Project Profiles: Historic Renovation

Maine State House Dome Restoration, Augusta, Maine

Team

COPPERSMITH: The Heritage Co., Waterboro, Maine
GENERAL CONTRACTOR: Consigli Construction Co. Inc., Portland, Maine
ARCHITECT: LEO A DALY, Minneapolis
ENGINEER: Becker Structural Engineers, Portland

To remain proportional with the larger building, a new, higher copper-covered dome was built to replace the original cupola.

To remain proportional with the larger building, a new, higher copper-covered dome was built to replace the original cupola.

Roof Materials

Working 200 feet in the air on elaborate staging, carpenters, coppersmiths, engineers and other construction workers replaced more than 7,000 square feet of copper on the dome. The existing unique, curved copper components were carefully removed and saved to serve as models for the new components.

A full sheet-metal shop, consisting of an 8-foot brake, 52-inch jump shear and benches, was set up onsite at the 63-foot elevation mark, along with five cases of 20-ounce copper (about 12,880 pounds). Each copper component was carefully measured, cut and bent onsite, and then installed.

The compound curving components were made in The Heritage Co.’s “home” shop, using a shrinker/stretcher machine and an English wheel. Then, the copper was handformed over custom-made wood forms. Care was taken to exactly match the size and configuration of the existing components, as well as the seam layouts that were prevalent in the original copper work

Approximately 15 to 18 percent of the copper was waste because of the curved nature of many of the components. The waste was made into copper clip stock for the roof installation or recycled.

COPPER MANUFACTURER: Revere Copper Products Inc.
COPPER SUPPLIER: Beacon Sales Co.

Roof Report

The Maine State House was originally designed by renowned architect Charles Bulfinch in 1832. The dome was added in 1910 as part of a major remodeling and expansion project that ultimately created the building’s current appearance based on designs by G. Henri Desmond.

The original façade was preserved during remodeling, though the length of the building was doubled to 300 feet by extending the north and south wings. To remain proportional with the larger building, a new, higher copper-covered dome was built to replace the original cupola. The new dome rises to a height of 185 feet and is topped by a gold-clad copper statue, called “Lady Wisdom”, designed by W. Clark Noble.

Over time, weather damage and holes caused by hail strikes on the top of the dome caused leaks in the building. The seams between the copper sheets also caused problems for the underlying steel and concrete structure of the dome. The work included the installation of expansion joints, repairs to prevent water infiltration and restoration of the cupola (located between the top of the dome and Lady Wisdom), using a highly durable paint system. Lighting upgrades, copper repairs and the restoration of the gilded Lady Wisdom statue located atop the dome were also part of the project.

The dome’s structural system and framing were analyzed by Becker Structural Engineering one year in advance of dome construction, so Consigli Construction could create a 3-D model for staging to eliminate interior shoring.

Overall, this project restored one of Maine’s most significant historic landmark buildings, returning its signature copper dome and gilded Lady Wisdom sculpture to their original intended conditions.

PHOTO: Consigli Construction Co. Inc.

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Project Profiles: Education Facilities

Leon Levine Hall of Medical Sciences, Campbell University, Buies Creek, N.C.

TEAM

ZINC INSTALLER: Baker Roofing, Raleigh, N.C.
ARCHITECT: Little Diversified Architectural Consulting, Charlotte, N.C.

A total of 40,000 square feet of interlocking zinc panels are used on the walls and standing-seam zinc panels are installed on the roof of the building to provide long-lasting durability and an impressive visual aesthetic.

A total of 40,000 square feet of interlocking zinc panels are used on the walls and standing-seam zinc panels are installed on the roof of the building to provide long-lasting durability and an impressive visual aesthetic.

ROOF MATERIALS

A total of 40,000 square feet of interlocking zinc panels are used on the walls and standing-seam zinc panels are installed on the roof of the building to provide long-lasting durability and an impressive visual aesthetic. As North Carolina’s first new medical school in 35 years, Campbell University regards this building as an investment in the state’s future needs for health-care professionals and a modern educational space. Campbell wanted a building with permanence to show its commitment to health sciences in the long term, and zinc provides it with a durable metal that can survive decades of internal and external activities.

ZINC MANUFACTURER: VMZ Interlocking panel in 1-millimeter QUARTZ-ZINC and VMZ Standing Seam panel 1-millimeter in QUARTZ-ZINC from VMZINC

ROOF REPORT

The Leon Levine Hall of Medical Sciences, which was completed in June 2013, consists of approximately 96,500 square feet on four floors. The building is designed to create a modern learning environment with simulation laboratories, traditional laboratories, an osteopathic manipulative medicine lab, student group-study rooms, student interaction areas, a resource library and small café. It hosts the School of Osteopathic Medicine and is designed to provide hands-on education for medical students.

PHOTO: VMZINC

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A Metal Roof Crowns a Residential New-construction Project

When Charles Callaghan purchased the two vacant lots next to his home in Ponte Vedra Beach, Fla., he thought they would form the perfect location for his family’s dream home. A team comprised of architects, contractors and manufacturers worked together to bring his ideas to life in the form of a new 7,500-square-foot residence. The building’s crowning feature is a metal roof system that was designed to complement the aesthetics of the home and stand up to the harsh oceanfront environment for decades to come.

The roof of the Callaghan residence in Ponte Vedra Beach, Fla., features 12,000 square feet of Petersen Aluminum’s Snap-Clad in Slate Gray.

The roof of the Callaghan
residence in Ponte Vedra
Beach, Fla., features 12,000 square feet of Petersen Aluminum’s Snap-Clad in Slate Gray.

“With the larger lot, we thought we could do something unique to the neighborhood,” Callaghan says. “When we first met with the architect, there were a few keys we wanted to stress. First, we didn’t want a boxy-looking house. We also wanted shingle-style siding and a metal roof. We like the look of the metal roof, we like the durability, and we thought it would be a good way of complementing the shingles on the house.”

At every phase of the project, the team of construction professionals ensured the project was executed with precision, down to the last detail of the metal roof.

THE DESIGN

The house was designed by Jaycox Architects & Associates, Jacksonville, Fla. According to William R. Jaycox, principal, the plan made the backyard pool the home’s focal point. “They wanted to do a casual, shingle-style beach house that wasn’t like everyone else’s house,” Jaycox notes. “We designed the house so it was mostly single-story and spread it out around the pool, which made for an interesting roof design. It’s all in small modules.”

The L-shaped home features a master-bedroom suite on one side while the other side contains the living room, dining room, kitchen, family room and guest bedroom. “This one also has a four-car garage under the main roof, and, because the house wraps continuously around the pool, you get a fun little foyer in the front with a little cupola up above, you get the dormers for the bedrooms in the attic, and the master suite is a little pod unto itself,” Jaycox adds. “The back has a pool pavilion separate from the house. When you put all of those elements together, you get a very interesting structure, and the metal roof was perfect because it accentuates the lines.”

The roof system specified included 12,000 square feet of aluminum panels in the cool-color Slate Gray. “This house is only a few blocks from the ocean, and in those cases we typically use aluminum,” Jaycox says. “We’ve had great success with that system. It’s absolutely bombproof from a corrosion standpoint with stainless fasteners, heavy-gauge aluminum and the Kynar finish.”

Thorne Metal Systems installed a high-temperature, self-adhered underlayment beneath the metal roof, as specified.

Thorne Metal Systems installed a high-temperature, self-adhered underlayment beneath the metal roof, as specified.

When applied by a certified installer, the system can qualify for a 20-year Oceanfront Finish Warranty from the manufacturer. In addition, the roof meets all Florida’s tough building-code requirements. The system, consisting of 0.040-gauge aluminum, 16-inch-wide panels with fastening clips spaced at 24-inches on-center, carries a Miami-Dade NOA with a -110 PSF uplift. (The UL 90 uplift is -52.5 PSF.)

THE INSTALLATION

The roofing contractor on the project was Thorne Metal Systems of Middleburg, Fla. Owner Bill Thorne has been installing metal roofs since 1989. He formed his own company 13 years ago, and it has become the go-to metal roof installer for Jaycox Architects
& Associates and the general contractor on the project, C.F. Knight Inc., Jacksonville.

Thorne has a lot of experience installing this particular aluminum roof system. “The system is a very easy system to install,” he says. “It’s very user- friendly. The panels have male and female joints that snap together and are held in place with stainless-steel clips.”

PHOTOS: Petersen Aluminum Corp.

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Project Profiles: Retail/Mixed-use

Outlet Collection at Niagara Niagara-on-the-Lake, Ontario, Canada

Team

DEVELOPER: Ivanhoé Cambridge, Montreal

The largest open-air outlet mall in Canada features approximately 23,000 square feet of PTFE fiberglass membrane walkway canopies.

The largest open-air outlet mall in Canada features approximately 23,000 square feet of PTFE fiberglass membrane walkway canopies. PHOTO: Birdair

Roof Materials

The largest open-air outlet mall in Canada features approximately 23,000 square feet of PTFE fiberglass membrane walkway canopies. The membrane canopies exhibit a flying-mast cone design that provides relief from the elements and creates a signature look for the shopping center.

PTFE, or polytetrafluoroethylene, is a Teflon-coated woven fiberglass membrane that is durable and weather-resistant. PTFE fiberglass membranes can be installed in climates ranging from the frigid arctic to the scorching desert heat with a project life in some cases exceeding 30 years.

PTFE fiberglass coating is chemically inert, and the low-surface free energy of the material results in an electrical-grade fabric membrane that is readily rinsed by rain-water. It is also immune to UV radiation. This combination makes PTFE-coated fabric membrane ideal for projects requiring weather endurance and fire resistance.

PTFE fiberglass is ENERGY STAR- and Cool Roof Rating Council-certified. During scientific tests of its solar properties, it was discovered that PTFE fiberglass membranes reflect as much as 73 percent of the sun’s energy while holding just 7 percent on its exterior surface. Certain grades of PTFE fiberglass can absorb 14 percent of the sun’s energy while allowing 13 percent of natural daylight and 7 percent of reradiated energy (solar heat) to transmit through.

PTFE FIBERGLASS MEMBRANE DESIGNER, FABRICATOR, INSTALLER: Birdair

Roof Report

Located beside the Queen Elizabeth II Highway, less than 20 kilometers from the U.S. border, the 520,000-square-foot shopping center features 102 retailers, including Canada’s first Pandora outlet, White House Black Market outlet and Bass Pro Shops Outpost. Other sought-after brands at the center include a Kate Spade Outlet, NIKE Factory Store, Calvin Klein Outlet and Michael Kors Outlet.

The Niagara Outlet Collection was developed to attract shoppers and visitors who might have otherwise crossed the U.S. border to shop in the Fashion Outlets of Niagara Falls, the Walden Galleria or the Boulevard Mall. David Baffa, Ivanhoé Cambridge senior vice president of retail development, said the developer wants the new outlet collection to be part of the Niagara experience.

Outlet Collection at Niagara is committed to corporate responsibility and environmental sustainability and has a number of design features throughout the property to raise awareness of its green initiatives. Its canopies make the open-air concept possible, reducing energy consumption because the common areas do not need to be heated or cooled. Some of the public buildings, like guest services and the eatery, have been designed so that they can be opened to the outdoors in favorable weather, thus saving energy and connecting people to the outdoors.

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Project Profiles: Health Care

Union Printers Home, Colorado Springs, Colo.

Team

ROOFING CONTRACTOR: Interstate Roofing, Colorado Springs

Roof Materials

Interstate Roofing recommended Valoré Slate in the Villa color blend of medium and dark grays for the reroofing project. Valoré synthetic slate roofing tiles are made using proprietary VariBlend technology to form varying shades from tile to tile, creating an infinite number of color shades. Each single-width synthetic slate roofing tile is crafted using virgin polymer resins to guarantee a sustainable product. Valoré Slate tiles come in 12-inch tile widths with a 1/2-inch tile thickness, making it a lightweight yet realistic slate roofing tile option. (The Valoré Slate product line no longer is available.)
VALORÉ SLATE MANUFACTURER: DaVinci Roofscapes

Interstate Roofing recommended Valoré Slate in the Villa color blend of medium and dark grays for the reroofing project.

Interstate Roofing recommended Valoré Slate in the Villa color blend of medium and dark grays for the reroofing project.

Roof Report

Fondly known in Colorado Springs as the Castle on the Hill, the Union Printers Home has a long history of caring for people. Built in 1892 by members of the International Typographical Union to offer specialized health care to their union members, the facility today serves the general public with a multitude of services, including assisted living, nursing care, rehabilitation and hospice.

In 2012, extreme hail damage made it essential to replace the roof on the structure, which is a State of Colorado Historical Site. Interstate Roofing removed more than 50-year-old asbestos tiles on the roof and recommended polymer roofing tiles that complement the existing architectural style. “Considering the age, condition and historical value of the structure, we needed a roofing product that could work with the building while ensuring longevity to the structure,” says Scott Riopelle, owner of Interstate Roofing in Colorado Springs.

Although Riopelle was confident in the selection of the roofing product, there were many challenges for this project. The 50-man crew first had to complete the safe removal of the existing asbestos-laden tiles.

“We had to erect scaffolding 5-stories high to access the roof,” Riopelle says. “Due to the 12:12 roof pitch and the multiple turrets on the structure, building containment areas and debris removal were extremely dangerous. During the entire process, we performed continuous air-quality testing to ensure the safety of the home’s residents, staff and our crew.”

The team worked through the winter months and experienced continuous rain, wind and snow. Riopelle explains: “This means we had abatement processes, plywood redecking, dry-in and loading crews, heavy-equipment contractors, installers and supply companies all working in extreme-weather conditions. For this project, logistics and coordination went minute-to-minute.”

The temporary removal of the large historic clock on the front of the Union Printers Home created the next challenge. Because of its age, there was concern for the clock’s condition. Staff at the home asked that the hands of the clock not be moved; they were permanently set at 8 o’clock to represent the union’s efforts in the past to encourage an eight-hour workday.

Reroofing the turrets on the project was easier because of the Turret Package from DaVinci Roofscapes. Interstate Roofing provided DaVinci with four dimensions (the distance from the peak to the turret to the edge of the drip cap, the turret pitch, the turret cap length and the coursing exposure). From that information, Turret Packages were created, including the starter tiles, numbered field bundles custom-engineered for each course and a turret map diagram to guide the team through installation.

The three-month project had a gratifying outcome for Riopelle and his team. “This was a once-in-a-lifetime project,” Riopelle says. “Although we’ve completed projects much larger and more complex, this one was special because of the history associated with the Printers Union Home and the importance of the facility to the community.”

Interstate Roofing embraced the challenge of tying the old historic structure in with the new technology of the polymer slate products. “The results are amazing. This historic structure has a new life thanks to this roof,” Riopelle observes. “And since the roofing tiles are impact- and fire-resistant, there’s greater peace-of-mind for the staff and residents at the Union Printers Home.”

PHOTO: DaVinci Roofscapes

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Green Roof Provides Learning Opportunities at the University of Iowa’s Pappajohn Biomedical Discovery Building

Established just 59 days after Iowa became a state in 1847, the University of Iowa, Iowa City, boasts a number of firsts. In 1855, it became the first U.S. public university to admit men and women; at that time, its enrollment consisted of 124 students—41 of which were women. In 1873, it was the first school to grant a law degree to a woman. In 1895, it became the first university to place an African American on a varsity sports team.

As such, the university’s new Pappajohn Biomedical Discovery Building was designed and built with sustainability in mind. PHOTO: Roof Top Sedums LLC

The university’s new Pappajohn Biomedical Discovery Building was designed and built with sustainability in mind. PHOTO: Roof Top Sedums LLC


In more recent years, the university has strived to lead via its environmental efforts. As a Green Power Partner of the Washington, D.C.-based U.S. Environmental Protection Agency, the university pledges to reduce the environmental impact of electricity generation through the use of renewables. In 2010, it established its first sustainability plan—2020 Vision UIowa Sustainability Targets, which contains the following goals:

  • Become a Net-negative Energy Consumer
  • Green Our Energy Portfolio
  • Decrease Our Production of Waste
  • Reduce the Carbon Impact of Transportation
  • Increase Student Opportunities to Learn and Practice Principles of Sustainability
  • Support and Grow Interdisciplinary Research in Sustainability-focused and Related Areas
  • Develop Partnerships and Advance Collaborative Initiatives, both Academic and Operational

Among the University of Iowa’s strategies to achieve its sustainability goals is ensuring all new construction and major renovations on campus achieve a minimum LEED Silver certification from the U.S. Green Building Council, Washington.

The 200,000-square-foot, 6-story building, which officially opened in October 2014, boasts many environmentally friendly attributes.

The 200,000-square-foot, 6-story building, which officially opened in October 2014, boasts many environmentally friendly attributes. PHOTO: Scott Nagel


As such, the university’s new Pappajohn Biomedical Discovery Building was designed and built with sustainability in mind. The 200,000-square-foot, 6-story building, which officially opened in October 2014, boasts many environmentally friendly attributes, including glow-emitting sealants, paints, carpet and other materials; water-efficient landscaping; and recycled content and regional materials. It also achieves an-other university first: three green roofs, one of which provides students the opportunity to grow medicinal plants.

Opting for Trays

Des Moines, Iowa-based landscape architecture firm Confluence has been completing projects at the University of Iowa for many years through its Iowa offices—Des Moines and Cedar Rapids. Confluence was hired by the project’s architect of record, Rohrbach Associates PC Architects, Iowa City, to complete landscaping around and on top of the Pappajohn Biomedical Discovery Building in the form of three green roofs that total approximately 6,440 square feet. Despite the building’s consider-able roof area, the design team opted to install the green roofs on lower roof areas upon which building occupants would be looking. The rest of the roof cover is a reflective membrane system.

Confluence provided the layout for a modular green roof on the three distinctive roof areas. Patrick Alvord, PLA, RA, LEED AP, a principal in Confluence’s Cedar Rapids office, notes the chosen tray system was off-the-rack, which is what made it appealing to him and his colleagues. “We spent a lot of time talking to the manufacturer and they were just great to work with,” Alvord says. “We had a number of case studies of work they had done in the Chicagoland area that had proven very successful, so we had a very high level of comfort right out of the gate.”

Alvord opted to use the 6-inch-deep tray model because it would provide some flexibility in the plant materials that could be specified. “We were able to specify different plant materials in the plan of the roof to coordinate with shade, densities and location,” he says. “In areas where the roof would be highly visible from floors above, we did some patterning with the plants. In areas where we had the opportunity to go deep, we planted deeper-rooting plants that will grow taller and provide a denser plant palette.”

The plants are a mix of native and adaptive Iowa plants, as well as recommendations from the green-roof supplier. “It’s a mix of perennials, grasses and forbs, ranging from sedums to liatris to a number of different things,” Alvord notes.

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Projects: Office

DPR Construction, Phoenix

Eighty-two Daylighting Systems were installed in the renovated 16,533-square-foot building.

Eighty-two Daylighting Systems were installed in the renovated 16,533-square-foot building.

Team

Roofing contractor: Arithane Foam, Corona, Calif.
Architect/engineer: SmithGroupJJR, Phoenix
Daylighting systems distributor: Norcon Industries, Guadalupe, Ariz.

Roof Materials

Eighty-two Daylighting Systems were installed in the renovated 16,533-square-foot building, formerly an abandoned retail boutique at the corner of 44th Street and Van Buren in Phoenix.

“The use of the Daylighting Systems was an integral part of our sustainability and lighting energy savings plans for the renovated space,” says Dave Elrod, regional manager of DPR Construction, Phoenix. “The products are a cost-efficient solution to provide lighting since they nearly eliminate the need for artificial daytime lighting.”

In addition, the roof is composed of foam with an R-25 insulation value (approximately 4-inches thick) over plywood sheathing.

Daylighting systems manufacturer: Solatube International Inc.
Foam roofing manufacturer: Quik-Shield from SWD Urethane

Roof Report

DPR Construction is a national technical builder specializing in highly complex and sustainable projects. In less than 10 months, the design-build team researched, designed, permit-ted, and built a highly efficient and modern workplace with numerous innovative sustainability features.

In addition to natural daylighting, the office features an 87-foot zinc-clad solar chimney, which releases hot air from the building while drawing cooler air in; shower towers that act as evaporative coolers to regulate building temperatures; 87 operable windows designed to open and close automatically (based on indoor/outdoor temperatures); and two “vampire” shut-off switches to keep electrical devices (radios, cell-phone chargers, microwaves) from using plug energy when no one is in the office.

Access to the building was limited during construction. Spray foam roofing, which took about seven days to complete, had to be done in small quadrants because of the tight schedule as work was progressing in the other sections. The roofing workers were challenged by the barrel-shaped roof, which created footing difficulties, and the many penetrations that had to be flashed, including all PV support legs, Solatubes, skylights and HVAC penetrations. Work was completed in the middle of winter, so additional protections and efficiencies were required.

The circa-1972 building has been officially certified as a Net-Zero Energy Building by the Seattle-based International Living Future Institute through its Living Building Challenge program. It also has received LEED-NC Platinum certification from the U.S. Green Building Council, Washington, D.C.

PHOTOS: Ted Van Der Linden, DPR Construction

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A Standing-seam Roof Protects a Bank and Its Offices for the Long Term

Located on a high-traffic, signature intersection in Taylorville, Ill., Palmer Bank sought a timeless design that would visually represent its strength and stability to the community of just more than 11,000 people.

Design for the project was provided by The Redmond Co., Waukesha, Wis. The design team blended extensive detailing and profiling of the metal roof with a masonry façade to create an attractive prairie-style look.

Design for the project was provided by The Redmond Co., Waukesha, Wis. The design team blended extensive detailing and profiling of the metal roof with a masonry façade to create an attractive prairie-style look.

Design for the project was provided by The Redmond Co., Waukesha, Wis. The design team blended extensive detailing and profiling of the metal roof with a masonry façade to create an attractive prairie-style look.

“We clearly wanted to take advantage of the great location with a strong, timeless design,” says Andy Young, The Redmond Co.’s director of project development and construction manager on the project. “We presented two options to the bank regarding the roof … It was pretty unanimous that everyone liked the standing-seam profile look. We also liked the life-cycle cost of the roof since the bank plans to be the owner of this building for the long term.”

Installation of the standing-seam roof was completed by E.L. Pruitt Co., Springfield, Ill.

Installation of the standing-seam roof was completed by E.L. Pruitt Co., Springfield, Ill.

Installation of the standing-seam roof was completed by E.L. Pruitt Co., Springfield, Ill. The crew, which consisted of six tied-off workers, installed fascia, gutters, downspouts and soffit. Flashing components were custom-fabricated in E.L. Pruitt’s shop.

The metal is coated with ENERGY STAR-approved colors and is vented for optimal airflow, which greatly in-creases the roof’s longevity and energy efficiency. The metal was installed over roof-deck protection and a self-adhered underlayment.

The metal is coated with ENERGY STAR-approved colors and is vented for optimal airflow, which greatly in-creases the roof’s longevity and energy efficiency.

The metal is coated with ENERGY STAR-approved colors and is vented for optimal airflow, which greatly in-creases the roof’s longevity and energy efficiency.

According to Dallas Stephenson, E. L. Pruitt’s project manager, the roofing job took about six weeks to complete. He explains: “The most difficult part was doing all the seam layout because the product requires a progressive install, which means you can’t really start in the middle of the roof and work both directions. You have to start in a corner and work out of a corner and then work into a corner and then work back out of the corner.”

The metal was installed over roof-deck protection and a self-adhered underlayment.

The metal was installed over roof-deck protection and a self-adhered underlayment.

Stephenson notes symmetrically lining up seams on the bank’s dormers and then across the roof was challenging. “Once we got all that figured out—took all the measurements on the job site and confirmed them—it went fairly smoothly,” he says.

“We knew the many hips and valleys would be somewhat of an installation challenge, but the installer did a terrific job,” Young notes.

Stephenson is quick to return the compliment: “Scott Brooks, site superintendent, and Andy Young from The Redmond Co. did an excellent job of picking a good team to build Palmer Bank. Everything just worked out great!”

PHOTOS: Petersen Aluminum Corp.

Team

Roofing installer: E.L. Pruitt Co., Springfield, Ill.
Designer: The Redmond Co., Waukesha, Wis.

Roof Materials

Approximately 9,000 square feet of 24-gauge, 16-inch Snap-Clad panels and 2,200 square feet of PAC-850 Soffit Panels were utilized to meet the design objectives. The Snap-Clad panels were finished in Charcoal and the 0.032 PAC-850 Panels were finished in Slate Gray.
Panels’ manufacturer: Petersen Aluminum Corp.
Roof deck protection manufacturer: Deck-Armor from GAF
Underlayment manufacturer: Grace Ice and Water Shield

Clay Tile Roofing Protects a Subdivision’s Clubhouse from the Hot Phoenix Sun while Providing an Old World Look

Located in the Sonoran Desert southeast of Phoenix, the Encanterra Country Club subdivision offers upscale living in houses built by Walnut, Calif.-based Shea Homes and surrounding an 18-hole golf course designed by Tom Lehman. The centerpiece of this vibrant community, however, is the 60,000-square-foot country club known as La Casa, The Club at Encanterra.

The centerpiece of the Encanterra subdivision in Phoenix is the 60,000-square-foot country club known as La Casa, The Club at Encanterra.

The centerpiece of the Encanterra subdivision in Phoenix is the 60,000-square-foot country club known as La Casa, The Club at Encanterra.

Designed to keep the community’s members active and entertained, La Casa, The Club at Encanterra contains four restaurants, a full-service spa, fitness center and three swimming pools. The club features Mediterranean-style architecture to essentially be an extension of the attractive homes in the subdivision.

To achieve a rustic, Old World appearance, Shea Homes specified a two-piece clay tile roof installed in mud set, accented with copper flashings; custom-fabricated ornamental details; and a spray-foam system on the low-slope roof areas. Only a roofing contractor with the experience and capabilities to do all facets would suffice.

Phoenix-based Century Roofing Inc., which has been in business since 1991, has a long history of commercial and custom residential projects. With crews experienced in installing all types of tile, as well as its own metal fabrication shop, the contracting company was chosen to roof the club as it was being built.

Hustling for the Job

Steve Schwoerer, president of Century Roofing, knows what it takes to hustle and land large jobs, like La Casa, the Club at Encanterra. Knowing the project was going to be a landmark building in the valley attracted him to it. “We got it off the permit list, pursued it, bid on it and landed it, although not quite so cut and dry,” he says. “We have a lot of custom-home
experience and in Phoenix that means clay tile roof experience, so it fit in perfectly with our abilities.”

Originally, the club’s designer specified a different type of clay tile than what was actually installed on the roof. However, Schwoerer invited Irvine, Calif.-based Boral Roofing to come up with a color match and submit a quote for its tile to be installed on the project. “Boral had their plant manager fly into Phoenix to look at the roofing on the existing guard house that Shea Homes was trying to match,” Schwoerer recalls. “Boral then formulated a custom-blended tile and shipped the tile to Phoenix so a mock-up could be done for the architect’s approval, which they received.”

In addition to its curb appeal, the tile offered other benefits. Manufactured from naturally occurring geologic material (59 percent of which is recycled content), Boral clay tiles have received Cradle to Cradle Gold certification from the Cradle to Cradle Products Innovation Institute, San Francisco. The certification program assesses products in five categories: material health, material reutilization, renewable energy and carbon management, water stewardship and social fairness. The tile product is wind, hail and fire resistant, as well as considered a cool roof, meaning it reflects heat from the sun, which reduces the need for air conditioning and provides savings on energy bills.

To achieve a rustic, Old World appearance, Shea Homes specified a two-piece clay tile roof installed in mud set, accented with copper flashings

To achieve a rustic, Old World appearance, Shea Homes specified a two-piece clay tile roof installed in mud set, accented with copper flashings

Working in Phases

The roofing work was completed in phases as La Casa, The Club at Encanterra was being built. “Anytime you do a project of this size, the general contractor has scheduling demands that add to the difficulty, especially when you’re working in stages and
they want you out there as it’s being built rather than all at once,” Schwoerer states. “Their version of what’s roof-ready versus what’s actually roof-ready is one of many things that causes a roofing contractor stress!”

Century Roofing’s five-man crew began by installing the spray-foam roof on the low-slope portions of the building, which compose 130 squares of the total roof area. Although spray-foam roofs in Arizona typically are 1-inch thick, the club’s roof is 2-inches thick to achieve additional R-value. The foam was sprayed directly onto the wood deck and two base coats were applied before the final topcoat, which features a #9 crushed marble cast into the wet topcoat by hand.

PHOTOS: US TILE BY BORAL

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Projects: Hospitality & Entertainment

The Lobby, Gerald R. Ford Amphitheater, Vail, Colo.

The Lobby, Gerald R. Ford Amphitheater, Vail, Colo.

The Lobby, Gerald R. Ford Amphitheater, Vail, Colo.

Team

Design Architect: Zehren & Associates, Avon, Colo.
Engineer: Monroe & Newell Engineers Inc., Denver
Owner: Vail Valley Foundation, Vail

Roof Materials

The Vail Valley Foundation envisioned an iconic entrance for the amphitheater that not only would accommodate guests, protect against the elements and provide facilities, but also would recognize and celebrate the Ford family and mirror the amphitheater’s atmosphere.

Under the Vail Valley Foundation, Zehren’s team of architects chose approximately 5,500 square feet of PTFE fiberglass membrane canopies to make the vision for The Lobby a reality. PTFE, or polytetrafluoroethylene, is a Teflon-coated woven fiberglass membrane that is durable and weather resistant. The PTFE fiber coating is chemically inert, capable of withstanding extreme temperatures and immune to UV radiation.

Designer, fabricator and installer of PTFE fiberglass membrane: Birdair

Building Report

The Gerald R. Ford Amphitheater is a remarkable outdoor venue nestled along a hillside with a stunning view of the Rocky Mountains. The Lobby, which is adjacent to the Betty Ford Alpine Gardens and Ford Park, serves not only as an impressive entrance to the amphitheater, but also as a shelter from inclement weather, a social gathering point prior to entering the amphitheater, and a place for ticket and bag check. The Lobby allows for a smooth transition into the venue.

Within the Lobby resides a mini-stage that can accommodate pre-show performances, along with a new stand for concessions and restrooms. Around the perimeter of the space rests informal boulder seating, and alpine landscapes border the surrounding walls. Overall, the aesthetics of the space mirror the pristine landscape and enjoyable outdoor atmosphere.

The Lobby also holds a Ford family tribute: a series of symbolic sculptures and interpretive elements intended to pay homage to President and Mrs. Ford and their family. This tribute is a new landmark in Vail celebrating the family’s commitment to their adopted hometown and the positive changes that they made to the community.

PHOTO: BIRDAIR

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