Metal Roof and Wall Panels Capture the Spirit of Shakespearean Theater

The Otto M. Budig Theater is the home of the Cincinnati Shakespeare Company. The new theater was designed by GBBN Architects in Cincinnati. Photos: Petersen Aluminum Corp

For many new arenas and theaters, the sheer size and scope of the project can pose the biggest hurdles. At the new Otto M. Budig Theater, home of the Cincinnati Shakespeare Company, the problem was the reverse. The intimate theater was shoehorned into an existing space up against an adjacent building, so logistics were tight. But that didn’t mean the roof system couldn’t be striking. Designed by GBBN Architects in Cincinnati, the building’s exterior features daring angles and multi-colored metal roof and wall panels that combine to help capture the spirit of the Shakespearean theater.

Matt Gennett, senior project manager and vice president of Tecta America Zero Company in Cincinnati, oversaw the roofing portion of the new construction project in the Over the Rhine section of Cincinnati on the corner of Elm Street and 12th Street. “This building was plugged in downtown, and they fit everything in real tight,” he says.

Approximately 5,400 square feet of PAC-CLAD 7/8-inch, 24-gauge Corrugated Panels from Petersen Aluminum Corp. were installed on the metal roofs and walls. Tecta America Zero Company installed the metal roof systems, as well as a TPO roof manufactured by Carlisle SynTec over the main structure and mechanical well. Work began in January of 2017 and the roofing portion of the project was wrapped up in late August.

The Metal Roof System

The building features two different metal roof systems. The roof on the Elm Street side is comprised of three intersecting triangle-shaped sections in two colors, Champagne Metallic and Custom Metallic Bronze. “There were several unique angles on the roof,” Gennett explains. “On the top, there was a second metal roof, a shed roof that went down to the 12th Street side.”

The theater’s roof and walls feature approximately 5,400 square feet of PAC-CLAD 7/8-inch Corrugated Panels from Petersen Aluminum Corp. in two colors. The wall panels are perforated. Photos: Petersen Aluminum Corp.

The metal roof systems were installed over a 2-inch layer of polyisocyanurate insulation and a 2-1/2-inch nail base from Hunter Panels, H-Shield NB. The nail base is a composite panel with a closed-cell polyisocyanurate foam core, a fiber-reinforced facer on one side and, in this case, 7⁄16-inch oriented strand board (OSB) on the other. The nail base was topped with Carlisle WIP 300 HT waterproofing underlayment to dry in the roof.

Crews also installed two rows of snow guards on the metal roof using the S-5! CorruBracket. “The snow guard was a little different,” Gennett says. “It was specifically designed for a corrugated roof.”

The TPO Roof System

The main roof and mechanical well were covered with the TPO roof system, which totaled approximately 8,300 square feet. After Carlisle VapAir Seal725 TR self-adhering air and vapor barrier was applied to the metal deck, crews installed two layers of 2-inch iso. Tapered insulation was applied over the top to ensure proper drainage. The insulation was covered with a 1/2-inch sheetrock and the 60-mil TPO was fully adhered.

Two large smoke hatches manufactured by Bilco were installed over the stage area. The ACDSH smoke hatches measured 66 inches by 144 inches, and are designed for theaters, concert halls and other interior applications that require limiting noise intrusion.

The Installation

The initial focus was to get the roof dried in so work could progress inside the building. The jobsite conditions posed a few challenges. The structure abutted an existing building, and the space was tight. The schedule necessitated multiple trips to the site, which can be a budget-buster on a small project. “We had a lot of trips in and out to accommodate the schedule and get everything dried in so they could meet the interior schedule,” notes Gennett. “We were sort of on call. We made three or four trips out to roof this small project, so it took a lot of coordination because it was completed in pieces.”

Crews tackled the TPO roof sections first. The mechanical well section provided several challenges. Changes in the mechanical well layout necessitated moving some curbs and making adjustments to the tapered insulation. “They were trying to get lot of equipment into a small space,” Gennett explains. “We had to make sure we could get the water to the low spots and route it around all of that equipment. That was probably the biggest challenge on the project.”

Staging material was also problematic, as traffic was heavy and parking space was at a premium. Material was loaded by a crane, which had to be set up in the street. “It’s a postage stamp of a site,” says Gennett. “This is a main thoroughfare, and there is a school right across the street. We had to work around school hours, and we couldn’t be working when the busses were coming in. We usually came in after school started, around 8 a.m., to load materials.”

When it came time to load the metal panels, the cramped jobsite actually paid off. “It was very convenient,” Gennett recalls. “We were able to load the panels onto the adjacent roof and just hand them over. We had a nice staging area for cutting, so all in all it wasn’t bad.”

The corrugated panels were installed with matching edge metal. “It’s not a complicated panel to install, and they look really nice,” Gennett notes. “On the Elm Street side, to the right of the valley was one color, and to the left was another, so we had to match the color with our coping. There were some interesting transitions with our metal. We also had to really pay attention to how the siding was being installed so we could match the metal to the siding and follow the transitions from color to color.”

The perforated wall panels were installed by ProCLAD Inc. of Noblesville, Indiana. “Once the walls were done, we came in and did the transition metal,” Gennett says. “We just had to make sure everything lined up perfectly.”

Planning Ahead

Ensuring a safe jobsite was the top priority for Tecta America Zero and Messer Construction, the general contractor on the project. “Both Messer Construction and Tecta America take safety very seriously. That’s why we’re good partners,” Gennett says. “We had PPE, high-visibility clothing, hard hats, safety glasses for the whole project. All of the guys were required to have their OSHA 10. Anyone outside of the safety barriers had to be tied off 100 percent of the time.”

Planning ahead was the key to establishing the safety plan and meeting the schedule while ensuring a top-quality installation. “This job had a lot of in and out, which is tough in the roofing business,” Gennett says. “But we planned ahead, we made sure everything was ready for us when we mobilized, and we did a good job of coordinating with the other trades. It took a lot of meetings and discussions — just good project management.”

Gennett credits the successful installation to a great team effort between everyone involved, including the general contractor, the subcontractors, and the manufacturers. “We pride ourselves on our great, skilled crews and our great field project management,” he says. “Our superintendents are there every day checking the work and making sure the guys have everything they need. Messer Construction is great to work with, and obviously having the manufacturer involved the project and doing their inspections as well helps ensure the quality meets everyone’s standards and holds the warranty.”

The theater is now another exciting venue in the Over the Rhine neighborhood. “It is really cool spot,” Gennett says. “It’s an up-and-coming neighborhood that’s grown in leaps and bounds in the last seven years. There is a ton going on in Cincinnati. It’s just another part of the city that makes it really fun to go downtown.”


Architect: GBBN Architects, Cincinnati, Ohio,
General Contractor: Messer Construction, Cincinnati, Ohio,
Roofing Contractor: Tecta America Zero Company, Cincinnati, Ohio,
Wall Panel Installer: ProCLAD Inc., Noblesville, Indiana,


Metal Roof:
Roof Panels: PAC-CLAD 7/8-inch Corrugated Panels, Petersen Aluminum Corp.,
Wall Panels: PAC-CLAD 7/8-inch Corrugated Panels, Petersen Aluminum Corp.
Nail Base: H-Shield NB, Hunter Panels,
Snow Guards: CorruBracket, S-5!,
Waterproofing Underlayment: Carlisle WIP 300 HT, Carlisle SynTec,

TPO Roof:
Membrane: 60-mil grey TPO, Carlisle SynTec
Waterproofing Underlayment: Carlisle WIP 300 HT, Carlisle SynTec
Smoke Hatches: ACDSH Acoustical Smoke Hatch, The Bilco Co.,

Green Span Profiles’ Roof and Wall Panel System Receives Florida Approval

Green Span Profiles has received Florida Approval for all profiles of its insulated wall panel system as well as its insulated roof panel system.

Green Span Profiles’ insulated wall panel system, with an interior and exterior steel facing bonded to a poured-in-place insulating polyisocyanurate foam core, complies with Florida Building Code 2014 Section 1405.2. The approved profiles are MesaLine, ShadowLine, WaveLine, VeeLine, Impression, Stucco and Infinity in thicknesses ranging from 2-6 inches with the Green-Lock interlocking tongue and groove side joint in widths up to 42 inches. The system demonstrated compliance with ASTM E1592-05 for structural performance and ASTM E84-09 for surface burning characteristics.

The company’s RidgeLine insulated roofing panel recently received Florida Approval for installation over open framing, demonstrating compliance with ASTM E 1592, ATM E84 and FM 4471. RidgeLine is a patented 2-3/8-inch-tall mechanically seamed roofing panel covering 42 inches, with thickness options of 2.5, 3, 4, 5 and 6 inches. The core is a continuously poured-in-place polyisocyanurate insulating foam. Exterior and interior metal panels are available in 26-, 24- and 22-gauge Galvalume steel. Exterior finish is standard gloss PVDF coating. RidgeLine panels can be used on slopes as low as 1/2:12 and are available in standard lengths measuring 12 to 53 feet, with custom lengths available on demand.

Brian N. Jaks, P.E., VP of Sales & Marketing at Green Span Profiles says, “Due to the preponderance of hurricane activity in Florida, the state felt a responsibility to approve all building products utilized within the state. The State of Florida Building Code is one of the strictest in the nation therefore, we believe these certifications are great achievements.”

AAMA Releases Document Clarifying Weathering Requirements for Solar Reflective Finishes

The American Architectural Manufacturers Association (AAMA) releases a document describing the test procedures and performance requirements for pigmented organic coatings applied to aluminum, fiber reinforced thermoset or wood and cellulosic composite profiles for windows, doors, wall panels, skylights, sloped glazing and similar products. The update is a clarification to the requirements for outdoor or accelerated weathering testing. The document Voluntary Specification, Performance Requirements and Test Procedures for Solar Reflective Finishes was originally released in 2013.

“Advances in coatings technologies for architectural products have provided the opportunity to expand the use of solar reflective coatings,” says Manny Mayer, architectural products manager at Tiger Drylac. “Selecting high-performance coatings with these solar reflective attributes can positively impact the energy efficiency associated with all exterior coated building components. The primary purpose for utilizing coatings with solar reflective properties is to keep the coated surfaces cooler than they would be with standard coatings.”

This specification is a supplement to the existing specifications (AAMA 613, 614, 615, 623, 624, 625, 653, 2603, 2604 and 2605) and does not in any way supersede the performance requirements contained in those documents, particularly the weathering requirements.

AAMA 643-16, as well as other AAMA documents, may be purchased from AAMA’s online store.

Metal Roofing and Siding Enhance Waste Collection Building

The Elk Grove Special Waste Collection Center celebrate the industrial chic nature of dealing with hazardous waste products with metal roofing and wall panels.

Metal roofing and siding help the Elk Grove Special Waste Collection Center celebrate the industrial chic nature of dealing with hazardous waste products.

The city of Elk Grove, Calif.’s Special Waste Collection Center opened in April 2014 with a commitment to a cleaner and greener community. The center, which features AEP Span’s architectural metal panels, has earned LEED Gold Certification and, to date, has accepted nearly 300,000 pounds, or 130 tons, of recyclable materials diverted from local landfills.

“With the Elk Grove Special Waste Collection Center project, we wanted to express and celebrate the industrial chic nature of dealing with hazardous waste products at the same time creating a safe, warm and comfortable environment for the center staff,” says Eric Glass, AIA, LEED AP and principal of Santa Rosa, Calif.-based firm Glass Architects. “The project is designed to take a heavily abused, neglected and contaminated site and revitalize it, turning it into a protected habitat.”

“Metal siding and roofing products were a natural choice for this project,” Glass adds. “The inherent durability and recycled content material speaks to the overall mission of this facility. The horizontal and vertical fluted siding creates a strong form and texture, enhancing the building’s character.”

The Elk Grove Special Waste Collection Center project features AEP Span’s 24-gauge Reverse Box Rib in ZACtique II on the lower section of the wall application; 24-gauge HR-36 in Metallic Silver in the upper wall and canopy application; 24-gauge Prestige Series in Metallic Silver in a soffit application; 16-inch, 24-gauge SpanSeam in Hemlock Green in a roof application; and 24-gauge Curved Select Seam in Hemlock Green for the curved canopy application.

The $4.6 million center is the first, and only, facility of its kind in the nation powered by solar energy.

The $4.6 million center is the first, and only, facility of its kind in the nation powered by solar energy.

The $4.6 million center is the first, and only, facility of its kind in the nation powered by solar energy. Since its grand opening in April 2014, the center has been used by more than 8,000 customers to dispose of paint, cleaning supplies, electronics and other household recyclables. The center has also received nearly 1,000 visitors to the reuse room, which offers a wide variety of new or partially used products for free.

Project Details

Project: Elk Grove Special Waste Collection Center, Elk Grove, Calif.
Architect: Glass Architects, Santa Rosa, Calif.
General Contractor: Bobo Construction Inc., Elk Grove
Installer: MCM Roofing, McClellan, Calif., (916) 333-5294
Manufacturer of Architectural Metal Panels: AEP Span

Thermal Spacers Create Continuous Insulation for Metal Buildings

SNS Thermal Spacers from Sealed “N” Safe are a cost-effective and easy-to-implement thermal bridge system between the outer shell and the inner frames of a metal building.

SNS Thermal Spacers from Sealed “N” Safe are a cost-effective and easy-to-implement thermal bridge system between the outer shell and the inner frames of a metal building.

SNS Thermal Spacers from Sealed “N” Safe are a cost-effective and easy-to-implement thermal bridge system between the outer shell and the inner frames of a metal building. Because the SNS Thermal Spacers reduce HVAC operating costs by as much as half or more, the return on investment is between 12 and 18 months. SNS Thermal Spacers are proven safe and effective, tested per AISI, ASTM, ICC and U.S. Energy Codes and structurally sound and watertight. The company provides solutions for architectural panels, standing seam panels, through-fastened panels, wall panels and complete building envelope systems.

NCI Building Systems Acquires CENTRIA

NCI Building Systems Inc. (NCS), one of North America’s largest integrated manufacturers of metal products for the nonresidential building industry, has closed its previously announced acquisition of CENTRIA, a provider of architectural insulated metal panel (IMP) wall and roof systems and coil coating services, for a net cash price of $245 million. NCI intends to immediately begin cross-company integration.

Norman C. Chambers, NCI’s Chairman, President and Chief Executive Officer, commented, “We are pleased and proud to welcome CENTRIA into the NCI family, and expect significant opportunities for growth and margin-expansion as insulated metal panels continue to gain share in the underpenetrated North American nonresidential construction market. The acquisition of CENTRIA underscores NCI’s long-standing commitment to strengthen its position as a leading manufacturer of insulated metal panel products for the cold storage, commercial and industrial and architectural metal panel markets. We see significant opportunities to leverage CENTRIA’s position in the architectural IMP segment of the nonresidential market for the benefit of our loyal customer base and all of our stakeholders.”

As previously disclosed CENTRIA is expected to be accretive to NCI’s earnings beginning in the fourth quarter of fiscal 2015, excluding transaction related charges and amortization of short-lived intangibles, and is expected to yield annualized run-rate synergies of approximately $7 million within 18 to 24 months of closing. In addition, as a result of the CENTRIA acquisition, NCI expects to receive incremental tax basis in the assets of CENTRIA estimated to be $200 million, expected to result in reductions to NCI’s cash payments for income taxes over the next several years. After adjusting for targeted annualized synergies and the tax cash flow benefit, the adjusted purchase price is approximately 7 times CENTRIA’s trailing twelve month EBITDA as of September 30, 2014.

Quality Metalcrafts/AMERICLAD Expands to Meet Customer Demand for Architectural Metal

Quality Metalcrafts LLC/AMERICLAD is excited to announce the acquisition of a second site in Rogers, Minn. The addition of the new site means the company will be operating out of a combined total of over 130,000 square feet of state-of-the-art manufacturing space in Rogers. The office portion of the new facility is currently under renovation and will serve as the company’s headquarters beginning in early 2015.

Quality Metalcrafts, LLC President, Mike Wallace, comments, “This expansion is necessary so that we can continue to efficiently support our customer base as well as the growth of the company.”

The company is a nationally recognized manufacturer of architectural metal products that cates to the architectural construction and industrial markets. Quality Metalcrafts’ AMERICLAD product line includes composite wall panels, aluminum plate wall panels, column covers, sunshades, trellis, louvers, flat sheet, standard and custom fabrication. The company is based in Rogers with another facility in Houston.