Historic Fleur du Lac Estates Gets New Synthetic Shake Roof

Fleur du Lac Estates is now a private condominium development located on the shore of Lake Tahoe. The Yacht Club and Boat House were the first structures to be re-roofed with synthetic shake. DaVinci Roofscapes

A prime filming location for the 1974 movie “Godfather II,” historic Fleur du Lac Estates in California is now a private condominium development located on the beautiful west shore of Lake Tahoe. A Yacht Club and Boat House, 22 individual homeowner units and a variety of shared recreational facilities make the historic 1938 compound a much-sought-after retreat.

Years of harsh weather conditions had taken their toll on the real cedar shake roofs at Fleur du Lac Estates. Damage from repeated leaks, hail, ice dam issues, snow and other weather conditions recently convinced the board of directors it was time to invest in new roofs for the entire estate.

Homeowners at Fleur du Lac Estates looked for a product that would mimic the look of cedar, but bring them advantages to protect their homes and buildings from Mother Nature. After a comprehensive search, they determined that the Class A fire and Class 4 impact ratings of Bellaforté polymer shake tiles from DaVinci Roofscapes met their needs.

“We started with our two most valuable community structures, the Yacht Club and Boat House,” says Stewart Dalie, maintenance supervisor and project manager at Fleur du Lac Estates in Homewood, California. “Our plans are to re-roof all of the buildings in the Tahoe Blend over the next five to seven years. We did a tremendous amount of research to determine what roofing products would look realistic in this setting, meet the new codes required for roofs in our area, yet offer us superior qualities and a long lifespan.”

“Selecting the fire- and impact-resistant Bellaforté shake material from DaVinci Roofscapes means we won’t have to be concerned with the potential spread of flames should our area ever be touched by wildfires,” Dalie continues. “That’s a huge concern for our geographic area. However, not having to worry about wind-blown embers landing on a roof and then catching the building on fire is a tremendous relief.”

The Class A fire and Class 4 impact ratings of the Bellaforté tiles bring peace-of-mind to residents within the community. The durable roofing tiles have the appearance of natural hand-split cedar shake with slanted sawn edges and staggered lengths, but with the hassle-free qualities of a manufactured product. At a 1-inch average tile thickness, Bellaforté Shake roofing tiles remind many residents of jumbo cedar shakes prevalent in the Lake Tahoe area.

Safeguarding a Historic Setting

It’s not surprising that homeowners at the upscale Fleur du Lac Estates want to invest in the best possible roofing material. This is a mountain and lakeside homeowners association where every home has a deeded slip in the marina, resort-style services are the norm and aesthetics of the community are vigilantly upheld.

Owners chose the Bellaforté polymer shake tiles from DaVinci Roofscapes, which offered Class A fire and Class 4 impact ratings. Photos: DaVinci Roofscapes

Originally the summer home of famous industrialist Henry J. Kaiser, the 15-acre lakeshore site was constructed beginning in 1938. After Kaiser sold the estate, it went through a series of transitional uses from the 1960s to 1979, including serving as a private school and as the site for many on-location scenes for Francis Ford Coppola’s film, “The Godfather II.” Only in the 1980s did the current project begin to refurbish existing key structures and transform original homes on the property to individually-owned homes.

“Our community has always embraced the history of this setting while looking toward protecting its future,” says Lane Murray, general manager at Fleur du Lac Estates. “That’s one of the key reasons we wanted a roofing product that has the look of real cedar shakes, but with man-made advantages like resistance to fire, impact and high winds.”

Despite a variety of challenges with removing the old roofs and prepping for the new synthetic shake tiles, the team at Bruce Olson Construction has successfully tackled their first DaVinci Roofscapes installation project at Fleur du Lac Estates.

“The roofing surface for the Yacht Club and Boat House were in bad shape and very uneven,” says Taylor Greene, general manager of Bruce Olson Construction in Tahoe City, California. “We had to plane these into workable surfaces before getting started. Once we got started the product installed beautifully. We added flashing material to cover some valley locations which made the project look exceptional. To achieve the realistic look, gable end flashing that concealed the manufactured edge of the DaVinci product was added.”

The company, which does residential and multi-family new construction work in several states including Hawaii, has already started work on several additional roofs in the Fleur du Lac complex.

“The Bellaforté roofing looks amazing,” says Greene. “Best of all, these polymer shakes are perfect for this geographic area. Traditional wood shakes ‘hold’ the water from melting snow. Those saturated shakes weigh more and cause the freeze line to be a part of the shake. With the DaVinci product, the water is not absorbed into the tile, so snow melting is faster and more efficient. This can also help reduce the ice damming effect in many locations.”

Laughing at Mother Nature

Nestled amidst stunning mountain peaks and world-famous ski conditions, Fleur du Lac Estates can experience heavy snowfall during the winter months. The property is just five minutes from Homewood Mountain Ski Resort, and the area usually sees snow in excess of 180 inches total. That’s one reason why the community decided to have the Bruce Olson team incorporate snow fences and snow guards from Rocky Mountain Snow Guards into the structures.

Photos: DaVinci Roofscapes

“In our area, it’s very common to use snow guards and fences to help keep snow from falling on individuals and property,” says Greene. “The previous structures at Fleur du Lac Estates didn’t have any type of snow retention system. We believe having these products in place now — which were very simple to put in during the polymer shake installation — will make life much easier for property owners no matter how much snow Mother Nature delivers each season.”

Rocky Mountain Snow Guards custom designed the snow retention system for Fleur du Lac Estates incorporating both their Drift III+ snow fences and the company’s Rocky Guard RG10 snow guards. The system was developed to handle the 180 PSF snow load that can occur in this geographic location.

“The snow guards are attached in a pattern above the snow fence that creates friction to hold the snow slab in place while the snow fence provides a barrier beyond which the snow slab won’t slide,” says Lars Walberg, president of Rocky Mountain Snow Guards. “Using the combination of snow guards and snow fences gives this project a balanced snow retention system that has the look the owners desired.”

For homeowners, the new Bellaforté roofs on the Yacht Club and Boat House are tempting reminders of what will come on their own homes within the community in the years to come.

“Now that the Yacht Club and Boat House roofs are complete, we’re hearing very positive comments from our residents,” says Murray. “Folks are eager for the work to continue in the common areas so that their individual homes can soon get these terrific-looking new roofs.”

Metal Roof and Wall Panels Capture the Spirit of Shakespearean Theater

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

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

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

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

The Metal Roof System

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

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

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

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

The TPO Roof System

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

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

The Installation

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

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

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

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

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

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

Planning Ahead

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

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

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

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

TEAM

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

MATERIALS

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

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

Expert Crew Is Called in for Copper Roof Restoration Project

The dome on the Bradford County Courthouse was restored with copper panels during the first phase of a $3 million renovation project. Photos: Charles F. Evans Roofing Company Inc.

The octagonal dome atop the Bradford County Courthouse has been a fixture on the Towanda, Pennsylvania, skyline for more than 120 years. It now shines brightly after being restored with copper panels as part of a $3 million renovation project.

Built in the Classical and Renaissance revival styles in 1898, the four-story courthouse was placed on the National Registry of Historic Places in 1987. The dome’s original roof tiles were recently replaced as part of the project, which also included the complete restoration of the structure’s main roof.

The Charles F. Evans Company Inc., the union division of Evans Roofing Company Inc., headquartered in Elmira, New York, has a long history of successfully tackling projects with historical significance. C&D Waterproofing Corp., the general contractor on the project, reached out to the firm for support assessing the roofing portion of the project. The two companies teamed up on the project, with C&D Waterproofing handling the masonry restoration work and Charles F. Evans Company installing the roof systems.

The roofing work consisted of two phases. Phase One, which began in April of 2016, involved replacing the deteriorated terracotta tiles on the dome with soldered flat seam copper panels. Phase Two, which began in April of 2017, involved installing batten seam copper roofing on main structure and new copper flashings, gutters and downspouts.

Safety First

Construction Manager Bill Burge of Charles F. Evans Company was thrilled to be part of this historic project. Before

Originally completed in 1898, the courthouse was placed on the National Registry of Historic Places in 1987. The building’s main roof was removed and replaced with a copper batten seam roof after work on the dome was completed. Photos: Charles F. Evans Roofing Company Inc.

concentrating on the installation details, he knew the company would focus on the top priority. “Safety is number one,” says Burge. “Safety comes before profits. Safety comes before everything. We always want to make sure we have the right safety plan going into the job, and throughout the job, we are maintaining that plan and working that plan. We want our guys to go home to their families at the end of the day, so that’s key for us.”

Burge worked as a union carpenter for 10 years before joining the company more than seven years ago. He found he had an affinity for sheet metal work. “The craftsmanship and quality goes hand in hand with carpentry,” Burge says. “Everything starts with the carpentry. You have to have your base perfect; otherwise, everything from there on out doesn’t work. Sheet metal is a finished product, typically, especially in our business, so things have to be done right. Things have to be done to the highest standard of quality, because that’s what people see.”

The dome was designed to be a showpiece, and Field Superintendent Brian Babcock and his crew of qualified union sheet metal mechanics knew they would be held to an exacting standard. “The key to this project and every project is our talented mechanics in the field,” Burge says. “Charles F. Evans Company is nothing without this talent—they deserve all of the credit.”

Around the Dome

Phase One began with the removal of the tiles on the dome. “The ceramic tile was laid over open steel purlins,” Burge notes.

Charles F. Evans Roofing Company handled the roofing portion of the project, while C&D Waterproofing Corp. served as the general contractor and performed masonry restoration work. Photos: Charles F. Evans Roofing Company Inc.

“There was open framing with quarter-inch steel angle for the purlins, and each piece if tile was wired on. The removal process was fairly simple. You could actually lift up the bottom of the tile and snap it off.”

The removal work had to be done in sections and dried in every night. “One of the hardest things about this process was we had to install two layers of half-inch plywood over the steel purlins and anchor those down,” says Burge.

The plywood was attached to vertical two-by-fours, which were screwed into the purlins. The plywood was covered with one layer of Warrior 30-pound felt paper, Meadows Red Rosin Paper, and Grace Ultra High Temp underlayment in gutter areas.

The built-in gutter at the base of the dome was torn out and re-framed. The new gutter was wider and deeper according to the recommendation of Levine & Company Inc., the architect on the project. “We did everything to specification as Levine & Company drew it,” says Burge.

Once the cladding was completed on the gutter, the copper panels of the dome were installed. The 20-inch panels were made of 20-ounce, cold rolled copper, supplied by Revere Copper Products. Both the panels and cladding were fabricated in Charles F. Evans Company’s fabrication shop. The copper panels clip to each other and have a hem on four sides that clips

Custom flashing pieces were fabricated and installed where the copper roof panels met the base of the dome. Photos: Charles F. Evans Roofing Company Inc.

to the adjacent panel fastened to the deck. At the top of each panel, a hook clips off to the plywood, and the hook is covered by the panel directly above it.

Burge points out that the octagonal structure of the dome helped speed up the installation of the copper panels. “There are eight hips on the dome,” he notes. “Every section of the dome is like a piece of pie, basically, so we were able to start the panels in various locations. We didn’t have to start at one end and go around the dome. We could move around.”

Repairing the statue on the top of the dome was also part of the scope of work. “We soldered copper patches on any damage the statue had,” Burge says. “C&D Waterproofing completely cleaned and buffed the statue and applied a copper coating.”

Across the Roof

After the work on the dome was completed, work began on the main roof. The existing roof was removed down to the existing steel deck. The lower roof also had a built-in, copper-clad gutter that had to be removed and reconstructed. After

Scaffolding systems were constructed for both phases of the project. Shown here is part of the system installed around the lower roof, which featured planks and guardrails at the eave and rake edges. Photos: Charles F. Evans Roofing Company Inc.

the gutter was completed, work on the main roof began. “After we completely cleaned the metal decking, we had to install a layer of Grace Ultra High Temp underlayment,” Burge recalls. “We then installed two-by-four wood sleepers, 2 feet on center.”

Crews installed 1.5 inches of polyiso insulation between the two-by-fours, followed by another 1.5-inch layer of polyiso. Pieces of 5/8-inch plywood were then screwed down to the sleepers. The plywood received 30-pound felt, and the battens were installed 20 inches on center. The seams were completed using a custom-designed mechanical seamer manufactured by Roll Former Corp.

Installation of the 12,000 square feet of copper panels went smoothly, but where panels met the dome, details were tricky. “Everything is pitched, and the dome has eight different sections sitting right in the center of the structure,” Burge explains. “A lot of time and energy went into fabricating and installing custom flashing pieces at the base of the dome.”

The Safety Plan

A scaffolding system was the key to the safety plan for both phases of the project. “For Phase One, we had to remove a portion of the roofing system and put down some plywood on top of the existing roofing in order to build a scaffold to access the dome,” Burge says.

This photo shows the main roof before restoration work began. Photos: Charles F. Evans Roofing Company Inc.

Scaffolding was constructed to the eave edge of the copper dome, allowing the gutter to be removed. Ladders were used to access the dome and personal fall arrest systems were attached into HitchClips from Safety Anchor Fall Equipment, LLC, which served as individual anchor points. “We continued that process as we went up, using ladder jacks,” says Burge. “We continued with that plan, and never deviated.”

After Phase One was completed, the scaffolding was removed, and another scaffolding system was installed around the entire lower roof. Phase Two required planks and pre-engineered guardrails at the eave and rake edges. “Part of process of installing this roof included installing new safety anchors at various locations, and as we finished up, we were able to use those anchors as tie-off points,” Burge points out.

Phase Two is scheduled for completion in early November, and Burge has high praise for everyone involved with the project. “Levine & Co. Inc. is the architecture firm on the project,” he says. “We didn’t deter from any details developed. They drove this thing. We have worked with them on a great many projects in the past, and we have a great comfort level with them.”

Copper panels, cladding and details were fabricated in Charles F. Evans Company’s metal shop. Photos: Charles F. Evans Roofing Company Inc.

The masonry and roofing work had to be well coordinated. “C&D Masonry & Waterproofing progressed ahead of us with items that we needed to be done, and then came back behind us to mortar all of the counter flashings back into the dome,” Burge says. “They were right there with us every step of the way.”

Finding the right combination of workers for this project was crucial, according to Burge. “We had one of our best crews on this project for a reason,” he says. “This project was led by Brian Babcock of Sheet Metal Local 112, and he was essential in putting this whole thing together. He’s been with Charles F. Evans Company for 20 years, and his leadership and focus is the reason this project is going to be successful.”

Ornate sheet metal work is rare these days, but the art is not lost at Charles F. Evans Company. “We’ve been doing this work for 60-plus years,” Burge says. “This knowledge and this workmanship has been handed down generation after generation. We wouldn’t have taken on this project if we didn’t have the confidence in our employees that we do.”

Historic restoration projects are becoming an increasingly bigger chunk of the company’s portfolio, notes Burge. “We do a lot of work with older universities and businesses that have these types of buildings,” he says. “A lot of buildings need this type of work, and it’s a trade not everyone else has. This is a craft that takes years to master. We harness that, we build from within, and we bring in young guys and teach them how to do it the right way. We have a great mix of people ages 23 up to 60, and it’s learned, it’s taught, and it’s preached.”

Burge is hopeful the new roof will last at least as long as its predecessor. “This is the one thing that makes Charles F. Evans Company special to me: the fact that what we do from an architectural sheet metal standpoint, from a slate, copper, tile roof standpoint—these roofs will last 100, 150 years, and it is artwork,” he says. “The fact that you’re a part of something that’s been around since the turn of the last century—to me it doesn’t get any better than that.”

TEAM

Architect: Levine & Company Inc., Ardmore, Pennsylvania, Levineco.net
Construction Manager: C&D Waterproofing Corp., Bloomsburg, Pennsylvania, CDwaterproofingcorp.com
Roofing Contractor: Charles F. Evans Roofing Co. Inc., Elmira, New York, Evans-roofing.com

MATERIALS

Copper Supplier: Revere Copper Products, Reverecopper.com
Synthetic Underlayment: Grace Ultra High Temp, GCP Applied Technologies, GCPat.com
Mechanical Seamer: Roll Former Corp., Rollformercorp.com
Anchor Points: HitchClip, Safety Anchor Fall Equipment, LLC, Hitchclip.com

Restoring the Saskatchewan Legislative Dome Is a Labor of Love

The Saskatchewan Legislative Building in Regina was originally completed in 1912. The structure had undergone deterioration due to poor drainage around the dome, and a restoration project was initiated to repair the masonry and restore the copper dome. Photos: Ministry of Central Services, Government of Saskatchewan

“At the end of the day, why do we go to cities?” asks Philip Hoad. “We go to cities to look at their beautiful old buildings. We don’t generally go to look at their skyscrapers. It’s the old building that gets our minds and hearts working. When you go to a city and look at these old buildings intermingled with new buildings—that’s what gives a city life.”

Hoad is with Empire Restoration Inc., headquartered in Scarborough, Ontario, Canada. He’s been restoring historic buildings for some 30 years, and when he found out about the project to renovate the dome on the Saskatchewan Legislative Building, he knew it was a once-in-a-lifetime opportunity. “The architect put out a pre-qualification across Canada, and four firms were successful. We were one of them,” he remembers. “Then we ended up securing the tender bid. I’ll never forget it because I did the tender estimate just after a hernia operation in my dressing gown. It was really a project I won’t forget.”

The building was originally constructed in Regina, Saskatchewan, between 1908 and 1912, and it serves as the seat of government for the province and houses the legislative assembly. Designed by architects Edward and William Sutherland Maxwell of Montreal in a mix of English Renaissance and French Beaux-Arts styles, the building features ornate stone elements and unique decorative copper finishes that accent its iconic copper-clad dome. It is designated as a National Historic Site of Canada and a Provincial Heritage Property, and is subject to strict regulations regarding materials and methods of repair.

Work on the dome was carried out in a fully enclosed and heated temporary structure that allowed crews to continue throughout the winter months. Photos: Ministry of Central Services, Government of Saskatchewan

The structure has undergone some restoration work over the past 100 years, but in 2013, planning began for a conservation project designed to repair and restore the tower. The reasons for the project were twofold, according to Hoad. “First of all, the copper panels were blowing off, and somebody had re-secured them with face screws back in the ’60s or ’70s. But more importantly, the water was coming off the dome and damaging the stone below it. The dome was originally never designed with gutters, and then they later put gutters on, and these failed. So those were the two things that drove the project in the first place.”

Hoad knew the project would be challenging, but it he was confident that his company had the experience and passion to handle it. “These projects come along, for most of us, once in a lifetime,” he notes. “It’s the scale and the detail and the level of commitment that you need to restore an old building that sets us apart from, say, new construction. It’s not cookie-cutter. Everything is different, and you never know what you’re getting into—although with our experience, we’ve done so many old buildings we sort of know what we’re going to run into. All of the people who work for us love to work on these old buildings. It’s very satisfying at the end of it.”

The goals of the project were perfectly aligned with Hoad’s business philosophy. “When I start with an old building, I don’t want to change it,” he says. “It might look a little newer, but I want it to be the same as when we found it. I don’t want it to stand out as a brand-new building. We just want it to last another 100 years and to know that we’ve helped preserve it for future generations.”

The ornamental copper elements were restored and reset over the new copper panels. Photos: Ministry of Central Services, Government of Saskatchewan

Repairing the Substructure

Work on the dome was more complicated than initially thought. During the pre-construction condition survey and assessment, additional problems were discovered by the conservation architect, Spencer R. Higgins of Toronto. “Once the architect had done all his work and surveyed the building, they also realized the original woodwork was not quite up to snuff,” Hoad explains. “Basically, much of the original wood framing was made up of old pallets. It was quite remarkable. So structurally, we had to re-frame the hips, which we call the ribs. We completely removed the old pallet framing and re-framed it. We also tried to straighten the slight twist in dome, but it wasn’t easy to do since it was a poured concrete structure underneath.”

New ribs were constructed out of Douglas fir plywood using a CNC machine from 3-D architectural drawings to create templates. It was also necessary to remove and replace approximately 40 percent of deteriorated wood deck on the concrete dome, with both the interior and exterior surfaces of the concrete being repaired by the general contractor on the project, PCL Construction Management of Regina. “Re-framing the ribs was quite a challenge,” notes Hoad. “Once the concrete deck was repaired, we screwed new Douglas fir roof boards into the repaired concrete dome, added an air vapor barrier, Roxul insulation, wood nailers and an additional layer of Douglas fir roof boards, with housewrap and asphalt saturated roofing felt as the underlayment system for all the new copper roofing and cladding that would follow.”

Internally drained stainless-steel gutters were installed at the base of the dome. The gutters were lined with sheet lead. Photos: Ministry of Central Services, Government of Saskatchewan

After the masonry restoration was completed by RJW-Gem Campbell Stonemasons of Ottawa, Empire Restoration installed new gutters at the base of the dome. According to the architect’s design, heavy stainless-steel plate gutters were formed and then lined with sheet lead. Projecting stone cornice ledges were also covered in sheet lead.

Restoring the Copper Dome

The existing 16-ounce copper panels were all removed, and they were replaced with new 20-ounce panels recreated to match the original sizes and profiles. More than 20,000 square feet of copper panels were custom fabricated and installed. Great care was taken to carefully remove and restore decorative elements, including the copper garlands.

Decorative elements that could be saved were installed on new brass armatures. The dome is topped by a cupola and lantern, which were carefully restored. “The mantel on the very top, we didn’t strip that off,” Hoad notes. “We just replaced and repaired selective components, so that’s why you have a mix of old and new.”

Logistics at the job site were well coordinated. “Access was quite remarkable because PCL had erected a steel frame onto which we erected scaffolding, so the dome was right there in front of us,” Hoad notes.

Cornice sections were restored, and extensive sheet lead flashings were installed over stone cornices and ledges. Photos: Ministry of Central Services, Government of Saskatchewan

When working on the dome itself, crew members had to be tied off with personal fall arrest systems, as it was possible to slip through gaps between the scaffold decks and the dome roof surface. Weather was not an issue, as the steel frame structure was totally enclosed with a heavy-duty insulated tarp system. “We had our own ventilation system, we had a heating system, we had electricity up there, we had pneumatic power—we basically had everything up there. PCL had it well set up for the various trades. There was a large crane on site to hoist all our materials up.”

Hoad cites the sheer size of the project as one of his greatest concerns. “The biggest challenge was just the scale of the project, being able to produce the amount of work necessary and get the job done in the prescribed time,” he says. “It was a lot of the same thing, albeit with some very complicated detailing. We had multiple skill sets on the site dealing with multiple materials and details.”

The project has won numerous awards, including a 2017 North American Copper in Architecture Award from the Copper Development Association. Hoad is proud of his company’s role in the project but relieved it is completed. “During it, I was at times tearing my hair out,” he recalls. “It was a very high-pressure project that lasted a long time. It was three or four days a week of constant men, materials, equipment, meetings, details, changes, extras, credits. From start to finish, it was two years of my life.”

The cupola and lantern at the top of the dome were repaired in situ. Photos: Ministry of Central Services, Government of Saskatchewan

Despite the pressure, Hoad found the work extremely satisfying. “What we are doing is permanent and built to last for future generations,” he says. “We’re using natural, traditional building materials of stone, wood, copper and other noble metals. That’s what drives me to love the industry and my job—because it’s permanent, sustainable and it’s for future generations.”

After all, it’s often the roof and flashings that play one of the most critical roles in fighting the elements of weather, notes Hoad. “Roofing and sheet metal deficiencies is where much of building damage and deterioration starts,” he says. “You can repair a masonry wall, but if you don’t stop it getting saturated, it’ll just deteriorate again in another few years. Regina was a good example of that. We’ve now provided great protection to these beautiful stone elements, allowing them to last another 100 years.”

TEAM

Conservation Architect: Spencer R. Higgins, Architect Incorporated, Toronto, Ontario, Higginsarchitect.com
General Contractor: PCL Construction Management, Regina, Saskatchewan, PCL.com
Sheet Metal Contractor: Empire Restoration Inc., Scarborough, Ontario, EmpireRestoration.com
Masonry Contractor: RJW-Gem Campbell Stonemasons Inc., Ottawa, Ontario, RJWgem.com

MATERIALS

Copper: 20-ounce copper sheet metal
Wood Framing: Douglas fir
Insulation: Rockwool Rigid Insulation, Roxul, Roxul.com

Striking Asphalt Shingle Roof Tops the Restored Music Hall in Cincinnati

Originally designed by Samuel Hannaford in the 19th Century, the Music Hall first opened its doors in 1878. The Music Hall Revitalization Company coordinated the restoration of the 139-year old Cincinnati landmark, which just reopened to the public Oct. 6, 2017.
Photos: CertainTeed

The Cincinnati Music Hall is considered one of the largest and most beautiful concert halls and theaters in the world. It has played host to iconic performances and events for more than a century, from the 1880 Democratic National Convention to performances that helped shape the American arts scene.

A vision and product of 19th century architect Samuel Hannaford, Music Hall—as it’s known across the Queen City—first opened its doors to the public in 1878. Yet the doors on the 225,000-square-foot facility have been closed since May 2016 to allow for a complex interior and exterior restoration effort that would propel the aging building into the modern era while also preserving its beautifully unique characteristics.

The Charge

Restoring the beauty of Hannaford’s showpiece was more than a simple facelift. According to the Music Hall Revitalization Company, the nonprofit coordinating and leading the renovation, engineers investigating the building discovered structural deterioration beyond what one would expect in a 139-year old building, and recommended actions secure the Music Hall’s long-term viability.

The $135 million Music Hall renovation began in the spring of 2016, with the Cincinnati Center City Development Corporation (3CDC) overseeing construction. Following a rigorous request for proposals, 3CDC chose Imbus Roofing to install the new roof.

The Music Hall has been traditionally adorned with high-end shingles, and Grand Manor luxury asphalt shingles from CertainTeed were chosen to replicate the slate aesthetic and stand up to the elements. Photos: CertainTeed

Principal Daniel Imbus and his team were more than up to the task. Not only had Imbus Roofing performed the bulk of the roofing work at Music Hall over the past few decades, they have a rich legacy in the greater Cincinnati area. Among the other high-profile projects with connections to Imbus roofing are the Proctor & Gamble Twin Towers, the Walnut Hills Copper Dome, Paul Brown Stadium and the original Riverfront Stadium.

The team at Imbus worked closely with 3CDC, PWWG Architects and local distributor Midwest Roofing Supply to nail the aesthetic and capture the original essence of Music Hall.

“The roof replacement was a big part of the project, not only for protecting all the interiors that were being restored or replaced, but for the overall look of the building,” Imbus explains. “With the older building and the amount of other work being performed, just getting around the building and scheduling work around other trades such as painting, masonry, HVAC, etc., required a lot of planning.”

The Installation

Imbus partnered with Seth Dorn, branch manager at Midwest Roofing Supply, to find the appropriate materials to for the front towers, Corbett Tower, and Opera House portions of the roof. According to Dorn, the Music Hall has been traditionally adorned with high-end shingles, so they chose Grand Manor luxury asphalt shingles from CertainTeed to replicate the slate aesthetic and endure the wind, rain, snow and other elements typical to Cincinnati. To recreate the distinctive striped pattern of the roof, crews installed approximately 600 squares of Grand Manor shingles in two colors, Stonegate Gray and Brownstone.

The roof’s distinctive striped pattern was recreated with 600 squares of Grand Manor shingles in two colors, Stonegate Gray and Brownstone. Photos: CertainTeed

“We serviced Imbus Roofing with all potential materials for the project,” Dorn notes. “In addition to the shingles, we supplied DiamondDeck and WinterGuard underlayments from CertainTeed to further enforce weather protection.”

A large part of the roof replacement was the Main Hall, which sits above lower sections of the building and has a steep slope. To perform this installation, the Imbus Roofing team had to build scaffolding along the full gutter lines to provide safe and secure roof access and work platforms.

“With the steep slope of the roof, the shingles are an integral part of the exterior look of this historic building,” says Imbus. “It’s an introduction to the amazing interior renovation and exterior restoration.”

The Reopening

The project, more than seven years in the making, was completed on Oct. 1, 2017. The doors officially re-opened on Oct. 6 to kick off a weekend of events that included an opening night gala, a community Open House, and a pair of concerts featuring the Cincinnati Symphony Orchestra.

“It looks awesome,” reflects Dorn. “We will spotlight this job for all of our contractors and customers.”

“We had a great experience with this project,” Imbus adds. “It was a quick schedule with a lot of work to a signature building of Cincinnati. It is great being a part of a successful project that I think will impress everyone in the community.”

TEAM

Developer: Cincinnati Center City Development Corporation (3CDC), Cincinnati, 3CDC.org
Architect: PWWG Architects, Pittsburgh, PWWGgarch.com
Project Coordinator: Music Hall Revitalization Company, Cincinnati, Musichallcincinnati.org
Construction Manager: Messer Construction, Cincinnati, Messer.com
Roofing Contractor: Imbus Roofing, Wilder, Kentucky, Imbusroofing.com
Local Distributor: Midwest Roofing Supply, Cincinnati, Midwestroofingsupply.com

MATERIALS

Steep-Slope Roof System: Grand Manor luxury asphalt shingles, CertainTeed, CertainTeed.com
Underlayments: DiamondDeck and WinterGuard, CertainTeed

Orlando Airport Project Necessitates Custom Fabrication, Precise Installation

 

Work on the first phase of the Orlando International Airport expansion project includes the South Airport Intermodal Terminal Facility and APM Complex, which features a standing seam metal roof

Architectural Sheet Metal Inc. has been in servicing the Orlando area for more than 23 years, specializing in commercial metal roofs and wall systems, primarily new construction. When Matthew Leonard, the company’s vice president, found out that the Orlando International Airport was proposing a new terminal project with a metal roof, he jumped at the chance to submit a bid.

He wanted to land the job because it would be the largest project the company has ever tackled, and one of its most prominent. He also wanted it for another reason—he knew he’d see it every time he drove to the airport. “For many years now, we’ve specialized in standing seam metal roofs. It’s our bread and butter,” he says. “We’ve done lots of schools, government building, military bases. It’s just something we enjoy doing. When this project came around, right here in our backyard, we knew we wanted to take it on. It’s larger than anything we’ve ever done, but it’s our specialty.”

The South Airport Intermodal Terminal Facility and APM Complex is a new construction project that coordinates mass transit for the airport, including regional rail systems and the Automated People Mover (APM). It’s part of the first phase of an ambitious $2 billion plan to almost double the size of the airport.

Architectural Sheet Metal installed the Berridge standing seam metal roof system, as well as internal aluminum gutters and a custom-fabricated aluminum bullnose that runs along the perimeter of the roof

The building encompasses approximately 200,000 square feet, and the structure is primarily covered with a standing seam metal roof. The scope of work for Architectural Sheet Metal included installing the metal roof system and internal aluminum gutters. It also included custom fabrication and installation of an aluminum bullnose that runs along the perimeter of the roof. “Every roof is radiused, and some sections have compound double raiduses,” Leonard notes. “The trickiest part of the project is probably the bullnose because all of the gable ends of the roof are radiused, and the large bullnose has to be welded on in 30-foot sections.”

Another tricky thing about the project is that the work was divided into two different contracts with two different construction managers. On one side of the building, which houses the monorail and parking garage, the project is overseen by Hensel Phelps, and on the other side, which handles the train lines, the construction is overseen by a Turner-Kiewit joint venture. The dividing point is a building expansion joint that runs across the middle of the roof. “We’re one of very few subcontractors out here that has a contract with both of the construction managers,” Leonard says. “They both have their own agendas, their own timelines, and their own completion dates, and it was a delicate balancing act working with the two of them.”

Installing the Roof

The roof system was designed to unify the elements of the structure and tie the building together. Some sections of the roof cover the building, while others serve as canopies, so there are two types of metal deck on the building. “The area we call the spine has a 3-inch-thick acoustical deck,” Leonard explains. “That was interesting because before we could put our 6 inches of polyiso on, we had to install batten insulation in the flutes. The acoustical decking is perforated, so you can see through it. That’s a little different, when you’re so high up. It spooked the guys at first to be able to see right through it.”

Crews dried in the entire roof with a waterproofing underlayment from MFM Building Products specifically designed for high-temperature applications.

The other sections were comprised of standard type B metal deck. Sections covering the interior were insulated, while canopy sections were covered with 5/8-inch DensDeck from Georgia-Pacific.

Crews from Architectural Sheet Metal dried in the entire roof with a peel-and-stick waterproofing underlayment from MFM Building Products specifically designed for high-temperature applications, MFM Ultra-HT. “It’s easy to install,” notes Leonard. “That’s our go-to underlayment for metal projects.”

After the underlayment was applied, the welded aluminum gutters were installed. “The longest piece was 78 feet,” says Leonard. “We fabricated the sections, water-tested them and shipped them out. We used a crane to lift them to the roof.”

The roof system was supplied by Berridge Manufacturing, and the 24-gauge galvalume metal panels were roll formed at the site. “Berridge has a ZEE-Lock double-lock standing seam panel,” Leonard says. “We own one of their portable roll formers, and we have it on site here. We pick it up with a crane, and lift it up to the edge of the roof, and we actually roll form our largest panels straight out to the roof. The guys just catch the panels as they come out of the roll former.”

Metal roof panels were roll formed at the site. For most roof sections, the roll former was hoisted by a crane, to the edge of the roof, and crew members stacked the panels as they come out of the roll former.

Panels were stacked in piles of 10 for installation. There were 12 different roof surfaces, so as the roll forming crew moved along, other crews would start installing the panels. “Every stack was tied down with strapping to ensure that it wasn’t susceptible to wind,” Leonard points out. “With a hurricane in the forecast, we were very careful about that.”

The panels in the spine area had a tighter radius, so those panels were formed on the ground using separate curving machine. Lining up the panels perfectly was critical. “With a radiused roof, it’s sometimes harder to find things to measure off to ensure your panels are straight. This panel is a left-to-right system. It’s a male-female overlay with a continuous clip that Berridge manufactures. The panels are hand-crimped together, and then you do the first and second stage of the double-lock panels with an electric seamer. You just turn it on and it goes up and over.”

Details, Details

Fall protection posts were installed during the framing process, which helped with safety planning but posed problems when it came to detailing. “It’s nice to have permanent fall protection points to tie into, as everyone had to be 100 percent tied off, but there are close to 200 fall protection posts on the project that we had to cut around and flash,” Leonard says. “I’ve never seen so many posts on a roof like that.”

The aluminum bullnose was constructed after precise measurements were taken at the site. After they were custom painted to match the roof, the 30-foot sections were lifted into place and installed.

Because the posts were tied into the structural steel and couldn’t be moved, the company designed and manufactured a welded aluminum flashing detail to ensure they all looked the same no matter where they landed in the panel profile. “We set up a welded aluminum flashing that should last forever, and it’s welded, so it shouldn’t leak. We try to go above and beyond in our flashing details.”

Leonard points to his company’s fabrication experience as a key to its strength. “We try to be more than just a roofing company,” he says. “We try to be a custom metal fabrication company that fabricates the panels to precise specifications determined by the site. We custom fabricate metal and then, as roofers, we install it. We like to have that double whammy. Not many people have that ability to do both.”

The company’s expertise came in handy on the bullnose. “The bullnose was originally bid as 22-gauge metal,” he says. “We looked at it and we didn’t like it. It’s a large, 9-inch radius, and we felt the thin, light-gauge metal would shake in the wind. Every 10 feet would be a lap joint with caulk, which would be susceptible to wind damage. We came up with the idea of using a welded piece of .080 aluminum. Once it was approved, we purchased a 100-ton press brake with a custom die to fabricate this bullnose.”

The bullnose was constructed from precise measurements taken at the site. “We took the radius off of the building and created jigs in our warehouse,” Leonard explains. “We welded pieces together in 30-foot sections, and we shipped them to a local painter who coated them with baked-on Kynar to match the roof.”

The bullnose was designed to hook into the gutter strap and wrap around onto the fascia, where it is screwed into the framing. In areas where there is no gutter, sections of the bullnose are equipped with a larger flange with an S-hook built into it to attach it to the roof. Corner pieces tie it all together.

Watching Out for Irma

Dealing with two different GCs was challenging, in part due to changes in the schedule. “Originally, we were supposed to finish one side first and then start the other side, but both phases of the project ended up starting around the same time,” says Leonard. “This doubled the manpower we needed on the job.”

Photos: Aerial Innovations

For changes like the bullnose, Architectural Sheet Metal had to make sure RFIs were submitted and approved by both sides. “Sometimes it was hard to keep track of who we submitted it to, but it worked to our benefit at times. Once it was approved by one side, it was easily approved by the other.”

The schedule had the crews working in hurricane season, and precautions were taken to make sure the job site was prepared for high winds. “When Hurricane Irma was approaching, I checked every single weather update every day until it made landfall,” Leonard recalls. “It hit on a Monday, and a full week ahead of that we were cleaning the roofs and preparing the gutters. We removed all debris on the jobsite because any trash on the roof could clog the downspouts. We added more and more men to the process throughout the week, and we shut the jobsite down on Wednesday. We took all of the material we had, stacked it, bundled it together, and we were able to move it all inside the building. We were pretty well complete on the Hensel-Phelps side, and Turner Kiewit brought in 40-foot Conex boxes for us to put our material in and secure it. They tried really hard to make sure the jobsite was secure.”

As the storm progressed, it deviated from the projected path, and no one could be certain which direction the winds might be coming from. “We just had to start battening everything down,” Leonard recalls.

Photos: Architectural Sheet Metal Inc.

Stacks of panels on the roof that were not yet installed were strapped every 2 feet on center. The entire state was in emergency mode, making things difficult. “For four or five days before the storm even hit, we couldn’t find water, rope and extension cords. Grocery stores were running out of supplies. Gas stations were running out of gas.”

After the storm passed, Leonard breathed a sigh of relief. The roof wasn’t damaged. The panels that had already been installed were in great shape, and the uninstalled panels weren’t harmed.

Elements like the weather are beyond anyone’s control, and Leonard notes his company tries to control as many variables as it can. “We have full control over the actual fabrication of the material and the quality of it,” he says. “When I call something in, I talk to our guy who works with me. Our company oversees it. Every morning I stop by the shop and follow up on the process on the way to the job site. We install it. I can make sure everything is OK.”

The project is nearing completion, and Leonard can’t wait to finish a landmark project he’ll see every time he makes a trip to the airport. “You can’t miss it,” he says. “It’s huge.”

TEAM

Architect: HKS Architects, Orlando, Florida, HKSinc.com
General Contractors: Hensel Phelps, Greeley, Colorado, HenselPhelps.com; and a joint venture between Turner Construction, Orlando, Florida, Turnerconstruction.com, and Kiewit, Sunrise, Florida, Kiewit.com
Metal Roofing Contractor: Architectural Sheet Metal Inc., Orlando, Florida, ASMfl.com

MATERIALS

Standing Seam Metal Roof: Berridge Zee-Lock Double-Lock, Zinc-Cote, Berridge Manufacturing, Berridge.com
Underlayment: MFM Ultra-HT Wind & Water Seal, MFM Building Products, MFMbp.com
Cover Board: DensDeck, Georgia-Pacific, Buildgp.com

Ultra-Steep Slope Roof Poses Challenges in Historic Church Re-Roofing Project

Century Christian Church is a landmark building in Owensboro, Kentucky. Completed in 1963, the church is included on the Kentucky Historic Register and recognized for its unique architectural style.
Photos: Owens Corning

At Century Christian Church in Owensboro, Kentucky, it is not the steeple that points toward the heavens above, but rather the entire roof. The church’s 50/12 pitch roof has become one of the most distinguishing features in the local landscape.

Completed in 1963, Century Christian Church is included on the Kentucky Historic Register and recognized for its unique architectural style. In fact, the roof is so eye-catching that it has been incorporated into the church’s website message which reads, “Our roof reaches up; our hearts reach out.” The roof ascends 40 feet and is divided into four quarters or “bows,” with each symbolizing one of the four Gospels in the Bible.

In 2016, the church’s building committee realized it was time for a new roof. Located in an open field apart from other structures, the roof had been struck by lightning on several occasions. The protective cable that ran down the sides of the church as a conduit for lightning strikes had been eroded and just one section of cable was intact. The building’s location also presented airflow challenges. Storms and strong winds crossing the field had caused shingles to loosen and fly off the building.

According to Harold King, a member of the Century Christian Church building committee, the church considered several criteria when selecting All American Home Improvement, LLC in Evansville, Indiana, to complete the re-roofing project. “We wanted a reputable company who was experienced in doing steep slope work, had an excellent safety record, and had a workforce equipped to meet the needs of this labor-intensive job,” he says, adding that the

The roof ascends 40 feet and is divided into four quarters or “bows,” with each bow symbolizing one of the four Gospels in The Holy Bible. Photos: Owens Corning

company’s Owens Corning Roofing Platinum Contractor certification provided additional confidence. “Our Owens Corning area sales manager, John Sabbak, explained the warranty for the re-roofing project and that was very important for us in selecting the materials for the project,” King says, noting that Sabbak also stopped by at different times during the installation to check in on the progress.

A Daunting Task

What were the challenges the roofing contractor faced in tackling the project? “What wasn’t a challenge?” asked Josh Long, Western Kentucky Sales Manager at All American Home Improvement. The metal capping required to protect the building from lightening, and the scorching summer heat during the installation were just a few of the challenges. By far, however, the two most daunting challenges were the safety concerns associated with the pitch and the wind issues that challenged shingle adhesion.

To help foster safety on the steep slopes, teams were assigned to cover each of the four “bows” comprising the roof. The teams used a precisely calculated system of ladders and walkboards to safely navigate and scale the roof. “Roofers getting home to their families safely every night will always be a top priority at Owens Corning,” says Sabbak, noting that All American Home Improvement teams were outfitted with personal protection equipment and participated in advance walk-through processes to safely tackle the project.

Installation teams from All American Home Improvement participated in advance walk-throughs to ensure everyone was well versed in the safety plan. Photos: Owens Corning

The building committee at Century Christian Church also wanted to avoid the safety and aesthetic concerns associated with shingle fly-off. That’s where Owens Corning SureNail Technology and Duration Shingles came into play. Developed to provide exceptional wind resistance, the system can qualify for a 130-mph wind warranty. “The Duration shingle delivered both the performance and the warranty we needed for a job with this kind of pitch and exposure to airflow,” says Long. According to Long, the shingles were also hand sealed as required by Owens Corning for the building’s pitch. “The SureNail Technology made it easy for the teams to install the shingle correctly because the white strip in the middle of the shingle leaves no doubt as to where the nail should go and facilitated a smooth installation,” he says.

As the roofing project progressed, so did public interest. The local newspaper stopped by to capture photos of residents watching the re-roofing spectacle from lawn chairs on the church lawn. The combination of re-roofing a challenging structure, improving the aesthetics of a historic building and scaling a very steep roof made it a memorable project according to Long. “It was a very unusual project from our daily jobs, and the challenges were part of what made the project so fun,” he notes.

TEAM

Roofing Contractor: All American Home Improvement, LLC, Evansville, Indiana, 1shingleatatime.com

MATERIALS

Steep-Slope Roof System: Duration Shingles with SureNail Technology, Owens Corning
Underlayment: ProArmor, Owens Corning

North Carolina Legislative Building Restoration Poses Unique Challenges

The North Carolina State Legislative Building was the site of a renovation project that included asbestos abatement in the interior and a complete restoration of the building’s roof systems.

The North Carolina State Legislative Building was the site of a renovation project that included asbestos abatement in the interior and a complete restoration of the building’s roof systems. Photos: SkySite Images

Some of the variables that can make a project difficult include a variety of complex, interconnected systems, unique design elements, and a tight schedule. These challenges are heightened on a highly visible, historic building, where the goal of keeping the design historically accurate must be balanced with making improvements to the structure and functionality of the systems. All of these elements and more were in play during the restoration of the one-of-a-kind roof on the North Carolina State Legislative Building in Raleigh, North Carolina. It took a talented team of design, engineering, and roofing professionals to bring the project to a successful conclusion.

Originally designed by architect Edward Durell Stone, the building has been the home of the state legislature since 1963, but water intrusion under its copper pyramids and at windows and doors on the promenade level precipitated a complete restoration project. Renovation work conducted in 2016 and 2017 included asbestos abatement in the interior and a complete restoration of the building’s roof systems.

The roofing phase of the project included removing and replacing the metal roof systems on the five copper-clad pyramids, as well as re-roofing the low-slope sections adjacent to the pyramids with a two-ply modified bitumen system. A liquid-applied waterproofing system was installed in the planter areas and under the pavers in the promenade section. The project also involved the removal and replacement of windows, doors, and skylights, as well as repairing and coating the concrete surfaces at the perimeter of the roof.

The design of the quilted flat lock copper panel system involved 17 different panel profiles. A false batten was added after the panels were in place.

The design of the quilted flat lock copper panel system involved 17 different panel profiles. A false batten was added after the panels were in place. Photos: SkySite Images

Companies involved in the project included Raymond Engineering, headquartered in Raleigh, North Carolina, which provided engineering and architectural services; Owens Roofing Inc., also located in Raleigh, which served as the general contractor on the roofing phase of the project and installed the low-slope systems; and The Century Slate Company, headquartered in Durham, North Carolina, which removed and replaced the copper roofs on the five pyramids.

Some of the key players in the project shared their insights with Roofing, including John Willers, a senior engineer with Raymond Engineering; Bert Owens, president of Owens Roofing; and Mike Tenoever, president of Century Slate.

“This is an iconic state building with a unique roof system which the owner and designer required to be aesthetically replicated,” Tenoever notes. “At the same time, some functionality and technical improvements were incorporated. This is a very high-profile project with a lot of complexity, particularly given the schedule. There were a lot of details compressed into a very short period of time.”

Design and Pre-Construction

Raymond Engineering conducted testing on the existing roofs and specified systems designed to match the originals and provide some necessary improvements, including added insulation and ventilation under the pyramids. Willers worked closely with Jason Mobraten, the senior architect on the project. “We provided the engineering and architectural services, beginning with design and then assisting with bidding and managing the construction phase of this project,” says Willers. “We engineered the copper roof, all of the detailing for the modified asphalt roof, and the detailing for the drainage, the pavers, and the sealants for the promenade.”

Crews from Owens Roofing removed the existing plants, media and drainage system from four 42-foot-by-42-foot fixed planters with skylights. After the substrate was cleaned and primed, a liquid-applied waterproofing system was installed.

Crews from Owens Roofing removed the existing plants, media and drainage system from four 42-foot-by-42-foot fixed planters with skylights. After the substrate was cleaned and primed, a liquid-applied waterproofing system was installed. Photos: SkySite Images

The schedule was an obvious challenge, as the majority of the work had to be completed while the legislature was in recess, and there were substantial financial penalties that would come into play if the work was not completed on time. “The client also required that the asbestos abatement be completed before re-roofing the copper-clad pyramids to avoid the risk of dislodging the asbestos-containing textured ceiling finish. However, doing the work in two phases allowed the asbestos contractor to get started while the rest of the job was designed and bid,” Willers states.

The building houses legislators’ offices, and it was open and occupied during construction, with the exception of the areas undergoing asbestos abatement. The schedule had to be carefully adjusted as the job progressed. “In addition to our role in monitoring the technical aspects of the construction, we closely monitored the construction phasing and sequencing, as it was directly driven by the schedule of the state legislature,” Willers notes. “We had to take a lot of care in developing the schedule and monitoring it.”

Willers and Mobraten knew that the details on this project would be crucial. “There were previously some issues where the copper and the low-slope membrane roofs met,” Willers says. “We detailed that very carefully so that we had redundancy in keeping that watertight.”

Extensive mock-ups of the copper pyramids were constructed and tested to ensure the quilted pattern could be exactly replicated while avoiding the leaks that plagued the existing structure.

Photos: SkySite Images

Photos: SkySite Images

As designers looked for ways to improve construction, they explored the design and construction of the quilted panels. “From a design standpoint, we wondered why we had this odd diamond-shaped pattern,” Willers recalls. “After we played with the dimensions a bit, we realized that if you fly over the building, from above all of those diamond sections look like squares.”

The key was to replicate the design with its false battens while avoiding leaks. “We were concerned about how to detail out the joining of the copper sheets that formed the diamond-shaped panels,” Willers says. “What had been done was susceptible to windblown rain getting in. We did two things differently: the little clips that supported these battens were secured by forming the clips with hooks that would be integral with the single-locked seams and soldering the clips to the top surface of the copper panels. Previously they were held in place by pop rivets, which went through the copper.”

The Secrets of the Pyramids

Century Slate was well prepared to tackle the copper roofing on the project. The company has been in business more than 20 years, and it specializes in historic restoration projects including slate, tile, wood, copper and other historical metals.

Crews from Century Slate removed the existing copper panels. The copper was salvaged and recycled.

Crews from Century Slate removed the existing copper panels. The copper was salvaged and recycled. Photos: SkySite Images

Tenoever knew the design of the original quilted flat lock copper panel system needed to be replicated exactly. “There were 17 different panel profiles, each within a very particular location within the roof’s quilted pattern,” Tenoever notes. “Proper placement of each different profile was essential to the whole system working correctly and looking like the original.”

The first step was to remove the existing copper roofs. “We tore off the entire system down to the deck,” Tenoever explains. “We then installed a semi permeable a vapor barrier, insulation, and a vapor retarder.”

Along with added insulation and Carlisle WIP 300HT self-adhering underlayment, crews also installed a vented nail base from Hunter Panels. “The Hunter Cool-Vent is a vented nail base that gets screwed down,” Tenoever says. “The goal was to have a breathable air cavity. All of the hip caps are actually vented to allow the air to get out.”

With the addition of the insulation and nail base, the roof was built up approximately 6 inches from the previous configuration. This added height necessitated changes in the custom flashing at the base of the pyramids but did not change the configuration of the copper panels.

In all, 22,500 square feet of copper panels fabricated by K&M Sheet Metal in Durham were installed. Each of the 17 different panels was labeled with a letter code. “When they were out at the site, we could just grab an A panel or a B panel, as needed, and bring them to that layout,” Tenoever explains. “Four of the pyramids were the same, and the center one was different, as that was the one that had skylights built into it.”

The areas between the pyramids were covered with a two-ply modified bitumen roofing system. Photos: SkySite Images

The panels feature flat-lock clips that were screwed down to the nail base. “It’s a typical flat seam panel system, and the panels interlock together,” says Tenoever. “You can see the batten panel above it, which is an aesthetic feature. The battens and the clips that held them were amazingly intricate, for what they were. They were cut out with a CNC machine and soldered onto the copper panels prior to installation. Later we came back and installed the batten system over the top.”

Century Slate built new curbs in the center pyramid for the new skylights, which were manufactured by Wasco. “The skylights were one of the last things to go on,” says Tenoever. “They were custom made because even though they look square, there isn’t a square angle on them.”

Custom copper flashings were installed at the bases. “One of the trickier parts for us probably would have been the tie-in of the modified roof, because Owens Roofing had to do their bit, and we were also replacing all of the wood blocking and everything all along the bottom edge before we could put our flashing on,” Tenoever recalls. “It took a lot of coordination between the two trades, but it all worked out.”

The Low-Slope Roof Systems

Owens Roofing served as the general contractor on the project and installed the low-slope roof systems. The company was established in 1986 in Raleigh, and focuses on commercial and institutional buildings, almost exclusively re-roofing. Much of its work is on historic buildings, so Owens was confident he could execute the project and complete it on schedule.

A scaffolding system offered secure roof access, but material had to be loaded and removed from one access point, so logistics had to be carefully mapped out.

A scaffolding system offered secure roof access, but material had to be loaded and removed from one access point, so logistics had to be carefully mapped out. Photos: SkySite Images

Crews from Owens Roofing installed 18,900 square feet of modified bitumen roofing from Soprema over concrete decks, including the areas between the pyramids. Tapered polyiso and half-inch DEXcell cover board from National Gypsum were installed using Duotack adhesive, followed by the two plies of modified bitumen membrane.

A liquid waterproofing system from Sika was specified for the large planter areas. Crews from Owens Roofing removed the existing plants, media and drainage system from four 42-foot-by-42-foot fixed planters with skylights. After the substrate had been cleaned and primed, the Sika RoofPro system was installed.

“Once it’s cleaned and primed, it’s pretty simple,” says Owens. “The product is one part, and you don’t even have to mix it. We applied it with rollers on this project. You embed fabric sheets in the system and then topcoat it. It was a cold-weather job, but fortunately we caught a break last winter in that it wasn’t as cold as usual, and we didn’t miss as much time as we might have.”

The 30,000-square-foot promenade section was originally covered by white granite pavers native to North Carolina. The old pavers were removed and replaced over a new roof system, which was comprised of modified bitumen sheets beneath the liquid-applied waterproofing system. “The concrete deck was primed and a modified bitumen base ply heat welded to the deck,” Owens explains. “This surface was primed in preparation for the Roof Pro system, which was then installed.”

Innovative Roof Services of Raleigh was called in to conduct a high-voltage electrical testing to ensure there were no voids in the system before the pavers were re-installed. The pavers had originally been set in a bed of mortar, and they had to be removed and cleaned, which revealed a problem. “When we took the pavers up, we found out that they ranged between 1-1/8 and 1-3/4 inches thick,” Owens notes. “That wasn’t a problem when they were set in a bed of mortar, but over extruded polystyrene, they would have been all up and down. We put in a change order and had the pavers set in a bed of sand on top of one layer polystyrene.” The sand was adjusted by hand to ensure the pavers were level. New pavers were added to replace those broken over the years.

On the roof’s concrete eyebrows, damaged areas of concrete were repaired, joints were sealed, and a cold-applied waterproofing system from Sika Sarnafil was used to cover 8,800 square feet of concrete.

Numerous Challenges

Important considerations on the project included safety and logistics, as well as the tight schedule. Safety was paramount, and a third-party safety monitor was on the site to ensure the safety plan was designed and executed properly. During the time between when the original skylights were removed and when their replacements installed, the voids in the roof deck needed to be cordoned off and covered according to OSHA regulations. Personal fall arrest systems were used on the pyramids and outside of the safety perimeter, which was marked with flags. “With the promenade, you had a wide concrete eyebrow, so it made it easier to set up the safety lines and keep everyone safely away from the edge,” Owens notes.

This aerial photo taken before the restoration project shows the copper roofs with their green patina. Photos: SkySite Images

“Safety is a key concern as on all jobs, but this one in particular was highly visible out the windows of the nearby Department of Labor,” Owens continues. “We were paid a courtesy visit and agreed with them that an on-site safety meeting conducted by their personnel might be useful. The owner allowed us use of one of their auditoriums and we had a very productive half-day meeting for all trades. Every week we had a meeting with a state construction monitor.”

A scaffolding system was set up that offered secure roof access, but there was only one point for loading and unloading material, so logistics at the site were a concern. “We had to use wheelbarrows and roof carts to transport materials back and forth to the scaffolding tower,” Tenoever notes. “Between the removal of the original roof and the installation of the multiple layers of the new roof system, over 150,000 square feet of roofing materials were moved by hand over an average distance of approximately 200 feet.”

Loading and unloading added another wrinkle to the complicated schedule. “The schedule was based on when the legislature was scheduled to come back to town—not how long the job was supposed to take,” Owens says. “We were all concerned with the ambitious time frame and $1,000 a day liquidated damages included with this job.”

Willers cited excellent communication as one of the keys to completing the project on time. “Fortunately, the project managers for the general contractor and other trades were highly organized individuals,” Willers says. “Regular site meetings were detailed and thorough. Although setbacks did occur, communication kept the ball rolling.”

The roof system on the building’s iconic copper clad pyramids was removed and carefully recreated, matching the original design while adding a vented cavity and increasing the thermal insulation. Photos: SkySite Images

A Unique Experience

Copper removed from the existing roof was salvaged and recycled, notes Willers, with the exception of a few pieces that

were cut into the shape of the state of North Carolina to serve as mementos of the unique project. “We’re very proud of the design and the outcome—and the assistance we got from all of the contractors involved,” Willers says. “We had some pretty heavy rains after the project was completed, including some high winds, and there were no leaks.”

Tenoever also looks back on the project with pride. “A one-of-a-kind roof system was custom built and delivered on schedule and with the owner and designer’s praises,” he says. “Taking something so amazing and restoring it to the beauty it originally had—we all get a kick out of that.”

TEAM

Design and Engineering Services: Raymond Engineering, Raleigh, North Carolina, RaymondLLC.com
General Contractor: Owens Roofing Inc., Raleigh, North Carolina
Metal Roofing Contractor: The Century Slate Company, Durham, North Carolina, CenturySlate.com
Leak Testing: Innovative Roof Services, LLC, Raleigh, North Carolina, IRS-LLC.net

MATERIALS

Metal Roof System
Copper: 20-ounce copper sheet metal
Vented Nail Base: Hunter Cool-Vent, Hunter Panels, HunterPanels.com
Underlayment: Carlisle WIP 300HT, Carlisle, Carlislewipproducts.com
Skylights: Wasco Skylights, Wascoskylights.com

Modified Bitumen Membrane Roof System

Membrane: Sopralene Flam 180 and Sopralene Flam 180 FR GR, Soprema, Soprema.us
Adhesive: Duotack, Soprema
Insulation: Sopra-Iso, Soprema
Cover Board: DEXcell, National Gypsum, NationalGypsum.com

Waterproofing System

Liquid Applied Membrane: RoofPro 641, Sika Corp., USA.Sika.com
Reinforcing Fabric: Reemat, Sika Corp.
Primer: Sikalastic EP Primer/Sealer
Extruded Polystyrene Insulation: Foamular 604, Owens Corning, OwensCorning.com

Contractor Restores the Roof on the Museum Beneath St. Louis’ Historic Gateway Arch

Western Specialty Contractors restored the roof of the Museum of Westward Expansion located beneath the Gateway Arch in St. Louis. This photo shows the protection board being installed prior to adding the leak detection system.

Western Specialty Contractors restored the roof of the Museum of Westward Expansion located beneath the Gateway Arch in St. Louis. This shows the protection board installed prior to adding the leak detection system.

The St. Louis branch of Western Specialty Contractors recently completed a project to restore and waterproof the roof of the Museum of Westward Expansion located beneath the iconic Gateway Arch on the St. Louis Riverfront. The work is part of a multi-phase project, spearheaded by nonprofit organization CityArchRiver Foundation, to expand and renovate the underground museum, plus renovate the grounds surrounding the Arch. The Jefferson National Expansion Memorial, which includes the Gateway Arch, Museum of Westward Expansion and the surrounding park, is maintained by the National Park Service.

Opened to the public in 1976, the Museum of Westward Expansion has undergone very few changes since its grand opening. The size of a football field, the museum features rare Native American Indian artifacts and materials documenting the days of Lewis and Clark and the 19th century pioneers who shaped the history of the American West.

Work on the 100,000-square-foot museum roof project began with removing sod and sandy soil covering the top of the roof and 10-28 inches of Elastizell engineered fill using a bulldozer. Next, the existing waterproof membrane was removed from the structural concrete deck.

After two layers of modified bitumen sheet waterproofing were installed, crews apply a coat of adhesive to adhere the asphaltic protection board.

After two layers of modified bitumen sheet waterproofing were installed, crews apply a coat of adhesive to adhere the asphaltic protection board.

Once the deck was exposed, Western crews went to work identifying and repairing leaks in the existing museum lid that had been present for many years, as the existing waterproofing had exceeded its lifespan. Several methods were used to evaluate the condition of the structural concrete deck, which included a chain-drag sounding along with visually identifying delamination and cracks.

Western crews then installed a two-ply Laurenco modified bitumen sheet waterproofing system covered with WR Meadows PC2 protection board. An electronic leak detection system followed by a permanent leak detection grid system were installed over the protection board. Crews then installed a layer of 1-1/2 inch, 60-psi Dow extruded polystyrene with an additional layer of the protection board and a J-Drain 780 drainage mat.

The next phase of the project involved waterproofing the 42,000-square-foot horizontal lid and the 37,000-square-foot vertical walls of the museum addition. Western’s scope of work in this area included installing a two-ply modified bitumen sheet waterproofing and protection board, as well as an electronic leak detection system, along with two layers of extruded polystyrene. A layer of extruded polystyrene was also installed on the vertical walls, followed by the drainage mat on both the horizontal and vertical walls.

During portions of the project Western crews were working over occupied space, as the museum was largely operational during construction.

During portions of the project Western crews were working over occupied space, as the museum was largely operational during construction.

Additional waterproofing of the north and south museum entrances encompassed approximately 13,800 square feet, which included approximately 5,000 square feet of deck around each leg of the Arch.

The museum was largely operational during construction, and for much of the project Western crews were working over occupied space. The company sequenced the removal of existing roofing material so that they could remove, clean and install new roofing material daily to keep the museum dry during construction.

Testing was a daily requirement during the waterproofing installation. Western was required to complete a pull test for every 500 square feet and take moisture readings for every 100 square feet. Daily observation reports had to be completed during the waterproofing application, with all testing results and location tests documented along with the weather conditions. Additionally, Western crews took 50 photos daily to document the testing and work area.

Construction on the Arch grounds began in August 2013, while renovations to the museum and visitor center began in April 2015. The multi-phase project is still underway, and the improved underground Museum of Westward Expansion is expected to be finished by summer 2018.

TEAM

Roofing Contractor: Western Specialty Contractors, St. Louis, Westernspecialtycontractors.com

MATERIALS

Waterproofing System: Laurenco Waterproofing, Laurencowaterproofing.com
Protection Board: WR Meadows, WRmeadows.com
Extruded Polystyrene: Dow, Dow.com
Drainage Mat: J-Drain, J-Drain.com

Fans and Community Rally to Replace Barrel Roof at Roadside America

Crews from Bachman’s Roofing, Building & Remodeling battled winter weather to install a new fully adhered EPDM roofing system from Mule-Hide Products Co.

Crews from Bachman’s Roofing, Building & Remodeling battled winter weather to install a new fully adhered EPDM roofing system from Mule-Hide Products Co. Photos: Mule-Hide Products Co. Inc.

Lovingly and meticulously crafted over a period of more than 60 years, the 6,000-square-foot display of miniature villages at Roadside America in Shartlesville, Pennsylvania, has been featured on the HISTORY channel and in such books as “1,000 Places to See in the USA & Canada Before You Die” by Patricia Schultz and “Weird Pennsylvania” by Matt Lake. To area families, however, the museum is more than just a funky tourist attraction. It is a treasure that has been shared by four generations—one that must be passed on to future generations.

So, when the building’s nearly 65-year-old barrel roof began to fail, threatening to shutter the museum and put its gems in storage for good, the community and fans far and wide rallied. Nearly $80,000 was raised, roofing crews worked in between winter storms, and a new EPDM roofing system was installed to protect the masterpiece below.

A Life’s Work

Dubbed “The World’s Greatest Indoor Miniature Village,” the display at Roadside America is the life’s work of its sole creator, Laurence Gieringer. Fascinated by miniatures from an early age, he made the first piece in 1902 and continued expanding the collection until his death in 1963. The result is a breathtaking snapshot of American rural life spanning more than 200 years, from a frontier town with saloons and horse-drawn wagons and carriages to a 1950s Main Street with a movie theater and tail-finned Chevys. The collection includes 300 hand-built structures, 600 miniature light bulbs, 4,000 tiny figurines, 10,000 hand-made trees, working model railroads and trolleys, moving waterways, wall paintings, and replicas of such landmarks as Mount Rushmore, the San Francisco-Oakland Bay Bridge, and Henry Ford’s original shop in Dearborn, Mich. The twice-hourly patriotic “Night Pageant” features an illuminated Statue of Liberty and the playing of America’s national anthem and Kate Smith’s rendition of “God Bless America.”

Originally housed in the basement of Gieringer’s childhood home and later in the carousel building of an abandoned amusement park, Roadside America moved to its current home in 1953. Still a family business, it is now owned by Gieringer’s granddaughter Dolores Heinsohn, and operated by his great-granddaughter Bettina Heinsohn and her husband Brian Hilbert.

A Preservation Mission

A carpenter by trade, Gieringer fabricated the rafters for the museum’s 80-square-foot-by-123-square-foot barrel roof

Years of water penetration had damaged the existing roof, and a complete tear-off and replacement was in order. The original rafters and roof deck were sound.

Years of water penetration had damaged the existing roof, and a complete tear-off and replacement was in order. The original rafters and roof deck were sound. Photos: Mule-Hide Products Co. Inc.

himself. In 2016—63 years later—they and the original wood plank deck were still in place. According to Carl Rost, general manager of contractor Bachman’s Roofing, Building & Remodeling Inc. of Wernersville, Pennsylvania, the hot-mop-down tar roof had been coated “20 times more than it should have been.” Time and weather had taken their toll. A severe snowstorm in January 2016 brought wind and tree damage. Consistent rain would cause leaks into the attic, with water sometimes dripping to the show floor below.

An elaborate water collection and removal system was created to protect the priceless miniatures. Buckets were placed in the exhibit and items moved whenever water started dripping to the show floor. Tarps—22-feet-by-22-feet—were hung in the attic, zig-zagging through the space to catch water and funnel it into 55-gallon barrels, which were then emptied by pumps.

Supporters Rally

While the patches and stopgap measures had done their job, they clearly were not a permanent solution. A new roof—and a major fundraising effort to pay for it—were needed.

Even with Bachman’s Roofing and the teams at roofing system manufacturer Mule-Hide Products Co. Inc. and the Reading, Pennsylvania, branch of building materials distributor ABC Supply working to keep costs as low as possible, the new roof would cost $80,000. Roadside America launched a GoFundMe.com campaign, raising nearly $19,000. Two anonymous donors contributed the remaining $60,000.

For many supporters, including Bachman’s Roofing Owner and President Eric Bachman and ABC Supply Branch Manager Jeff Smith, helping Roadside America was a matter of ensuring that a family tradition spanning four generations lives on. Their parents had brought them to the museum as children. They, in turn, took their kids, who are now sharing it with their families.

There was no question about helping Roadside America, Rost says. “Eric met with Brian and, within minutes, told him ‘We have to make this work.’”

EPDM Roofing System Selected

A 60-mil EPDM roofing system was chosen for its ease of installation on a barrel roof, its durability and its cost-effectiveness.

After the original roof system was removed, fiberboard insulation boards were fastened to the existing deck with screws and plates. The EPDM membrane was fully adhered using a fast-drying, freeze-resistant, low-VOC bonding adhesive. Photos: Mule-Hide Products Co. Inc.

The original plan was to recover the existing roof, reducing costs and, with winter weather at hand, allowing the crew to get the job done as quickly as possible. Once work began, however, the damage caused by years of water penetration was evident and the job switched to a complete tear-off and replacement.

EPDM roofing systems are common in Berks County, where Shartlesville is located. The membrane’s ease of installation on a barrel roof reinforced the choice to use it on Roadside America’s building.

“We’ve done quite a few barrel roofs and have found that EPDM works best,” Rost says.

Roofing membranes have “memories,” he explains. Rolled tightly for shipping, they want to snap back to that state when laid out on the jobsite. They must be given sufficient time to flatten out prior to installation, or wrinkling can occur. EPDM membranes “relax” much more quickly than other membranes do, particularly in the cold temperatures that the Bachman’s Roofing crew would be working in. The membrane also remains flexible in hot and cold temperatures, enabling it to be easily curved over the barrel roof’s rafters.

“We knew that EPDM would give us a fast, wrinkle-free installation,” Rost says.

EPDM also is less slippery than other membranes, points out Rob Keating, territory manager with Mule-Hide Products, helping ensure that snow will not slide off the curved roof, potentially injuring a museum guest or employee walking below. A snow rail manufactured by Alpine Snow Guards was specified and installed to alleviate previous issues with snow and ice sliding down the roof and damaging an air conditioning compressor.

A black membrane was chosen for its lower cost and because, with eastern Pennsylvania having more heating days than cooling days, it could help the museum manage its heating costs, Rost says. A 60-mil membrane was selected for its durability and long expected lifecycle, he adds, helping the museum reduce its ongoing maintenance costs and prolong the day when re-roofing would again be required.

The rafters—made of one-by-twos, one-by-fours, one-by-sixes, one-by-eights, one-by-tens and one-by-twelves to create the roof’s barrel shape—were still sound.

Fiberboard insulation boards were fastened to the existing deck boards with screws and plates. To accommodate the roof’s irregular shape and the cold temperatures, the EPDM membrane was fully adhered using a fast-drying, freeze-resistant, low-VOC bonding adhesive.

In addition to the barrel roof, the crew replaced an existing 625-square-foot low-slope section of EPDM roofing on one side of the building’s front.

Working Around Winter Weather

January and February bring snow, sleet, ice and wind to Shartlesville—certainly not ideal conditions in which to undertake a re-roofing project. Despite unfavorable weather forecasts, the Bachman’s Roofing crew began work as soon as the necessary funds had been raised and Roadside America gave the green light.

Roadside America is dubbed “The World’s Greatest Indoor Miniature Village.” On display at the museum are more than 300 hand-built structures, 600 miniature light bulbs, 4,000 tiny figurines, and 10,000 hand-made trees, as well as working model railroads and trolleys. Photos: Mule-Hide Products Co. Inc.

“The displays inside are priceless, and if they were damaged by water they couldn’t be replaced,” Rost says. “So, we said we’d work through the bad weather, taking time off as necessary.”

Work began on January 9, 2017. Thanks to some interference by Mother Nature, what normally would have been a one- or two-week job took six weeks. A crew of 10 completed the tear-off and eight professionals installed the new roofing system.

“Our crew endured,” Rost says. “One morning they called to tell me that they wouldn’t be able to work that day. I said ‘The storm went through last night. What’s the deal?’ They said that the parking lot was a sheet of ice. I had to see for myself, so I drove out there. The moment I got out of the car, I fell onto the completely iced-over parking lot.”

Given the roof’s slope, extra attention was paid to safety. Crew members worked carefully, without rushing—particularly when working along the roof’s steep edges. Everyone was harnessed while on the roof and followed all other relevant safety regulations. Rost and the firm’s safety inspector spent extra time monitoring the jobsite.

Mission Accomplished

With the re-roofing project complete, the buckets, tarps, barrels and pumps that once kept Roadside America’s miniature villages dry have been put away. A spring, a summer and an early fall have come and gone, with no leaks. The museum has been saved.

Hilbert extended thanks to those who made it possible. “Without the generous support of so many donors, this project wouldn’t have happened,” he says. “Where do you find that these days?”

Rost adds, “Now future generations can come and enjoy what four generations of our families have already enjoyed.”

TEAM

Roofing Contractor: Bachman’s Roofing, Building & Remodeling Inc., Wernersville, Pennsylvania, Bachmansroofing.com
Local Distributor: ABC Supply Co. Inc., Reading, Pennsylvania, ABCsupply.com

ROOFING MATERIALS

EPDM Membrane: Mule-Hide Products Co. Inc., Mulehide.com
Low-VOC Bonding Adhesive: Mule-Hide Products Co. Inc.
Fiberboard Insulation: Continental Materials Inc., Continentalmaterials.com
Snow Guard: Alpine Snow Guards, Alpinesnowguards.com