New Roof Flashing Provides All-Weather Maintenance

New Seal-Fast Repair Hero roof flashing from Mule-Hide Products Co. is an all-system, all-weather maintenance and repair product.

A universal solution, the solvent-based, fiber-reinforced terpolymer sealant adheres to all roof substrates, including asphalt, modified bitumen, metal, TPO, EPDM, PVC, Kynar, concrete, Elvaloy/PVC, Hypalon (CSPE) and polyisobutylene (PIB).

Ready to work in all conditions, Repair Hero can be applied to dry or wet surfaces and under water. It can be used in any weather – rain or shine and in any ambient temperature.

According to the manufacturer, its exceptional elongation and high tensile strength enable Repair Hero to out-perform asphalt-based cements and silicone-based roof patches.

  • It delivers excellent adhesion, out-sticking silicone-based patches in TPO and EPDM applications.
  • It withstands soaring temperatures and intense exposure to ultraviolet light – conditions that can cause asphalt-based cements to become brittle and crack.
  • It is 50 percent more elastic and more than 9 times stronger than silicone-based roof patches, enabling it to better withstand building movement, foot traffic and the poundings dealt by Mother Nature.

Repair Hero complies with VOC-related regulations in all 50 states and does not need to be mixed or stirred before use and does not skin over or separate in the can after opening.

For more information, visit www.mulehide.com

 

Commercial Roofing Contractor Flexes Its Muscles on 1.3 Million-Square-Foot Project

The new Under Armour distribution warehouse roof encompasses 1,286,000 square feet. It was topped with a TPO roof system manufactured by Johns Manville. Photo: Orndorff & Spaid Roofing Inc.

Industrial projects exceeding one million square feet of roofing might give some contractors pause, but at Orndorff & Spaid Roofing Inc., it’s just another day at the office.

The third-generation family run roofing contractor has been in business since 1953. Orndorff & Spaid services the Baltimore-Washington metro area, as well as parts of Virginia, Pennsylvania, and Delaware. It focuses primarily on large-scale commercial projects, including warehouses, distribution centers, retail businesses, schools and data centers.

Orndorff & Spaid routinely tackles roofing projects up to 1.5 million square feet. The company strives to keep as much work as possible under its own control, and the necessary supplies and equipment are always on hand at its 13-acre headquarters in Beltsville, Maryland.

“We’re a little bit unique as a roofing company in that we self-perform almost everything,” says Richard Harville, vice president of estimating. “We have our own cranes, all our own lifts. We do our own trucking. We have an in-house mechanic’s shop that repairs all of the equipment. All fuel servicing is done from our yard here. We also warehouse a fair share of material here because the logistics of running a job.”

Photo: Johns Manville

A recent new construction project at the former location of a Bethlehem Steel factory in Tradepoint St. John’s was right up their alley. “This was a new construction project, fairly conventional in most regards except for one, and that had to do with the site,” notes Harville. “Most of the site had been infilled over the years, and there was a lot of slag and other materials on this site, so it is not bedrock, for sure.” Due to the potential for movement, seismic expansion joints were specified. The gaps in the deck were as wide as 9 inches.

The owner of the complex was kept under wraps during construction phase, but the completed Under Armour distribution warehouse is now an area landmark. The roof encompasses 1,286,000 square feet, and the project had to be completed under a very tight schedule.

The general contractor on the project, FCL, reached out to Orndorff & Spaid during the design phase, and they recommended a TPO roof system manufactured by Johns Manville.

Harville shared his insights on the project with Roofing, along with members of the project team including Dane Grudzien, estimator; Carl Spraker, project manager, single ply; and Mike McKinney, project manager, sheet metal.

The Clock Is Ticking

Work began in April 2017 with a deadline to finish by the end of July. “The schedule was what made this project difficult,” notes Harville. “They had an end user set to come in and they were in an extreme hurry to get this thing done.”

Workers outside the safety perimeter were tied off 100 percent of the time using AES Raptor TriRex Safety Carts. Photo: Orndorff & Spaid Roofing Inc.

Harville and Spraker were confident the experienced team would be up to the task. “Once we got our bearings, we rock and rolled this job,” Spraker says. “We had up to 40 employees on the site and worked six days a week.”

The roof system installed over the structure’s metal deck included two layers of 2.5-inch polyiso and a 60-mil TPO membrane. “This job was mechanically attached at 6 inches on center, with perimeter and corner enhancements as required by FM,” notes Grudzien.

The roof installation began with a 10-man crew, and crews were added as the work ramped up. “We ended up with four 10-man crews, with the foreman on the first crew in charge the team,” Spraker recalls. “We just did as much as we could every day and kept track of everything. We averaged 700 squares a day. One day we did 1,000 squares.”

Crews worked on half of the building at a time, with falling back as needed to install flashings or strip in the gravel stop. “We started on one side of the building and went from end to end, following the steel contractor,” says Spraker. “When we finished one side, we came all the way back to the end where they started and followed them down the opposite side.”

The roof system incorporates 276 VELUX skylights that provide daylighting in key areas of the facility. Photo: Orndorff & Spaid Roofing Inc.

The roof also incorporated 276 VELUX skylights to illuminate key areas of the facility. Logistics Lighting delivered them all in one shipment, as Orndorff & Spaid requested. The 4-foot-by-8-foot skylights were stored on site and loaded to the roof with a crane for installation after a plasma cutter was used to cut holes in the deck. Prefabricated curbs were installed and flashed. “I had a separate crew designated just to install skylights,” Spraker notes

Safety precautions included perimeter warning lines, and workers outside that area were tied off 100 percent of the time, as they were when the skylights were installed. AES Raptor TriRex Safety Carts were used as anchor points.

Safety is always crucial, notes Harville, and the company makes it a priority on every project. “Our safety parameters go above and beyond standard state or federal mandating,” he notes.

Metal Work

The scope of work included large external gutters, downspouts and edge metal. According to McKinney, the sheet metal application was pretty straightforward. “There was just a lot of it — long, straight runs down two sides,” he says. “The coping was installed on the parapets on the shorter ends.”

Gutters were installed after the roof system was in place. “The roof wasn’t 100 percent complete, but once areas of the roof were installed and the walls were painted white, we could begin to install the gutters,” says McKinney. “After work was completed on one side, crews moved to the other side.”

The large gutter featured internal and external hangers, alternating 36 inches on center. All the metal was fabricated in house, and the exterior hangers were powder coated to match the steel.

Once the external hangers were installed, the gutter sections were lowered into place and secured by crew members in a man lift. “Once you had your hangers up, you could just lower the gutter over the side and into the external hangers,” McKinney explains. “We put the internal hangers into place after that. After the drip edge is installed, the single-ply crews come back and flash the drip edge into the roof system.”

Downspouts were custom-designed to match the building’s paint scheme. Photo: Orndorff & Spaid Roofing Inc.

Installation of the downspouts had to wait until the walls were painted. One wrinkle was the change in color of the downspouts. About two-thirds of the way up the wall, the paint scheme went from black to white, and the building owner wanted the downspouts to change colors to match. “We reverse-engineered it,” notes McKinney. “We measured from the paint line up and put in a 30-foot section of downspouts there, because we put our bands at the joints and we didn’t want to have the bands too close together in the middle of the wall.”

Talented Team

The project was completed on budget — and a month early. FCL hosted a barbecue to celebrate. “FCL had a big cookout for the contractors with a steak dinner for everyone,” notes Harville. “They really went over and above on that.”

The Orndorff & Spaid team credits the effort of all companies involved for the success of the project. “The steel contractor was phenomenal, and FCL did an excellent job of coordinating everything,” Spraker says.

The large gutter featured internal and external hangers. Photo: Orndorff & Spaid Roofing Inc.

The manufacturer also did an excellent job, notes Harville, who commended the work of Melissa Duvall, the JM sales rep on the project, and Barney Conway, the field rep, who visited the site at least once a week. “JM did a good job keeping us well stocked with material and getting us deliveries when we needed them,” Harville notes.

The team members at Orndorff & Spaid believe their confidence comes from experience and knowing that most of the variables are under control. “A lot of that has to do with the equipment we can bring to bear when we need to,” Harville states. “We control the logistics all the way through. Most companies are going to rent a crane or hire trucking — we do all of that. We have our own lifts, we have our own cranes, we do all of our flatbed trucking. We bring a unique process to the table. Beyond that, and our project managers are well versed at doing this. It’s not our first rodeo.”

TEAM

Architect: MacGregor Associates Architects, Atlanta, www.macgregorassoc.com
General Contractor: FCL Builders, Chicago, www.fclbuilders.com
Roofing Contractor: Orndorff & Spaid Roofing Inc., Beltsville, Maryland, www.osroofing.com

MATERIALS

Membrane: 60-mil TPO, Johns Manville, www.jm.com
Insulation: Two layers of 2.5-inch ENRGY 3 Polyisocyanurate, Johns Manville
Skylights: Dynamic Dome Skylights Model 4896, VELUX, www.veluxusa.com

Conductive Primer Designed for Electronic Testing of Conventional Roof Assemblies

Detec Systems has developed TruGround, a conductive primer which enables accurate electronic leak detection (ELD) testing on conventional roof membranes including black EPDM, TPO, PVC, modified bitumen, hot and cold fluid applied. According to the manufacturer, TruGround must be installed directly below the membrane per ASTM D7877. TruGround can be used for quality assurance testing on newly installed membranes and is chemically compatible with fully adhered, mechanically attached and torch-down membranes. Once applied, ELD testing can be performed for the life of the roof. Future breaches or seam voids can be quickly pinpointed, allowing repairs to be done immediately, preventing costly moisture damage from occurring.

For more information, visit www.detecsystems.com.

Industrial Maintenance Coating Designed for TPO and PVC Roofing Systems

EverprimeEverest Systems offers Everprime All Ply, a primer for various new and aged single-ply membranes. According to the manufacturer, this high-quality, plasticizer free, single component, solvent based primer can be applied by a spray brush or a roller. The product is designed to provide exceptional adhesion to new and aged TPO and PVC membranes. In addition, this high-performance coating provides excellent surface for subsequent application of acrylic, 100 percent solids Silicone and fluoropolymer coatings.

For more information, visit http://everestsystemsco.com.

Rooftop Decks Add Outdoor Living Space to Sacramento Town Homes

The three-story homes are built on narrow lots without a backyard, so the decision was made to offer a roof deck package to provide an area to enjoy the outdoors. Photo: The Grupe Company

More and more, builders, architects and designers are looking to the rooftop as an area for usable living space — especially in urban areas, where lots are narrow. For a new town home development in Sacramento, the idea to add rooftop decks emerged late in the design process, but it’s proved so popular the builders are not only glad they made the change — they are considering making it a standard feature in future projects.

Designed by Ellis Architects and built by The Grupe Company, the neighborhood is known as 20 PQR. “The project fronts on 20th street in mid-town Sacramento and runs from P Street down to R Street,” notes Ron Rugani, vice president and purchasing manager for Grupe. “Q Street runs down the middle of the project, so that’s how we came up with the name 20 PQR.”

The 32 town homes are arranged in four groups of eight. The three-story residences have two different floor plans, one with 1,750 square feet and the other 1,850 square feet. “It’s an interesting concept,” Rugani says. “They are really considered single-family homes. They have their own lot, and they are detached from the next unit. There is a 6-inch space between the units, and they don’t share a common wall. However, the way we trim out that space, on the top and sides, you would view the eight units as one building, but they are actually eight individual single-family detached town homes.”

The narrow lots left no room for a yard, so that’s what inspired the idea to create usable outdoor space on the roof. “If you can imagine the urban setting — the fronts of these units are right on the city sidewalk. All of the units have two-car garages in the back and are accessible through a common alley. But there is no outdoor living space, and so that’s essentially what’s driving these roof decks,” Rugani says. “The backyard is where people are going to have outdoor living in a typical single-family home, and the rooftop deck is where they are going to have outdoor living in a town-home setting.”

The low-slope roofs were designed with internal drains and parapet walls. A GAF TPO roof system was specified. When the decision was made to add the rooftop living area, Ellis Architects recommended installing rubber roof deck tiles from sofSURFACES on top of the TPO roof. “The architect steered us in this direction because they liked the product,” notes Rugani. “After the roofer installs his regular TPO roof, it gets inspected to make sure there are no leaks before the roof deck tiles are installed. It’s a really unique product. It allows water to go through to the TPO roof for drainage. It has an excellent warranty, and so we have a long-term warranty for the entire roof system.”

Applying the Roof System

The TPO roof system was installed by PetersenDean Roofing and Solar, Fremont, California. “We are a roofing subcontractor for Grupe on several projects in the Northern California area,” says Mark Vogel, president of PetersenDean’s Builder Division. “We have built a great relationship with them over the years.”

Photo: sofSURFACES

There was approximately 900 square feet of roof area on each structure. PetersenDean crews mechanically attached the 60-mil GAF EverGuard TPO membrane over quarter-inch Georgia-Pacific DensDeck roof board and rigid insulation. “It is a flat roof with low slope conditions,” Vogel says. “This is absolutely a great system for this type of work.”

The parapet walls greatly simplified the safety plan, but safety is never taken for granted, according to Vogel. “We have 22 safety engineers nationwide, with 14 in California,” he says. “Safety is our biggest concern, and we invest to ensure we send everyone home at night. Our workers are considered our most valuable asset and we strive to maintain a world-class safety culture. Having a skilled and talented workforce that truly cares about safety drives everything that we do.”

Everything on the project went smoothly, notes Vogel. “It was not tough to coordinate the work with the other trades,” he says “It is what we do, and there is no one better. We are a full-service roofing contractor and solar power installer. We handle estimating, design, permitting, and installation for roofing and solar roofing systems for all our clients and this project is a great example of this.”

Installing the Roof Tiles

The deck area on each roof encompassed approximately 700 square feet. The interlocking duraSTRONG tiles are made from recycled rubber and are ideal for outdoor rooftops, walkways and patio projects, notes Chris Chartrand, director of marketing for sofSURFACES. “This space was ideal for our product as the rooftops are flat and have proper slope with a contained edge,” Chartrand says. “The design allows for efficient drainage of surface water.”

The low-slope roofs were covered with a TPO roof system manufactured by GAF, and the deck areas were topped with interlocking rubber paving tiles from sofSURFACES. Photo: sofSURFACES

The tiles were applied by a manufacturer-certified installer, Leonard’s Construction of Fontana, California. “Coordinating delivery and installation of our product within Grupe’s required timelines was a fairly easy task, as we were the last phase of the project,” notes Chartrand.

Paulo Carrillo, installation supervisor, typically installs the product in gyms and playground areas, but recently he’s found himself doing a lot of work on terraces and rooftops. After the roof system was completed on the homes at 20 PQR, a second sheet of TPO membrane was installed as a protective barrier. “We chalked our lines on that,” Carrillo notes. “We measure out the whole rooftop and chalk it off into a 2-foot-by-2-foot grid. Every other square is a keystone — those are the tiles that we put in first that hold everything in line.”

After the keystones are glued in place, the crews cut pieces to fit along the perimeter and then begin to add tiles in strategic lines. After those tiles cure, tiles are laid in opposite directions, both horizontally and diagonally. “We do it step by step,” Carrillo notes. “When we put the final squares in at the end, they are all interlocked together. After we do the final step, we glue each seam, so everything is 100 percent glued.”

The tiles all interlock, and compression allows for expansion and contraction. “Every tile is 24-1/8 inches, but they go into a 24-inch space,” Carrillo explains. “They are all compressed. With any perimeter cuts, we add another 1/8 of an inch to get our compression.”

Stacking the Deck

According to Rugani, Phase 1 and Phase 2 of the 20 PQR have been completed and are sold out, while Phase 3 and Phase 4 are currently under construction.

The interlocking duraSTRONG tiles are made from recycled rubber. They are designed for use on rooftops, walkways and patio projects, as well as gyms and playground areas. Photo: sofSURFACES

Originally the roof deck area was offered as an option, but it’s proved so desirable all of the units in the last phase are being built with decks. “It’s been an interesting dynamic,” says Rugani. “When we started, we weren’t sure how many people would want this option. For the first phase, we had to spec those, so, we said, let’s build six of the eight with the roof deck. It started to gain in popularity, and the price didn’t seem to be an issue, so in the last phase, we said, let’s build them all. It’s become very popular.”

Based on the success of the roof decks at 20 PQR, Grupe is exploring roof deck options for other projects in development. “We are building a mid-rise apartment complex just a few blocks away, and we said from the get-go in that project that we are going to have some type of roof deck for outdoor living space for the tenants,” Rugani says. “For that project we did develop a rooftop deck, and I believe that is going to be the M.O. moving forward in any project we do. Otherwise there might be no place for tenants to gather on site and have some outdoor living space. It makes perfect sense to go to the roof. So, yes, I see this as a trend, especially in urban settings.”

In the 20 PQR project, the homes were not originally designed with roof decks, and the decision made to add them later meant a lot of extra time and work for engineers and architects. “A lot of people might walk away from that and say it is too much work,” Rugani says. “We said, this is something we need to do, and it’s going to benefit the people who buy it. We were happy in the end that we spent the time and effort to do it.”

TEAM

Architect: Ellis Architects, Sacramento, California, www.ellis-architects.com
General Contractor: The Grupe Company, Stockton, California, www.grupe.com
Roof System Installer: PetersenDean Inc., Fremont, California, www.petersendean.com
Rubber Paving Tile Installer: Leonard’s Construction, Fontana, California

MATERIALS

Rubber Paving Tiles: duraSTRONG, sofSURFACES, Petrolia, Ontario, Canada, www.sofsurfaces.com
Roof Membrane: 60-mil TPO, GAF, www.GAF.com
Cover Board: DensDeck, Georgia-Pacific, www.densdeck.com

Easy-to-Use Discs Enable Induction Welding of PVC and TPO Membranes Over EPS Insulations

With induction welding, the membrane is heat bonded to the top of each plate and there are no penetrations in the membrane. Photo OMG

Over the past ten years, North American roofers have begun to adopt induction welding as a fast, simple and secure way to mechanically attach TPO and PVC membranes. The method also helps create a high-performance roof assembly by eliminating fastener penetrations of the membrane.

For most of its history, induction welding was limited to installations over thermoset insulations such as polyiso or over other rigid insulations with a cover board. But now, a deceptively simple and easy-to-use disc enables roofers to use induction welding over expanded polystyrene (EPS) insulations that don’t have cover boards. The result is faster and more affordable insulation installation and lower fatigue for work crews.

The Induction Welding Method in Brief

A roof fastener manufacturer pioneered induction welding attachment as a way for roofers to streamline TPO and PVC membrane installation, while avoiding membrane penetrations, for a more watertight roof assembly.

A roofing technician seals the seam with hot-air welder. Photo: Insulfoam

In a typical mechanically fastened membrane system, roofers secure the membrane with 2-inch to 3-inch diameter plates on the seams held down by screws that pass through the membrane and insulation layers to the underlying deck. With the induction welding method, each plate becomes a fastening point for the membrane, and the membrane is heat bonded to the top of each plate. With this method, crews screw down the insulation layer as usual, then unroll the membrane over the insulation. They then place a stand-up or handheld induction welding tool on the membrane at each plate location. In less than five seconds, the tool heats the plate under the membrane to about 400 degrees Fahrenheit, bonding the membrane to the plate. Heating is accomplished via electromagnetic induction between the tool and the plate, rather than via direct application of heat (think of an induction cooktop compared to conventional stove heating coils). Induction welding meets the FM 4470 approval standard and is accepted by most membrane manufacturers.

Induction welding typically requires 25 percent to 50 percent fewer fasteners and plates than typical mechanically fastened installations, as well as fewer seams, resulting in both labor and material savings. As the fasteners are spread across the roof in a grid pattern, the resulting assembly enhances resistance to wind uplift and reduces membrane sheet flutter.

EPS Insulations and Induction Welding

Until now, the induction welding process could not be used with EPS insulations that lacked a cover board, as

EPS insulations can be used in both new construction and roof recovers. Photo: Insulfoam

the 400-degree heated plates caused the insulation to soften and draw back. This resulted in numerous depressions in the roof assembly (at each fastener location), where water could pond.

To enable use of the induction welding process with a broader range of rigid foam insulations, fastener manufacturers have developed a simple solution. For each fastener, crews place a thin disc between the fastener plate and insulation. This separation medium protects the EPS from the high heat of the induction welding process, without interfering with the bond between the membrane and the fastener plate. Manufacturers typically refer to these separators as “induction welding cardboard discs.” While they are paper-based products, calling them “cardboard” understates their performance, as they are densely compressed and have a moisture-resistant coating, so they work well in high-performance roof systems.

Why This Matters

For roofers who prefer using EPS insulations for the products’ thermal performance and ease of installation, the discs allow them also to achieve the benefits of the induction welding process discussed above.

Induction welding cardboard discs enable use of the induction welding attachment process for TPO and PVC membranes over EPS insulation. Photo: Insulfoam

While induction welding has always been possible using EPS insulation products that have standard cover boards, the discs make it possible to induction weld over EPS products with glass facers and fanfold EPS with polymeric facers. Glass-faced EPS products can be used in new applications and recovers while roofers typically use fanfold EPS in roof recovers.

Fanfold EPS bundles, like R-TECH FF and others, are available in standard sizes up to 200 square feet, comprised of 25 panels that are 2 feet by 4 feet each, and come in various thicknesses. A typical two-square bundle weighs less than 11 pounds, so it is easy for one person to carry. EPS fanfold bundles require fewer fasteners per square foot than most roofing insulations and are less expensive than virtually every recover board. The man-hours needed to install fanfold bundles are about 60 percent less than working with individual sheets. Material costs are also lower than wood fiber, perlite, or gypsum board. On large projects, the

Induction welding typically requires fewer fasteners and plates than mechanically fastened applications, resulting in both labor and material savings. Photo: OMG

total savings can add up to tens of thousands of dollars. As with other EPS insulations, the product’s light weight also means less crew fatigue.

As roofers look for ways to create cost-effective, high-quality roof assemblies, new methods provide the opportunity to boost the bottom line by reducing labor and material costs. A simple, affordable disc now enables you to obtain the benefits of both the induction welding method for fastening TPO and PVC membranes and the advantages of EPS insulations.

Hospital Pedestrian Overpass Poses Logistical and Safety Challenges

The elevated pedestrian walkway at the BJC Healthcare/Washington University Medical Center complex connects the parking garages to buildings in the medical campus. It is approximately 1,200 feet long. Photo Paric Corporation and KAI Design & Build.

“The more complicated and complex the project, the more it is up our alley,” says Drew Bade, project manager for Bade Roofing Company in St. Louis, Missouri.

The company’s recent work roofing the new 1,200-foot-long elevated pedestrian walkway at the BJC Healthcare/Washington University Medical Center complex in St. Louis certainly qualifies as complex. The fully enclosed walkway connects the parking garages to buildings in the medical campus. Constructed atop 14 concrete pillars at an elevation of approximately 40 feet over busy roadways, the 13-foot-wide structure posed obvious logistical and safety challenges.

Bade Roofing’s union-affiliated workforce focuses on commercial projects, and the lion’s share of the company’s work is in the re-roofing arena. But for this new construction project, designed and executed through a joint venture between KAI Design & Build and Paric Corporation as part of a long-term project to update the medical campus, Drew Bade knew his company was the right candidate for the roofing portion of the job. The successful roofing installation proved him right. “We teamed up with Paric and KAI and made this thing happen,” says Bade.

The Roof System

The heated and air-conditioned walkway features carpeting, LED lighting, security intercoms, windows and metal wall panels. It also features a durable roof system. “It’s a walkway, but this thing was built like a tank,” notes Bade.

The walkway was constructed atop 14 concrete piers that elevate it over busy roadways. Photo Paric Corporation and KAI Design & Build.

The roof is a Firestone TPO system that includes R-20 polyiso insulation and a half-inch DensDeck cover board from Georgia-Pacific. The 60-mil UltraPly TPO membrane was attached using Firestone’s InvisiWeld induction welding system. The base of the system is the walkway’s 18-gauge steel deck, which features interior drains, scuppers and downspouts. Tapered insulation was used to provide proper drainage.

To make the project’s logistics even more complicated, work was scheduled on the fly as different areas of the walkway were completed. “There were some areas that weren’t built yet when we started to put this roof on,” Bade recalls. “It was a fluid situation. It was a challenge just to keep up with the changes, and we had to bounce around a lot. We couldn’t just start at one end and roof our way over to the other end. We had to hop around and handle what was finished at the time, tying the sections in together as they were completed.”

The short parapet walls were capped with edge metal after the roof was installed. “In some spots, after the roof was put on, it was more like a drip edge than a parapet,” Bade says. “At the highest, it was about 8 inches. We installed edge metal that tied into the metal wall panels they used on the sides of the bridge. It was all integrated together.”

Loading components proved tricky. “Getting material to each section and moving it around was a challenge in itself,” Bade explains. “We had to coordinate certain time frames that we could get our crane into an area to drop the material off. Because of how the safety systems were set up and how narrow this bridge was, you couldn’t really transport material along it very far. The crane essentially had to put the material right where it was going to go for that day.”

Loading the roof was usually done first thing in the morning, as use of the crane could mean blocking off roads or going into gated areas. “We’d try to beat all of the other trades in there,” Bade says.

The Safety Plan

The key to executing the project was finding the right safety plan. Initially the team explored the use of a

The Beamguard lifeline system from Guardian Fall Protection was installed in the center of the roof deck by workers in a boom lift. Photo Bade Roofing Company.

temporary guardrail system, but it proved infeasible due to the short parapet walls. “We use temporary guardrails on almost 100 percent of our projects, but the engineer came back and said the parapet walls weren’t strong enough to support a guardrail system,” Bade recalls.

The company looked for other options. “We looked at a special system that is more commonly used on road bridges during construction,” he says. “It uses a cable that runs between stanchions, and crew members can clip off to the cable.”

The system chosen was the Beamguard lifeline stanchion system from Guardian Fall Protection. The posts were attached to the steel I-beams every 30 feet. “We had to cut the metal deck out and clamp the posts to the I-beams,” Bade explains.

Crew members’ personal fall arrest systems were connected to the lifeline, but only two workers could tie off to the cable in between the stanchions. “We were tied off 100 percent of the time,” Bade says. “Safety was a huge issue for everyone on this project. There were no warnings. Everyone knew that if someone wasn’t tied off, they’d immediately be thrown off the job.”

The stanchions for the lifeline system were attached to the steel I-beams under the roof deck. Photo Bade Roofing Company.

The cable system posed some limitations on crew movement, which affected the delivery of materials. “With the cable system, you could only go so far because only two people could be tied off to a 30-foot section at a time. Essentially you had two guys walking 30 feet to hand insulation boards to the next two guys. It was kind of like a chain gang, moving material down each section of the roof.”

Ensuring the safety of pedestrians and vehicles below was also crucial. “There was a sidewalk area in the parking garage that was fully functional during the project, as there was a walkway constructed of scaffolding that offered overhead protection,” Bade notes.

However, other areas of sidewalk and roads had to be closed in order to complete work on some sections. “It depended where you were working that day,” Bade says. “Some areas of sidewalk had to be closed, and sometimes we had to redirect traffic. If you were working in areas without scaffolding, you would have to have two guys on the ground with flag lines directing traffic and blocking people off.”

One crucial section over a busy road posed some additional challenges. The three-lane road could only be shut down on one weekend. All of the trades had to complete their work that weekend, so the roofing installation had to be completed in just one day. “We did a 120-foot stretch of the roof that crossed this main road, and we did it all on a Saturday. It was the only opportunity we had. Otherwise we would’ve had to pay to shut the road down lane-by-lane, as we went. We were lucky that we were able to get in there on that one day and finish the whole length.”

The roofing installation was completed in sections as they were constructed after the 18-gauge steel deck was in place. Photo Bade Roofing Company.

Communication between all of the companies involved in the project was essential, notes Bade. “The foremen for every trade met every morning before work started. All of the contractors on the project had their meeting every week to plan and go over everything,” he says. “There were multiple forms you had to fill out every morning. The paperwork on this project was flying like you wouldn’t believe.”

After the work was completed in each section, the safety system had to be disassembled and removed. The last chore completed on each portion of the roof was to fill in the patches of roofing material where the stanchions had been. Workers completed these last steps tied off to a snorkel lift.

Despite the logistical hurdles, the project went smoothly and feedback has been positive, notes Bade. “It ended up being a great project for us,” he says. “It turned out really nice.”

It’s just another tough project now in the rear-view mirror. “The coordination, the safety, and the complexity of the actual roof system itself — not that it was necessarily a difficult roof to install, but given where it was, and how difficult it was to access — it all shows how dedicated and skilled our company is,” Bade concludes. “I don’t think there are a lot of companies out there that could do this project.”

TEAM

Architect: KAI Design & Build, St. Louis, www.kai-db.com
General Contractor: Joint venture between KAI Design & Build and Paric Corporation, St. Louis, www.paric.com
Roofing Contractor: Bade Roofing Company, St. Louis, www.baderoofing.com

MATERIALS

Membrane: 60-mil UltraPly TPO, Firestone Building Products, www.firestonebpco.com
Cover Board: DensDeck, Georgia-Pacific, www.densdeck.com

Adhesive-Free Roofing System Eliminates Temperature Restrictions

Carlisle SynTec Systems introduces its RapidLock (RL) Roofing System. This adhesive-free system uses VELCRO Brand Securable Solutions to fully attach 115-mil FleeceBACK RL EPDM or FleeceBACK RL TPO to InsulBase RL or SecurShield HD RL polyiso insulation. According to the manufacturer, the RapidLock system does away with temperature restrictions, has no VOCs or odors, offers wind uplift ratings comparable to traditional fully adhered single-ply systems and has a Factory Mutual 1-90 approval rating. The adhesive-free system also saves time and labor.

Carlisle’s new RapidLock Roofing System was unveiled at the 2018 International Roofing Expo in February 2018, where it won Best Commercial Product in the Expo’s Product Showcase. Judges reviewed new products and selected winners based on a number of criteria including innovation, productivity, and cost-effectiveness.

“We’re very excited about this product, seeing that it’s an industry first – a fully adhered system that’s adhesive-less,” said Chad Buhrman, Carlisle’s Insulation Product Manager.

“Carlisle’s RapidLock system is a game-changer for contractors. RapidLock installations are quick, quiet, and odor-free, making this system an ideal solution for occupied buildings,” said Austin Kulp, Carlisle’s FleeceBACK Product Manager.

For more information, visit www.carlislesyntec.com.

Silicone Coating Restores the Roof, Reduces Utility Costs at Mixed-Use Complex

At the Shoppes of Johnson’s Landing in Angier, North Carolina, ACC applied a high-solids silicone roof coating on the 20-year-old metal roof to seal penetrations, restore the roof, and provide a white reflective coating. Photos: All-County Contracting (ACC)

Glenn Wujcik, the owner of All-County Contracting (ACC), headquartered in Raleigh, North Carolina, has been fascinated with spray rigs since he and his brother first used one in 1979 to insulate a van with spray polyurethane foam (SPF). His company specializes in applying SPF and roof coatings on existing buildings. Lately, he’s found silicone roof coatings are making up an increasing share of his company’s workload.

“The coatings industry in general is booming right now,” Wujcik says. “A lot of the TPO and EPDM roofs are nearing the end of their service life, and instead of tearing them off, if you catch them in time, you can go over it with the silicone coating and get a new 10-year warranty. Silicones have a proven track record. When you put it on properly, it weathers really well. It has excellent elongation.”

Wujcik characterizes himself as a hands-on owner who strives to be on the site for every job. He believes there is an art as well as a science to operating a spray rig properly, and experience is crucial. “I love doing this,” he says. “I’ve been doing it for more than 30 years, my business partner’s been doing it more than 30 years, and our best sprayer has sprayed more than both of us combined. We know what we have to do, we know how long it’s going to take, and we have the right equipment. We are really good about the preparation and the application.”

Coatings and spray foam are excellent products, but only in the right situations, notes Wujcik. They should only be used on the proper substrates and applied in the right conditions. “In spraying, the most important thing is knowing when not to spray,” he says. “Right now, I’m working on a job, and for the last two days, there have been 10-20 mph winds, and I haven’t finished it yet. I told the owner, ‘I haven’t oversprayed anything yet, and I don’t want to.’ I’d rather do it right and not have any problems.”

Wujcik points to a recent project on a mixed-use building in Angier, North Carolina, to illustrate some of the benefits of a silicone roof coating. “It’s a U-shaped building with about 14,000 square feet of roof space,” Wujcik notes. “There’s a bakery, a restaurant, a pharmacy, and a doctor’s office, and there are a lot of penetrations on the roof.”

The penetrations were the site of multiple leaks. Wujcik decided to use a high-solids silicone coating, GE Enduris 3502, to prevent leaks and extend the life of the roof. The monolithic coating will seal the penetrations, and the white reflective surface will provide an additional benefit: reduced cooling bills in the summer. “Putting a white coating on it is going to reduce their energy load in the summer pretty substantially,” he says.

Applying the Coating

On this project, the first step was to pressure wash the existing roof. “That’s where most coating jobs fail — surface preparation,” Wujcik states. “Washing the roof properly is one of the most important steps.”

The high-solids silicone coating was applied to the existing standing seam metal roof. Care had to be taken to ensure all sides of the metal ribs were properly covered with the material. Photos: All-County Contracting (ACC)

The company uses 4,000 psi belt-drive power washers, so care has to be taken not to damage the roof or skylights, which are covered and marked for safety reasons. The company follows all OSHA regulations, which in most cases means setting up safety lines 6 feet from the edge, with stanchions 10 feet apart, to establish a safety perimeter.

“Safety is my number one thing,” Wujcik says, “I’ve been doing this a long time and I’ve never had a lost-time accident. I preach safety. That is absolutely the most important — and accidents are expensive.”

The next step is to apply the GE Seam Sealer at the penetrations. “When this roof was originally installed 20 years ago, they did it textbook perfect,” Wujcik notes. “Each 4-inch pipe coming though had at least 20 fasteners holding it down.”

However, over time, the rubber grommets on the fasteners can degrade, and expansion and contraction can take their toll. “We have really hot summers here, we’ve seen roofs where literally thousands of fasteners have backed out,” he says.

The seam sealer is typically applied with a brush. “Any horizontal seams, any termination bars, any penetration that goes through the roof that has a screw, we apply the seam sealer,” he says. “It goes on quite thick — at about 80 linear feet per gallon.”

After the seam sealer cures for one day, the coating is applied. Spraying flat roofs with EPDM, TPO, and PVC membranes is a fairly straightforward process, according to Wujcik. “You basically spray it just like you would spray paint a wall,” he says. “You overlap your spray pattern 50 percent. I’ve been doing it for so many years, and you get a feeling for how fast you can go.”

After the roof was power washed, the seam sealer as applied to the seams and penetrations. After it cured, two coats of the high-solids silicone product were sprayed on the roof. Photos: All-County Contracting (ACC)

A wet mil gauge is used to ensure the proper thickness. Wujcik notes the high-solids silicone formulation has very little shrinkage as it dries.  “As we’re spraying, we insert the gauge into the wet coating and it tells you how many mils you have sprayed down. In this case, we were applying to achieve 21 dry mils.”

The spray rig is set up on the ground and operated by one man, while the sprayer and the hose man are working on the roof. “It’s a minimum of a three-man crew per coating rig,” he notes. “You’re dealing with about 6,000-7,000 psi of pressure, so you need special hoses rated for at least 7,000 psi. You never want to kink them. If you busted a hose, by the time someone came down from the roof to the machine, you could pump out 20 gallons on the ground. That’s why you need a ground man.”

Flat roofs are sprayed perpendicular to the roof, but the standing seam metal roof on this project called for a different technique. “On metal roofs with high ridges, if you don’t angle your gun you’ll miss the sides of the ribs,” Wujcik points out. “You have to do it from one direction, working one way, and then turn around and do it from the other direction, working the other way. If you try to spray straight down on the roof, you’re going to miss the nooks and crannies in all of those ribs.”

The surface area of the ribs also has to be taken into account when calculating the amount of liquid that will be applied, notes Wujcik.

The final step in the process is to touch up the applications at the penetrations to ensure a clean look. On vertical surfaces including parapet walls, crews ensure the coating is applied to a uniform height. “On the last day, we take up brushes and rollers and cut in straight lines,” he says. “That really finishes the job. The detailing gives it that final touch.”

Open for Business

The active and open jobsite posed some challenges. “There were a lot of cars around the building, so we had to be very careful not to hit them with overspray,” Wujcik notes. “When you’re working on a plant, you might be able to move all of the cars to a different location, but at doctor’s offices and restaurants, you have traffic in and out of the parking lot all of the time. We can use car covers if there are a few cars there, but when they are in and out like that, it’s not practical, so you have to be very careful when you do the job.”

The job was completed in the winter, and bad weather resulted in some delays. “A job like this in the summertime would have been a weeklong project at most,” Wujcik notes. “This project took almost a month because we had an exceptionally cold winter with a lot of high winds. It took extra time, but that’s my philosophy: If it’s not the right conditions, I just won’t do it.”

The project qualified for a 10-year warranty, and when it expires ACC plans to be there to pressure wash and recoat the roof for another 10-year warranty.

“We inspect our jobs every year,” Wujcik says. He notes that annual roof inspections and routine maintenance are the simplest and most cost-effective ways to ensure the roof’s life span. Yet these steps are often neglected.

“It’s amazing that some of these multi-million-dollar companies don’t send their maintenance guys up on the roof for 10 minutes to check the drains,” he says. “If a roof has 2 inches of pine needles around the drain, the whole roof has to have 2 inches of water on it before it begins to drain. That puts tremendous, tremendous stress on a roof. Keeping your drains clear is really important.”

TEAM

Roofing Contractor: All-County Contracting (ACC), Raleigh, North Carolina

MATERIALS

Roof Coating: Enduris by GE 3502, GE Performance Coatings, www.GE.com/silicones
Seam Sealer: GE Seam Sealer, GE Performance Coatings

Multifaceted Residential Project Puts Contractor to the Test

Photos: Petersen

Diversification has always been a key component of Paul Graham’s business philosophy. Graham is the president of StazOn Roofing Inc., headquartered in Dallas, Texas. The company has been in business 38 years, handling all types of roofing, custom sheet metal fabrication and specialty wall panel systems.

Graham designed his company to be able to tackle multiple scopes of work on complicated projects. “Through time and through practice on all of these jobs, we’ve just been able to step up to the plate and maintain a multi-level task force to handle different types of work on the job,” he says.

The company’s diverse portfolio has been on display at Craig Ranch, a multi-phase residential development in McKinney, Texas. “It’s a high-end multi-family project,” Graham notes. “The most recent phase of the project involved a few five-story and predominately four-story buildings, all wood-framed. There are pools and courtyards with amenity areas for the residents.”

The buildings featured a blend of different roof systems. Crews from StazOn installed 60,000 square feet of shingles on roofs with a 4:12 pitch, 52,000 square feet of TPO on low-slope areas, and 8,500 square feet of standing seam metal roofing on roofs with an 8:12 pitch. They installed 22,000 square feet of standing seam wall panel cladding. The metal roof and wall panels were custom fabricated by StazOn with PAC-CLAD metal from Petersen in two colors, Zinc and Weathered Steel.

The company also fabricated and installed trim, flashing, gutters, collector boxes and rectangular downspouts. “We have our own sheet metal shop, so we can manufacture any type of architectural sheet metal product for our own jobs,” Graham says. “We also provided the builder with a proprietary door pocket at each of the door locations.”

Up on the Roof

The roofing work came first. On the large multi-family buildings, GAF EverGuard 60-mil white TPO was applied on the low-slope sections, which house the mechanical units and serve as a design feature on the project. “These were on the

Craig Ranch is a multi-phase residential community in McKinney, Texas. Condominiums and town homes feature shingles and standing seam metal roofs. The metal wall panels are a distinctive focus of the design. Photos: Petersen

perimeter of the buildings, primarily,” Graham explains. “The architect likes to showcase the walls, so to create that effect, they design a flat roof adjoining the pitched roof sections.”

GAF Timberline Dimensional Shingles in Weathered Wood were installed on the steeper sections of the large multi-family buildings. “These roofs had long, big runs,” Graham notes. “It was kind of like a roofer’s dream if you will, to shingle up there with nothing in the way. It was pretty wide open.”

Metal roofs were installed on a section of town homes. Where the intersecting roof sections formed valleys, crickets were installed to provide adequate drainage. These cricket sections were covered with TPO, and the details where the TPO roof and metal roof came together were crucial. “We terminated the TPO at the sloped roof with a receiver flashing that we heat welded to the TPO,” says Graham. “We take it one step further with that application, so we have a complete watertight transition from the TPO to the bottom of where the metal panel starts.”

The crickets divert water to the exterior, where it drains through the custom-made collector boxes. “The downspouts in those locations are oversized four-by-six downspouts fabricated at our shop from the Petersen material,” Graham notes. “Along with the other sheet metal items, we did the coping, the pre-flashing and flashing, the edge trim, and miscellaneous other vertical and horizontal expansion details.”

On the Walls

After waterproofing inspection of the exterior facade was completed, crews first applied a peel-and-stick building wrap from Grace, Vycor enV-S. “We took field measurements and we custom made all of the trim out of the four-by-eight sheets that Petersen supplied for the job,” Graham explains. “We make all of the trim to fit the windows, doors, penetrations, the steel support beams, which all get pre-flashed and clad.”

The metal roof and wall panels were custom fabricated with 24-gauge aluminum supplied by Petersen. Photos: Petersen

The 16-inch-wide wall panels were fabricated on the site. “We keep the panels protected until the guys are ready to install them,” Graham says. “We have everything we need right there on hand so we can keep up with the needs of the job as it is evolving.”

Panels are installed using a man lift. “From a safety standpoint and a production standpoint, it made sense to use the man lifts,” says Graham. “It’s the most maneuverable way to do the installation. We work in synchronization, moving three or four lifts at a time along the side of these walls as we work our way around the project.”

One unexpected challenge was a section of the leasing office that did not line up perfectly. “The builder came to us and asked if we could build the wall out and make sure all of the wall panels on the facade would be flush once the building was completed,” notes Graham. “We made some custom 16-gauge steel hat channels and Z-members and installed them as structural members to the wall. Then we installed the panels over the steel framing, so that we would have that same elevation and same build-out across the front of the building.”

Coordinated Attack

Phase III of the project was just completed, and Phase IV is now underway. Graham points to a few keys to navigating complicated projects like these. “It usually is a tight schedule, so coordinating with the builder to keep everything on schedule is the key,” says Graham. “You have to fabricate the necessary components and deliver them to the job in a timely fashion to keep the crews on target.”

Crews from StazOn Roofing installed the roof systems and wall panels, as well as custom-made trim, flashing, gutters, and downspouts. Photos: Petersen

Maintaining the consistency and quality of the details is also important, and experience helps. “We know what works best for the long haul,” he says. “At the end of the day, you want those details to line up with what the architect had as his vision, but we will make recommendations if we think there is a better way to construct a detail for specific conditions.”

The wall panels on this project were a top priority. “The specialty wall panel systems are so architecturally significant,” he says. “We kind of live and breathe them. We understand them. We’ve come across many, many challenges along the way on other jobs, so when we run into a new challenge, we just roll up our sleeves, get it figured out, design it with all of the people involved, and get going with it.”

Graham credits the Dallas-based builder and the Dallas-based architecture firm, JHP, for spearheading the successful project. “It’s nice when you have a team you’ve worked with and everyone understands what needs to be done to satisfy the client’s desires,” he says.

TEAM

Architect: JHP, Dallas, Texas, www.jhparch.com
Roofing Contractor: StazOn Roofing Inc., Dallas, Texas, www.stazonroof.com

MATERIALS

TPO: EverGuard 60-mil white TPO, GAF, www.GAF.com
Asphalt Laminate Shingles: Timberline Dimensional Shingle in Weathered Wood, GAF
Metal Roof and Wall Panels: PAC-CLAD 24-gauge aluminum in Zinc and Weathered Steel, Petersen, www.Pac-Clad.com
Building Wrap: Vycor enV-S, Grace, www.gcpat.com