ABC Supply Honors A.J. Foyt’s Distinguished Racing Career With Tribute Car at Indy 500

ABC Supply Co. Inc. is celebrating the 60th anniversary of A.J. Foyt’s first Indy 500 win by sponsoring the No. 1 tribute car for AJ Foyt Racing at this year’s Indianapolis 500 presented by Gainbridge. 

ABC Supply is a longtime supporter and friend of AJ Foyt Racing, sponsoring the team and various races over the past 17 years. Race fans can tune in May 30 for the 105th Running of the Indy 500 to watch J.R. Hildebrand pilot the No. 1 ABC Supply Chevrolet. 

Foyt’s award-winning racing career spans decades, and he is renowned for being the first driver to win the Indy 500 four times. A.J. Foyt’s career and legacy will be honored at this year’s event in the following ways: 

  • Chip Ganassi Racing, the reigning NTT INDYCAR SERIES champion, will release its No. 1 race car number to Foyt’s team. J.R. Hildebrand will drive the No. 1 ABC Supply Chevrolet.
  • The car will sport a throwback paint job featuring a large red No. 1 over a primarily white body. The car’s candy-apple-red nose will be trimmed with black stripes. This vintage design is a nod to the Bowes Seal Fast Offenhauser roadster that Foyt drove in 1961.
  • Hildebrand and the ABC Supply crew will wear uniforms modeled after what Foyt and his team wore in 1961. Hildebrand will wear solid white, and the crew will wear white shirts and fire suits that have collars trimmed in black and feature a black pocket with black pants.

“Our associates have been longtime fans of the Indy 500 and AJ Foyt Racing, and we’re excited to share this celebratory moment with them,” said Mike Jost, COO of ABC Supply. “A.J. is a living legend and part of our ABC family, and we’re honored to be part of the 60th anniversary of his first Indy 500 win.”

For more information, visit www.abcsupply.com.

ABC Supply Co. Inc. Opens Location in Salt Lake City, Utah

ABC Supply Co. Inc. has opened a new location at 4228 W 1730 S in Salt Lake City, Utah. Jade Robison manages the new location. He first joined ABC Supply in 2008 as a roof loader at the company’s Orem, Utah, location. Robison spent the last three and a half years managing the Spokane Valley, Washington, location, where he consistently increased sales every year.

“Our Salt Lake City branch is our fifth location in Utah and will allow us to meet the growing demands for building products and support in the area,” said Matt Cooper, vice president of ABC Supply’s West Region. “Jade and his team will do a great job of ensuring that contractors get the support they need to make their jobs easier.”

Branch hours are 7:00 a.m. to 4:00 p.m. MT, Monday through Friday. The phone number is (801) 906-7770. Contractors can also place and review orders and track deliveries using myABCsupply.

For more information, visit www.abcsupply.com.

The First-Ever IRE Virtual Edition Connected Industry Professionals and Leaders from Across the Globe

The International Roofing Expo’s (IRE) first virtual event was held March 2-4, 2021 and brought together professionals from the roofing and exterior construction industries. The event connected contractors, remodelers, and builders with manufacturers and suppliers to discover the latest products, technologies, and services while further developing their professional and technical skills.

The live portion of the event took place March 2-4, and then the platform remained open for on-demand viewing through April 2. During the event, attendees participated in educational sessions, special events, supplier meetings, and were able to browse a directory of the latest products and services on the market.

The IRE Virtual Edition hosted 63 suppliers and had 2,447 participants from 32 countries. Over the course of the event, there were 321 confirmed meetings, 15,432 product category views, and 1,975 hours of content watched.

“With the IRE in-person show being rescheduled to August, we felt it was important to help the industry connect during the first part of the year,” said Ray Giovine, group director for the International Roofing Expo and Informa Markets. “We are pleased with how the industry came together during the virtual event and we’re glad we could provide them with more of the education and content they want each year.”

“IRE Virtual Edition 2021 was an overall great experience. I thought the content and options were well thought out and offered a wide variety of options for everyone,” said Maureen Greeves with Tremco.

The virtual event highlights included: 

  • Three Ask the Experts Live Sessions: Each day of the event started with a live session covering trending topics followed by a Q&A with industry experts.

Mark DeFreitas of Soprema said “One of the best opening talks I have ever heard. I have been in this industry for over 30 years, so I have heard a few! So many life/business lessons and great guidance. It came across as sincere and from a personal level.  It will resonate with a lot of people.  Reid (Ribble) never disappoints and I just want to thank all that were responsible to make this happen.  A great way to start the IRE virtual conference.”

  • 25+ Educational Sessions: Sessions covered a variety of topics that were organized by tracks that included Business, Technical, Legal/HR, Workplace Safety, Windows & Siding and Exhibitor Presented Seminars.

“I really enjoyed the IRE Virtual Edition 2021.  The sessions were very informative and educational,” said Jeremy Ball of Lobo Construction

  • Virtual Exhibitor Directory: Attendees were able to connect with manufacturers, suppliers and technology vendors via pre-scheduled meetings, drop-in meetings, or they could drop their virtual business card off.
  • Product Directory: Attendees were able to browse hundreds of the latest products and services for the roofing, window, and siding industries.
  • Windows & Siding Community: This dedicated community page featured education, exhibitors, and products specific for the windows and siding categories located all in one place on the platform.
  • Special Events: During the virtual event there were a number of fun sessions participants could attend including a whiskey and cigar tasting presented by SRS Distribution and Versico, a virtual poker night sponsored by National Women in Roofing, and a Cirque du Soleil presentation courtesy of Visit Las Vegas.

Renae Bales of NWiR, and vice president of KPost Roofing & Waterproofing, said “The NWIR poker event was GREAT.  Our players were across the board on skills from beginners and to experienced, yet we all came together and shared laughs and learn from our dealers. Congrats to our winners! We will definitely be going this again, so get ready card sharks.”

“Now that the virtual event has closed, we are thrilled to be in full planning mode for the IRE live event taking place August 10-12, 2021,” said Giovine. “We are looking forward to reconnecting with everyone in person in Las Vegas.”

The live, in-person version of IRE will adapt Informa AllSecure, an approach to ensuring the highest standards of safety, hygiene, cleanliness and quality for operating events. In addition to AllSecure, the show will follow all local government guidelines, as well as the Mandalay Bay Convention Center guidelines.

Registration for the live event will open in April, however the hotel block is now open.

The International Roofing Expo is sponsored by NRCA, and Roofing Contractor is the official show publication. GAF is the title sponsor of the IRE Virtual Edition.

For more information about the International Roofing Expo and the events, visit www.theroofingexpo.com

To book your hotel for the IRE live event, visit https://www.theroofingexpo.com/en/travel/housing.html.

For more information about exhibiting with International Roofing Expo, visit  www.theroofingexpo.com/exhibit.

Roofing Alliance Invites Industry to the 2021 Student Competition Award Ceremony

The Roofing Alliance, celebrating 25 years as the foundation of the National Roofing Contractors Association (NRCA), is proud to invite the roofing industry and all interested to the 7th annual Roofing Alliance construction management student competition virtual awards ceremony on April 16, 2021. The oral presentations for this well-known event will be available before the awards ceremony beginning April 12 on the Roofing Alliance YouTube channel

During the virtual ceremony, awards will be presented for first and second place best overall team presentations along with first- and second-best individual presenter awards. This first-time virtual award ceremony allows the entire roofing industry to celebrate these very talented university-level construction management teams as they focus on the roofing trade.

The four finalist teams are:

  • Clemson University, Clemson, South Carolina
  • Colorado State University, Fort Collins, Colorado
  • Texas A&M University, College Station, Texas
  • University of Florida, Gainesville, Florida

This year’s competition challenges the four finalist teams through written and oral presentations testing their roofing knowledge, project management capabilities and presentation skills. The teams had to research the project, review the plans and specifications, and assemble a full estimate and qualified bid package proposal that was submitted to the Roofing Alliance judges.

This year, the teams were tasked with submitting a qualified bid package for a new roof system on the Las Vegas Raiders’ practice facility, part of the new Intermountain Healthcare Performance Center in Henderson, Nevada.  Working with Dennis Conway, owner of Commercial Roofers Inc. of Las Vegas and the founder of the student competition, the Roofing Alliance student competition committee has prepared the following timeline:

  • Oral presentations of the four finalist teams presenting virtually to the panel of judges will be on the Roofing Alliance YouTube channel starting April 12.
  • Virtual award presentations will be April 16 at 3 p.m. Eastern to announce the winning teams and the Best Individual Presenters. 

Below are the instructions to join the April 16 Zoom event:

https://nrca.zoom.us/j/96417970809?pwd=WXhYNE9ydkZVa3dHaHA1Q1JGMnA1QT09

Meeting ID: 964 1797 0809

Passcode: 616946

888 475 4499 US Toll-free

“We know that many schools are not allowing faculty or students to travel – so we have created a fully virtual competition.  The finalist teams will present oral presentations virtually,” stated Allen Lancaster, current student competition chair and vice president of Metalcrafts A Tecta America Co., Savannah, Georgia. “We are excited about the caliber of the teams competing.  We want this competition to continue to be a favorite amongst construction management programs.”

For more information about the Roofing Alliance student competition, the April 16 virtual awards event, and overall information about the Roofing Alliance, contact Bennett Judson, the Roofing Alliance’s executive director, at bjudson@roofingalliance.net or visit www.roofingalliance.net.

Elastomeric Acrylic Protective Coating for Metal Roofs

Nationwide Protective Coatings expands its roof coating lineup for elastomeric applications to include PERMAKOTE Metal Roof Paint. PERMAKOTE Metal Roof Paint is a matte finish, bright white, elastomeric acrylic protective roof coating designed to work on a metal roof system. It is a water-based, high-build formula that possesses Acrylic Waterproofing Technology. PERMAKOTE Metal Roof Paint also qualifies for a CLASS A Fire Rating Test as per ASTM E84-01, NFPA 101 Life Safety Code. Using PERMAKOTE Metal Roof Paint in conjunction with the company’s Primer, Seam Tape and Elastomeric Caulk options provides a full-scale metal roof restoration system with up to a 15-year warranty.

The roof coating system is designed to be easy to apply and will provide many years of durable protection and will extend the roof’s life. Nationwide Protective Coatings can match standard colors or custom colors. PERMAKOTE Metal Roof Paint is an inexpensive, alternative solution to roofing and re-roofing. 

For more information, visit www.nationwidecoatings.com

One-of-a-Kind Home Gets One-of-a-Kind Composite Roof

AllPro Roofing Inc. installed a new composite shake roof featuring DaVinci Select Shake. Photos: DaVinci Roofscapes

What’s a dream home without a dream roof? One new homeowner got both when he recently purchased a one-of-a-kind lodge-type home in Canada. The newly-installed DaVinci Roofscapes composite shake roof perfectly accents the three-story house where David and his family will work and play for years to come.

“This structure is incredibly impressive and has a roof to match,” says David. “When I initially drove up what struck me immediately was the towering size of the glass windows. They’re 32 feet high in the great room. After that, I was impressed by how the home is framed by the massive roof. The roof is critical to properly anchoring and framing a house of this size and structure. One of the first things I thought was to wonder how roofers would ever get up there. Given the pitch, this could not have been an easy job.”

Reliable Composite Shake

Jamie Bates agrees with David — it was not an easy job.

The house, located in Caledon East in Ontario, was being put on the market. The owners wanted to enhance the home’s curb appeal, therefore they decided to replace the roof. Bates and his team at AllPro Roofing Inc. were tasked with tearing off old cedar shakes and adding on composite shakes.

“The real cedar shakes were beginning to deteriorate and age,” says Bates. “The owners wanted a product that replicated the existing cedar roof. However, they also wanted a roof shingle that was maintenance free with a lifetime warranty.”

That search led the previous owners to DaVinci Select Shake in a Tahoe color. Bates recommended the DaVinci product because the impact- and fire-resistant roofing tiles require little maintenance. In addition, they come with a Lifetime Limited Materials Warranty that is transferable to the new owner.

“Our Canadian seasons change quickly,” says Bates. “We have cold and snowy weather. Then it gets warm and rainy very quickly. Composite roofing has been proven to withstand this type of weather quite well.”

“DaVinci Select Shake was specifically chosen for this estate property,” he continues. “The composite shake is the most aesthetically appealing product on the market. We install up to 10 DaVinci roofs a year. The profiles and colors available from DaVinci set this company’s product apart.”

Re-Roofing Challenges

According to Bates, there are several unique details to the massive roof. These include the rounded bell curves in the eaves, an array of skylights and copper accents.

“Most obviously, the height and pitch of the roof makes this a demanding project,” says Bates. “We used an articulated boom for most of the installation.”

“Removing the dry, deteriorated old cedar roofing was a challenge,” Bates notes. “It created more dust and debris than normal. In addition, there are many cuts and angles in this roof. We took our time to make this installation exceptional in every way.”

Unique details of the home’s roof include rounded bell curves at the eaves, skylights and copper accents.

One of the aspects that took time and talent were the skylights. Several large 5-foot-by-12-foot skylights had to be hoisted and installed on the roof. After that, the team also had to work around a side solarium with skylights.

All the roofing work took place just weeks before David saw his one-of-a-kind new home for the first time. He’d been looking for the right property for years. This home checked all the boxes.

“First of all, the out-of-city location in Caledon East is ideal,” says David, who resides in the Toronto area. “It’s not too remote, has a temperate climate, is close to amenities and has privacy.”

Then came the “wow factor.”

“Inside and out, this home is visually impressive,” says David. “The home feels like a lodge. There’s post-and-beam construction, towering fireplaces and lots of glass. Outside the grounds and pool are spectacular. There’s even a coach house on the property. That’s great for helping make it a retreat for family and friends to come visit.”

Peace-of-Mind Roofing

Because this is an investment in his future, David appreciates that the former owners didn’t “go cheap” with the roof replacement.

“With the DaVinci roof I believe it will look great for decades to come,” says David. “Knowing that the composite shake product will maintain its aesthetic appeal is a huge comfort. The DaVinci product resists mold, moss, cracking, insects and algae growth. It’s even Class 4 rated for hurricanes and up to 110 mph for high winds. This gives me great peace-of-mind. I can just enjoy the home and stay off the roof!”

TEAM

Roofing Contractor: AllPro Roofing Inc., Orangeville, Ontario, allproroofinginc.ca

MATERIALS

Synthetic Shake: DaVinci Select Shake in Tahoe, DaVinci Roofscapes, davinciroofscapes.com

Wall Panels Provide Striking Façade for University Office Building

Partnership Building 3 on Wichita State University is part of a larger development called The Innovation Campus. Photos: Alan Blakely

When general contractor Crossland Construction faced a complicated wall panel installation on a tight schedule, the company tapped a long-time partner to get the job done — Mahaney Group.

Headquartered in Wichita, Kansas, Mahaney Group is a commercial construction company that provides low-slope roofing, steel erection, architectural sheet metal and facility services. Mahaney was brought in by Crossland Construction to install the wall panels for an office building on the campus of Wichita State University known as Partnership Building 3. The structure is part of a larger development called The Innovation Campus, which is designed to provide research facilities, laboratories, and office space for local companies. Partnership Building 3 houses temporary offices for NetApp, which is currently building a headquarters facility on the Innovation Campus.

The Wall System

The design for the wall panels incorporates three types of PAC-CLAD panels manufactured by Petersen. Crews installed 20,000 square feet of Highline S1 panels in Silver, 2,200 square feet of Snap-On Panels in Bone White, and 9,000 square feet of Flat-Lock Panels in Matte Black. The Highline S1 Panels were delivered to length by PAC-CLAD, while the Snap-On and Flat-Lock Panels were fabricated in Mahaney Group’s shop.

“Due to the building’s size, budget, and aggressive schedule, we had to select a material that would not only look great, but also allow us to install at a rapid pace,” says Kyle Harryman, Vice President, Metals Division, Mahaney Group. “We were able to purchase 22-gauge flat sheets, lay them out, and water-jet (cut) the profile required to fabricate Flat-Lock panels with as little waste and as much efficiency as possible.”

To install the Highline S1 panels, crews added a 1.5 inch, 18-gauge hat channel vertically and attached the horizontal panels with clips. The vast majority of the installation was done from a boom lift.

The vertical and horizontal reveals were made from extruded aluminum, painted to match the panels. “We installed all of the extrusions, measured for panels, then cut them with our CNC routing machine on a weekend rain day,” notes Harryman. “We finished the install with the pre-cut panels to save time with no wasted ‘weather’ days.”

The installation of the Flat-Lock panels went smoothly, according to Harryman. “The general contractor installed 5/8-inch plywood at these locations to make our install even faster,” he notes. “The color and panel types all went together perfectly, and the final look proves just that.”

Bustling Jobsite

Challenges included an aggressive schedule, which required multiple trades to be working at the same time. “We had a three-month schedule on the project, which was really tight for the amount of work required,” Harryman says. “That made it tough, but we got it done with four crews, four boom lifts, and a telehandler on the project for three months solid.”

The building’s exterior features three different types of PAC-CLAD wall panels in three different colors.

Mahaney Group brought the project in on time, thanks in part to seamless material delivery. “We were 100 percent complete in approximately 11-12 weeks, which was an amazing accomplishment, given the size and detail required on this project,” Harryman says. “There can be zero delays or issues with the product, or your schedule is busted. PAC-CLAD did an amazing job the entire project, which is why we are a big supporter of PAC-CLAD/Petersen.”

The safety plan had to encompass not only Mahaney’s four crews but members of other trades as well. “Other than the aggressive production schedule and coordinating deliveries and staging areas for four different panel systems, the biggest challenge would have been accommodating other building envelope trades and our four metal crews onsite at one time,” Harryman says. “Here at Mahaney we require 100 percent tie-off in any boom lift or scissor lift. So, the key safety concern was with all of the other trades around while we were in the boom lift — we had to make sure no one was below our work area.”

The architectural details on the project also puts crews to the test. “There were numerous window and door trims, four different panel types, all with a tight schedule and a lot of trades/workmen around the building envelope for the duration of the project,” says Harryman. “It was a daily challenge to make sure everybody had enough material, had the right material, and knew what they were doing. We never had to wait for material, so that helped us a lot to keep moving forward. There were no setbacks.”

The success of the project demonstrates the strengths of Mahaney Group, according to Damon Young, the company’s president. “Relentless problem solvers, elevating the craftsman and elevating excellence are some of our core values and pillars, and this project highlights each of those,” Young says. “This project brings together the components of estimating, design, planning, problem solving, communication, and excellent craftsmanship to culminate in a beautiful result.”

TEAM

Architect: GLMV Architecture, Wichita, Kansas, glmv.com

General Contractor: Crossland Construction, Wichita, Kansas, crossland.com

Wall System Installer: Mahaney Group, Inc., Wichita, Kansas, mahaneygroup.com

MATERIALS

Wall Panels: PAC-CLAD Highline S1 panels in Silver, Snap-On Panels in Bone White, Flat-Lock Panels in Matte Black, Petersen, pac-clad.com

Adhesive Spray Rig and Dispensing Gun

The Heated Urethane Low-rise Adhesive Kart (HULK) from 4C’s Spray Equipment features an impressive 110-foot heated hose that keeps your crews working and reduces the amount of time they must spend moving hoses, barrels and pumps on the rooftop. Only 34 inches wide, the HULK is easy to wheel through standard door openings. The dead leg prevents it from rolling during use and features an easy tilt for use when it is time to move it. The aluminum, weather-resistant frame and cart hold two 15-gallon drums.

The patented HULK dispensing gun features an air purge handle and a fluid handle that allow you to quickly switch between a spatter/splatter installation to a bead pattern, making it convenient for every commercial roofing adhesive job. The HULK gun can be used with either heated or non-heated systems as well as with other manufacturers’ equipment. The new and improved patented design will have your crews operating efficiently and with improved accuracy.

“We designed the HULK after many years of repairing spray equipment for contractors,” explained company founder Mike Calaman. “Because we understand the unique needs of spray adhesive application and were familiar with the problem areas experienced by other machines, we were able to design the HULK and its patented dispending gun to avoid those common issues, allowing contractors to stay productive with less downtime.”

The HULK Spray Rig and HULK Dispensing Gun are manufactured by 4C’s Spray Equipment in Carlisle, Pennsylvania.

LEARN MORE

Visit: 4cssprayequipmentrental.com

Call: (888) 485-5355

Email: 4cssprayequipmentrental@comcast.net

Wind-Ballasted Engineered System Is the Answer for Technology Park

When Marymont Technology Park’s roof system began to fail, Versico’s VacuSeal V2T System was installed over the existing roof. Photos: Versico

The Marymont Technology Park, a 100,000-square-foot complex in San Antonio, Texas, is home to a wide variety of businesses and community service offices. When the complex was experiencing roof leaks, they needed a specialized solution so tenants could continue to conduct business as usual.

Market Makers Inc., a Houston-based firm that specializes in residential and commercial roofing sales and design, was called to assess the roof and make recommendations on repairs or replacement. An initial inspection revealed that the roof had been coated with an asphalt-based product. Market Makers made several trips to the project site and did multiple core samples to determine the existing roof system, layers of roofing, and deck type.

It turned out that underneath the coating, the existing roof was about 80 percent built-up tar and gravel and 20 percent granulated modified membrane. The core samples revealed what would ultimately be the project’s biggest obstacle — a specialized roof deck that consisted of a light-gauge corrugated metal with a half-inch gypsum board mechanically attached to the metal. The deck had experienced a lot of wear and tear over the years and was not a suitable substrate for mechanically attached systems, and fully adhering another roof over the coating was out of the question. Tearing off the roof down to the deck would have compromised the deck and repairs would have been exorbitant. Further complicating things were the numerous skylights, HVAC units, drains, and scuppers on the roof.

The Absolute Roofing & Waterproofing crew installed the cover board on top of the existing roof, then rolled out the TPO membrane. Vents were installed at predetermined locations.

Market Makers originally thought that the best solution was to completely remove the roof, including the deck, and install a new metal deck with a mechanically attached Versico TPO single-ply roof. However, these extensive renovations were significantly over the client’s budget, so it was back to the drawing board.

Luckily, Market Makers had an alternate solution — Versico’s VacuSeal V2T system. VacuSeal V2T is a wind-ballasted engineered system that is loose-laid over the existing roof with no penetrations into the roof or the decking substrate. The assembly uses special vents that harness the power of the wind to lock the roof membrane in place, and it can be great for retrofit and monolithic deck applications.

It turned out that the Marymont Technology Park was a good candidate for a VacuSeal roof, which was much less expensive than tearing off the old roof and deck and starting from scratch. VacuSeal systems are quick and easy to install and help save money and labor by substantially reducing the amount of glue, ballast, or fasteners a project requires.

Absolute Roofing & Waterproofing, with offices in Austin and the Dallas-Fort Worth area, was the contractor selected for the project. The company is specifically focused on large commercial projects and has partnered with developers, architects, and general contractors to provide services ranging from complete roof recoveries, new construction, leak repairs, and annual preventative maintenance.

The project started with the Absolute Roofing & Waterproofing crew receiving two days of guidance from Jeremiah Robinson from V2T and Jay Rodriguez from Market Makers. “This was our first V2T install and we wanted to ensure all details were installed to specs the first time around,” says Dustin Guess of Absolute Roofing & Waterproofing.

Versico’s DuraStorm VSH Cover Board was chosen for this project, which is an engineered composite building material sourced from post-industrial and post-consumer waste streams and offers an ultra-high compressive strength of 3,990 psi in addition to achieving FM’s Very Severe Hail approvals. The crew began by laying out Versico’s DuraStorm VSH Cover Board directly over top of the existing roof, placing the Distribution Strips for the vents, then rolling out the VersiWeld TPO membrane on top of the cover board. The crew then marked the membrane at the predetermined locations for the V2T Vents. At each location, they cut and removed a 5-inch circle of TPO membrane, aligned the V2T Vent, and flashed it before moving on to the next. Everything was loose-laid; the only securement was along the perimeter into the parapet walls and around the HVAC units and skylights.

The 100,000-square-foot re-cover project was completed in about two months. “Installation throughout this project was smoother than most,” notes Guess. “Versico and V2T were available for the entirety of this project, and it’s a true testament to what trade partners are about. We were a bit skeptical of the V2T system at first, but in the end were very impressed. The roof ‘sucked’ down to the DuraStorm board and was so smooth in the end. This was also our first time using DuraStorm board and it is now our recovery board of choice.”

Rodriguez summed up the project by saying, “With nothing penetrating the deck and not having to fully adhere anything on the roof surface, we were able to provide a roofing solution that not only made sense structurally, but also monetarily.”

TEAM

Roof System Sales and Design: Market Makers Inc., Houston, Texas, marketmakersinc.com

Roofing Contractor: Absolute Roofing & Waterproofing, Austin, Texas, absoluterooftx.net

MATERIALS

Roof System: VacuSeal V2T System, Versico, versico.com

Membrane: VersiWeld 60-mil TPO, Versico

Cover Board: DuraStorm VSH, Versico

Roofing Contractor Tackles Obstacles Both Seen and Unforeseeable

Clark Roofing installed nearly 40,000 square feet of TPO from Mule-Hide Products Co. on three buildings in Waco: the McLennan County Sheriff’s Office (lower center), McLennan County Records Management (upper right), and the McLennan County Courthouse Annex. Photos: Clark Roofing

When Clark Roofing of Waco, Texas, was selected to re-roof three McLennan County facilities in downtown Waco, they knew there would be challenges. The roofs were all 35-plus years old and leaked; one was notorious for ponding water. There was 95 tons of gravel ballast to remove. Product deliveries would require navigating busy streets, power lines and rooftop-mounted communication towers. The buildings’ historic features needed to be preserved.

What the crew could not have predicted were the added challenges of working during the early weeks of the COVID-19 pandemic and during protests for racial justice.

But attention to detail, determination, and a knack for finding creative solutions are deeply engrained in the Clark Roofing culture. The crew completed the work in just 20 working days, delivering new TPO roofing systems that will stand up to the Texas heat and hail. Most important, everyone remained safe.

The built-up roofing (BUR) systems on the McLennan County Sheriff’s Office, the McLennan County Records Management building, and the McLennan County Courthouse Annex were in rough shape. At 35 years old, 45-50 years old, and 45-50 years old respectively, each had significant leaks. They remained structurally sound, however, so recovering them, rather full tear-offs, was chosen.

Designed to Take What Texas Dishes Out

Waco is in “Hail Alley,” and average high temperatures top 90 degrees Fahrenheit from mid-June until mid-September. To create roofing systems that would withstand those conditions over the long haul and receive the desired 30-year no-dollar-limit system warranties, Clark Roofing looked to their go-to single-ply roofing system — 80-mil-thick standard TPO in white, fully adhered.

Nearly 400 squares of TPO from Mule-Hide Products Co. was installed on the three buildings.

The Records Management building was originally constructed in 1916 and expanded in the early 1950s. Its failing built-up roof was replaced with a fully adhered TPO system.

“In our experience, the thicker TPO is by far the best option in terms of durability and getting hail ratings and FM Global coverage,” says Clark Roofing General Manager Mike Anderson. “TPO can handle the Texas heat.”

The fully adhered systems also will withstand the hailstorms Waco experiences every year better than mechanically attached system would.

“If a large piece of hail strikes a plate or screw, it can damage the membrane,” Anderson explains. “With full adhesion, you’re only using fasteners on the perimeter to meet wind uplift or FM Global requirements.”

Full adhesion costs 10 percent to 20 percent more than mechanical attachment, but given the pounding that Texas roofs take, it is an investment that will be recouped in roofing system durability and longer lifespan, according to Anderson.

The key is the wrinkle-free installation that full adhesion provides. “To withstand hail, the roof needs to be very tight,” Anderson says. “If there are places where the membrane isn’t touching the substrate, hail has a better chance of puncturing it. You’re also less likely to have ponding water when the membrane is wrinkle-free.”

One of the signature features of the Records Management building is the clay tile parapet, which was preserved during the roof replacement project.

TPO Bonding Adhesive from Mule-Hide Products was used to adhere the membranes. “Solvent-based adhesives flash off faster than water-based adhesives, deliver a stronger bond, and can be used on cooler days,” Anderson says.

In each roofing system, a single layer of 1.5-inch-thick Mule-Hide Poly ISO Flat insulation was used as a top layer insulation and a separation board. The insulation was adhered using Helix Max Low-Rise Adhesive from Mule-Hide Products.

Heavy Lifting

But before the new roofing systems could be installed, 95 tons of gravel ballast had to be removed. To ensure proper adhesion of the adhesive, the substrate must be clean and dry before the adhesive is applied. Many contractors would have simply shoveled the gravel off, filling three dumpsters, and called it a day.

From their previous, off-the-jobsite experimentation, the Clark Roofing crew knew that extra attention paid to surface preparation would result in a stronger bond. So, after shoveling, they swept the surfaces with a motorized broom and blew away the remaining dust, filling 19 dumpsters.

On the roof of the Sheriff’s Office, Clark Roofing installed six TPO-clad troughs to drain water to the scupper outlets on the building’s perimeter.

All three rooftops were ballast-free and clean before installation of the first new roofing system began, ensuring that crew members cleaning one roof section did not track dirt onto newly installed TPO.

It took nearly two full days to complete the clean-up, but it paid off in a tight bond between the insulation and the substrate.

Eliminating Problems

The roof of the Sheriff’s Office building had been plagued by ponding water for years. The original project specifications called for using tapered insulation to remove the water. But Clark Roofing had another solution that cost approximately $40,000 less to implement. Six TPO-clad troughs — 12 inches wide and 200 feet long — were instead installed, each connecting to scupper outlets on the building’s perimeter to direct the water off the roof.

The Clark Roofing crew installs the TPO membrane on the Sheriff’s Office.

The roof of the Courthouse Annex building was littered with 40 obsolete, damaged or torn-off penetrations for exhaust fans, sewer fans and air-conditioning units. They created an obstacle course and were the source of many of the roof’s leaks.

The crew removed the penetrations, along with miles of unneeded conduit and wire, reducing the potential for future leaks and making navigating the rooftop far easier.

“When we started, you couldn’t walk 3 feet without bumping into something,” Anderson says. “Now you can go 10 or 15 feet without any trouble.”

Preserving History

The Records Management building, constructed in 1916 for the Texas Telephone Co. and expanded in the early 1950s, is an architecturally significant fixture in downtown Waco. One of its signature features is its clay tile parapet walls.

Following the standard practice of installing wood blocking, then plywood, and finally the TPO membranes would have taken away from the building’s historic look. So, the Clark Roofing crew stopped the TPO membranes short of the parapet caps and terminated them inside the walls, out of sight from the street. They then refilled the joints and applied Foxfire Matrix Pro SS-WB for waterproofing. The roof was watertight, with the building’s character preserved.

Challenging Roof Access

Busy streets and the presence of high-voltage power lines made material deliveries challenging at all three buildings. Crews blocked off streets as necessary, working quickly to minimize disruptions. Many deliveries were scheduled at night or on weekends when traffic was lighter.

The crew removed 40 obsolete, damaged or torn-off penetrations, along with miles of unneeded conduit and wire, as they installed the new roof on the Courthouse Annex building.

Deliveries at the Courthouse Annex required flawless communication between the crane operator and roofing crew. There was only a 15-foot area in which to work. Communication towers used by the Sheriff’s department and other county agencies are located on the building’s roof, anchored by big guidewires. The building’s parapet wall is 5 feet high.

The crane operator could not rely on visual signals from crew members on the rooftop to direct him, as he could not see them over the wall. So, they used two-way radios, with crew members verbally guiding the crane operator inch by inch.

“You have to really trust someone to do that,” Anderson says. “He was spot-on.”

Early Days of COVID-19

The COVID-19 pandemic arrived just as the projects were beginning. But the roofs had been leaking for months, so there was no thought of postponing the work.

A variety of protocols were followed to keep everyone safe, including:

  • A supervisor was always on the jobsite for quality control and safety. Sometimes two were there — one on the ground and one on the roof.
  • All meetings were conducted virtually.
  • To avoid going inside the buildings, crew members rode a manlift to the rooftops. It took a full hour to get the eight- to 12-person team in place, adding a full day to the job.
  • All crew members wore face coverings, safety goggles and disposable gloves and regularly sanitized their hands. The crew went through as many as 200 disposable facemasks each week, and gaiters reminded them not to touch their faces.
  • Social distancing was practiced. “We don’t even think about staying 6 feet apart anymore,” Andersons says. “It’s automatic.”
  • Hand tools were not shared. If equipment, such as welders, needed to be shared, it was sanitized before changing hands.
  • Crew members had their temperature taken multiple times a day, and anyone found to be running warm was required to get a COVID-19 test.
  • Disposable water cups were provided. No bottles or cans were allowed on the roofs.
  • At lunchtime, crew members left the roof and cleaned up before eating.

The precautions worked. There were no known cases of COVID-19 among the crew.

Protests for Racial Justice

Sheriff’s deputies shut down the Courthouse Annex jobsite on three occasions, having received word that protesters for racial justice were planning to assemble outside the building. The crew was ordered to get off the roof. Anything that could be used to cause injury or damage property — from sharp tools to the Sky Trak — was removed from the jobsite.

Approximately 95 tons of gravel ballast had to be removed before the new roof systems could be installed.

On one occasion, the crew had just removed the exhaust fans from the roof. Anderson says, “We told the deputies, ‘There are 3-foot openings in the roof. If it rains, the building will flood.’ They said, ‘Get off the roof. If it leaks, it leaks; we’ll take responsibility.’ Luckily, it didn’t rain.”

Thankfully, the protests were peaceful, with no injuries and no damage to property. The shutdowns ranged in length from one to three days and delayed completion of the job by four or five days.

Three roofs. Twenty working days. Four hundred squares of new hail-resistant TPO roofing installed. Challenges — from the expected to the unforeseeable — overcome. No leaks during the active hail season that followed. Just another day at the office for the Clark Roofing team.

TEAM

Roofing Contractor: Clark Roofing, Waco, Texas, clarkroofingtx.com

Roofing Materials Distributor: ABC Supply Co. Inc., Branch #040, Waco, Texas, abcsupply.com

Crane Operator: Wales Crane & Rigging Service, Woodway, Texas, walescraneandrigging.com

Equipment Rental: Equipment Depot, Waco, Texas, eqdepot.com

Gravel Disposal: Rise Up Refuse Dumpster Rental & Demolition, Waco, Texas, thetexasdumpster.com

MATERIALS

Membrane: 80-mil Standard TPO in White, Mule-Hide Products Co., mulehide.com

Roof Insulation: Mule-Hide Poly-ISO Flat insulation, Mule-Hide Products Co.,

Adhesives: TPO Bonding Adhesive (to adhere membrane) and Helix Max Low-Rise Adhesive (to adhere insulation), Mule-Hide Products Co.

Edge Metal: TPO-Coated Edge Metal with Attached TPO Skirt, Mule-Hide Products Co.,

Roof Drains: TPO-clad retrofit roof drains, Mule-Hide Products Co.