About Chris King

Chris King is the editor in chief of Roofing magazine. He has covered the construction industry for 18 years, previously serving as editor of Roofing Contractor, managing editor of the Air Conditioning, Heating & Refrigeration News, and associate editor of Plumbing & Mechanical. He can be reached by email at chris@roofingmagazine.com.

Waterproofing Membrane Is Solvent Free

NOVALINK WMChem Link launches NOVALINK WM, a waterproofing membrane available in two- or five-gallon pails. NOVALINK WM is a cold-applied, single-component waterproofing membrane that cures by exposure to atmospheric and substrate moisture to form a continuous, tough, reinforced elastic seal. It is solvent-free and compliant with all known environmental and OSHA requirements, allowing its use in confined spaces with standard personal protection equipment.

For more information, visit www.chemlink.com.

The Power of Vacations

My dad keeps telling me that kids today don’t work very hard. By kids he means me — and I’m 57. It seems every time I turn around, though, I see an article that offers the opposite conclusion: Americans work too hard. They work longer hours and take less vacation time than their counterparts in other countries. By some accounts, the majority of American workers don’t even use all of the time off they are entitled to take. The sad part is, most workers do so because they want to be more productive. But working too long and too hard makes us less productive, not more. Vacation time is not only beneficial for personal health and well-being. Vacations also increase productivity.

Human bodies and brains have their limitations. We need some downtime to stay healthy and focused. It’s also during periods of rest and relaxation that some of the greatest discoveries have been made.

Whether it’s Newton resting by an apple tree or Watson and Crick taking a break by the seaside, it seems every scientific breakthrough I read about in high school came about when someone was goofing off. The notion of an epiphany — a flash of insight that solves a troubling problem — often seems to coincide with a break from work.

The “eureka” moment is said to derive its name from the story of the ancient Greek mathematician Archimedes, who came up with a method of solving a tricky problem after he slid into a nice hot bath. The story goes that he was trying to figure out how to measure the volume of irregularly shaped objects. Stumped, he took a break at the local bath house, where he suddenly realized that he could make the determination by the amount of water an object displaced. He then ran through the streets screaming “eureka,” which apparently means either “I found it!” or “I forgot my clothes!”

As I worked on this issue of the magazine, which focuses on education projects, I thought of the long summer breaks we had as students, which I now know are frenzied periods of construction for the roofing industry. I also spent a week in northern Michigan, where I hiked some beautiful trails with my wife, Patti, and Josie the Wonder Dog.

I can’t claim that I had any great insights into the nature of physics or science — or even better ways to produce Roofing magazine — but I did manage to locate some dog-friendly craft breweries and take in some glorious views of lake Michigan. Here’s hoping it makes me more productive.

Roof System Helps School Stand Up to Severe North Atlantic Weather

Crews from North Shore Roofingdried in the entire roof system and then installed the two-ply modified roof system manufactured by IKO. Photos: IKO

The new Brookside Intermediate School in Portugal Cove-St. Philips, Newfoundland and Labrador, Canada is a $24 million project. The two-story structure serves students in grades five through nine, and includes 31 classrooms, a gymnasium, and a commercial kitchen, as well as a library, science labs, a home economics room, a technology and fabrication lab, two music rooms, an art room and a computer lab.

The durability and sustainability of the roof and wall systems were crucial considerations during the specification process, as the building would have to perform well in the extreme weather conditions common in the easternmost province of Canada.

The roof system specified, a two-ply SBS modified bitumen application, is one Terry Casey knows like the back of his hand. Casey is the general manager of North Shore Roofing, Ltd., headquartered in Paradise, Newfoundland. Its parent company, Atlantic Roofers, Ltd., headquartered in Cocagne, New Brunswick, has been in business for 42 years. The Newfoundland branch was established in 1992, adopting the name of North Shore Roofing.

North Shore Roofing specializes in low-slope roof systems, both new construction and retrofit. “Primarily our business is two-ply modified bitumen systems, single-ply membranes — TPO, EPDM, PVC — and the occasional roof coating,” Casey notes. “We will travel all over the province, but our dominant market is the metropolitan St. John’s area.”

Brookside Intermediate School was one of a number of new construction projects initiated by the government in the past three years that the company has worked on. “This was a brand-new school put out to tender by the government of Newfoundland and Labrador,” Casey says. “We were the low bidder to Marco Services, who was the general contractor.”

Casey believes durability was a key consideration in the roof system specified, which has been a staple on government projects. “The government of Newfoundland has a standard roofing spec, and this is the system that was specified,” he says. “In this one, we chose to go with IKO.

The wall system incorporates IKO Enerfoil Insulation, which was utilized as the masonry cavity wall insulation due to its high R-value per inch and weather-resistant aluminum facers. Photos: IKO

The IKO two-ply modified roof system was primarily installed over a steel deck, which was topped with 1/2-inch DensDeck Prime cover board, a vapor barrier, tapered extruded polystyrene (EPS) insulation, 2 inches of IKOtherm polyisocyanurate insulation, and a 6-millimeter protective board. The two-ply IKO SBS modified system was then torched down. The TorchFlex TP-180-FF base sheet was torched to the protective board, and the TorchFlex TP-250 cap sheet was torched to the base sheet. “The EPS was adhered to the vapor barrier with IKO Millennium adhesive,” Casey explains. “The same adhesive was used to adhere the 2 inches of polyisocyanurate insulation to the EPS.”

One 12,000-square-foot section of the roof was covered with a concrete deck, which was designed to allow another story to be added to the building in case of future expansion. In this section a TorchFlex base sheet was installed to serve as a vapor barrier. North Shore also installed permanent fall arrest anchors — a feature Casey would like to see replicated more often. “I wish every project was like it,” he says.

IKO also supplied the wall systems on the project, which were installed by Reddick Brothers Masonry.

Smooth Installation

As sections of the deck were put in place, North Shore Roofing sprang into action. “We made the building watertight with the DensDeck and vapor barrier so that the general contractor could continue on with construction inside the building,” Casey says. “We did that over the entire roof area before we installed the rest of the system.”

Work began on the concrete section first, and as the spring weather improved, the roofing work began in earnest. “Once the vapor barrier was on, each section of the roof had a plan for the tapered insulation,” says Casey. “We put the pieces together like a puzzle so that the drainage was 2 percent slope to the roof drains to avoid any ponding water.”

The new Brookside Intermediate School in Portugal Cove-St. Philips, Newfoundland and Labrador, Canada, is a $24 million project. The durability of the roof system was a key consideration, and the government specified a two-ply modified bitumen system. Photos: IKO

Tapered insulation was installed to meet the design for four-way positive drainage. Casey explains that staging the area properly can make installation much more efficient. “There’s a bit of skill involved in that your foreman has to know where and when each piece has to be put in place,” he notes. “Your materials have to be placed on the roof so you’re not chasing the product all over the place. You have to make sure everything is up on the roof in the right spot to maximize your labor on the job.”

After the rest of the insulation and protection board were in place, the base sheet was torched directly to the protection board. “The membrane sheets have to be sealed to the board you’re torching to as well as sealed to one another,” Casey says. “You want to make sure you have a good bleed out of bitumen to ensure the membranes have been bonded together to form one monolithic sheet, if you will.”

Once the base sheet is installed, all of the details are flashed, so North Shore crews made sure all of the penetrations were completed before installing the cap sheet. “Once all your base sheet is installed, any projections going through the roof — your exhaust fans, air conditioning units, plumbing stacks and fall arrest anchors — they are all installed before the cap sheet is installed. Once your finished cap sheet is on it should look like everything was all is place and ready to go. You don’t want to be doing patchwork afterward.”

When installing the gray cap sheet, care must be taken to make sure the application is aesthetically pleasing. With contrast between the black bitumen and the gray top sheet, the goal is to be consistent and clean with your bleed out. “There was uniformity in our bleed out, so when you’re looking over the laps, it looks like it’s one long, continuous sheet,” he says. “When you’re looking against the laps, you can see the bleed out, but as long as it’s a consistent bleed out, it looks very neat. The boys do a great job of doing that.”

The skill of the crew is the key to a successful torch application, according to Casey. “It’s got everything to do with experience,” he says. “With anybody that’s doing this for the first time, you’re going to have areas where there’s no bleed out, and areas where there’s too much bleed out. When you’re doing this consistently and you’re doing it well, you’ll typically have right around 1/4 inch.”

Before the cap sheet was installed, permanent roof anchors from Thaler Metals were installed. “There is a square plate with four bolts that go down through the roof, and there is another plate that goes on the underside of the deck,” Casey says.

Because the permanent anchors were installed near the end of the project, the safety plan featured safety rails and temporary anchor points. Crews installed the safety rails on top of the parapets and had the system inspected by OSHA. For areas in which the railings could not be installed, crews tied off to temporary, removable and reusable roof anchors, also manufactured by Thaler.

Penetrations were flashed at the base sheet stage and again at the cap sheet stage per the manufacturer’s specifications. “All of the manufacturers, including IKO, have specific detailing for many, many types of penetrations going through the roof,” Casey says.

The installation process, led by foreman Shawn Higdon, went very smoothly. The jobsite was easily accessible and the weather posed no big problems. “This one was pretty wide open,” Casey says. “It’s a fairly large school with multiple roof areas. There were very few times where somebody was in our way or we were waiting for somebody. Change orders for other trades created some minor problems, but nothing serious.”

Juggling crews as the work progressed was perhaps the toughest part of the project, according to Casey. “Labor is always a challenge,” he says. “We had to move people from one job to the next job because everything wasn’t ready for us at one time. Moving back and forth from project to project was probably the most challenging thing on that job.”

TEAM

Architect: Fougere Menchenton Architecture, St. John’s, Newfoundland, www.fougeremenchenton.ca
General Contractor: Marco Services, St. John’s, Newfoundland, www.marcogroup.ca
Roofing Contractor: North Shore Roofing, Ltd., Paradise, Newfoundland
Wall System Installer: Reddick Brothers Masonry, Church Point, Nova Scotia

MATERIALS

Roof System
Modified Bitumen Membrane: TorchFlex TP-180-FF base sheet, TorchFlex TP-250 cap sheet, IKO, www.iko.com
Protection Board: Protectoboard, IKO
Insulation: IKOtherm, IKO
Vapor Barrier: MVP Vapour Retarder, IKO
Adhesive: Millennium Adhesive, IKO
Cover Board: 1/2-inch DensDeck Prime, Georgia-Pacific, www.densdeck.com
Roof Anchors: Thaler Metal, www.thalermetal.com

Wall System
Vapor Barrier: AquaBarrier, IKO
Insulation: Enerfoil, IKO

Tough Questions

I spent Father’s Day in a less than optimal spot — visiting my dad in the local hospital.

My father is 87, and a fall down the stairs resulted in life-threatening injuries. As I headed to the intensive care unit that first night, I didn’t know what to expect. However, I did know what my father’s wishes were regarding his care.

My dad is an attorney, and he prides himself on his estate planning, which is guided by two principles: taking care of his family and not paying a penny more in taxes than he has to. My brother, my sister and I know the details and who to contact when he passes away. But when my mom passed away unexpectedly more than a decade ago, we realized we didn’t know what her wishes were regarding critical care or even her funeral.

We learned from those mistakes. Our family discussed not only dad’s estate plan but his preferences for a funeral service (less funeral home, more Irish wake) and his thoughts about being kept alive by artificial means (no). I have a durable power of attorney in my briefcase and a form designating me as his patient advocate.

I was able to concentrate on the most important thing: making sure my dad got the care he needed. With the help of some talented and dedicated health care professionals, he’s doing much better now; he’s in a rehab unit and back on his feet. Hopefully we won’t need to look at his estate plans for a long time to come.

I can’t imagine going through the experience without that preparation. I thought back on the article about exit and succession planning in our last issue by Angie Lewis titled “Leaving Your Business Legacy.” In it, she details the advice of business planning experts Kevin Kennedy and Joe Bazzano of Beacon Exit Planning, who spell out retirement strategies. They also stress the importance of contingency planning — preparing for an unexpected illness or death.

If you haven’t read that article yet, I strongly urge you to do so. You can also log on to view an on-demand webinar on the same subject sponsored by Atlas Roofing.

Contact your attorney and get advice specifically tailored for your situation. Then talk to your family members and ask some tough questions. Take it from me, these conversations are not easy, but asking tough questions now can make difficult times a lot easier.

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

Coordination Is the Key to Re-Roofing Active Port Terminal

Owned by the Port of New Orleans, the Nashville Ave. Terminal Complex offers more than a million square feet of cargo space. When the structure’s original built-up roof reached the end of its service life, a standing seam metal roof was manufactured and installed by Ray Bros. Inc. on the vast majority of the building. Photo: Aero Photo.

Construction projects on active jobsites can mean coordinating a lot of moving parts. Projects don’t get much more complicated than the recent roof replacement at the Nashville Ave. Terminal Complex, owned by the Port of New Orleans. The scope of work was multifaceted, the schedule was daunting, and everyone entering the facility had to have the proper security credentials. All of the work was performed next to the Mississippi River on top of an active wharf building, with cargo coming in and going out on trucks and forklifts as ships were loaded and unloaded. Materials housed inside the building were sensitive to moisture, dust and debris — and often had to be moved as work progressed.

Gino Ray Sr., president of Ray Bros. Inc., the roofing contractor on the project, likened it to a giant, three-dimensional puzzle. “It was almost like a Rubik’s Cube,” he says. “They had to move a section of material, and then when we finished a section, they slid the material over there so we could move on the next one. The whole time, the port was in operation. There was a lot of dancing involved.”

The Terminal

The Nashville Ave. Terminal Complex, operated by Ports America Louisiana Inc., offers more than 1 million square feet of storage space. Built in the 1960s, the structure was a rigid-frame, iron building with a ballasted tar and gravel roof over a heavy tongue-and-groove wooden deck. Decades of problems had seriously deteriorated the wooden deck, as well as the four-by-four wood nailers that were bolted to the rafters and purlins.

Key members of the team on the project included (from Left) N. Guy Williams of ECM Consultants, Kevin Haslauer of Glendale Enterprises, Gino Ray Sr. of Ray Bros. Inc., Craig Clark of Gulf Coast Service Group, and Curtis Shinogle of Gulf Coast Service Group.

The structure’s failing roof was replaced in three phases. During Phase 1, undertaken about a decade ago, a new built-up roof system was installed on one end of the building. When that section experienced performance issues, the owners looked for other options. Ray Bros. had the answer: an architectural metal roof.

Ray Bros. has been in business in New Orleans since 1996, when it was founded by Gino Ray Sr. The company has always focused primarily on metal roofing, and in the late ’90s it began roll forming and manufacturing its own panels and systems. “Today we manufacture everything we install,” Ray notes. “We’re kind of a hybrid — a manufacturer/contractor.”

The company’s metal panel system had been installed on several other port buildings, and the owners specified it for Phase 2 of the project, which covered a 230,000-square-foot section near the center of the building on either side of the firewall. Phase 2 was completed in 2014. Phase 3 encompassed 420,000 square feet to complete the sections on either side of Phase 2. Work began in August of 2016 and completed in May of 2017.

Ray Bros. manufactured and installed all of the metal roofing on the building — a total of 650,000 square feet — and served as both the prime contractor and the roofing contractor on the third phase of the project. Ray credits his dedicated team, the cooperation of all of the companies involved, and an innovative strategy for coping with the project’s many hurdles as the keys to a successful outcome.

Beefing Up the Structure

The standing seam metal roof system recommended by Ray Bros. was specified for its durability and low maintenance. The new system would give the port the long lifespan the owners desired, but it would necessitate some structural changes.

“Before we put the metal roof on, we had to beef up the existing trusses and reinforce the existing structure because it was such a light building now,” Ray notes. “There was an enormous amount of welding to the exiting trusses and existing purlins that had to be done before we could begin to put the roof on.”

Metal panels were roll formed directly onto the roof for installation. The panels on one side of the roof were 180 feet long. Photo: Ray Bros. Inc.

The plan was to beef up the structure from the inside and install the new gutters. Then the old roof could then be torn off and the new metal roof installed. The roof installation would be completed in sections, with crews moving from one area to the next in sequence.

Gulf Coast Service Group served as the structural steel and demolition contractor. Crews on man lifts set up inside the building reinforced the existing steel structure. New angle irons were welded to the bottom of the purlins. The existing sprinkler system had to be reconfigured, as it was attached to the four-by-four wood nailers that had to be removed. Work on the sprinklers was performed in conjunction with S & S Sprinkler Company. “We didn’t have to dismantle the sprinkler system, just move it,” Ray explains. “New hangers were mounted to the steel. We had to put a hanger on, take a hanger off. That was part of the tango dance as well.”

After the welders completed their work, crews from RK Hydrovac vacuumed the ballast off the roof. Prior to the demolition work, approximately 4,100 linear feet of gutters were installed. Oversized gutters were manufactured from 16-gauge stainless steel in the Ray Bros. metal shop, and all of the joints were welded together. Gutter sections were raised into place with a lift and secured with stainless steel brackets and hangers. “That gutter weighed about 11 pounds per running foot, and we made it in 21-foot lengths,” Ray notes.

The Roof Installation

The demolition crews and installation crews then swung into action. After sections of the deck were removed, metal panels were roll-formed on the site and installed. “The demo people would tear out a bay — which is a 20-foot section — all the way up to the ridge,” Ray explains. “On one side of the roof, the panels were 180 feet long. So, they would tear out a 20-foot-by-180-foot section, and we would come in right after that and put a 20-foot section of 180-foot panels down.”

Crew members on lifts reinforced the existing steel structure before the new roof was installed. Photo: Ray Bros. Inc.

Panels were made from 22-gauge galvalume. Zimmerman Metals supplied roll forming machines to Ray Bros. Inc. so the company could manufacture its proprietary product. The RBI MT-240 panels were 18 inches wide and interlock using continuous clips. A batten cap was installed over the top and then mechanically seamed using a machine manufactured by D.I. Roof Seamers.

The roll-up bay doors along the sides of the building and at the gable ends of the warehouse qualified it as a partially enclosed structure, which necessitated strict engineering standards. “In order to meet engineering standards, we had to use continuous clips,” Ray notes.

Every third bay had a skylight system to light the interior. Skylights used on the project were manufactured by CPI Daylighting Systems and installed by Glendale Industries. Custom-made curbs and crickets were fashioned by Ray Bros.

When skylights could not be installed right away, the openings were covered with plywood and felt to eliminate safety hazards and keep the interior of the building dry. “When the Glendale Industries people would show up, we’d remove the plywood and they would put on their system,” Ray notes. “As the job progressed, we’d re-use the same plywood and temporary coverings as we went along. We’d just leapfrog the plywood from curb to curb.”

After the roof was completed, the last step was to replace the wall panels in the interior that were designed to trap the smoke in the event of a fire. The old corrugated smoke panels were wired to the steel, but that system would not comply with today’s standards, so Ray Bros. created a sub-framing system to attach new ones. “We had 500 squares of smoke panels to install beneath the roof system,” Ray states. “We put in some16-gauge furring channels and attached the panels with screws. We manufactured all of that in house.”

After the roof was installed, 50,000 square feet of new corrugated smoke panels were installed. Photo: Ray Bros. Inc.

The demo crews, installation crews, and skylight crews kept moving in sequence under the direction of Jobsite Superintendent Robert Sinopoli, a 30-year industry veteran who has been with Ray Bros. ever since the company was founded. Sinopoli monitored everyone’s progress on the site and made sure everyone knew their assignments each day. “Everybody leapfrogged everybody else,” Ray notes. “Everyone had their own song and dance, and if one person got out of rhythm, it would domino back.”

Everyone involved on the project also needed to have a dance card, as security on the site was tight. Workers needed to have a background check and Transportation Worker Identification Credential (TWIC). Every vehicle had to have proper registration, insurance and inspection tags. The jobsite did not allow personal vehicles, and this posed a problem for Ray Bros., as the company routinely had 40 to 50 workers on site. “Everybody had to be on a company vehicle in a seat with a seat belt,” Ray notes. “I had to buy a used bus to transport workers in and out. We painted it, put our logo on it and made it look pretty. We just drove it 1.5 miles a day. At the end of the job, I sold the bus.”

Big Chunks

The project was wrapped up ahead of schedule, and it was the sequencing of work that was the key its success, according to Ray. “We didn’t want to tackle this project one bay at a time; we were looking at big chunks at a time,” he says. “We were able to develop a rhythm quicker that way. Instead of changing hats several times in the course of a day or a week, we put a hat on, let it stay on, got a big section done and moved on to the next. We didn’t want to change tools and change personnel. We wanted to look at it like a monolithic application.”

In the end, it all boiled down to pride — no one wanted to be the one to falter. “We self-perform a lot of our work, and we have existing relationships with all of the subcontractors we use,” Ray says. “I’m never going to let them down or leave them hanging, and I know they are going to do the same for me. That’s what made that job go — no one wanted to be the weak link. Everybody had a job to do and they did it. It worked out great.”

It was a true team effort. “This was like our Super Bowl, and we won,” Ray concludes. “I’m real proud of my company, our people, and all the people we worked with. I know that on our next job, I can count on them and they know they can count on me.”

TEAM

Architect: ECM Consultants, Metairie, Louisiana, www.ecmconsultants.com
General Contractor and Roofing Contractor: Ray Bros. Inc., New Orleans, Louisiana, www.raybrosinc.com
Structural Steel and Demolition Contractor: Gulf Coast Service Group, Harvey, Louisiana
Skylight Installer: Glendale Enterprises, Norco, Louisiana, www.glendaleinc.com
Sprinkler Repair Contractor: S & S Sprinkler Company, Baton Rouge, Louisiana, www.sssprinkler.com

MATERIALS

Metal Roof Panels: 18-inch wide, 22-gauge galvalume MT-240 standing seam panels, Ray Bros. Inc.
Skylights: CPI Daylighting Systems, www.cpidaylighting.com
Roll Former: Zimmerman Metals Inc., www.zimmerman-metals.com

Spring Forward, Fall Protect

Spring arrived late here in Michigan, and before the weather — and construction — began to heat up, I saw a press release from MIOSHA indicating the second year of its “Stop Falls. Save Lives.” safety awareness campaign would focus on the roofing industry. I called Nella Davis-Ray, Director of MIOSHA Consultation Education and Training (CET) Division in Lansing, to ask her why.

“Nationally and at the state level, we are pleased to see that overall, when you look at general industry and construction, there is a downward trend in work-related fatalities and injuries, and we like to think we play a part in that downward trend,” she said. “Even though we are seeing this downward trend, when you look at roofers’ fall-related incidents, and particularly when you look at roof-related fatalities, their rate is 10 times higher than the rate for construction workers as a whole. So, if there is any trade we can talk to about falls, the data shows the one group we should be focusing on is the roofers.”

The statistics were sobering, but the overall message was hopeful. “Our message is that all falls are preventable,” Davis-Ray said. “We really do believe that in MIOSHA.”

The key is making sure every employee is properly trained, has the proper safety equipment — and knows how to use it — and follows the jobsite-specific safety plan. According to Davis-Ray, the MIOSHA can help with all of those things — and the services are free.

The CET Division works independently of the Enforcement Division. It provides guidance to employers and employees through a variety of methods, including classroom training and educational materials including literature, videos, and a fall protection website, www.michigan.gov/stopfalls. The greatest tool of all, noted Davis-Ray, is a staff of consultants who can provide individualized training.

“I’m surprised how many employers, particularly contractors, are not aware that all they have to do is pick up the phone and call us,” she said. “At their request, we can schedule a time and location for one of our construction safety consultants to come out and work with them directly on safety and health issues.”

Consultants can review written requirements, explain interpretations of the standard, and answer specific questions about a project and whether or not a contractor might be in compliance. They can also help in crafting a comprehensive safety program. “We always try to look at the big picture,” Davis-Ray says. “The overarching issue is to have an effective system in place so that you ensure that safety is considered as a part of every contract.”

Davis urges contractors in every state to explore the free educational resources OSHA can provide. Michigan contractors can call 800-866-4674 or visit www.michigan.gov/miosha to learn more.

 

National Women in Roofing Taps Into a Powerful Force

Photos: National Women in Roofing

In 2014, an organization devoted to helping advance the careers of women in the roofing industry was just an idea. Since then, the idea has become a movement. National Women in Roofing (NWIR) was officially launched at the International Roofing Expo (IRE) in 2016. The volunteer-based organization focuses on connecting and empowering women, and it has the support of more than 1,000 members — many of them men — and nearly two dozen sponsors. They all share the goal of working together to raise the professionalism of the roofing industry, bring more people into the field, and provide the education and training necessary to ensure its future success.

This February, Heidi Ellsworth handed over the position of NWIR chair to Shari Carlozzi. The two women shared their insights on the founding of NWIR with Roofing, detailing its current initiatives and plans for the future.

A Movement Is Born

Carlozzi and Ellsworth first discussed the idea of an organization to support women during a break at a meeting of the Midwest Roofing Contractors Association in 2014. As they shared their thoughts about working in a male-dominated industry,

Officers and directors of National Women in Roofing include (from left) Jennifer Stone, vice chair, executive committee; Jennifer Ford-Smith, secretary; Ellen Thorp, executive director; Shari Carlozzi, chair, executive committee; and Heidi Ellsworth, past chair, executive committee. Photos: National Women in Roofing

a light bulb went on. “We started talking, and we realized there are a lot more women in this industry than people give it credit for,” Carlozzi says. “There’s a lot of women! And we said, ‘We should start an organization where women can gather to network, to learn from each other, to mentor one another, and to help empower each other’ — because we are in an industry that we love.”

Ellsworth and Carlozzi shared the concept with Steve Little of Dallas-based KPost, who was then MRCA president. “He said, ‘That’s a great idea! We’ll help incubate you.’ And that’s how we got started,” Carlozzi remembers. “It went viral.”

As they traveled the country in their respective work roles — Ellsworth as a partner in RoofersCoffeeShop.com and Carlozzi as national sales manager for HAPCO Inc. — they soon realized that a lot of other women had the same needs. Many were even exploring the same idea. “At every trade show we went to, both of us would hear this from so many women,” Ellsworth says. “They would say, ‘We need to spend time together. We need to network.’ And networking is a big one because it’s sometimes a lot easier for guys to get together to network and women are left out. It was something that a lot of women truly believed in.”

Shari Carlozzi thanks the founding sponsors of the organization at NWIR Day. Photos: National Women in Roofing

After talking to others in the industry, it became clear the organization had to have a national presence. “We looked ahead to the IRE in New Orleans in 2015 and decided to have a little get-together and see if people are truly interested,” Ellsworth recalls. “We had 75 women show up. It just grew from there.”

The group formed a leadership committee and held meetings at industry trade shows throughout 2015. “It was at IRE in 2016 that we officially launched National Women in Roofing,” Ellsworth says. “We realized very quickly that there was a tidal wave — a tsunami — of women behind us who really needed this. We realized we had to take this to a national level, and we did.”

The Four Pillars

Overarching goals of the organization are exemplified by its four pillars: networking, mentoring, education and recruitment.

Heidi Ellsworth welcomes attendees to the inaugural NWIR Day, held February 4, 2018. Photos: National Women in Roofing

“Our four pillars we started with — networking, mentoring, education and recruitment — have been the focus of what we’ve wanted to do from the start,” Carlozzi says. “Some people are a little bit more involved in education, some people are a little bit more involved in networking — it all depends on what works for you. We’ve stayed true to our four pillars, and that has been extremely helpful in giving women opportunities to engage in what’s most important to them.”

Ellsworth agrees, pointing out that networking events and mentoring initiatives developed hand in hand. “Our first events were networking events,” she says. “One of our themes is ‘from the rooftop to the boardroom,’ and we had top leaders at companies including GAF, ABC, Owens Corning, Johns Manville — all of these ladies showed up early and then stayed on and helped to drive this. We partnered with 28 founding sponsors that first year.”

Mentoring relationships seemed to blossom. “I wish we could all take credit for it, but it just happened so naturally,” Ellsworth says.

Kelly Wade, CEO of North American Roofing, gives the keynote address at the National Women in Roofing’s Mentor Reception during the 2018 International Roofing Expo. Photos: National Women in Roofing

NWIR is launching a mentoring program this year, under the leadership of Mallory Payne and Melissa Walker, who head up the mentoring committee. “Mentoring has always been a big part of what we do,” Carlozzi says. “Men have more mentors than women do, and we want to change that.”

The education committee, led by Shelly Duhaime and Jennifer Keegan, is working on a full slate of educational sessions at industry events, as well as a series of webinars on topics such as networking, safety and business management. “Our education committee is on fire this year,” says Carlozzi. “People crave information. The only way we can excel in what we do is to keep learning.”

Carlozzi points to the NRCA’s ProCertification program as a model for educating the industry’s workforce and boosting professionalism. “We have to elevate the perception of the roofing industry,” she says. “We share the same values as the NRCA, and we want to speak with one voice to get the message across to people that this is a viable career option for you, whether you are a man or a woman in the trade, or whether you are looking for a career as a chemist, or an engineer, or a salesperson, or in data entry. It is a solid, reputable industry.”

It’s also an industry facing a worker shortage, so recruiting a new generation of workers is essential. The recruitment committee, led by Michelle Boykin and Chelsea Welsh, is active at employment fairs and career days, and NWIR is reaching out to other trade groups across the country to increase the visibility of the industry.

Part of the recruitment effort includes a commitment to helping women in crisis find employment and pursue a true career path.

Memberships and Sponsorships

The organization might be national, but it is also active at the local level. NWIR is developing councils across the country to cater to local educational needs and reach out to area community service opportunities. There are 29 local councils now, with a goal of reaching 50 by the end of 2018.

NWIR members participate in a breakout session at a mentoring workshop. Photos: National Women in Roofing

“It’s the best of both worlds for everybody because they get that national input through our epicenter — our newsletter and our website — and they can apply the information to what they are doing locally,” Carlozzi says. “We give local councils a lot of latitude to put together what works for them as long as they stay true to our four pillars and our national outreach program with women in crisis.”

Carlozzi and Ellsworth encourage all women and men to join the association. The membership fee is $60 per year. Half of the membership fee goes to develop and support local councils. “We made a very conscious decision to keep our membership dues very reasonable, and they are owned by the member,” Ellsworth notes. “If your career path takes you to another company, the membership goes along with you.”

Companies can help NWIR as sponsors. There are four levels of sponsorships. “We are also in the middle of our sponsorship drive, and that is a great way to get involved as a company,” Ellsworth says. “The value to the company — and its employees — is incredible.”

A Bright Future

Looking back at her tenure as the first chair of the organization, Ellsworth is proud of the group’s achievements and thankful for the friendships she’s made along the way. “It’s one of the greatest experiences I’ve had in my life,” she says. “The women I have met and the experiences we’ve had have been so empowering.”

Networking and mentoring have always been key areas of focus for NWIR members. Photos: National Women in Roofing

As Carlozzi takes the helm, she plans to lean on the talented team of women ready to take the organization into the future. “It’s a little overwhelming when you look at it at first because we came so far, so fast, and we have to keep that momentum going,” says Carlozzi. “In the process, we’ve had some exceptional, outstanding women who have stepped up and taken on the leadership roles that are needed to develop and maintain a national organization like this.”

When the industry taps into everyone’s talents, everyone wins. Carlozzi sees that spirit every day at NWIR. “Everyone comes up with new ideas of how to make things better,” she says. “Everyone is open to new ideas and assistance, and everyone is freely offering it. No one feels threatened — we’re all empowered. That’s the beauty of it.”

For more information about NWIR, visit www.nationalwomeninroofing.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

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