Coating System Makes Roofing and Cladding Appear Aged, Weathered

Bossier City, La.-based McElroy Metal’s Cor-Ten AZP Raw is new to the company’s product line, offering the look of aged or weathered roofing and cladding.

Cor-Ten AZP Raw is a fluoropolymer coating system that uses cool pigment technology that McElroy Metal applies over Galvalume-coated steel sheet. It’s available in a variety of McElroy Metal standing-seam and through-fastened panel profiles. The look of aged or weathered roofing and wall cladding is growing in popularity and used in commercial, residential and industrial applications. Cor-Ten AZP Raw provides the appearance of rusted metal with the advantages of a highly reflective PVDF coating.

“We’re offering the appearance of weathered steel without having to wait for time and Mother Nature,” says Ken Gieseke, vice president of Marketing at McElroy Metal. “As soon as it’s installed, the weathered aesthetic is evident, attractive and durable. It’s sure to become a popular choice of architects and building owners seeking the look of weathered steel.”

In 2005, U.S. Steel introduced Cor-Ten AZP prepainted steel sheet to provide architects, building owners and homeowners with an enhanced performance product to its Cor-Ten steel. McElroy Metal offers the moderately weathered Cor-Ten AZP Raw, a carefully crafted and engineered system to provide any roofing or cladding project with the authentic look of timelessness.

Raw is produced by McElroy Metal in collaboration with Valspar and U.S. Steel.

To learn more, visit here or call (318) 747-8000.

Project Profiles: Historic Preservation

CATHEDRAL OF ST. PAUL, BIRMINGHAM, ALA.

Team

ROOFING CONTRACTOR: Midland Engineering Co., South
Bend, Ind.
ARCHITECT: ArchitectureWorks LLP, Birmingham
GENERAL CONTRACTOR: Hoar Construction LLC, Birmingham,
MASONRY CONTRACTOR: Ziolkowski Construction Inc., South Bend

The cathedral’s intricate slate tile patterns incorporated three slate colors and square and deep bevel cut tiles.

The cathedral’s intricate slate tile patterns incorporated three slate colors and square and deep bevel cut tiles.

Roof Materials

The Catholic Archdiocese of Birmingham required the cathedral’s new roof system be a historically accurate reproduction of the original in materials, design and craftsmanship. The cathedral’s intricate slate tile patterns incorporated three slate colors and square and deep bevel cut tiles. Six large slate crosses and multiple accent patterns, barely visible on the faded original roof, required exacting measurements prior to tear-off and a high level of precision to recreate and maintain over such a large field and on octagonal steeples.

Because of metal thinning brought on by their advanced age, every copper architectural and functional feature in the existing roof system had to be carefully removed and shipped to Midland Engineering’s South Bend facility to be historically replicated in its metal shop. This included seven ornate crosses (up to 17-feet tall), finials, turret caps and more. There were more than four dozen components, for which no original prints existed, as well as over 500 feet each of custom copper cornices and radius gutters with matching straps. More than 20,000 square feet of 16- and 20-ounce copper was utilized for fabrication of architectural elements and flashing.

Midland Engineering was asked to make improvements to the original roof system to improve attic ventilation while maintaining the Gothic Revival period look. To accomplish this, the crew integrated bronze screen (invisible from the ground) into the original copper cornice and eave design to provide improved cold air intake while new louvered copper dormers replaced the original painted roof ventilator.

An updated lightning protection system was incorporated into the new roof design, hidden within many of the new copper crosses and other architectural elements. The system was fabricated in Midland Engineering’s shop to maintain the Gothic Revival look.

The metal shop also clad 10 previously painted windows and mullions in copper, effectively eliminating frequent and costly maintenance. These windows, reachable only by crane at considerable expense, formerly required painting and other maintenance every five to seven years.

About 6,500 square feet of lead-coated copper, which patinas to a limestone color, was utilized to cap all limestone exposed to weather, reducing ongoing maintenance of limestone joints.

Extensive termite damage to structural framing required repair prior to installation of the new roofing system. Upon removal of the original slate roof and completion of the structural repairs, the new roof was dried-in and installation of the new slate roof began. The historically accurate replacements of the original copper architectural features were installed according to schedule.

SLATE SUPPLIER: North Country Slate
COPPER SUPPLIER: Hussey Copper

Roof Report

The Cathedral of St. Paul is the centerpiece of the Roman Catholic Diocese of Birmingham. Completed in 1893 at a cost of $90,000, the cathedral is widely considered to be a handsome example of the American Neo-Gothic variant of the Gothic Revival style. The cathedral measures 96-feet wide by 140-feet long and encompasses more than 60,000 square feet. It features twin octagonal steeples, rising 183-feet high.

Work schedules on this project were a challenge. The contract required parishioner and clergy access to the church must be maintained 24 hours a day, seven days a week, throughout the eight-month duration of the project. Further, because of the noise inherent in roof construction, work schedules had to be planned around regular church services and events and rescheduled several times a month for funerals and other unscheduled events.

“We could not have been more pleased with the work accomplished by the team from Midland Engineering,” says Very Rev. Kevin M. Bazzel, V.G., J.C.L., rector of the Cathedral of St. Paul. “It is a marvel to us to be able to see the church in its original glory, and all of this thanks to Midland!”

The National Roofing Contractors Association, Rosemont, Ill., awarded Midland Engineering the prestigious Gold Circle Award in 2016. Midland was recognized in the Outstanding Workmanship—Steep-slope Category.

Photo: Rob Culpepper

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Roof and Cladding Panels Look Like Rusted Metal

Cor-Ten AZP Raw offers the look of aged or weathered roofing and cladding.

Cor-Ten AZP Raw offers the look of aged or weathered roofing and cladding.

McElroy Metal has made available Cor-Ten AZP Raw, which offers the look of aged or weathered roofing and cladding. Cor-Ten AZP Raw is a fluoropolymer coating system that uses cool pigment technology McElroy Metal applies over Galvalume-coated steel sheet. It’s available in a variety of McElroy Metal standing-seam and through-fastened panel profiles.

ARMA Helps Update Wind-resistance Standard for Asphalt Shingles

DURING THE past year, the Washington, D.C.-based Asphalt Roofing Manufacturers Association (ARMA) has led the process to update the ASTM International wind-resistance standard for asphalt shingles to help ensure that it complies with the latest methods to determine design loads for roofs and cladding used on buildings. ASTM standards are consensus standards that are used around the world to improve product quality and build consumer confidence.

The 2016 version of ASTM D7158 is now coordinated with the American Society of Civil Engineers standard ASCE 7-10, “Minimum Design Loads for Buildings and Other Structures”, which is the document that the International Building Code relies on for its structural provisions. The ASCE 7-10 standard had significant revisions in wind design. ARMA worked with recognized structural engineers who are leaders in the wind-engineering field and industry stakeholders who provided specific updates to D7158 that ensure consistency with ASCE 7-10. Although the building code includes conversion factors to account for differences between versions of ASCE 7, ARMA and other industry stakeholders recognized the value of correlating D7158 with the latest version of ASCE 7. The updates were balloted and approved via the ASTM consensus process.

“ARMA has always been a leader of progress and innovation in the roofing industry,” says Reed Hitchcock, executive vice president of ARMA. “Spearheading the revision of the test standard that determines wind resistance of asphalt shingles shows ARMA’s commitment to the roofing community, building owners and home-owners alike. We continue to strive to make asphalt the leading roofing technology.”

ASTM D7158-16, “Standard Test Method for Wind Resistance of Asphalt Singles (Uplift Forces/Uplift Resistance Method),” is now available for purchase on the ASTM website. Learn more about ARMA at AsphaltRoofing.org.

AkzoNobel Combines Sales and Marketing Teams from Its Liquid and Powder Coatings Businesses

AkzoNobel will combine the sales and marketing teams from its liquid and powder coatings businesses that serve the aluminum architecture and façade and cladding markets. The move reflects the growing importance of powder coatings in that sector, and will help customers and specifiers to make the right coatings choices, says Ben Mitchell, manager, Extrusion Coatings at AkzoNobel.

”Because liquid and powder coatings are not always interchangeable in aluminum applications, it is important for customers to understand which are most appropriate,” he says. “Having a combined team will ensure a unified approach to helping designers, specifiers and fabricators to select the optimal solution for their project.”

The new team builds on an effort to educate industry professionals about powder and liquid coatings choices for aluminum, Mitchell adds. These include an AkzoNobel research paper presented at the Council on Tall Buildings and Urban Habitat 2015 Conference and the AEC Daily continuing education course “High Performance Coatings for Aluminum Fenestration”.

“Specifiers need accurate information on all available products in order to make the best decision for a given application, Mitchell adds. “AkzoNobel prides itself on superior customer service, so our priority is to keep internal experts networked throughout our organization and provide clients with optimal solutions for their specific application, regardless of chemistry or application method.”

AkzoNobel’s products for metal coil and extrusions include TRINAR, CERAM-A-STAR, POLYDURE, ACRA-BOND, INTERPON D3000, INTERPON D2000 and INTERPON D1000.

MCA Publishes Technical Resource on Selecting Proper Types of Fasteners

The Metal Construction Association (MCA) has published a new technical resource to assist designers and installers in selecting the proper type of fastener: Fastener Compatibility with Profiled Metal Roof and Wall Panels.

Found in the technical resources section of the MCA website at www.metalconstruction.org, the new bulletin includes a convenient table that serves as a guideline to check fastener compatibility with different types of cladding materials. The table references corrosion resistance between eight common types of metal roof and wall cladding materials and nine different fasteners. With it, users can quickly determine if they are matching the right fastener with the right roof or wall material to ensure performance over time and a strong, weather tight attachment.

The integrity and aesthetics of a building is at risk when the wrong type of fastener is used with a metal roof or wall cladding system. Premature corrosion of the metal panel and/or the fastener may occur under certain conditions. Known as galvanic corrosion, this is often a result of corrosion between the dissimilar metals that are in contact with each other. To prevent dissimilar metal corrosion at the connection point, fasteners should be made of a compatible or the same material as the roof or wall material whenever possible. At the very least, the fastener should display equivalent corrosion resistance to the material being fastened.

The bulletin also provides a discussion on the fastener durability and the roles (primary or secondary) and type (self-drilling, self-tapping and self-piercing) of fasteners that will help designers and installers achieve high fastener performance.

The MCA updates its education/technical resources section on its website on a regular basis, addressing practical and educational topics related to the metal construction industry. All materials are available free to website visitors to download in PDF format.

Roofinox Expands Sales and Distribution of Products in the U.S.

Roofinox International, a European-based, 30-year-old manufacturer of metal roofing materials, has announced plans to expand sales and distribution of three key products in the U.S. through its subsidiary, Roofinox America Inc.

Products include Roofinox Classic, a brush-rolled material designed for roofing and wall cladding, Roofinox Plus .0157, a ribbed surface material for smoother roofing results and economy and Roofinox Terne-Coated with a tin-plated surface that develops a matt grey patina finish over time.

The announcement comes in response to an increasing demand for Roofinox products since 2012 when the only domestic manufacturer of terne-coated steel products went out of business.

“From then on we supplied to various projects all over the U.S. with increasing quantities every year,” notes Pascal Metzler, who with his brother, Marc, own the company. “In 2014 we decided to move to the U.S. by opening an office and warehouse from where we could service the increasing demand,” he notes. Meanwhile, sales in Europe were also continuing to grow with marketing and distribution to Poland, Russia, Slovenia and Sweden. The company also regularly supplied its unique products to various commercial projects in strong markets like Australia, New Zealand, Malaysia and Singapore. Last year, the company started selling the Roofinox product range in Turkey as well. And while Roofinox is currently examining business relations in several more countries, Metzler emphasizes the main efforts are now to grow market share in the U.S.

He notes the technology for his products date back to 1995 with the development of inoxidable (stainless) steel as a roofing material. The idea behind the product was to create a stainless steel specifically designed for roofing and roll-forming. “We found two major features that made it ideal for the application—mechanical properties and surface design with an architecturally distinctive matt finish for rollformed roofing panels. The product features within these two areas differentiated Roofinox from any other product in the roofing market, he contends and the success of Roofinox Classic and Roofinox tin-plated led to the development of several more products available today.

Architectural demand for Roofinox as a natural metal is very high, notes Metzler. “Aging is no problem for Roofinox because the surface is all natural and typically does not change over time.” In addition, he notes that Roofinox products achieve superior results for LEED-related construction and the sustainability of building products. “More and more building owners are looking into long-lasting and environmentally friendly products,” he notes. And there’s the issue of durability.

“Increasing weather extremes require more durable solutions for roofing and Roofinox stainless steel is the best solution for these environments because it was originally developed for Switzerland and Austria in a region known for challenging weather conditions.”

The current goal is to develop nationwide relationships with metal fabricators and installers who need a reliable source for quality architectural grade stainless steel and tin-plated materials the company offers.

Roofinox materials also offer growth potential to contractors who can now differentiate through specializing into more sophisticated work. “Some of the largest institutional building owners, such as the armed forces, school and education authorities, hospitals and churches, are specifying stainless steel for these reasons—it simply is a very high-quality roofing material,” Metzler notes.

One of the brothers’ first steps toward expansion has been the recruitment of David Rowe, a 28-year veteran of the metal roofing and wall panel industry, who has been named vice president-sales of Roofinox America Inc. Rowe joined Roofinox from Englert Inc., an American manufacturer of metal and aluminum roofing and wall panel coil, where he was director of product management responsible for the planning, development and introduction of all new products.

Roofinox America Names Vice President of Sales

David H. Rowe, a 28-year veteran of the metal roofing and wall panel industry, has been named vice president of sales for Roofinox America Inc., a supplier of quality Roofinox stainless steel coil, featuring mechanical properties and an architecturally distinctive matt finish for rollformed roofing panels.

Rowe joins Roofinox from Englert Inc., an American manufacturer of metal and aluminum roofing and wall panel coil, where he was director of product management responsible for the planning, development and introduction of all new products.

At Roofinox America, Rowe will be responsible for the direction and management of all sales and business development operations, including distribution and fabricator and installer relations for the Roofinox stainless steel product line; Roofinox Classic, a brush-rolled material designed for roofing and wall cladding; Roofinox Plus 0.0157, a ribbed surface material for smoother roofing results and economy; and Roofinox Terne-Coated with a tin-plated surface that develops a matt grey patina finish over time.

Rowe’s roots run deep in this market. He joined Englert in ’92 as a member of its sales force and since then held a variety of management positions in regional and national sales, project management and product development. During his career, he was responsible for the development and launch of more than 30 roofing and wall panel products and programs and several strategic partner alliances for related materials.

Among his responsibilities at Roofinox will be the development of alliances with distributors and metal wholesalers, leading manufacturers for roofing and wall-cladding panels and sheet metal workshops—all looking for Roofinox stainless steel’s combination of high longevity with a dull surface without artificial coating. This natural metal was developed in Europe especially for roofing and wall cladding.

Rowe also brings to Roofinox a proven track record for creating, developing and completing architectural detailing and material specifications for high-end commercial, institutional, and residential projects, and will be responsible for counseling, assisting and training customers, including designers, specifiers and roofing contractors.

He is well-known in the roofing fabrication and contracting industry and early on in his career was associated with Bass Associates, a Massachusetts-based contracting company, installing metal roofing and wall panels.

PVC Liner Panels Are Easy to Clean and Install

AG-TUF and AG-TUF UV corrugated PVC liner panels from H&F Manufacturing Corp.

AG-TUF and AG-TUF UV corrugated PVC liner panels from H&F Manufacturing Corp.

AG-TUF and AG-TUF UV corrugated PVC liner panels from H&F Manufacturing Corp. are fire-retardant and provide efficient cladding of structures, offering many benefits for all types of agricultural and industrial applications.

AG-TUF and AG-TUF UV can be used in applications ranging from hog barns to dairy sheds, from poultry houses to wineries.

AG-TUF and AG-TUF UV panels are also ideal for interior applications such as car/truck wash liners, and commercial/residential garages. The panels withstand harsh treatment from chemicals, impacts from livestock and farm equipment, and are easy to clean and install.

AG-TUF UV panels are ideal for exterior applications where a heavier panel with all the same characteristics as the standard AG-TUF panel are required, but with added UV protection.