A Durable Solution

Photo: IKO

Located the heart of Halifax’s Spring Garden Road district, City Centre Atlantic features a mix of urban retail, office and residential space totaling 31,600 square feet. The site has 194 underground parking spaces servicing the office and retail components of the property.

Multiple challenges came with the City Centre Atlantic project for installing roofing contractor IC Roofing and Sheet Metal of Bedford, Nova Scotia. I.C. Roofing and Sheet Metal Limited is a Maritime-based company servicing Nova Scotia, Prince Edward Island, New Brunswick, Newfoundland, and Southwestern Ontario. The site offered limited street access and rooftop storage space was limited, necessitating extra movement of materials up on the roof.

The building owner was looking for a durable system with a proven track record, so a heat-welded modified bitumen system manufactured by IKO was selected. After the concrete deck on the 2,936-square-foot City Centre Atlantic roof was covered with Modiflex MP-95-FS vapor barrier, IKOTherm and IKOTherm Tapered insulation were installed using Millennium adhesive. After the cover board was installed. I.C. Roofing crews then heat welded the Torchflex TP-180-FF base sheet and light gray Torchflex TP-250 cap sheet. They also fabricated and installed the edge metal on the project.

Everything on the job went smoothly, according to Mike Croft, Atlantic Regional Manager, I.C. Roofing. The key to success on projects like this? “It’s experience,” Croft says. “I.C. Roofing ensures a quality installation through project management and employing journeyman roofers that are great tradesmen. The guys we have undertake these jobs are great journeyman roofers who do two things: they understand the tasks they are doing, and they take a lot of pride in what they are doing. You can have journeyman roofers that can install most things, but it takes a special journeyman roofer to make it look worthy. That’s stuff you can’t teach. A guy has to have that. Our guys take personal pride in their work.”

TEAM

Roofing Contractor: I.C. Roofing and Sheet Metal Limited, Bedford, Nova Scotia, www.icroofing.ca

MATERIALS

Vapor Barrier: Modiflex MP-95-FS, IKO, www.iko.com

Insulation: IKOTherm and IKOTherm Tapered, IKO

Cover Board: Protectoboard, IKO

Base Sheet: Torchflex TP-180-FF-Base

Cap Sheet: Torchflex TP-250-Cap

Restoring Multiple Roof Systems on Historic Structure Is a Labor of Love

The Evans family restored the mill’s main roof as well as the flat roof over a retail space. Crews also re-roofed the large covered porch on the side of the mill and the one-story log cabin residence added to the back of the mill. Photo: Evans Candy

The first thing longtime roofer Dave Fisher will do is correct your pronunciation of Lancaster County, Pennsylvania — it’s traditionally pronounced “Lang-kiss-ter” for anyone wondering. And tradition is important where Fisher’s from.

Founded in 1729, Lancaster County is one of the oldest communities in America. The area is the heart of Pennsylvania Dutch country and has a strong farming and milling history. At the height of the milling industry, the area had more than 300 various types of mills operating.

The list of historical buildings in Lancaster County is long, so working on old structures is nothing new to Fisher, who runs I & D Contracting Ltd. in Lancaster. But re-roofing a 130-year-old mill to protect the interior while preserving its key historic characteristics presents unique challenges. Throw in local attachment to the building and a personal relationship with the owner and the stakes for doing the project right get even higher.

The mill had many names and many owners over its history before the Evans family purchased it in 1983. Photo: Evans Candy

This was the challenge presented to Fisher’s crew in re-roofing the Evans Candy Store in Lancaster County, done in stages over the last several years, with the most recent project being completed in 2018. The candy store is located inside a flour mill that serves as a recognizable piece of Lancaster’s history. The structure was originally built in the 1700s, but dust from grinding flour was a perpetual fire risk, and the mill burned twice over its history. The existing structure has been in place since 1889.

The mill has had many names and many owners over its history, but the Evans family purchased the mill in 1983 and has worked to bring it back to its former glory. Coming from a line of Lancaster milling families themselves, the Evans have used the historic structure to create a destination retail location that keeps people coming back for more — more chocolate, that is — oftentimes long after they have moved out of the area.

The flour mill is an iconic structure in Lancaster County. The existing structure dates back to 1889. Photo: Lancaster Historical Society, Lancaster, Pennsylvania

“I refer to us as a very large mom-and-pop store. We still get most of our business from word of mouth and know many of our customers by name or what they order, but we’ve grown and branched out into grocery stores and specialty shops,” says Steve Evans, second-generation owner of the Evans Candy Store located in the old mill. “Still, about half of the people who order through our website are people who moved out of the area, but still want their Evans chocolate.”

Fisher is no stranger to the area, the old mill or the Evans family either. “I was born and raised in Lancaster County, so I’ve been familiar with this building since I was a kid,” Fisher says. “I’ve been doing work for the Evans family for 20 years now — sisters, brothers, parents. I’ve been glad to get to work on it and be a part of its story.”

Franken-Roof

Affectionately referred to as “Franken-roof” by both Fisher and Evans, the roof on the 10,000-square-foot Evans Candy Store consists of four separate roofs — a three-story, steep-slope roof; a two-story, flat roof over a retail space; a large covered porch attached to the side of the mill; and a long, one-story log cabin residence attached to the back of the mill. Each of these roofs has a different type and color of roofing installed for various reasons, and each presented its own challenges.

At one point, an owner of the mill covered the siding with red asphalt shingles, visible in this photo at the upper right. Photo: Evans Candy

The “Franken-roof” extended to nearly every part of the mill’s exterior as a previous owner nailed red-colored asphalt shingles over all of the building’s original 1889 wood siding in an effort to protect the historic structure.

“I’ve lived in this area my whole life and I’ve never seen anything quite like it,” Evans says of the shingle-covered exterior. “When my family started restoring the mill — I was like 10 or 11 years old — I can’t tell you how many dumb asphalt shingles I picked up. That was my job. My brothers knocked them off the house and I picked them up and put them in the trash.”

Since then, the entire bottom floor of the building has been retrofitted to house to the candy store, while the upper floors have been converted into 3,000 square feet of residential space that a number of Evans family members have called home over the years.

The Steep-Slope Roof

It’s difficult to know for certain, but Fisher thinks the original roof over the main portion of the mill was slate. By the time the Evans bought the mill in 1983, the roof had been replaced with asphalt shingles. Evans hired Fisher and the I & D Contracting crew to re-roof this largest portion of the building — a 2,400-square-foot steep-slope roof — 10 years ago. To protect the historic building, Fisher wanted to start from scratch and make sure the job was done right. When he tore off the old roof, he found no real roof decking, just old barn wood in random sizes fitted together.

To preserve as much of the historical nature of the building, Fisher kept the original board decking, shoring it up where needed, and applied TAMKO Moisture Guard Ice and Rain Underlayment. To help create a more uniform surface for the shingles, Fisher chose a thick felt paper — TAMKO No. 30 Underlayment — to cover the barn wood roof deck and started laying the Heritage Premium asphalt shingles.

The shingle application required some extra care and an attentive ear due to the old barn wood deck. “There were gaps between the old barn wood pieces, so we had to listen to the sound each nail made as it went in — you could hear the difference when the nail hit one of the gaps and didn’t get any wood,” Fisher says. “In those cases, we had to move the nail and try again, because we wanted to know that it was really solid.”

Evans chose the very light-colored Olde English Pewter shingle in an attempt to reduce the heat coming in to the third story. Energy efficiency is always a concern in buildings of this age. When the Evans family purchased the building, it had no drywall or insulation, just open studded walls. Over the years, the family added spray foam insulation, insulation batting and roof vents to help address heat flow in and out of the massive historic building.

Fisher notes his crew took extra care around the 130-year-old brick chimney, which had been re-pointed in the past but needed some additional work. Fisher fabricated aluminum flashing and counter flashing out of coil stock on an aluminum brake to further protect the historic structure from potential damage.

The Flat Roof

Before Evans befriended Fisher and the two started their working relationship, Evans hired another roofer friend, Josh Miller of Miller’s Roofing in Wellsville, Pennsylvania, to update the flat roof portion of the old mill. The existing asphalt roll roofing installed in the early 1980s had reached the end of its life and Evans and Miller worked together to add foam sheeting over top of the existing rolled roofing and finished it by installing a Versico EPDM roofing system in the late 1990s.

The original roof deck over the flat roof portion of the mill was tongue and groove, and the men worked carefully to preserve the integrity of the original decking as they modernized the covering.

The Covered Porch

Fast-forward to 2018, and Evans contacted Fisher to replace and repair the roof over a large covered porch connected to the side of the building. The 450-square-foot cedar shake roof was added in an effort to blend with the rest of the historical structure, but after several decades, the moss-covered shakes succumbed to water damage and began to fail.

Fisher and his crew removed the cedar shakes and found part of the reason for the roof’s failure — zero flashing connecting the shake to the side of the building, just some old caulk. As part of the re-roofing project, Fisher added new flashing where the porch roof connected to the side of the mill.

“We had to get creative — flashing underneath the existing siding to try and prevent the same problems from recurring,” Fisher says.

Evans loved the old cedar shake roof and felt torn when choosing a replacement shingle. He ended up going with Heritage Premium asphalt shingles for their durability and selected the Rustic Slate color to differentiate the covered porch from the rest of the structure.

“It was a toss-up — would I match the new shingles to the other parts of the building?” Evans recalls. “But then I realized, I kind of liked the covered porch being a separate entity unto itself. It had always had a different shade of roofing, signifying a separate area of the building, and I liked that. I chose the Rustic Slate color because it still gave that rustic, historic feel that I loved about the cedar shake.”

The Log Cabin Residence

The other roof Fisher’s crew updated on the old mill in 2018 was on the long, log-cabin residence attached to the side of the three-story structure. Despite looking like an original part of the mill’s construction, the log cabin was added to the building in 1992, as a retirement home for Evans’ aging parents.

The log cabin addition was constructed in 1992. The roof was recently replaced with TAMKO Heritage Premium asphalt shingles in Rustic Cedar to help it blend in with the rest of the historic structure. Photo: Evans Candy

By the time Fisher got a good look at the log cabin roof in 2018, he realized the existing asphalt shingles were at the end of their service life, and one particular section of the roof had been patched multiple times and had additional layers of shingles stacked on the roof in an attempt to repel water.

Fisher took the 1,600-square-foot roof down to the decking, installed ice and water shield, new felt paper and installed TAMKO Heritage Premium asphalt shingles. Evans chose the Rustic Cedar color for the new roof as it was similar to the previous shingle color that added to the rustic, historic look that Evans hoped the log cabin would have in an effort to have it meld with the rest of the 130-year-old mill structure.

“I liked that Rustic Cedar look, pairing it with the log front,” Evans notes. “I think back to olden times with the cedar shake and wanted to emulate that. And I think we accomplished it. It is fun — it makes us smile when people ask us, ‘How old is that log home?’ and we get to tell them it’s only 26 years old.”

Fisher has grown to appreciate what he calls the “hodge-podge” of roof styles and colors on the old mill, and says the most important thing is that the building’s owner got exactly what he wanted and is a happy customer.

“Sometimes if people want to see installed examples of different colors of TAMKO shingles, I just send them to the mill because they can see a variety there,” Fisher says, laughing. “I jokingly asked Steve the other day if he had a shed that we could roof for him … just to see how many different colors we could do.”

About the author: Melissa Dunson is an award-winning journalist with more than a decade of experience writing about a wide variety of business sectors, including the construction industry, and as a technical and creative writer for TAMKO Building Products.

TEAM

Roofing Contractor: I & D Contracting Ltd., Lancaster, Pennsylvania

Roofing Contractor: Miller’s Roofing, Wellsville, Pennsylvania

MATERIALS

Underlayment: No. 30 Asphalt Saturated Organic Felt, TAMKO, www.tamko.com

Waterproofing: Moisture Guard Ice and Rain Underlayment, TAMKO

Asphalt Shingles: TAMKO Heritage Premium Laminated Asphalt Shingles in Olde English Pewter, Rustic Slate and Rustic Cedar

Low-Slope Roof: Versico EPDM Roofing System, www.versico.com

Silicone Coating Restores the Roof, Reduces Utility Costs at Mixed-Use Complex

At the Shoppes of Johnson’s Landing in Angier, North Carolina, ACC applied a high-solids silicone roof coating on the 20-year-old metal roof to seal penetrations, restore the roof, and provide a white reflective coating. Photos: All-County Contracting (ACC)

Glenn Wujcik, the owner of All-County Contracting (ACC), headquartered in Raleigh, North Carolina, has been fascinated with spray rigs since he and his brother first used one in 1979 to insulate a van with spray polyurethane foam (SPF). His company specializes in applying SPF and roof coatings on existing buildings. Lately, he’s found silicone roof coatings are making up an increasing share of his company’s workload.

“The coatings industry in general is booming right now,” Wujcik says. “A lot of the TPO and EPDM roofs are nearing the end of their service life, and instead of tearing them off, if you catch them in time, you can go over it with the silicone coating and get a new 10-year warranty. Silicones have a proven track record. When you put it on properly, it weathers really well. It has excellent elongation.”

Wujcik characterizes himself as a hands-on owner who strives to be on the site for every job. He believes there is an art as well as a science to operating a spray rig properly, and experience is crucial. “I love doing this,” he says. “I’ve been doing it for more than 30 years, my business partner’s been doing it more than 30 years, and our best sprayer has sprayed more than both of us combined. We know what we have to do, we know how long it’s going to take, and we have the right equipment. We are really good about the preparation and the application.”

Coatings and spray foam are excellent products, but only in the right situations, notes Wujcik. They should only be used on the proper substrates and applied in the right conditions. “In spraying, the most important thing is knowing when not to spray,” he says. “Right now, I’m working on a job, and for the last two days, there have been 10-20 mph winds, and I haven’t finished it yet. I told the owner, ‘I haven’t oversprayed anything yet, and I don’t want to.’ I’d rather do it right and not have any problems.”

Wujcik points to a recent project on a mixed-use building in Angier, North Carolina, to illustrate some of the benefits of a silicone roof coating. “It’s a U-shaped building with about 14,000 square feet of roof space,” Wujcik notes. “There’s a bakery, a restaurant, a pharmacy, and a doctor’s office, and there are a lot of penetrations on the roof.”

The penetrations were the site of multiple leaks. Wujcik decided to use a high-solids silicone coating, GE Enduris 3502, to prevent leaks and extend the life of the roof. The monolithic coating will seal the penetrations, and the white reflective surface will provide an additional benefit: reduced cooling bills in the summer. “Putting a white coating on it is going to reduce their energy load in the summer pretty substantially,” he says.

Applying the Coating

On this project, the first step was to pressure wash the existing roof. “That’s where most coating jobs fail — surface preparation,” Wujcik states. “Washing the roof properly is one of the most important steps.”

The high-solids silicone coating was applied to the existing standing seam metal roof. Care had to be taken to ensure all sides of the metal ribs were properly covered with the material. Photos: All-County Contracting (ACC)

The company uses 4,000 psi belt-drive power washers, so care has to be taken not to damage the roof or skylights, which are covered and marked for safety reasons. The company follows all OSHA regulations, which in most cases means setting up safety lines 6 feet from the edge, with stanchions 10 feet apart, to establish a safety perimeter.

“Safety is my number one thing,” Wujcik says, “I’ve been doing this a long time and I’ve never had a lost-time accident. I preach safety. That is absolutely the most important — and accidents are expensive.”

The next step is to apply the GE Seam Sealer at the penetrations. “When this roof was originally installed 20 years ago, they did it textbook perfect,” Wujcik notes. “Each 4-inch pipe coming though had at least 20 fasteners holding it down.”

However, over time, the rubber grommets on the fasteners can degrade, and expansion and contraction can take their toll. “We have really hot summers here, we’ve seen roofs where literally thousands of fasteners have backed out,” he says.

The seam sealer is typically applied with a brush. “Any horizontal seams, any termination bars, any penetration that goes through the roof that has a screw, we apply the seam sealer,” he says. “It goes on quite thick — at about 80 linear feet per gallon.”

After the seam sealer cures for one day, the coating is applied. Spraying flat roofs with EPDM, TPO, and PVC membranes is a fairly straightforward process, according to Wujcik. “You basically spray it just like you would spray paint a wall,” he says. “You overlap your spray pattern 50 percent. I’ve been doing it for so many years, and you get a feeling for how fast you can go.”

After the roof was power washed, the seam sealer as applied to the seams and penetrations. After it cured, two coats of the high-solids silicone product were sprayed on the roof. Photos: All-County Contracting (ACC)

A wet mil gauge is used to ensure the proper thickness. Wujcik notes the high-solids silicone formulation has very little shrinkage as it dries.  “As we’re spraying, we insert the gauge into the wet coating and it tells you how many mils you have sprayed down. In this case, we were applying to achieve 21 dry mils.”

The spray rig is set up on the ground and operated by one man, while the sprayer and the hose man are working on the roof. “It’s a minimum of a three-man crew per coating rig,” he notes. “You’re dealing with about 6,000-7,000 psi of pressure, so you need special hoses rated for at least 7,000 psi. You never want to kink them. If you busted a hose, by the time someone came down from the roof to the machine, you could pump out 20 gallons on the ground. That’s why you need a ground man.”

Flat roofs are sprayed perpendicular to the roof, but the standing seam metal roof on this project called for a different technique. “On metal roofs with high ridges, if you don’t angle your gun you’ll miss the sides of the ribs,” Wujcik points out. “You have to do it from one direction, working one way, and then turn around and do it from the other direction, working the other way. If you try to spray straight down on the roof, you’re going to miss the nooks and crannies in all of those ribs.”

The surface area of the ribs also has to be taken into account when calculating the amount of liquid that will be applied, notes Wujcik.

The final step in the process is to touch up the applications at the penetrations to ensure a clean look. On vertical surfaces including parapet walls, crews ensure the coating is applied to a uniform height. “On the last day, we take up brushes and rollers and cut in straight lines,” he says. “That really finishes the job. The detailing gives it that final touch.”

Open for Business

The active and open jobsite posed some challenges. “There were a lot of cars around the building, so we had to be very careful not to hit them with overspray,” Wujcik notes. “When you’re working on a plant, you might be able to move all of the cars to a different location, but at doctor’s offices and restaurants, you have traffic in and out of the parking lot all of the time. We can use car covers if there are a few cars there, but when they are in and out like that, it’s not practical, so you have to be very careful when you do the job.”

The job was completed in the winter, and bad weather resulted in some delays. “A job like this in the summertime would have been a weeklong project at most,” Wujcik notes. “This project took almost a month because we had an exceptionally cold winter with a lot of high winds. It took extra time, but that’s my philosophy: If it’s not the right conditions, I just won’t do it.”

The project qualified for a 10-year warranty, and when it expires ACC plans to be there to pressure wash and recoat the roof for another 10-year warranty.

“We inspect our jobs every year,” Wujcik says. He notes that annual roof inspections and routine maintenance are the simplest and most cost-effective ways to ensure the roof’s life span. Yet these steps are often neglected.

“It’s amazing that some of these multi-million-dollar companies don’t send their maintenance guys up on the roof for 10 minutes to check the drains,” he says. “If a roof has 2 inches of pine needles around the drain, the whole roof has to have 2 inches of water on it before it begins to drain. That puts tremendous, tremendous stress on a roof. Keeping your drains clear is really important.”

TEAM

Roofing Contractor: All-County Contracting (ACC), Raleigh, North Carolina

MATERIALS

Roof Coating: Enduris by GE 3502, GE Performance Coatings, www.GE.com/silicones
Seam Sealer: GE Seam Sealer, GE Performance Coatings

SBS System Delivers Roof Design for the Brewery District

Brewery District Building 3, New Westminster, B.C., Canada

Owner Wesgroup Properties wanted an aesthetically pleasing pattern for their roof design as well as the option to expand and add additional stories.

Owner Wesgroup Properties wanted an aesthetically pleasing pattern for their roof design as well as the option to expand and add additional stories.

The Brewery District is a dynamic, progressive area in in Metro Vancouver offering a mix of residential high-rises, shops and office buildings. The Brewery District provides quick access to the area and is connected via a SkyTrain to public
plazas, greenways, view decks, cycling paths, and a central community green gathering place. This master-planned community includes groceries, pharmacies, restaurants and other mixed-use retail outlets.

Roof Report

The project included roof areas of varying heights totaling approximately 21,320 square feet. Owner Wesgroup Properties wanted an aesthetically pleasing pattern for their roof design as well as the option to expand and add additional stories. IKO was able to meet their expectations with an SBS system using IKO TP 180 Granular Cap in a pattern of multiple colors. The IKO SBS Roofing System was recommended by GRC Columbia Roofing Inc., based on the specific client requirements to create a colorful rooftop pattern.

Team

Client/Owner: Wesgroup Properties
Architect/Designer:
Henrizquez & Partners Architects
Roofing Contractor: GRC Columbia Roofing Inc.
The Roof System:
IKO MVP Vapour Barrier
IKO MF 95 SF (Poly/Sand) Vapour
Barrier
IKO Therm III Insulation
IKO 3/16-inch Protectoboard
IKO TP 180 FF Base Sheet
IKO TP 180 SF Base Sheet
IKO TP 180 Granular Cap Sheet

Flagship Store Is Topped with Metal Roofing Panels

Made In America Store: Elma, N.Y.

Dutch Seam, continuous standing seam metal roof panels, eliminates the need for separate seam caps and field seaming.

Dutch Seam, continuous standing seam metal roof panels, eliminates the need for separate seam caps and field seaming.

Mark Andol is the owner and founder of General Welding and Fabricating, with locations in Elma and Rochester, N.Y. That business, which manufactured structural and decorative steel components for this store, has been operating since 1989. When the recession hit almost 10 years ago, Andol lost much of his business to companies located overseas, forcing him to cut his workforce to half its size. At that point, he began envisioning a store that would only carry products that are 100 percent American made, to help grow manufacturing within the United States. Andol’s vision became a reality in 2010 when he opened the doors to the first Made in America store in Elma.

Roof Report

The mission of the Made in America Store is to create and save jobs in the United States by increasing American manufacturing. By installing ATAS’ Dutch Seam metal roofing panels, which are made in America, on this new flagship store, it only further reinforced this mission. Dutch Seam, a continuous standing seam metal roof panel, features an integral lock and seam which prevents “blow-off” or “creeping” of the seam. It also eliminates the need for separate seam caps and field seaming.

When ATAS International announced the company’s 2016 Project of the Year winners at an awards banquet on May 8, the Made In America flagship store project took first place in the commercial roofs category.

Team

Architect: Lydon Architectural Services, Buffalo, N.Y.
General Contractor: Kulback’s Construction Inc., Lancaster, N.Y.
Installing Contractor: Bayford Construction, Lancaster, N.Y.
Roof System Manufacturer: ATAS International, Allentown, Pa.

Planning and Teamwork Are Essential in Tackling Retail Project

Peach State installed a mechanically attached TPO system over the existing modified bitumen roof system on two buildings totaling approximately 75,400 square feet.

Peach State installed a mechanically attached TPO system over the existing modified bitumen roof system on two buildings totaling approximately 75,400 square feet.

Headquartered in Atlanta, Peach State Roofing Inc. has 15 branches and covers clients across the nation. The company specializes in commercial and industrial roofing, and excels at large-scale single-ply jobs. The goal of every branch is to provide the same level of service for clients no matter where they are in the country, as exemplified by a recent project at a large retail mall in South Carolina.

Peach State’s Charlotte branch is located in Rock Hill, S.C. The company has re-roofed three of the five roofs at Gaffney Premium Outlets in Gaffney, S.C., including two roofs completed this year in just two weeks. Anthony Wilkerson, the branch manager, and Blake Wideman, strategic accounts, shared their insights on the project.

Peach State’s Charlotte branch focuses primarily on re-roofing, service and maintenance work for existing customers and property managers. Most of the company’s work involves TPO, EPDM and PVC, but crews have to be able to handle almost every type of system on the market. “If there is a hotel with some shingles or metal on it, we want to be able to complete every facet of the job, but most of our work revolves around single-ply roofing,” Wilkerson states. “We are certified with every major single-ply manufacturer.”

Anthony Wilkerson (left) and Blake Wideman of Peach State Roofing’s Charlotte branch inspect the completed project at Premium Outlets in Gaffney, S.C.

Anthony Wilkerson (left) and Blake Wideman of Peach State Roofing’s Charlotte branch inspect the completed project at Premium Outlets in Gaffney, S.C.

According to Wilkerson and Wideman, Peach State’s strength lies in building relationships with its clients by providing quality workmanship and excellent customer service. “We do that through our project management, our expertise and our training,” says Wilkerson. “We put a lot into training our employees so that they know how to do the technical details that the manufacturers are asking for.”

Wilkerson believes Peach State offers the best of both worlds—flexibility at each branch and the depth of knowledge from the large corporate organization. “We’re independent, but I work with the corporate office every day,” says Wilkerson. “We have local representation around the country, but at the same time we have that teamwork, so you’re still getting the same quality from each office that you’re getting from the corporate office. We try to be as close to the way Atlanta does things—the Peach State Way—all across board, all over the country.”

Landing a Big One

In the case of the recent project at Gaffney Premium Outlets, the work was an outgrowth of the company’s previous successful projects, including a re-roofing job at the same complex last year. “Our bid was what they were looking for,” Wideman says. “We gave them the price they were looking for and the quality they wanted. That’s how we were awarded this project.”

This aerial view shows the five buildings of the Gaffney Premium Outlets mall. Peach State Roofing re-roofed the two buildings on the left this year, after completing work on the building at the far right last year.

This aerial view shows the five buildings of the Gaffney Premium Outlets mall. Peach State Roofing re-roofed the two buildings on the left this year, after completing work on the building at the far right last year.

The mall is made up of five buildings, and the company re-roofed two this year totaling approximately 75,400 square feet. Peach State installed a mechanically attached TPO system from Firestone over the existing modified bitumen roof system. “We came up with a plan to cover the old roof with a half-inch high-density cover board,” Wilkerson says. “Then we mechanically attached a Firestone 60-mil white TPO system over the cover board.”

The system was chosen for its durability, according to Wilkerson. “They were looking for a long-term solution,” he says. “We went with a re-cover because it was more cost-effective for their budget, but we could still offer them the same warranty and the same guarantee that the system would be just as effective if they had torn the old system off and started from scratch.”

The company used 8-foot rolls of TPO on the project for several reasons. “We went with 8-foot rolls on this project because it was easier to apply the rolls,” notes Wilkerson. “They are not as heavy as the 10-foot rolls. It’s easier to let the rolls relax when you roll them out and easier to keep them tight when you are securing them to the deck.”

Fasteners were installed every 12 inches on center at the edge of the TPO sheets, and the next sheet was heat welded over the top of the screws and plates, and then mechanically fastened at the other end.
Extra care had to be taken with the details, especially walls and curbs. “We tore all of the old membrane off the curbs and off the walls, and we used bonding adhesive to go up the walls,” Wilkerson explains.

At the walls, the field sheets were run up the wall 12 inches and mechanically attached. “We adhere a sheet to the wall, and we heat weld that to the field sheet,” explains Wilkerson, “At the top of that, we use a water cutoff behind the sheet, and we use a termination bar. The termination bar is installed 12 inches on center, and then we use a sealant at the top of the termination bar. We came back with a surface-mount counterflashing, which basically just goes over the top of the termination bar. It has a little kick-out on it, so once that’s attached, it gives you double protection where your membrane is terminated.”

Curbs were handled in a similar fashion. “With the curbs, you run the field sheet right up to the curb, and then you mechanically attach it 12 inches on center,” Wilkerson notes. “Then we use bonding adhesive to install a piece of membrane on each side of the curb. We don’t do one piece and wrap it all the way around. We use four separate pieces, and we adhere them to the curb. Then we heat weld those pieces to the field sheet. For the curbs, we use a flashing that goes underneath the curb itself, and we attach that 12 inches on center all the way around. That lets the water shed over the HVAC unit and then down onto the membrane past the flashing, so there’s nowhere for the water to penetrate.”

Meeting the Challenges

The sheer size of the project was a challenge, but Peach State is used to handling large-scale projects. Logistics and scheduling were also demanding due to customer activity at the mall. “It was a good project for us, but I’d say one of the biggest challenges was that the mall remained open the whole time we were doing the roof,” Wilkerson says. “We had to check in with each tenant in every building to make sure everything was OK from the night before.”

Extra care had to be taken with the details at walls and curbs. Bonding adhesive was used to install a piece of membrane on each side of the curb. Then those pieces were heat welded to the field sheet.

Extra care had to be taken with the details at walls and curbs. Bonding adhesive was used to install a piece of membrane on each side of the curb. Then those pieces were heat welded to the field sheet.

The project called for roofing specific sections each day to make sure the roof stayed watertight at all times. “We sealed the roof up every night 100 percent, so if it rained in the evening, it had to be like we had never been up there,” Wilkerson recalls. “If we took three air conditioners apart in a section that we did one day, at night before those guys went home the air conditioners were wrapped back up, the flashing was put back around the air conditioner and all of the edges of the roof were sealed to the old roof so everything was watertight.”

Safety was also a concern, especially with pedestrian traffic below. “We had to make sure all of our safety procedures were in place for our crews and for the members of the public going in and out of the doors,” Wilkerson says.

The crews used safety lines at the perimeter, and anyone outside the safety lines had to be tied off at all times. “We had to make sure we had a man strictly watching out for the safety of the crews. You have to make sure any little pieces of membrane don’t blow off the roof. You have to make sure all of that is being cleaned up steadily as the job is going on. You don’t want the public to see anything except the flag stands on the roof.”

Staging was complicated, but luckily the jobsite offered ample space for trucks and cranes to be moved between the buildings. The key was to tackle high-traffic areas early in the morning and move to less busy spots as the day wore on.

Proper staging is crucial to jobsite efficiency, notes Wilkerson. “We like to stage the material as we put it on so we’re not dragging it across the roof,” he says. “It’s all right there for them, laid out as they go.”

Support and teamwork are essential up and down the line. “We work really well as a team, so if anyone has any small questions, they can ask the superintendent and call me, so we can make sure we take care of it the Peach State Way.”

Flexing Their Muscles

The project went off without a hitch, says Wilkerson. The mall traffic was never disrupted. “Not one leak, not one complaint on this project,” he says. “Our project management on this project was spot on. Our superintendents held their own out there. And our guys—it’s the attention to quality and all the time we put into training our guys that allows them to do this and make it look almost seamless. It’s one of those situations where you want it to look easy while you’re doing it, but when you’re in the mix of it and you’re trying to get it all done, it’s not as easy as it looks.”

Customer service was crucial. It wasn’t just the property management company that had to be kept informed—it was each individual retailer in the building. “There were so many people to deal with,” notes Wideman. “Every manager of each of those units had to be kept informed of the process. Roofing is not as hard as people think, but keeping up with the owners, keeping people happy, letting people know ahead of time what’s going on is a big challenge. We had to make friends with everyone ahead of time and let them know where to call with any questions.”

“The project, as far as roofing goes, was pretty straightforward,” concludes Wilkerson. “The key is to keep up with everyone on a daily basis and let them know what’s going on so if there is a small problem, it doesn’t keep brewing until it’s a big problem.”

Photos: Peach State Roofing Inc.

Re-Roofing of Shopping Center Poses Logistical Challenges

Southgate Shopping Center: Sebring, Florida

The re-roofing project of the shopping center totaled 79,556 square feet.

The re-roofing project of the shopping center totaled 79,556 square feet.

Roofing contractors often find themselves tackling re-roofs at shopping centers in piece-meal fashion, doing sections over the years as the budget allows. When property manager Southern Management and Development decided to remodel the entire Southgate Shopping Center in Sebring, Fla., in conjunction with Publix Markets’ replacement of their existing store at the location, they looked to Advanced Roofing to get the job done.

The scope of work included re-roofing three large sections of the retail plaza and a drugstore on the property. The roofing portions totaled 79,556 square feet.

Roof System

The roof specified was a two-ply modified bitumen system from Johns Manville. In the three large sections of the plaza, the existing built-up roof was completely torn off, while the drugstore was a re-cover project, notes Andrew Vik, estimator and project manager with Advanced Roofing’s Tampa branch, which operates under branch manager Michael Landolfi.

Roofing work started in November 2016 and was completed in February 2017. After the existing roof was removed, crews installed 2-inch polyiso to the steel deck. “We mechanically fastened that with a half-inch USG SecuRock cover board through the steel deck,” notes Vik. “The two plies of modified bitumen were then torch applied, a smooth base sheet and a white granulated cap sheet.”

On the drugstore, the roof was vacuumed, and the cover board and two plies were installed over the top of the old roof system.

In addition to the roofing scope, Advanced Roofing’s HVAC division installed and removed heating and air conditioning units and replaced some obstructive ductwork. “We had our own HVAC people working with our roofing crews, so it was easy to coordinate everything,” notes Vik. “We had HVAC installations on three of the buildings, and we remounted existing units on two of the buildings. There was also a lot of demolition on the south building, as there were several derelict units that
had been sitting there for quite some time. Those had to be hoisted off there and taken out.”

A Challenging Project

In addition to the roofing scope, Advanced Roofing’s HVAC division installed and removed heating and air conditioning units and replaced some obstructive ductwork.

In addition to the roofing scope, Advanced Roofing’s HVAC division installed and removed heating and air conditioning units and replaced some obstructive ductwork.


Logistics are often a challenge with a shopping center that remains open to the public, notes Vik. “You have to load and unload multiple levels of the roof at different times,” he says. “Customer relations is also a challenge; you have to keep everyone happy and ask a lot of questions. The construction manager has to do a lot of P.R. when he’s there.”

Demolition portions of the project were done at night and application during the day, so business at the mall was never disrupted. Traffic in the parking area was also a key concern.

“Setup areas had to be barricaded and marked off while we were loading and unloading,” Vik says. “There was even a drive under bridge connecting two buildings that had to be re-roofed, so we always had to be mindful of people below.”

Parapet walls did not surround all portions of the roof, so safety precautions included a safety perimeter; employees outside the perimeter had to be harnessed and tied off to a portable fall protection anchor system by Raptor.

The project went off without a hitch, according to Vik. “The mall was 100 percent open during the entire project,” he says. “Things went very smoothly— especially for everything that was involved. One of our mottoes is, ‘The harder the job, the better.’ We like a challenge. We take on a lot of projects other companies shy away from.”

The keys to his company’s success are coordination and versatility, states Vik. “We do it all,” he says. “We didn’t have to get anybody from outside the company to work on the project. We did all the roofing, all of the HVAC, and all of the hoisting was done in-house. We’ve also got lightning protection inhouse, and we have a solar division. We have a great team. Everyone does their part to get the bids out and get the jobs done. It’s the best team I’ve ever worked with.”

Team

Roofing Contractor: Advanced Roofing Inc., Tampa, Fla.
Consultant: CBA Roof Consulting LLC, Lake Worth, Fla.
Roof System Manufacturer and Technical Support: Johns Manville, Denver

Synthetic Shake Roof Helps Hotel Fit in Mixed-Use Area of Biltmore Estate

Village Hotel, Biltmore Estate: Asheville, N.C.

The four-story, 130,000-square-foot hotel was designed to ensure it fit comfortably within the Antler Hill Village and Winery area of the Biltmore Estate.

The four-story, 130,000-square-foot hotel was designed to ensure it fit comfortably within the Antler Hill Village and Winery area of the Biltmore Estate.

Nestled on 8,000 acres of pristine land in the mountains of western North Carolina, Biltmore welcomes more than a million visitors each year. Facing increased demand for additional on-site lodging, the new Village Hotel on Biltmore Estate was commissioned.

“The task of designing the four-story, 130,000 square foot hotel to ensure it fit comfortably within the Antler Hill Village and Winery area of the estate fell to PGAV Destinations. Antler Hill Village was intended to look like a series of buildings that belonged together but maintain an individual identity through the use of different roofing materials and trim treatments,” says Emily Pelcak, director of practice and innovation for PGAV Destinations. “With the Village Hotel, we wanted to continue that story. We specified DaVinci Roofscapes synthetic shake roofing to complement the general aesthetics of the area but also to create a distinctive personality for the hotel.”

The sprawling 209-room hotel is tucked next to restaurants, shops and a winery that all have real or simulated shake roofing. Each of the structures has a natural, rustic feeling, inspired by the eclectic mix of cottages and farm homes original to the estate that opened in 1895 belonging to George Vanderbilt.

“The look of the DaVinci shake roofing is convincing as a shake shingle, which is a traditional building material in western North Carolina,” says Pelcak. “Their ability to create unique blends so the hotel could have subtle color shifts across the building roof was a key reason the DaVinci shake roofing was specified.”

To ensure a distinctive look to the roof, Pelcak and her team worked with DaVinci to gain samples of multiple color blends of Bellaforté Shake tiles. The final decision was to create and install three unique color blends with the predominant colors including a range of Tahoe colors (Light, Medium Light, Medium and Dark), plus Dark Chesapeake.

“The color selection was an arduous process since we wanted a subtle variation across the roof to blend with the adjacent existing structures and complement the main exterior facade treatment,” says Pelcak. “We’re proud of this project and pleased that The Biltmore Company is happy with the look and performance of the DaVinci product. Based on their feedback, we may specify these tiles again on future projects throughout the estate.”

The sprawling 209-room hotel is in a complex with restaurants, shops and a winery. Each of the structures has a natural, rustic feeling, complemented by a real or synthetic shake roof.

The sprawling 209-room hotel is in a complex with restaurants, shops and a winery. Each of the structures has a natural, rustic feeling, complemented by a real or synthetic shake roof.

Roof Report

With the design work complete, the installation task for the massive roof system fell to Benton Roofing. From start to finish, the project took nine months to complete, with 45 days dedicated to installation of the synthetic Bellaforté Shake roof.

“The multiple roof lines on the project give the hotel an appealing look,” says Caleb Benton, president and owner of Benton Roofing. “The project went smoothly and the roofing material was easy to install.”

“These roofing tiles are the perfect fit for this hotel since they’re impact- and fire-resistant, plus they’re basically maintenance-free. This was our first time installing DaVinci products and we were impressed.”

Although the Asheville area is not known for large amounts of snowfalls, the hotel designers took extra caution to specify snow guards be installed on the roof in key public areas. Manufactured by Rocky Mountain Snow Guards, the snow guards on the Village Hotel help prevent any collected snow from sliding off the roof in large pieces onto walkways.

Now open for more than a year, the Village Hotel provides easy access for visitors to the estate’s gardens, 10 shops, 15 dining venues, winery, equestrian center and outdoor activities. The main feature of the estate, Biltmore House, has 250 rooms with tours available daily.

Photos: The Biltmore Company

Project Profiles: Retail

Sierra Nevada Brewery, Mills River, N.C.

About 58,000 pounds of copper were installed on the brewery.

About 58,000 pounds of copper were installed on the brewery.

TEAM

Roofing Contractor: The Century Slate Roofing Co., Durham, N.C.
Architect: Matthew Galloway of Russell Gallaway Associates Inc., Chico, Calif.

ROOF MATERIALS

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project. This was close to 750,000 pounds of slate, or 375 tons.

About 3,000 feet of custom copper gutters and downspouts, conductor heads and 100 squares of painted standing-seam panels were fabricated, and pre-built copper clad dormers and decorative copper cornices were installed.

The project also included 35 squares of copper standing-seam roofing, 25 squares of soldered copper flat-seam roofing and 115 squares of copper wall cladding. About 58,000 pounds of copper were installed on the brewery.

Everything on the building is oversized and that meant everything had to be built to support the heavy structural loads and live loads from wind and mountain snow. The large roof faces called for 10-inch custom copper gutters. When you have gutters that large in the mountains of North Carolina you have to consider the extraordinary weight of the annual snow.

In addition to snow guards being installed on the slate roof, custom 1/4-inch-thick copper gutter brackets fastened the gutter to the fascia. It is typical on steel-framed construction, particularly on this scale, that the framing is out of square and there is widely varying fascia and rake dimensions.

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project.

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project.

However, these items should not appear out of square or have varying dimensions. Great care had to be taken to measure and custom bend onsite all the detail flashings so everything appeared perfect. This took many skilled craftsmen, a great deal of time and the absolute drive to provide the highest quality work.

Slate Manufacturer: Evergreen Slate Co. Inc.
Copper Fabricator: K&M Sheet Metal LLC
Supplier of Underlayment, Copper Sheets and Coil, Insulation and Nailbase Sheathing: ABC Supply Co. Inc.

ROOF REPORT

The new-construction project began in November 2013 and was completed in September 2015.
The team completed the slate installation so well that The Century Slate Co. was awarded the 2015 Excellence in Craftsmanship Award by Evergreen Slate for the project.

PHOTOS: The Century Slate Roofing Co.

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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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