SPF System Solves Problems for Arizona Homeowners

Overson Roofing specified a spray polyurethane foam re-roof for this Scottsdale residence to eliminate ponding issues and reduce energy costs. Photos: Overson Roofing LLC

Pat Overson has been running roofing companies since 1982. He currently co-owns Overson Roofing LLC in Mesa, Arizona, a company he founded along with his son Brett in 2005. Approximately 85 percent of the company’s work is residential, most of it re-roofing. A large chunk of that work — Overson estimates 20 percent — involves spray polyurethane foam (SPF), which is common on houses in Arizona.

“With the heat we have out here, it really helps insulate your home as well as provide good roof over your house,” Overson says. “It is the only roof out there that provides an insulation factor somewhere around R-7, which is close to about 4 inches of fiberglass insulation.”

Overson Roofing strives to recommend the best roof system for each project. Overson often finds himself recommending spray foam for existing low-slope roofs, especially those with drainage issues. He pointed to a recently completed residential project as an example. The 3,100-square-foot home in Scottsdale had a three-ply hot tar built-up roof. The homeowners noticed ponding problems, and they were also looking for ways to make their home more energy efficient. Overson felt the house was a great candidate for a Lapolla spray polyurethane foam roofing system with an elastomeric coating. The white elastomeric coating protects the SPF from ultraviolet rays and provides reflectivity to minimize temperatures on the roof.

“Sometimes customers ask us for a foam roof, and we evaluate it and make sure that it would be a good roof for their project,” he notes. “Often we recommend a foam roof when there are drainage problems because it’s a very easy system to help modify or enhance the drainage on a roof that has ponding problems. In this case, the homeowners were also very interested in the insulation factor, and they were looking to save money on electric costs and make it more economical to heat and cool.”

Roof Removal and Installation

The first step was preparing the house for the roof removal, which was done by a separate tear-off crew. The work area was covered with tarps, and the roof system was removed and taken away in a trailer. Magnets are used as part of the clean-up process to ensure nails and other debris are not left behind.

The Lapolla SPF was applied in two layers, each a half an inch thick. The system was topped with an elastomeric coating.

The substrate was then cleaned and primed before the SPF system was applied with a sprayer. When the two-part system is applied, parts A and B combine to form a closed-cell roofing system. “The result is a monolithic roof,” Overson says. “Foam roofs usually don’t have leak problems because there are no seams, and that’s a big advantage. It will also seal to almost everything. It will seal to metal, it will seal to wood, it will seal to stucco, and it will seal to almost every type of roof system.”

The keys to a successful project include proper substrate preparation and being aware of weather constraints. “It has to be, as we call it, ‘clean, dry and tight,’” Overson says. “It has to be a clean roof surface. It has to be dry — foam doesn’t adhere to any kind of moisture or water at all. And it has to be tight, which means there can’t be any bubbles or blisters in the systems you’re going over.”

After the roof is removed, the surface must be cleaned with brooms or blowers. Then the area must be secured and taped off to ensure the foam won’t be sprayed anywhere it’s not required. For example, windows and walls might need to be covered.

“It’s almost like you are a painter up there,” notes Overson. “You often have to do extensive tarping and taping. You also have to make sure it’s not windy. You don’t want winds in excess of 5 or 10 miles per hour. Preparing the area is very important step. You don’t want any overspray.”

The spray foam is applied in two layers. “You spray it on a half-inch think the first lift, and you have a second lift, also a half an inch,” Overson says. “It dries pretty quickly — often in a few minutes — so you can put on the second layer almost immediately. Similarly, after the second coat dries, you can apply the coating. We used an elastomeric coating in this project, while others might call for a polyurethane, silicone, or acrylic coating.”

In coping with different types of substrates, the skill and experience of the applicator can be crucial. “It’s an art as much as a skill,” he says. “You have to have the right rhythm and the right touch. We have really skilled applicators, and they do a great job. The techniques vary, but you are just trying to get an even surface, an even spray.”

In this case, the application was designed to eliminate drainage problems. In low areas, crews added another inch of insulation and created the proper slope toward the scuppers. “You can feather it in, and that’s where the skill of the applicator really shows,” he says. “It’s exciting that you can help people with these issues. You can’t do this with other products.”

As part of the safety plan, applicators wear white body suits that cover their skin and clothing, as well as goggles and protective breathing equipment. Proper fall protection plans must be in place for each project.

Benefits for Homeowners

Feedback from the owners has been positive, according to Overson. “We were able to enhance the drainage quite a bit and eliminate all of the ponding and drainage issues they had,” he says. “They were happy about that, and they also were excited to find out how much they saved on their monthly bills. They haven’t gone through a full cooling season yet, but many of our homeowners stay in touch with us over the years, and some find they are saving $40 to $50 a month on their electric bills.”

Overson summed up the project this way: “Around here, we say roofs have to do two things: they have to not leak and look good. And we achieved both of those things on this project. This is a nice-looking roof. It’s white, and it will reflect the sun, and that’s a big factor here in Arizona. We take pride in our jobs, our crews take pride in their jobs, and we know it’s not going to leak. The customer was very happy, and if the customer is happy, we are happy.”

TEAM

Roofing Contractor: Overson Roofing LLC, Mesa, Arizona, www.oversonroofing.com

MATERIALS

Roof System: Lapolla Spray Polyurethane Foam and Elastomeric Coating, Icynene-Lapolla, www.lapolla.com

Planning Ahead Sets Up Warehouse Re-Roofing Project for Success

Citizens Service Center is the primary document storage facility for El Paso County, Colorado. When the roof had to be replaced, protecting the interior of the facility was critical. Photos: Exterior Solutions Group

The most crucial decisions on a project are often made before work even begins. According to Ken Flickinger Jr., president of Exterior Solutions Group, that was the case with the recent Citizens Service Center re-roofing project in Colorado Springs. Owned and managed by El Paso County, the building is the primary document storage facility for the county. The building’s historic documents — some dating back to the 1800s — were under threat of damage due to an active roof leak. The existing roof also had extensive hail damage, so the roof replacement project was put out for bid.

With offices in Colorado, Iowa and Oklahoma, Exterior Solutions Group does all types of roofing work, but its focus is primarily on commercial roofing, both re-roofing and new construction. Flickinger, who heads up the location in Parker, Colorado, was definitely intrigued by the project.

The scope of work involved removing old HVAC equipment on the roof, which would be done by a separate party in coordination with the roofing contractor. The HVAC equipment was obsolete; it had been replaced and relocated a few years earlier. “It was an interesting project because there was equipment everywhere on this roof,” he says. “It looked like an automotive manufacturing plant. For us, we like those types of projects. We like ones that are a bit out of the ordinary and require a little bit higher level of project management. So, that’s what drew us to bidding the job.”

Tim Hicks, the salesperson at Exterior Solutions who sold the job, explains that the original spec called for white EPDM, with TPO as an accepted alternate. “Oddly enough, they didn’t require you to do the base bid to bid the alternate,” he notes. “We chose to just bid the TPO. We ended up being the low bidder on that, and that’s how we got the project.”

After obsolete HVAC equipment was removed, crews from Exterior Solutions Group installed a TPO system from Johns Manville.

The logistics of the removal and roof replacement would be complicated, and it became obvious that access to the roof would also be an issue, as it was a high-security building. “This is a multi-story building, and the amount of security we would have to go through to enter the building and get up to the roof hatch would’ve created all kinds of problems,” Hicks explains. “So, we suggested putting a stair tower up and giving us complete access from the outside. We’d never have to enter the building. They had never even considered that option, but as we walked them through it and said, ‘This is how we’d like to set the job up,’ they replied, ‘We love it.’”

The next step involved coordinating equipment removal with the HVAC contractor. Again, a suggestion from Exterior Solutions helped increase efficiency and cut costs. The HVAC contractor’s original plan called for roofing crews to take out the roof system around the HVAC units, allowing HVAC crews to cut out sections of the steel decking below the equipment. The deck sections would have to be replaced before temporary roofs could be installed to keep the building watertight. The team at Exterior Solutions pointed out that there was no need to remove the decking. Instead, the equipment supports could be cut off as close to the deck as possible, and the ends of the supports could be buried in the insulation of the new roof system.

Equipment Removal

In the end, that’s the plan they executed. A fire watch was set up inside the building as equipment was removed. Crews from Exterior Solutions removed the existing roof to give the HVAC crews access. “We basically created a hole in the roof for them so they could see what they were doing,” Hicks explains. “We would slice the existing TPO back and take out the insulation. They would put down welding blankets in the area and then use cutting torches to cut the I-beam and L-beam steel supports off. Our roofers were on site to make sure supports were cut down to the proper length. As soon as the supports were cut off, we basically filled the hole.”

The deck was left intact, making it much faster and easier to patch the existing roof. It was critical to ensure the roof was weathertight every night to protect the documents inside the building. “We put the insulation back, we replaced the membrane, and we used an Eternabond product or welded a small cover strip around it, depending on the size of the hole,” notes Hicks.

The HVAC equipment was taken off the roof with a crane. Once the equipment was removed from one side of the roof, crews began installing the new system.

Roof Installation

With the equipment gone, the rest was clear sailing. “In all honesty, the roof was easy,” Flickinger says.

The existing roof system was torn off down to the deck and a TPO system from Johns Manville was installed. New polyiso insulation was topped with a fully tapered system to ensure proper drainage. After DensDeck cover board was installed, the 60-mil TPO membrane was adhered into place.

“We worked from one side to the other,” Hicks says. “The high point of the roof with the tapered system was in the center, and water is pushed to both sides where there are internal drains and overflow scuppers. We started at the low point and roofed up the hill to the center on one side, and then turned around and did the exact same thing on the other side.”

Details were minimal — just a few penetrations and a curb around the roof hatch. The edge metal installed was the Anchor-Tite system manufactured by Metal-Era. “We offered an upgrade on the metal edge,” notes Hicks. “Instead of a shop-fabricated metal edge, we recommended Anchor-Tite all the way around. After all, the area is subject to high winds. We felt that was a better way to go.”

The TPO system installed was ideal for the project, according to Flickinger. “I’ve been a thermoplastic guy my entire career,” he says. “I’m a big believer in heat-welded seams. We thought the heat-welded seams and adhered walls offered a better approach. We think it’s a very good-looking roof, and with the addition of a cover board — which the original roof didn’t have — it would definitely improve its hail performance.”

Hicks credits the manufacturer for assistance on the project. “Manville was very supportive,” he says. “They were local, and their technical support is excellent. We thought that for a project like this, to have a partner who was right there with you was important.”

The project was completed in less than a month, and Flickinger believes the key to executing the job efficiently was the decision to set up the stair tower. “That was the suggestion of our project manager,” says Flickinger. “Our company likes using stair towers, especially when we’re talking about long ladder runs. For us, it’s partly about safety for our own people, but because the building was secured, and as they talked to us about the steps we would have to take on a daily basis to just get access to the roof, we realized it was just going to kill us on production. We were going to waste so may man-hours on a weekly basis just getting to and from the roof. That was one of the driving factors that got the owner to agree to the stair tower, and we got a change order for it.”

The cost of the change order was minimal compared to the time and money it saved. “We have some really bright people,” says Flickinger. “They are all really good at looking at something and seeing if there is a better way. One of our strengths is we are really good at creative solutions, whether it’s something as simple as avoiding the grief of going through a secured building or taking a step back and asking, ‘Why cut holes in the deck? Why can’t we just cut these supports off above the deck because we are burying them in 6 inches of insulation anyway?’”

“The other piece for us is that we focus on the safety side of it, not only for our own people, but also the site safety and the safety of the people inside the building,” Flickinger continues. “We are very aware of that as we set our jobs up and decide where to set our materials and those types of things.”

The last component of a successful project is top-quality workmanship. “We focus on doing it right the first time,” Flickinger says. “Getting that customer satisfaction, not only at the end of the job with a great roof, but also during the project by trying to minimize the pain that an owner typically goes through in a roofing project, that’s one of our strengths that this project demonstrates.”

TEAM

Roofing Contractor: Exterior Solutions Group, Parker, Colorado, www.exteriorsolutionsgroup.com

MATERIALS

Roof Membrane: 60-mil TPO, Johns Manville, www.jm.com

Cover Board: DensDeck Prime, Georgia-Pacific, www.buildgp.com

Edge Metal: Anchor-Tite, Metal-Era, www.metalera.com

Helping Make a Little Girl’s Dream Come True

Isabella Tadlock recently received a Hero Arm, a lightweight bionic hand. Through the Helping Our Own Program, the Roofing Alliance donated $5,000 to the Tadlock family to help with expenses that were not covered by insurance.

A $5,000 donation to the Tadlock family will help their daughter get the second hand she needs to climb the monkey bars and ride a bike.

This past holiday season, the Roofing Alliance helped to make a little girl’s dream come true. They donated $5,000 to the Tadlock family to help pay for their daughter’s new Hero Arm and related medical expenses.

Dale Tadlock, the president of Tadlock Roofing in Tallahassee, Florida, wrote in an email about his daughter’s unique story and her holiday wish. He starts with, “I would like to tell you a story. It is about a special little girl. It didn’t start out to be happy ever after, but it will be.” Isabella came into the world eleven years ago with multiple birth defects. Her birth parents were unable to care for her, so they gave her to the Children’s Home Society.

“This tiny baby would have a lot to overcome because she had a gaping cleft in her lip and palate. Her tiny right leg was turned in; the doctors called it clubbed. And then there was the problem with her hands. Her left arm was shorter than her right with a little nub on the end. And her right hand, well, it didn’t have any fingers at all,” Dale explains.

He and his wife had been wanting to adopt a girl for five years. When they heard about Isabella, they knew she was the special little girl they had been waiting for. Dale shares, “We brought her home to three sisters and two brothers who couldn’t wait to shower her with love and show her how special she really is.”

Throughout her eleven years, Isabella has had ten surgeries and nine casts. The Tadlocks were able to find a doctor who created fingers on her right hand by taking bones out of her toes. These bones were placed in her right hand, as well as pins and rods that had to be turned and cleaned three times a day. She now has three fingers and a thumb on her right hand. While the fingers don’t look or bend like her brothers and sisters do, they work!

However, Isabella became self-conscious about her hands and began to hide them because they weren’t like her friends. Dale says, “It is heartbreaking to watch a school production when all the other children wave their hands in the air, but never Isabella.”

To be more like her friends and do the things she’s been dreaming of, Isabella needs a second hand. This hand will give her the ability to ride a bike, tie her shoes, hold a brush while she dries her hair, and most importantly, climb on the monkey bars, which is “something that she has always wanted to do,” according to Dale.

Luckily, they found a solution. Isabella was approved for a Hero Arm, which is a lightweight bionic hand with a posable wrist and thumb. It has customizable plates to fit each person’s unique style and personality. While it is the most affordable bionic hand available, it still costs approximately $20,000. The Tadlock’s insurance agreed to cover $8,900 of the hand, but they still needed $11,100 to pay for the rest.

Tadlock Roofing gives so much to the community in Tallahassee and the roofing community as a whole. Earlier this year, Tadlock was recognized by Leon County Schools for donating $2,000 and 2,000 food items to the high school’s food bank. The company also helped facilitate free roof replacements for those in dire need, such as an Army veteran whose numerous medical bills inhibited him from replacing his 20-year-old roof.

Tadlock Roofing is the first privately owned business to join with Florida State University, Florida A&M University, and the Children’s Home Society to support the first Leon County Schools Community Partnership program in Tallahassee. In 2018, Tadlock was the title sponsor for Children’s Home Society Gala helping raise over $80,000 for that organization. During “Giving Tuesday,” Tadlock Roofing committed matching funds up to $10,000 each year for the last three years for Boystown, an organization that provides healing and hope to children and families who find themselves facing adversity. Tadlock Roofing has adopted the roof of the Ronald McDonald House of Tallahassee.

The Roofing Alliance recognizes everything Tadlock Roofing has done and wanted to help. Through the Helping Our Own Program, The Roofing Alliance donated $5,000 to the Tadlock family for Isabella’s arm. While the Roofing Alliance originally worked to help advance the roofing industry by funding technical, educational, and safety-related studies, it has since expanded its outreach to encompass so much more. The Roofing Alliance’s outreach also helps “fund efforts dedicated to good works and charitable giving.” The Roofing Alliance recognizes that sometimes there are circumstances outside of people’s control that impact them significantly, and they want to do what they can to take care of their own by easing the financial burden.

Through this generous donation, the Tadlock family is so much closer to raising all the money they need for Isabella’s Hero Arm. Soon Isabella will be climbing on the monkey bars and waving her hands in the next school production.

For more information about the Roofing Alliance, visit www.roofingalliance.net.

About the author: Lauren White is a reporter for RoofersCoffeeShop and a freelance writer covering the roofing industry.

IMPs Are Key to Construction of New Warehouse at Manufacturing Complex

The new warehouse at the Komatsu manufacturing complex in Longview, Texas, features insulated metal panels from Metl-Span in both the roof and wall systems. Photos: LMCurbs

When a warehouse at the Komatsu manufacturing complex in Longview, Texas, sustained extensive tornado damage, the company decided to build a new, state-of-the-art warehouse in its place.

Komatsu turned to a trusted business partner, Transet Co., a Longview-based design-build contractor, to demolish the old structure and construct its 81,438-square-foot replacement. The new warehouse features insulated metal panels (IMPs) from Metl-Span in both the roof and wall systems, as well as a permanent rooftop walkway system from LMCurbs, which was installed to facilitate ongoing maintenance of the rooftop HVAC units.

According to Dale Pickard, project manager for Transet Co., the IMPs not only made for smooth construction, but they helped the warehouse meet building envelope energy requirements.

Challenges on the project included a tight schedule, unseasonably rainy weather and accommodating nearby manufacturing facilities that were continuously operational.

The LMCurbs Roofwalk System was installed to facilitate ongoing maintenance of the rooftop HVAC units and protect the roof.

The scope of work included the removal of the previous structure and subgrade remediation. After the footings and slab were in place, the Pre-Engineered Metal Building (PEMB) was erected. The system was supplied by Houston-based Mid-West Steel Building Co. and erected by Cannon Steel Erection Co., located in Tyler, Texas.

After the metal frame and roof purlins were in place, Cannon Steel Erection installed the IMPs to complete the wall and roof systems. “You basically go in sequence from left to right with the IMP roofing panels,” Pickard explains. “You just start at one end, work to the other end, and then come back and install the panels on the other side. It’s basically a straight line process from one end to the other.”

The roofing panels were 42 inches wide and 4 1/2 inches thick and incorporated a standing seam. “The panels attach at the purlin with a concealed fastener clip,” says Pickard. “The IMP has a finished skin on the upper and lower sides.”

The seams were hand crimped and then mechanically seamed. At the eave, a gutter system was installed after the roof and wall panels were tied in together.

Workers on the roof were tied off with personal fall arrest systems and retractable lifelines attached to non-penetrating temporary anchor points. “All facets of construction safety were of paramount importance to Transet Co.,” Pickard states. “Safety was and is the first order of business for everybody.”

Completing the Roof Installation

The roof system features Kingspan skylights, which were installed using custom curbs supplied by LMCurbs, headquartered in Longview, Texas. LMCurbs also supplied curbs for the HVAC units, as well as the rooftop walkway system.

The LMCurbs Roofwalk System was installed using H90 clamps from S-5!

The walkway was installed after all of the HVAC equipment was in place and the roof system was completed. The LMCurbs Roofwalk System was designed to provide a safe way to access HVAC equipment while protecting the roof. “It’s basically a roof access area for the maintenance personnel to enter,” Pickard says. “It’s a railed walkway gated at one corner of the building for access, and it goes to each one of the rooftop units (RTUs). In all, there is more than 1,400 linear feet of walkway.”

The system was mounted using S-5! H90 clamps. “There were no penetrations in the roof,” Pickard points out. “It’s a durable system that will protect the owner’s investment in the roof.”

According to Aaron Combs, product manager at LMCurbs, the project was one of the first to use the company’s redesigned LMCurbs Roofwalk System with upgraded handrails. “It was designed to be both a better looking, more professional end product for the building owner, and a more user-friendly system for the installers in the field,” Combs says. “The new handrail assembly utilizes Speed-Rail fitting by Hollaender and is now down to four pieces — from 28— so the number of man-hours needed to install the system is drastically reduced. It also streamlined the warehousing and distribution process because the redesigned support plates eliminated multiple manufacturing processes. With this redesign and stackable plates, we are able to maintain better stocking levels and provide our customers with a faster shipping timeframe.”

Field installations often present unique and unforeseen obstacles. On this project, when the location of some HVAC units was adjusted from the initial layout, Combs was ready to help ensure the walkway would be installed correctly. “We are always available to offer advice and technical support, and that can be especially important with a first-time installer,” Combs says. “They can contact us any time and we can help walk them through it and assist with any issues that might arise.”

Work began in April 2019 and wrapped up February 2020. “We had a wet start, which made soil remediation difficult,” notes Pickard. “In the latter part of our project, we had an extremely wet January and February, and that presented challenges in erection and finish out. Despite the bad weather, the building came together ahead of schedule.”

Coordinating all phases of the project at an active manufacturing campus also posed some logistical hurdles. “The existing plant, of course, was in operation the entire time,” recalls Pickard. “The site where the new warehouse was being built was where the old warehouse facility was, and the existing loading dock had to remain in operation until they were in the new building. That encroached on the footprint of the new facility.”

Final touches included new loading docks, interior offices and restrooms. “This project shows our ability to deliver an outcome that meets the client’s needs from design to finished product — safely, under budget, and ahead of schedule,” notes Pickard.

“It demonstrates our ability to provide a first-class warehouse facility for the owner. We’ve been doing it a long time. Our company has been in business for 38 years. We are a safety-oriented company with vast experience in most phases of commercial, industrial, and institutional construction, and we are there for our customers.”

TEAM

Design Builder: Transet Co., Longview, Texas, www.transetco.com

Engineer: Johnson & Pace Inc.,Longview, Texas, www.johnsonpace.com

Steel Erector: Cannon Steel Erection Co., Tyler, Texas, www.cannonsteel.com

PEMB Supplier: Mid-West Steel Building Co., Houston, Texas, www.mid-weststeel.com

Rooftop Curb and Walkway Supplier: LMCurbs, Longview, Texas, www.lmcurbs.com

MATERIALS

Roof and Wall Panels: Insulated Metal Panels, Metl-Span, www.metlspan.com

Rooftop Curbs: LMCurbs, www.lmcurbs.com

Rooftop Walkway: LMCurbs Roofwalk System

Rooftop Walkway Clamps: H90 Clamps, S-5!, www.s-5.com

Skylights: Kingspan, www.kingspanlightandair.us

Sensitive Re-Roofing Project Necessitates Durable System, Flawless Execution

The 250,000-square-foot Pepper River data center project would pose challenges including a tight schedule and difficult weather conditions. Utah Tile and Roofing Inc.

Utah Tile and Roofing Inc. prides itself in its ability to tackle difficult projects. When Okland Construction approached the company to help prepare budgets for a bid on a roof replacement on a building that would become a data processing center, they immediately knew this one would fit the bill.

Founded in 1948 in Price, Utah, Utah Tile and Roofing (UTR) relocated to Salt Lake City in 1966. The company handles all types of commercial roofing projects, as well as waterproofing, sheet metal, and wall panels. The current owners are Paul and Andrew Seppi, who took over from their father, founder Herman Seppi, in 1977. According to J.C. Hill, vice president, the company continues to build a reputation for craftsmanship as it works on some of Utah’s iconic buildings. “We’ve done a lot of high-end work here in the state of Utah,” Hill says. “A lot of the architectural gems here locally have our fingerprints all over them. The higher-end, more difficult work is where we’ve found our niche.”

The Aligned Energy data facility known as Pepper River in West Jordan, Utah, would also have its challenges, including a tight schedule and difficult weather conditions. Approximately 250,000 square feet of existing roof would have to be removed and replaced, but the sensitive nature of the building would require not only a durable temporary roof to keep everything dry during construction, but a resilient, long-lasting finished roof to protect the equipment below. The answer was a hybrid roof system from Sika with a vapor barrier set in hot asphalt. It would be topped with insulation, a cover board, and an 80-mil Sarnafil PVC membrane.

The design for the roof system was developed by UTR in conjunction with the architect, roof consultant, general contractor, and the manufacturer. “The vapor barrier would be set in hot asphalt as a temporary roof. The insulation and the tapered insulation would also set in hot asphalt,” Hill says. “That gave them some redundancy, which is a term those tech guys like.”

Roof Removal

The building’s original gravel-surfaced built-up roof had been covered over at some point with a mechanically attached white TPO roof on one side and a mechanically attached black EPDM roof on the other.

“We had to keep the building watertight as we tore it off,” says Hill. “We put the temporary roof down and crews would do a nightly seal to keep everything watertight as they progressed across the building.”

The existing roof systems included the building’s original gravel-surfaced built-up roof. It was cut into sections and pried off the metal deck.

Work was done in sections, beginning on one half the roof and then finishing up on the other. The expansion joint in the center of the building was the dividing line.

The safety plan included a perimeter flag system, and those outside the warning line were tied off 100 percent of the time. A scaffold stair tower was built to provide safe access to and from the roof.

Debris from the tear-off was removed using chutes and dumpsters. First the roof membrane was sliced up into manageable sections, rolled up, and deposited into a dumpster, along with the cover board. Then the built-up roof was cut into 3-foot-by-3-foot squares and pried off the metal deck.

The deck was swept clean of debris and inspected. Some of the decking had to be replaced, including sections where skylights were eliminated. A 5/8-inch DensDeck cover board was then screwed down to the metal deck. The vapor barrier sheets were unrolled and allowed to relax in the hot sun, and then set in hot asphalt. “We were able to do about 2,000 or 2,500 square feet a day with the tear-off and dry in,” notes Hill.

One unusual obstacle was a Canadian goose that had set up her nest in the expansion joint. “We had to leave that section undisturbed while she was waiting for her chicks to hatch,” says Hill. “Actually, there was a pretty good-size section of the roof in the middle that we weren’t able to address until she left. Luckily there was plenty of roof to work in, and we didn’t want to disrupt her. Even after she left with her chicks, she would come back and chase the guys around every once in a while.”

After the temporary roof was installed, the existing parapet walls were raised. The durable temporary roof allowed carpenters other trades to work on the roof without excessive fear of damage. After the trades completed their work, the finished roof system was installed right over the temporary roof.

The PVC System

First a layer of polyiso insulation was set in hot asphalt. Next the tapered insulation layer was also set in hot asphalt, followed by another layer of insulation to achieve R-30. Half-inch DensDeck Prime was then set in low-rise adhesive and the white PVC membrane was fully adhered.

To provide the durability the project needed, a hybrid roof system from Sika was specified. It included a vapor barrier set in hot asphalt and an 80-mil Sarnafil PVC roof system.

“We actually had two crews for that phase: a hot crew and a single ply crew,” Hill states. “The hot crew would be laying the insulation out in front, and then the single-ply crew would lay the cover board in the low-rise foam and start fully adhering that membrane down. It took a coordinated effort with the guys we had out there to make sure that there was no asphalt contamination of the PVC membrane and that white roof remained clean.”

As work continued on the second half of the roof, cold weather set in. Due to the temperature limitations of the membrane adhesive, the decision was made to switch to a self-adhered membrane. “We were having production issues with the cold weather, and we went back to Sarnafil and they recommended putting the SA down,” notes Hill. “It was the first time we had ever installed the self-adhered membrane. It saved our production, and we were able to install nearly as much as we were doing in the better weather days.”

The last steps on the project included installing edge metal. “We did a Sarnafil high-wind edge detail with their clad metal and a pre-finished metal fascia plate over the top,” says Hill. “It gave the building a nice finishing touch from the ground and also from the roof side.”

Meeting the Challenges

The biggest challenge on the first phase of the project was the tight schedule. “We had to get that first phase operational so they could get the data hall up and running,” says Hill. “We had to get the first section dried in so the trades — electricians, drywallers, painters, and tech guys — could get in there and do their work.”

Work began in April of 2019 and wrapped up in December of the same year. After the first phase was completed, the weather posed the greatest difficulties. “The winter was quite heavy,” Hill says. “We had to remove snow quite often to be able to go back to work.”

In the last phase of the project, cold weather and heavy snow affected the schedule.

Hill credits the teamwork between all of the principals and the excellent craftsmanship of job foreman Rudolfo Garcia and his crew for the success of the project. He also cites durability of the temporary roof and the extra protection the hybrid system provides as critical components in the design. “With carpenters and steel guys working over that temporary roof, the typical peel-and-stick vapor barriers simply wouldn’t have been durable enough,” he says. “This building has to remain dry. That temporary roof with a cap sheet over the top of it could have been a completed system, so it gave them the backup that they needed. If there ever is a problem on the top layer with that single ply, there is still that temporary roof underneath to keep them dry.”

Utah Tile and Roofing received first place in the 2019 Sika Sarnafil Project of the Year Awards in the Low-Slope Re-Roof category. “The award is a testament to how good our guys in the field are,” Hill says. “Because we have such good field mechanics, we are able to take on these tougher projects that take more critical thinking and more experience. They are the best at what they do, the engine that drives this thing. They are the ones that make it happen.”

TEAM

Architect: HKS Inc., Salt Lake City, Utah, www.hksinc.com

General Contractor: Okland Construction, Salt Lake City, Utah, www.okland.com

Roofing Contractor: Utah Tile and Roofing Inc., Salt Lake City, Utah, www.utahtileandroofing.com

MATERIALS

Roof Membrane: Sarnafil G410 80-mil PVC, Sika, https://usa.sika.com/sarnafil/

Insulation: Sarnatherm ISO, Sika

Vapor Barrier: HA-87 SBS Ply Sheet, Sika

Cover Board: DensDeck Prime, Georgia-Pacific, www.buildgp.com

Persistence Pays Off for Roofer

After the Muirfield Design Control Committee agreed to allow the installation of DaVinci synthetic slate and shake in their community, Great Roofing and Restoration re-roofed this home in late 2019 with shake composite. Photos: DaVinci Roofscapes

Determined. Resilient. Stubborn. Those words could easily describe Ryan Lephart. Whether it’s a single home project or the challenge of securing roofing for a community, Lephart digs in for perfection.

One of Lephart’s longest quests was to secure approval to install composite roofing on homes in the Muirfield Village community in Dublin, Ohio. It took nine years, but his patience and diligent efforts paid off.

“Acceptance of new products comes slowly to some people,” says Lephart, director of business development for Great Roofing and Restoration. “This is a planned community. In the past it has only accepted real slate and shake roofing materials. Now we’ve finally gotten a toehold. We’ve gained approval for composite materials in Muirfield. As a result, we’ve installed our first DaVinci Multi-Width Shake roof there.”

Developing Muirfield

The Muirfield concept was started in 1968. That’s when golfer Jack Nicklaus teamed up with design and building professionals in Ohio. His goal was to convert unspoiled land into a world-renown golf club and living area.

The family-friendly community of Muirfield now boasts nearly 2,400 families. A winding complex of tree-lined streets includes condos, patio homes and single-family homes. And, two Jack Nicklaus golf courses.

Fast-forward about 40 years. That’s when Lephart started lobbying for composite roofing tiles at Muirfield.

The Wenners chose DaVinci synthetic shake for their residence in Findlay, Ohio.

Many of the original shake and slate roofs at Muirfield have deteriorated over time. The Design Control Committee for the development does not allow roof repairs — only roof replacements.

“Design standards are very high at Muirfield,” says Lephart, a licensed general contractor. “For nine years I presented the DaVinci product option because of its high aesthetic and performance values. Recently I met with their board again. New, more progressive people are now on the board. I brought in six boxes of DaVinci tiles and laid them out on the tables. I wanted people to see and feel the quality of the products.”

Thanks to Lephart’s persistence, the Muirfield Design Control Committee finally agreed to allow the installation of DaVinci Multi-Width Shake and DaVinci Multi-Width Slate in their community. Lephart re-roofed his first DaVinci home at Muirfield in late 2019.

“We had a beautiful shake composite in a Chesapeake color installed on a home on Aryshire Drive,” says Lephart. “We see this as a starting point in this community. With the DaVinci product now being an option for homeowners to choose for roof replacements, we believe residents will select the product for its beauty and durability.”

 “We’re confident that we’ll be re-roofing up to 10 houses in this community in 2020,” he continues. “That gets the ball rolling for future composite re-roofing projects in Muirfield.”

Single Home Attention

Lephart and the team at Great Roofing and Restoration put as much attention and effort into single family re-roofing projects as they do into multi-family communities. One example of this is homeowner Steve Wenner, a resident of Findlay, Ohio.

Amid constant worry that his real cedar shingles were blowing off in wind storms, Wenner decided to take action. He began investigating composite roofing options.

“My wife and I liked the DaVinci roofs we saw locally,” says Wenner. “We contacted several roofers and the DaVinci corporate headquarters. They gave us locations throughout northwest Ohio where we could see the composite roofing installed.”

So, the Wenners went on a mini-road trip. They spent an entire day driving around looking at dozens of roofs. And they liked what they saw.

The next step in replacing the 1991 cedar shake shingles on their home came in making the color decision. Wenner did what many homeowners do in the same situation. He took a ladder out and placed the samples on the roof. His wife Nancy stood back and evaluated the color options.

“When Nancy kept coming back to the Mountain blend color I knew we had our choice,” says Wenner. “The combination of the three shades of Mountain tones really complements the other elements of our home exterior.”

After receiving several bids for the project, the Wenners decided they liked the personal attention offered by Lephart and his company. “Selecting Great Roofing and Restoration was one of the best decisions I’ve ever made,” says Wenner. “That roofing crew has an exceptional work ethic. They took care of our property at all times and worked from sun up to sun down. I just can’t say enough good things about working with Great Roofing.”

According to Lephart, the Wenner home was a dream project. “Helping the Wenners gain a low-maintenance, top-quality DaVinci roof means they’ll have years of worry-free enjoyment,” says Lephart. “Demand for composite slate and shake shingles is up in all our locations. From Ohio to Colorado, people want impact- and fire-resistant roofing. They want roofing with a strong warranty and incredibly appealing looks. Basically, they want everything that DaVinci has to offer them in a roofing product.”

TEAM

Roofing Contractor: Great Roofing and Restoration, Cleveland, Ohio, www.greatroofing.com

MATERIALS

Composite Shingles: Multi-Width Shake and Multi-Width Slate, DaVinci Roofscapes, www.davinciroofscapes.com

Illinois Manufacturing Facility Incorporates PV Panels With Roof Re-cover

McElroy Metal’s manufacturing facility in Clinton, Illinois. Photos: McElroy Metal

After completing successful solar panel installations with roof re-covers at plants in Peachtree City, Georgia, and Adelanto, California, McElroy Metal recently completed a third solar conversion at its plant in Clinton, Illinois.

The original R-panel metal roofing on the plant, constructed in the 1970s, was re-covered using McElroy Metal’s 238T symmetrical standing seam roofing. The 238T metal roofing panels were roll formed on site, run directly on to the roof and installed by Prairieland Roofing of Arthur, Illinois. After the new roof sections were complete, Inovateus Solar installed 1,116 Hanwha Q-Plus L-G42 350W panels on the facility using roof attachment solutions from S-5!

The large-scale, multifaceted solar installation at the Clinton plant required a two-pronged approach, as the facility consisted of two different metal roof types: a face-attached trapezoidal profile on one section of the facility and a standing seam profile on another.

S-5!’s engineering team collaborated with McElroy Metal to determine which clamps and brackets were most appropriate based on the two different types of roofs, their respective load capacities, resulting load distribution and best fit of mounting components. They analyzed roof-specific data and CAD drawings to determine precise attachment points across the massive solar array and to determine the bill of materials, including clamps, brackets and PVKITs.

This photo shows S-5!’s S-5-T Mini clamps and PVKIT 2.0 MidGrabs and EdgeGrabs mounted on a McElroy Metal 238T standing seam roofing system.

S-5-T Mini clamps were selected to attach the solar panels to the facility’s new 238T symmetrical standing seam roof system. Featuring a two-piece design to allow easy installation anywhere along the length of the panel seam, S-5-T Mini clamps are specifically designed to fit profiles with a T-shaped seam configuration like the 238T. Beyond the fit, this clamp, in tandem with all S-5! attachment solutions, was specifically load tested on the 238T in the gauge used for the project, enabling comprehensive system engineering specific to this project. This process is routine for S-5!, and the company has more than 500 individual load test results published and accessible on its website.

The solar installation on the facility’s existing Multi-Rib Panel roof system required S-5!’s RibBracket II. These brackets are specifically designed to attach to this type of roof profile. The RibBrackets offered the best fit and provided more than enough tested holding capacity for the dimensions of the rib.

In addition, the entire solar array was mounted using S-5!’s PVKIT 2.0 Solar Solutions, comprised of MidGrabs and EdgeGrabs, which enabled solar installers to mount the solar panels directly onto the clamps and brackets. The pre-assembled components reduced installation time and cost for PV mounting, eliminating the need for an elaborate rail system, while also providing better load distribution into the roof and substructure.

“As a leader in the metal construction industry, we have had the privilege of working alongside McElroy in many venues, industry trade groups and supply relationships, now spanning almost 40 years,” says S-5!’s Founder and CEO, Rob Haddock. “We are proud industry partners and look forward to continuing working together in expanding the use of solar.”

TEAM

Roofing Contractor: Prairieland Roofing, Arthur, Illinois

Solar Installer: Inovateus Solar, South Bend, Indiana, www.inovateus.com

MATERIALS

Metal Roof Panels: 238T, McElroy Metal, www.mcelroymetal.com

Solar Panels: Q-Plus L-G42 panels, Hanwha, www.hanwha.com

Clamps and Solar Attachments: S-5-T Mini clamps, RibBracket II, and PVKITs, S-5!, www.S-5.com

Boulder Lumber Warehouse Needed a Roof Built to Last in Tough Conditions

Boulder Lumber’s 19,512-square-foot warehouse needed a roof that could withstand high winds and extreme weather. Photos: Versico

Since 1927, Boulder Lumber has served the building contractors of Boulder, Colorado, providing lumber, millwork, doors, windows, decking, and other building materials. In 2019, Boulder Lumber’s built-up tar and gravel roof needed to be replaced, largely because of damage caused by wind events. The wood nailer at the perimeter had become dislodged and the built-up system had begun to peel back from the concrete deck.

The city of Boulder is located in the Boulder Valley where the Rocky Mountains meet the Great Plains. Wind uplift is a major concern for buildings in this area, as high winds come off the canyons from the Rocky Mountains. The wind intensifies as it travels over buildings, which creates high pressure at roof perimeters. Winter conditions in Boulder range from mild to bitterly cold, with an average of 88 inches of snow per season.

The unpredictable weather in northern Colorado shortens their roofing season compared to other areas in the country. Winters can be very cold, and the Boulder area receives an average of 88 inches of snowfall per season.

Key Priorities

When selecting a new roof for the 19,512-square-foot warehouse, Boulder Lumber was looking for something with excellent wind uplift resistance to avoid the problems they’d experienced in the past. They also wanted a system that could be installed quickly in a variety of temperatures, since the weather in Boulder can be very unpredictable and the labor market is tight. Lastly, they wanted to work with a skilled, dependable roofer who would get the job right the first time around.

Boulder Lumber enlisted Black Roofing to install a tough, durable roofing system that would be able to withstand the high wind uplift pressures at the perimeter of the roof. Black Roofing suggested Versico’s RapidLock Roofing System due to the ability of this roofing system to perform well in this environment.

The RapidLock Roofing System uses Velcro Brand Securable Solutions’ hook and loop attachment method to provide a fully adhered system without adhesives. The backing on the VersiFleece membrane attaches to a specialized facer on the insulation boards.

RapidLock roofs are designed to be quick and easy to install and there are no installation temperature restrictions, making this system an ideal fit for the Boulder Lumber project. According to the manufacturer, RapidLock installations provide up to 80 percent labor savings compared to traditional bonding adhesive and up to 25 percent labor savings compared to a traditional VersiFleece system.

The Installation

The 20-year-old existing built-up roof system had to be torn off to the structural concrete deck, including scraping residual asphalt.

Because of the damage to the concrete deck, the existing wood nailer was deteriorating. Black Roofing decided to use Metal-Era’s Eliminailer to provide a strong connection on the perimeter and protect the roof against high winds.

Black Roofing used CAV-GRIP 3V to prime the deck. The product promotes adhesion and can be used in temperatures as low as 15 degrees Fahrenheit when used as a primer.

Flexible DASH Adhesive was used to adhere a layer of 1-inch SecurShield Polyiso insulation to the concrete deck. Alan Nedelea with Black Roofing says, “We used Flexible DASH to eliminate any of the fasteners that would have been needed to penetrate into the concrete deck, and also to provide a good adhesion for the wind uplift required for this system.”

A layer of 6-inch SecurShield HD RL was then adhered to the base layer. The product has a specialized facer that allows for membrane attachment without using adhesives.

VersiFleece RL EPDM was attached to the SecurShield HD RL. Black Roofing simply positioned the RapidLock EPDM sheets, removed the release liners, then broomed and rolled the membrane into place. Once the job was complete, a 15-year, 55-mph wind speed warranty was issued.

Nedelea cited the roof system’s wind uplift resistance and the lack of temperature restrictions for installation as the key reasons it was chosen for this project. He also pointed to RapidLock’s labor-saving benefits, which allow the roofing system to be installed in far less time than a traditional roofing system.

“This is the first RapidLock roofing system that Black Roofing has installed,” Nedelea says. “We really enjoyed doing this project.”

TEAM

Roofing Contractor: Black Roofing Inc., Boulder, Colorado, www.blackroofing.com

MATERIALS

Membrane: 115-mil VersiFleece RL EPDM RapidLock, Versico, www.versico.com

Insulation: SecurShield HD RL Polyiso RapidLock Insulation and SecurShield Polyiso, Versico

Metal Nailer: Eliminailer, Metal-Era, www.metalera.com

IMPs Provide Aesthetics, Durability for Houston Renovation

A 70-year-old manufacturing facility in West Houston was transformed into The Cannon, an entrepreneurial hub, office complex and event space. Photos: Metl-Span

Renovating and transforming a 70-year-old manufacturing facility into a contemporary office building with impressive amenities requires some imagination, careful planning and a lot of communication. The Cannon, an entrepreneurial hub in west Houston, also called for more than 90,000 square feet of insulated metal panels (IMPs) for walls and roofing.

The Cannon, a 120,000-square-foot modern, flexible workspace, provides innovators with everything they need to establish a home base for their companies. Home to more than 500 of Greater Houston’s most talented and accomplished entrepreneurs, creatives and small business owners, The Cannon includes 131 offices, 300 open and dedicated desks, a movie theatre, game room, event space, full-service kitchen, a health and wellness room, and a courtyard with outdoor seating. The facility is marketed as “a citywide ecosystem for Houston’s entrepreneurs, small businesses, freelancers and creatives.”

The renovation incorporated more than 90,000 square feet of insulated metal panels for walls and roofing.

Insulated metal panels from Metl-Span helped achieve the desired appearance, inside and outside. “We could have gone the conventional route, with insulation and drywall, but we really wanted to maintain some of the original look of the building,” says Ken R. Harry, AIA, NCARB, LEED AP, Principal of Abel Design Group of Houston. “With the insulated metal panels, we were able to leave the interior beams and columns exposed. Plus, we got the levels of insulation that were required for the roof and walls. Right from the start, it seemed like the logical way to go.”

The original building was stripped down to the steel structure. Some of the 70-year-old purlins and cross members had to be replaced. “We had to verify every dimension of all the beams so shop drawings could be accurate,” says David Baldwin, Sales Manager at FSR Services of Houston. “The beams were painted, and the insulated metal panels were installed. The bright blue beams against the white interior finish of the insulated metal panel is a very modern and clean look.”

The project called for approximately 67,775 square feet of Metl-Span’s CF42R insulated metal roofing panels, with 4 inches of urethane insulation, in the color of Burnished Slate. The exterior panels were 24-gauge Galvalume. The wall panels were two profiles and colors: 37,858 square feet of CF7.2 InsulRib in Burnished Slate and 9,437 square feet of CF36A in Chestnut, both with 22-gauge Galvalume exterior panels. All interior panels were 24-gauge Galvalume in Igloo White.

Baldwin says FSR needed 180 working days to install the IMPs, but crews ran into weather delays during the rainy Houston summer of 2019, which pushed back the original completion date approximately 90 days. The project was completed in August 2019.

“We were basically working in a mudhole all summer,” Baldwin says. “There were a lot of days we couldn’t get anything done. Our equipment was buried in the mud.”

The Cannon is the largest IMP project completed by FSR Services. Baldwin says his team, led by owner Steve Seibert and project manager Tommy Pavlicek, did its best to keep the project moving along. Seibert says it was a challenging project, retrofitting an existing structure, but the end product turned out amazing.

“Insulated metal panels are easy and quick to install,” Baldwin says. “The larger panels cover a lot of space in a single pass. It’s a lot easier than making several passes for the exterior system, interior system and insulation.”

TEAM

Architect: Abel Design Group, Houston, Texas, www.abeldesigngroup.com

IMP Installer: FSR Services, Houston, Texas, www.fsrservices.com

MATERIALS

Roof Panels: CF42R in Burnished Slate, Metl-Span, www.metlspan.com

Wall Panels: CF7.2 InsulRib in Burnished Slate and CF36A in Chestnut, Metl-Span

Dickies Arena Plaza Deck Extends the Experience

The Dickies Arena plaza deck hosts a variety of outdoor events and protects visitors and livestock in the exhibit space below. Photos: Trail Drive Management Corp.

Commemorative events to celebrate the grand opening of Dickies Arena in fall 2019 ranged from a ribbon cutting party to Monster Truck competitions, and performances by Twenty One Pilots, the Black Keys and the Harlem Globetrotters. The arena is home to the Fort Worth Stock Show and Rodeo and other sporting events.

Not all the action takes place under the domed roof, however. The Dickies Arena plaza deck provides not only breathtaking views of the Fort Worth skyline, but offers a high level of functionality, strength and performance to protect visitors and livestock.

According to Bill Shaw, operations manager at Dickies Arena, the plaza is designed to serve as an extension of the rodeo, enabling visitors to watch the livestock from above. Ten-to-12-foot windows built into the plaza deck provide a view of the 100,000 square foot warm-up area where animals work with their handlers before barrel racing and other rodeo events. A roadhouse tent hosts musicians for plaza deck performances held following the rodeo. And instead of a conventional courtyard, Dickies Arena boasts a “cork yard” wine and food space.

Functionality Fuses With Performance

From lush green spaces that provide a scenic vantage point for taking in the iconic Fort Worth skyline and views of nearby barns and stables to fire lanes for emergency vehicles and concert equipment deliveries, Dickies Arena requires a plaza deck that can deliver outstanding strength. And in Fort Worth’s unpredictable weather, it must also successfully manage storm water runoff. The insulation used in the roof — Owens Corning Foamular extruded polystyrene (XPS) — is key to delivering compressive strength and storm water management performance. But the team specifying insulation for this unique landmark encountered some unusual challenges.

Exhibit areas underneath the plaza deck can be configured to house livestock. During rodeos, a warm-up area for horses is set up underneath the pavilion.

With a plaza deck encircling the main arena of about 140,000 feet, the size, scale and slope of the Dickies Arena plaza deck all presented challenges for the insulation team, beginning with the estimating process. The plaza’s design required a blend of tapered, flat filler, and reverse tapered installation.

Each phase was broken into three layers. The reverse taper layer brings the slope of the roof back to a flat slope. The flat fill section raises the height of the roof without adding the weight that concrete would have contributed to the plaza. A traditionally sloped area above the slab and pavers directs water back to the drainage assemblies located in the top layer of the roof. These layers had to be carefully calculated for many sections around the jobsite that changed in priority as construction surged ahead of schedule.

All the calculations required an experienced team who could coordinate and collaborate in real time. Sunbelt Building Services LLC was the insulation distributor on-site and team members’ experience in the roofing industry proved to be an invaluable asset. As Sunbelt prepared the drawings, Owens Corning calculated the insulation estimates by computer and by hand to ensure accuracy, piece by piece, and then Sunbelt reviewed them again. “You’ll never get the correct material count if you don’t know how the roof is sloping, where the drains are located and how to interpret the structural architectural drawings,” says Darrell Evans, project manager at Sunbelt Services. The result of the estimating process showed the collaboration and teamwork were successful. The estimated insulation for one of the first phases was within two pieces of the material used on the jobsite.

Managing Storm Water

Based on the “sandwich” of the roof design, Dickies Arena required two sets of drains sloping in different directions, according to Eric Nelson, AIA, RID, CCCA, and vice president at HKS, the architect of record for Dickies Arena.

The plaza deck had to be designed to withstand heavy stresses including emergency vehicles and equipment deliveries. Owens Corning Foamular extruded polystyrene insulation was specified for its compressive strength and storm water management performance.

The structure has one set of drains at the lowest level, where TREMproof 6100, a waterproofing membrane from Tremco, was hot-mopped into place over the concrete slab. On top of the waterproofing layer is the insulation and filter fabric, as well as the sand bed, Hanover pavers, and planters with trees. Slot drains at the top level collect surface water, and the drains at the lower level collect any water that works its way through that system. Extensive modeling was helpful in determining not only the placement of drains but precisely how much insulation should be used — and its depth and location — in various parts of the plaza deck.

Given all the activity taking place on the plaza roof, material weight was a huge consideration when selecting the roofing insulation. Emergency vehicles must be able to navigate the fire lanes that encircle the deck. Semi-truck trailers need to unload concert equipment and staging. From a building material perspective, the plaza deck supports 5 inches of concrete in addition to the weight of the insulation, with reverse tapering depths varying from 3 to 5 inches. In some areas, the plaza deck’s insulation is 12 to 13 inches deep.

While the project was originally specified to require 100-psi insulation, the team evaluated the Dickies Arena design structure and determined its design would allow weight to be distributed in a way that could be effectively managed by a 60-psi insulation. This exercise in value engineering revealed the lighter compressive strength XPS could deliver required strength and offer better economics. The plaza can support weight loads of 25,000 pounds.

Logistics Require a Team Effort

With the estimating complete and materials specified, supply chain management became an area of focus. Owens Corning worked with its manufacturing plants across the nation to coordinate logistics involved with production of XPS product and delivery to the jobsite.

A best practice on any construction project is to ensure products are not left unprotected and exposed to the elements, so communication and jobsite staging were coordinated between Owens Corning, Sunbelt and various contractors on the job. As XPS continues to expand slightly after manufacturing, the insulation was “aged” for 30 days after it came off the line. Owens Corning production plant teams, product managers and sales managers worked with a dedicated purchase order processor and a team of 20 to manage the plaza deck insulation project through to completion.

This detail from architect of record HKS Inc. shows the “sandwich” design of the plaza roof, which required slot drains at the surface and drains in the underlying slab. Image: HKS Inc.

On the jobsite, tapered pieces were sent up the slope and cut into specific rectangular sizes. Easily cut with a knife, structurally sound XPS isn’t prone to breaking into messy pieces and avoids random materials blowing away from the construction site. Given the sunny and windy climate in Fort Worth, the contractor kept exposed materials protected from sunlight and glued loose pieces together with a product that would not harm the insulation. Ordering the right amount of the right products at the right time was essential when considering up to 700 people were working on the project during peak construction periods.

The effect of the plaza deck gracing Dickies Arena can be summarized by modifying a common statement about Texas: “Everything is bigger and better in Texas.”

About the author: Tiffany Coppock, AIA, NCARB, CSI, CDT, LEED AP, ASTM, RCI, EDAC is the Commercial Building Systems Specialist at Owens Corning where she provides leadership in building science, system development, testing, and documentation.  

TEAM

Architect of Record: HKS Inc., Dallas, Texas, www.hksinc.com

Plaza Deck Installer: Sunbelt Building Services LLC, Dallas, Texas, www.sunbeltllc.com

MATERIALS

Waterproofing Membrane: TREMproof 6100, Tremco, www.tremcosealants.com

Insulation: Foamular 600, Owens Corning, www.owenscorning.com

Brick Pavers: Hanover, www.hanoverpavers.com