Standing Up to Mother Nature

When this home’s failing roof had to be replaced, it was restored with a composite shake product from DaVinci Roofscapes. Photo: Ron Berg Studio

Decisions. Decisions. When Sheri Stamper recently purchased a home in the Village of Loch Lloyd in Missouri, she faced numerous remodeling decisions — including the search for a new roof. The one she “inherited” on her home was made of concrete foam to replicate slate or concrete tiles, but the surface was cracking and the roof was leaking.

Fortunately for Stamper the decision on a replacement roof was an easy one. She went with a composite roofing product she knew and trusted: DaVinci Roofscapes.

“I installed this company’s composite roofing tiles on a previous home,” says Stamper. “I did research prior to selecting both roofs. The DaVinci product wins out for quality, performance and style.”

For her new home, Stamper was pleased to learn that the company now offers the Black Oak color in its Nature Crafted Collection. “I like this new color offering,” says Stamper. “It has a natural look along with good texture and dimension.

“My goal was not to install a wood shake look, but rather a natural look with colors from nature. The darker tone of the Black Oak roofing appears natural, with not such a harsh appearance.”

Out With the Old

The 1995 modern/contemporary style home Stamper purchased was in distinct need of a new roof, placing it high on her list of remodeling projects. “The roof was only about seven years old, but it was a poor-quality roof,” says Stamper. “Storms had damaged it and replacing it became a top priority for me.”

To help get the new composite roof she wanted, Stamper turned to M&M Roofing out of Olathe, Kansas. “This is the second DaVinci composite roof we’ve installed for Sheri over the years,” says Craig Meyer, operations manager with M&M Roofing. “She was very correct in her assessment of the existing roof … it was in bad shape and needed replacement.”

Photo: Ron Berg Studio

According to Meyer, the Village of Loch Lloyd wants homeowners to invest in higher-performance roofing materials. If residents need a new roof, M&M Roofing’s goal is to be there to offer assistance. “We help homeowners make the connection between the investment in a composite roof and years of peace-of-mind,” Meyer says. “A roof like this may initially be more expensive than other options, but then again, there are many benefits. This composite roof resists flame spread, impact, insects and algae growth. There is the potential for yearly discounts on homeowners insurance. Easy-care roofing that requires no yearly maintenance fees is a bonus. These benefits really add up for homeowners.”

When the M&M Roofing team arrived onsite, the job of removing the existing roofing material couldn’t have been easier. “That old roof literally peeled right off,” says Meyer. “There were no nails holding it in place. It came off piece by piece, using only our hands. This may explain why some of the pieces were coming off in high wind storms.”

The ability of the roof to stand up to extreme weather is essential. “Here in the Missouri/Kansas area, our roofs have to hold up to hail, wind and snowstorms,” Meyer notes. “The only products that we’ve seen truly stand up to those conditions are impact-resistant, top-quality composite roofing.”

Proving his point, Meyer relates that his company receives calls regularly from customers praising the composite roofing they’ve had previously installed by the M&M Roofing team.

“They tell us how a hailstorm destroyed roofs in their neighborhood — except for theirs,” he says. “That’s when we really feel good about making the recommendation of an impact-resistant DaVinci roof.”

Tackling the Job

After removing the old roof on the Stamper home, the M&M Roofing team got to work on installing the new composite shake roof. First came a radiant barrier roof decking, then drip edge was installed. An ice and water shield product was added next, followed by metal in the valleys.

“This home has tons of valleys so we added the ice and water shield for extra protection,” says Meyer. “It takes more time, but it’s essential for the design of this home to help protect it from our weather conditions.”

Finally, the DaVinci Single-Width Shake tiles were installed. Arriving in pre-mixed bundles saved the installation crew time on the jobsite.

Photo: Ron Berg Studio

“Any roofing project has its challenges,” says Meyer. “For this home it was keeping our crew tied off at all times. The home goes up four stories in the back and we wanted everyone to be as safe as possible while keeping the courses straight during installation. For us, our longstanding, top-quality crews and loyal customer base are the backbone of our business. That’s why we make every effort to treat each project individually with special attention to safety.”

Introduced to the marketplace in early 2018, the Nature Crafted Collection includes realistic, nature-inspired colors including Aged Cedar, Mossy Cedar and Black Oak. “This is one of the few products on the market that looks like natural wood, but without weight or performance issues,” says Stamper. “The impact resistance, fire rating and low maintenance aspects were all features that helped me once again decide to invest in a DaVinci roof.”

With the job now complete, Meyer agrees with the homeowner. “It’s great when we can work with a repeat customer like Sheri who was so impressed with her first composite roof that she wants another one for a new home,” says Meyer. “We were really pleased that she was excited about the new Black Oak color for the composite shake shingles. The house looks spectacular with those tiles and you can easily see that they give the home a clean, natural appearance on the exterior that will last for decades to come.”

New Multi-Width Composite Shake Tiles Resemble Traditional Cedar

DaVinci Roofscapes has added a fourth shake profile to its composite roofing product offering: DaVinci Select Shake. Created with the authentic look of real cedar shake taken from natural wood profiles, the multi-width DaVinci Select Shake tiles resemble a traditional cedar shake look.

Available in 8-inch and 10-inch widths, each DaVinci Select Shake tile is 22 inches long and has a 5/8-inch thickness. The 10-inch wide pieces have a simulated keyway to give the appearance of 4-inch and 6-inch width shakes placed together. The unique tile design of DaVinci Select Shake allows for faster installation than previous DaVinci single- and multi-width products.

“In 2016 we updated our slate products to make them more realistic looking and this year we’ve done the same thing for our shake offering by launching the new DaVinci Select Shake,” said Michael Cobb, president and chief marketing officer of DaVinci Roofscapes. “If someone is looking for a jumbo shake look, we’d suggest our Bellaforté Shake product. However, if someone is searching for a multi-width shake tile with a truly authentic and traditional shake profile, then we’d recommend the new DaVinci Select Shake product.”

The new DaVinci Select Shake product line comes in eight color blends, including Autumn, Chesapeake, Mountain, Tahoe and Weathered Gray. The additional three color blends come from the Nature Crafted Collection and include Aged Cedar, Black Oak and Mossy Cedar. Introduced in 2018, the Nature Crafted Collection colors reflect different progressive aging processes found on real shake shingles. These colors recreate the natural warmth and softness of a patina previously only created by time and exposure to the elements.

DaVinci Select Shake products are currently undergoing testing and are expected to meet the same testing classifications as with other DaVinci roofing products. According to the manufacturer, the tiles are backed by a Lifetime Limited Warranty and resist fading, rotting, cracking and insects.

“As we enter our 20thyear of manufacturing composite roofing materials we continue fine tuning our product offerings,” said Cobb. “DaVinci Select Shake results from our desire to constantly ‘make a good thing better.’ We’re excited to provide visual versatility to meet aesthetic vision and budget.”

With the addition of the DaVinci Select Shake product line, DaVinci now offers four composite shake tile options: DaVinci Multi-Width Shake, DaVinci Single-Width Shake, Bellaforté Shake and DaVinci Select Shake. 

For more information, visit www.davinciroofscapes.com

Project Profiles: Health Care

Mount Carmel New Albany, New Albany, Ohio

Team

Roofing Contractor: Smith Roofing, Columbus, Ohio

Bellaforté Slate composite roofing in Smokey Gray was installed on the 117,668-square-foot hospital.

Bellaforté Slate composite roofing in Smokey Gray was installed on the 117,668-square-foot hospital.

Roof Materials

Bellaforté Slate composite roofing in Smokey Gray was installed on the 117,668-square-foot hospital. The composite roofing has achieved a Class A Fire Rating in the ASTME E 108 fire test and withstands straight-line winds up to 110 mph in the ASTM D 3161 test. The roof tiles also resist impact, severe weather conditions and wind-driven rain. Bellaforté Slate tiles not only add safety to the structure, they also add aesthetic appeal.

Composite Roofing Manufacturer: DaVinci Roofscapes

Roof Report

The 60-room hospital features eight operating rooms and specializes in outpatient and inpatient orthopedic, neurologic and musculoskeletal care. The roof was installed in May 2015.

PHOTO: DaVinci Roofscapes

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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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300,000 Pounds of Polymer Roofing Tile Scraps Are Recycled Annually at DaVinci Roofscapes

The 45th anniversary of Earth Day in 2015 puts a shining spotlight on recycling efforts around the country—including at DaVinci Roofscapes in Kansas. That’s where more than 300,000 pounds of polymer roofing tile scraps are recycled each year.

“Most manufacturing operations have scrap materials,” says Bryan Ward, vice president of operations at DaVinci Roofscapes in Lenexa, Kan. “The difference here is that every roofing tile we create is 100 percent recyclable, so we are able to reuse every pound of scrap that comes off our production line into our roofing material’s starter shingles. This saves a significant amount of material from going to the landfill, along with making us an efficient, environmentally friendly operation.”

With more than 300,000 pounds of scrap recycled annually, DaVinci doesn’t stop there. The polymer slate and shake roofing manufacturer offers two recycling programs that provide a way for roofers to return scraps, cuttings and unused synthetic roofing material to the company’s facility for recycling.

Waste products from a job site can be returned to DaVinci’s Kansas plant for recycling (with shipping paid for by DaVinci within a 500-mile radius of the plant) and expired tiles (those older than 50 years old) can also be returned for recycling. Ward estimates that almost 5,000 pounds of product are returned from field projects each year for recycling.

Selecting polymer roofing tiles also helps save trees and energy. “Every time someone chooses a DaVinci roof instead of wood shakes, trees are saved—often young growth cedars that are difficult to harvest, produce low-quality shingles and further deplete our limited resources,” says Ward. “Natural slate roofs present other problems. The quarrying process consumes large amounts of labor and fuel and can be harmful to the local ecosystem. Up to 15 percent of natural slate tiles crack or break up during installation, so waste is significant. Because DaVinci tiles weigh one-third as much as natural slate of comparable thickness, transportation energy costs and carbon emissions are lower.

“Just as it’s important to us that all our sustainable roofing products are Made in America, it’s also vital that we keep our earth as clean and healthy as possible for future generations,” says Ward. “We’re a company that celebrates Earth Day every day of the year. By creating roofing products that meet Leadership in Energy and Environmental Design (LEED) certification process standards, we’re taking a step toward saving valuable resources.”

Single-width Slate Tile Features an Enhanced Profile and Dark Gray Color

The single-width slate 12-inch tile from DaVinci is available in Smokey Gray.

The single-width slate 12-inch tile from DaVinci is available in Smokey Gray.

DaVinci Roofscapes launched the single-width slate 12-inch tile with an enhanced profile and a Smokey Gray color.

The single-width slate 12-inch tile from DaVinci now boasts a more authentic quarried look.

The refined profile is produced in eight 12-inch slate tile variations and will be included in DaVinci’s blended bundles, including all color and blend options for single-width Slate.

Already a provider of a variety of color options in the polymer roofing industry, DaVinci introduces a color for 2015, Smokey Gray.

Smokey Gray is the 50th color offered by DaVinci, and the darkest gray available from the company. Slate Gray, Medium Gray, Light Gray, Dark Gray, Light Weathered Gray, Medium Weathered Gray, Medium Light Weathered Gray, Medium Dark Weathered Gray, Dark Weathered Gray, Light Chesapeake, Medium Light Chesapeake, Medium Chesapeake and Dark Chesapeake are also available from DaVinci.

The experienced team members at DaVinci Roofscapes develop and manufacture polymer slate and shake roofing systems with an authentic look and superior performance. DaVinci has an extensive selection of colors, tile thickness and tile width variety. The company’s products have a limited lifetime warranty and are 100 percent recyclable. All DaVinci high-performing roofing products are made in America where the company is a member of the National Association of Home Builders, the National Association of Roofing Contractors, the Cool Roof Rating Council and the U.S. Green Building Council.