Studio Five; and Lawal Scott Erickson Architects Inc., http://lse-architects.com
General Contractor: Mortenson Construction, Minneapolis, Minnesota, www.mortenson.com
Roofing Contractor: Berwald Roofing Company Inc., North St. Paul, Minnesota, https://berwaldroofing.com

MATERIALS

Roof System: 60-mil PVC, Johns Manville, www.jm.com/roofing
Vapor Barrier: Johns Manville
Insulation: ENRGY 3® Insulation, Johns Manville
Cover Board: DensDeck Prime, Georgia-Pacific, www.gp.com

Johns Manville Joins NRCA’s One Voice Initiative, Becomes NRCA Partner Member

The National Roofing Contractors Association (NRCA) has announced Johns Manville, Denver, has joined NRCA’s One Voice initiative, upgrading its associate membership to “partner member.”

In early 2017, NRCA launched its One Voice Initiative to unite the roofing industry and speak with one voice about matters critical to the roofing industry’s continued success. To ensure all industry sectors are given an opportunity to participate, NRCA amended its bylaws to allow manufacturers, distributors, architects, engineers and consultants that choose to participate to become full members of the association. Previously, such rights were reserved only for contractor members.

“There is unique opportunity for the roofing industry to address the major issues we face. However, our work can only be accomplished with commitments from leaders from all sectors of this great industry,” said Reid Ribble, NRCA’s CEO. “Only together as a roofing community can we take this transformational approach to address our issues and concerns and achieve success in the future.”

Issues currently affecting the roofing industry include workforce development and certification; advancing the industry’s public policy agenda; building codes and insurance; and increasing professionalism throughout the industry.

“Johns Manville is proud to have been part of the roofing community for more than 160 years. We are always looking for ways to invest further to help move the industry forward,” says Joe Smith, president of Roofing Systems at Johns Manville. “Joining NRCA’s Once Voice initiative gives us a chance to be a part of something that helps our industry overcome challenges and make an impact where we think it matters most.”

For more information about NRCA and its One Voice initiative, visit www.nrca.net/onevoice.

New Construction Project Tests Contractor’s Mettle

Photos: Lynn Cromer Photography, Ferris, Texas

Photos: Lynn Cromer Photography, Ferris, Texas

Independence High School in Frisco, Texas, was conceived as an impressive new construction project on a tight schedule. The standing seam metal roof of the building was a key component in the architectural planning, as it was designed to provide aesthetic appeal for the massive structure while minimizing the view of mechanical equipment for passers-by on the ground.

The roof also was comprised of several low-slope sections, which were covered with a modified bitumen system. Both the metal and modified systems contributed to the building’s energy efficiency, helping the project achieve LEED Silver status.

The roof systems were installed by the Duncanville, Texas, branch of Progressive Roofing Services. Randy Dickhaut, the company’s general manager, indicated the project was completed in approximately one year—an ambitious schedule for a job of this size. “It was a challenging new construction job,” he says. “There were a lot of logistics involved, but in general, the job went very well.

A Tale of Two Roofs

The first goal of the project was drying in the metal decking. A two-ply, hot–mopped modified bitumen system manufactured by Johns Manville was installed on 24 decks totaling approximately 195,000 square feet of low-slope roof area. The system was applied over two layers of 2 1/2-inch polyiso insulation and 1/2-inch JM Securock cover board. The system was topped with an Energy-Star rated cap sheet, DynaGlas FR CR.

Photos: Lynn Cromer Photography, Ferris, Texas

Photos: Lynn Cromer Photography, Ferris, Texas

In the nine sections where the 88,000 square feet of metal roofing was installed, two layers of 2 1/2-inch polyiso insulation were attached, along with plywood decking and self-adhering TAMKO TW Tile and Metal underlayment. The standing seam metal roof system was manufactured by McElroy Metal, and the company provided the manpower and equipment to roll form the panels on the job site. Roof panels were the company’s 22-gauge Maxima 216 panels in Weathered Galvalume. These panels were complemented by 24-gauge Flush panels on walls and soffits.

The roll former was mounted on a scissor-lift truck. The eaves of the building were approximately 36 feet off of the ground, so a sacrificial panel was used to create a bridging effect to help guide panels to the roof. “Basically, the roll former went right along with us,” Dickhaut recalls. “We would pull 30 or 40 squares of panels, then drop the machine and move to the next spot. We were able to roll the panels right off the machine and lay them in almost the exact spot they would be installed.”

Photos: Lynn Cromer Photography, Ferris, Texas

The length of some of the panels posed a challenge, and as many as 12 crew members were needed to guide them into place for installation. In the steep-slope sections, crew members had to be tied off 100 percent of the time, so retractable lanyards were used to help keep safety lines out of the way.

The roof was mechanically seamed using a self-propelled industrial roof seamer manufactured by D.I. Roof Seamers. “We call it walking the dog,” notes Dickhaut. “One man can operate the equipment, and he just walks it every inch of every seam.”

The metal roof was designed to hide the mechanical equipment for the building, and Progressive Roofing completed work on two deep mechanical wells before the HVAC equipment was installed. “In the wells, we used McElroy’s Flush panels for the vertical surfaces and transitioned to the metal roofing,” notes Dickhaut. “In the bottom of the mechanical wells, we installed the Johns Manville modified roof and flashed the curbs.”

Rising to the Challenge

Dickhaut points to a few challenges on the job, including the length of the panels and the weather. “Overall, the job went really well,” he says. “The architects did a great job on the design, and McElroy has really good details. It was a pretty straightforward process. There was a lot of wind and rain we had to cope with. When you have a 100-foot panel that you can’t kink or scratch, it can get kind of tricky. You just have to be very careful.”

Photos: Lynn Cromer Photography, Ferris, Texas

Photos: Lynn Cromer Photography, Ferris, Texas

The Texas weather made the schedule unpredictable. “We were on that job over a year, so we caught all four seasons,” he says. “Weather had a huge impact. We dealt with extreme heat, humidity, snow, ice, mud, monsoon-type rains. Texas throws anything and everything at you.”

Whatever the conditions, Progressive Roofing was ready. “We show up locked and loaded,” Dickhaut says. “We attack it. We have seasoned veteran roofers that lead the pack. On that particular project, we had an architect, roofing consultants, an owner’s rep, and a general contractor. We would also bring in the McElroy and JM reps periodically for consultation. It’s really a team effort.”

TEAM

Architect: Corgan Associates Inc., Dallas
General Contractor: Lee Lewis Construction Inc., Dallas
Roofing Contractor: Progressive Roofing Services Inc., Duncanville, Texas

Johns Manville Partners With Logistics Lighting

Johns Manville announced the company has formed a partnership with Logistics Lighting to create the Johns Manville skylight program. The skylight program was established to allow JM to integrate skylights into clients’ projects and incorporate a seamless process for including a complete system with the roofing package. This program includes various skylight products with different brands in order to provide the most cost-effective option, with up to a 20-year warranty. The products offered through the program include skylights, smoke vents, tubular skylights, safety screens, burglar bars and roof curbs. There are also several services offered through the JM skylight program, including design and layout of skylights, energy savings calculations, specification review, submittal packages, and project specific meetings with designers and contractors.

This program has allowed JM to broaden the company’s offering and create more opportunities for customers to diversify based on their needs. The goal of the partnership was to combine Logistics Lighting’s extensive knowledge of skylights with the expertise that JM brings to roofing, creating real value for the consumers. According to JM, this partnership provides consumers with quality products, a competitive price, and a guarantee that is backed by a trusted company.

The JM skylight program includes a skylight warranty, issued by JM, as an addendum to the 20-year roof guarantee. The 20-year guarantee is only available on Velux and Kingspan products. The other two brands that are offered are Sunoptics and Wasco, and those have up to five and 10-year warranties, depending on the product.

President of Logistics Lighting Eric Huffman stated, “We are proud to be a part of the Johns Manville skylight program. We are honored to serve Johns Manville clients and sales team, and to provide the finest skylight and smoke vent options for their projects, combined with the best warranty available. The skylight program allows JM to help their clients to cost-effectively meet their daylighting and sustainability goals, and serve as a single source for the entire roof guarantee.”

For more information about the skylight program, contact Huffman at EHuffman@LogisticsLighting.com or call (307) 633-9696.

Re-Roofing of Shopping Center Poses Logistical Challenges

Southgate Shopping Center: Sebring, Florida

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

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

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

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

Roof System

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

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

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

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

A Challenging Project

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

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


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

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

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

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

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

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

Team

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

Johns Manville Roofing Innovations to Be Featured on Episode of TV Show

Johns Manville (JM) will be featured in an episode of “Office Spaces” during its third season. “Office Spaces” reports on innovations in commercial construction and design spaces to explore cutting-edge products and technologies that impact the way we live, work and play. The segment featuring JM, titled “Meet the Innovators behind Johns Manville Commercial Roofing: Innovations for Efficiency & Longevity,” will air July 9 at 5 p.m. ET on FOX Business Network.

Aside from its initial broadcast on FOX Business, the footage and reporting from JM manufacturing plants will be made available for syndication to more than 100 stations across the country.

“Johns Manville started as a roofing company nearly 160 years ago and has a long history of innovation,” said Joe Smith, SVP and GM of Roofing Systems. “We look forward to highlighting our products and the people who make them on ‘Office Spaces.’ This is a great opportunity to tell our story and to showcase why Johns Manville is a leader in the markets we serve.”
 

Reflective Granulated Cap Sheet Is for BUR Systems

The reflective granulated cap sheet may be used as a cap or flashing sheet in built-up roof systems.

The reflective granulated cap sheet may be used as a cap or flashing sheet in built-up roof systems.

Johns Manville has introduced a highly reflective granulated cap sheet called GlasKap CR G, which may be used as a cap or flashing sheet in built-up roof systems. The CR G membranes are surfaced with white reflective minerals and can be installed using standard granulated cap sheet installation methods. GlasKap CR G joins the larger offering of JM cool roof membrane solutions. These products are approved by FM Global and UL. They are also listed with CRRC and meet current Title 24 requirements. GlasKap CR G provides an additional option for customers who want a reflective cap sheet as part of a reliable BUR system.