OMG Roofing Products demonstrated its new RhinoBond Foil Tool, an induction welding system for securing single-ply commercial roofing membranes, at the BAU show in Munich.
OMG’s RhinoBond Foil Tool is specifically designed for use over foil face PIR insulation. The welding tool includes plate sensor technology to help users locate RhinoBond Plates installed under the roofing membrane, and assists with tool alignment for optimum bonding. A tone and a visual indicator light lets operators know when the weld cycle is complete.
The RhinoBond System is induction based technology used for installing commercial roofing systems. To date, more than 170 million m2 of commercial roofing membranes have been installed around the globe with RhinoBond, including more than 125 projects in Europe accounting for more than 3,200,000 m2.
The company was also looking for new distribution partners in targeted geographies throughout Europe during the show.
“As more roofing contractors have seen the labor savings and roof performance benefits that the RhinoBond System can offer, we have had tremendous growth,” says Lennard Spirig, Europe market manager. ”With updated technology and expanded distribution, we expect acceptance of the RhinoBond System across the region.”
RhinoBond is a method for installing thermoplastic and soon will be available for certain clean EPDM membrane. The system consists of a stand-up induction welding tool and magnetic cooling clamps. Contractors install roofing insulation using fasteners and specially coated plates designed specifically for the type of membrane being installed – PVC, TPO or Clean EPDM. Each plate is then bonded to the roof membrane installed over the top with the RhinoBond plate welding tool. The result is a roofing system that can provide enhanced wind performance with fewer fasteners, fewer membrane seams and zero penetrations of the new membrane.
Currently the RhinoBond System conforms with CE requirements and is approved for use in Europe by many roof system providers, including Bauder, Carlisle/Hertalan, Danosa, Fatra, FDT, Firestone, GAF, IcoPal, IKO, Renolit, Sika, Siplast, and Soprema/Flag.
Headquartered in Agawam, Mass., OMG Roofing Products is a supplier of commercial roofing products including specialty fasteners, insulation adhesives, roof drains, pipe supports, roof repair tape as well as productivity tools such as RhinoBond. The company’s focus is delivering products and services that improve contractor productivity and enhance roof system performance. For additional information, please contact OMG Roofing Products at (413)789-0252 or visit the website.
OMG Roofing’s RhinoBond System has left marks across Europe with more than 125 completed projects and more in the pipeline. Collectively, these projects represent more than 300,000 square meters (3.2 million square feet) of single-ply roofing.
“In last two years, the RhinoBond System has started to take off across Europe, as more roofing contractors have seen the roof performance benefits that the system can offer,” states Web Shaffer, vice president of marketing for OMG Roofing Products. “We have completed projects across Europe and we are expanding to new countries in the region, most recently, into South East Europe.”
RhinoBond is a method for installing thermoplastic and now also clean EPDM membrane. The system consists of a stand-up induction welding tool and magnetic cooling clamps. Contractors install roofing insulation using fasteners and specially coated plates designed specifically for the type of membrane being installed – PVC, TPO or Clean EPDM. Each plate is then bonded to the roof membrane installed over the top with the RhinoBond plate welding tool. The result is a roofing system that can provide wind performance with fewer fasteners, fewer membrane seams and zero penetrations of the new membrane.
The RhinoBond System is approved for use in Europe by many roof system providers, including Bauder, Carlisle/Hertalan, Danosa, Fatra, FDT, Firestone, GAF, IcoPal, IKO, Renolit, Sika, Siplast, and Soprema/Flag.
Headquartered in Agawam, Mass., OMG Roofing Products is a supplier of commercial roofing products including specialty fasteners, insulation adhesives, roof drains, pipe supports, emergency roof repair tape as well as productivity tools such as RhinoBond. The company’s focus is delivering products and services that improve contractor productivity and enhance roof system performance. For additional information, please contact OMG Roofing Products at (413)789-0252 or visit the OMG Roofing website.
Kevin Clausen has faced a lot of challenges during his 30 years at Great Lakes Systems, a Jenison, Mich.-based construction company specializing in single-ply commercial roofs. But when he received a call several years ago from a Kent County official about an unusual upcoming project, Clausen knew he might be taking on a challenge unlike any other.Kent County is home to Grand Rapids, Mich. To understand the challenge that Clausen was about to face, it’s important to understand a little Grand Rapids history. In the late 1960s, swept along by the tide of enthusiasm for urban renewal, the city demolished 120 buildings in its aging downtown core and built a new City Hall and County Administration building, surrounded by a concrete plaza. The new government buildings were designed by architects who were shaped by mid-century ideas of good urban design: sleek, boxy single-use structures, easily accessed by automobile and, therefore, providing ample parking. Pedestrians were something of an afterthought.
At about the same time, the National Endowment for the Arts initiated its Art in Public Places Program. There was general agreement in Grand Rapids that the broad plaza in front of the new buildings seemed empty and generally lacked visual interest. The city applied for a grant to support the funding of a monumental sculpture to serve as a focal point for its new plaza and selected renowned sculptor Alexander Calder for the commission. Two years later, Calder’s sculpture—bright red, 43- feet tall, 54-feet long, 30-feet wide, weighing 42 tons—took its place on the central plaza. It was named “La Grande Vitesse”, which roughly translates into “Grand Rapids”. For obvious reasons, the broad plaza has been called Calder Plaza—and has been the focus of controversy ever since.
The Calder sculpture at ground level on the plaza inspired another important work of art in the area. The flat, unadorned roof of the administration building adjacent to the plaza was drawing attention for the wrong reasons. It was easily viewed from the nearby taller buildings, including the new City Hall, and several city administrators thought some sort of added visual element was necessary for the space. Calder again was pressed into service and designed a large mural for the roof of the administration building. When it was completed in 1974, the 127-square-foot red, black and white mural painted on the roof of the Kent County Administration building was the largest Calder painting in the world.
A DURABLE ROOF
Fast-forward three decades and the aging modified bitumen roofing membrane, which supported the Calder mural, had weathered badly and was in need of repair or replacement. The challenge? How to repair the roof and still preserve the Calder mural. Given the deteriorated condition of the roofing membrane, a complete tear-off was required. Basically, the task at hand was to replace the canvas of a painting and recreate the painting, maintaining its original appearance.
The team at Great Lakes Systems has a long track record of doing work for Kent County, including the jail, juvenile facility and several libraries. Therefore, county leaders turned to Great Lakes Systems when they realized they need- ed a creative solution to repair their unique roof. Clausen says the county wanted to preserve the mural, but a long-lasting, durable roof was a top priority. “They definitely wanted a high-quality roof,” he says.
The project faced other constraints, in addition to the painted surface. The administration building is located in a prominent spot in the middle of downtown Grand Rapids, near the museum dedicated to former President Gerald Ford and adjacent to two major expressways. No interruption of normal activities could be allowed—either on the plaza or in the building supporting the Calder mural. And—perhaps most challenging—Great Lakes Systems was given three weeks to complete the project before the inaugural ArtPrize competition would take over much of downtown Grand Rapids. That meant the team would have two weeks for the roof installation, leaving one week to repaint the mural. This was less than half the time usually required for a comparable project.
For Clausen, one part of the project was easy. He had used EPDM membrane on a variety of prior projects for county buildings, and county officials had been pleased with the results, especially the balance of cost-effective installation and long service life. “We looked at other membranes, given the nature of the project, but we always came back to EPDM, given its 30-year plus lifespan,” Clausen notes. “If we have to paint again, that’s OK, but we don’t want to reroof.”
For this project, fully adhered EPDM, as well as insulation ad- hered to the concrete deck, offered two important benefits: a painting surface that would be appropriate for the repainted mural and minimal noise (compared to a mechanically attached system) so that work in the building below could continue as normal.
Great Lakes Systems used 60-mil EPDM to replace the aging modified bitumen system. The 18,500-square-foot roof was backed by two layers of 2-inch polyiso insulation, and the EPDM membrane was covered with an acrylic top coat to provide a smooth surface for the new painting. The top coat matched the three colors of the mural—red, black and white. The red was a custom tinted acrylic paint deemed to be compatible with the EPDM membrane and the black and white acrylic top coat provided by the EPDM manufacturer.
A BEAUTIFUL ROOF
The Great Lakes Systems’ team applied a creative approach to recreate the mural, adhering carefully to the original design. Because the county used the same colors on its street signs as in the original mural, color codes were available to allow the team to access colors that were identical to those specified by Calder.
Great Lakes Systems took aerial photos of the existing roof, created a grid of the roof and—scaling the design from the photos—recreated the mural exactly, a sort of large-scale paint-by-number approach. The most intricate part of the painting was the layout. Although some free-hand painting had to be done along several jagged edges, the team painstakingly followed the scaled grid and applied chalk lines to outline the original design on the repaired roof. Roller applications were used at the border of the chalk lines to define individual spaces and mark the stopping and starting points for the different colors. Following this “outlining” work, the large areas were sprayed to complete the painting process. The three-man painting crew finished the job with several days to spare, helped along with very good weather.
The roofing project was an informal jump-start toward reimagining uses for Calder Plaza. This past summer, Grand Rapids residents were given the opportunity to voice their preferences for new landscaping for the plaza, provide input for activities that would attract more families and children, and generally make the space more pedestrian friendly. The new proposals are generating excitement and enthusiasm in Grand Rapids. As the new plans become reality, the citizens of Grand Rapids can be assured the Calder mural and the roof supporting it will be doing their part to add beauty and shelter to Calder Plaza and its buildings for decades to come.
60-mil EPDM: Firestone Building Products Co.
2-inch Polyiso Insulation: Firestone Building Products
Black and White Acrylic Top Coat: Firestone Building Products
PHOTOS: Great Lakes Systems
The millions of passengers who pass through Denver International Airport each year no doubt have the usual list of things to review as they prepare for a flight: Checked baggage or carry-on? Buy some extra reading material or hope that the Wi-Fi on the plane is working? Grab
a quick bite before takeoff or take your chances with airline snacks?
DIA, which opened in 1995, is located 23 miles northeast of the metropolitan Denver area, on the high mountain desert prairie of Colorado. Its location showcases its spectacular design incorporating peaked tent-like elements on its roof, meant to evoke the nearby Rocky Mountains or Native American dwellings or both. Unfortunately, this location also places the airport smack in the middle of what is known as “Hail Alley”, the area east of the Rockies centered in Colorado, Nebraska and Wyoming. According to the Silver Spring, Md.- based National Weather Service, this area experiences an average of nine “hail days” a year. The reason this area gets so much hail is that the freezing point—the area of the atmosphere at 32 F or less—in the high plains is much closer to the ground. In other words, the hail doesn’t have time to thaw and melt before it hits the ground.
Not only are hail storms in this area relatively frequent, they also produce the largest hail in North America. The Rocky Mountain Insurance Information Association, Greenwood Village, Colo., says the area experiences three to four hailstorms a year categorized as “catastrophic”, causing at least $25 million in damage. Crops, commercial buildings, housing, automobiles and even livestock are at risk.
Statistically, more hail falls in June in Colorado than during any other month, and the storm that damaged DIA’s roof followed this pattern. In June 2001, the hailstorm swept over the airport. The storm was classified as “moderate” but still caused extensive damage to the flat roofs over Jeppesen Terminal and the passenger bridge. (It’s important to note that the storm did not damage the renowned tent roofs.) The airport’s original roof, non-reinforced PVC single-ply membrane, was “shredded” by the storm and needed extensive repair. Lovato and his team at CyberCon assessed the damage and recommended changes in the roofing materials that would stand up to Colorado’s climate. Lovato also oversaw the short-term emergency re- pairs to the roof and the installation of the new roof.
Under any circumstances, this would have been a challenging task. The fact that the work was being done at one of the busiest airports in the world made the challenge even more complex. The airport was the site of round-the-clock operations with ongoing public activity, meaning that noise and odor issues needed to be addressed. Hundreds of airplanes would be landing and taking off while the work was ongoing. And three months after the storm damaged the roof in Denver, terrorists attacked the World Trade Center, making security concerns paramount.
INSPECTION AND REROOFING
Lovato’s inspection of the hail damage revealed the extent of the problems with the airport roof. The original PVC membrane, installed in 1991, was showing signs of degradation and premature plasticizer loss prior to being pummeled by the June 2001 storm. The storm itself created concentric cracks at the point of hail impacts and, in most cases, the cracks ran completely through the membrane. In some instances, new cracks developed in the membranes that were not initially visible following the storm. The visible cracks were repaired immediately with EPDM primer and EPDM flashing tape until more extensive repairs could begin. Lovato notes that while nature caused the damage to DIA, nature was on the roofing team’s side when the repairs were being made: The reroofing project was performed during a drought, the driest in 50 years, minimizing worries about leaks into the terminal below and giving the construction teams almost endless sunny days to finish their job.
The initial examination of the roof also revealed that the existing polystyrene rigid insulation, ranging in thickness from 4 to 14 inches, was salvageable, representing significant savings. Although a single-ply, ballasted roof was considered and would have been an excellent choice in other locations, it was ruled out at the airport given that the original structure was not designed for the additional weight and substantial remediation at the roof edge perimeter possibly would have been required.
Lovato chose 90-mil black EPDM membrane for the new roof. “It’s the perfect roof for that facility. We wanted a roof that’s going to perform. EPDM survives the best out here, given our hailstorms,” he says. A single layer of 5/8-inch glass-faced gypsum board with a primed surface was installed over the existing polystyrene rigid insulation (secured with mechanical fasteners and metal plates) to provide a dense, hail-resistant substrate for the new membrane.In some areas adjacent to the airport’s clerestory windows, the membrane received much more solar radiation than other areas of the roof. When ambient temperatures exceeded 100 F, some melting of the polystyrene rigid insulation occurred. “That section of the roof was getting double reflection,” Lovato points out. To reduce the impact of this reflection, the roof was covered with a high-albedo white coating, which prevented any further damage to the top layer of the polystyrene rigid insulation board and also met the aesthetic requirements of the building.
Lovato’s observations about the durability of EPDM are backed up by field experience and controlled scientific testing. In 2005, the EPDM Roofing Association, Washington, D.C., commissioned a study of the impact of hail on various roofing membranes. The study, conducted by Jim D. Koontz & Associates Inc., Hobbs, N.M., showed EPDM outperforms all other available membranes in terms of hail resistance. As would be expected, 90-mil membrane offers the highest resistance against punctures. But even thinner 45-mil membranes were affected only when impacted by a 3-inch diameter ice ball at 133.2 feet per second, more than 90 mph—extreme conditions that would rarely be experienced even in the harshest climates.
Lovato travels frequently, meaning he can informally inspect the DIA roof at regular intervals as he walks through the airport. He’s confident the EPDM roof is holding up well against the Denver weather extremes, and he’s optimistic about the future. With justified pride, Lovato says, “I would expect that roof to last 30-plus years.”
90-mil Non-reinforced EPDM: Firestone Building Products
Gypsum Board: 5/8-inch DensDeck Prime from Georgia-Pacific
Plates and Concrete Fasteners: Firestone Building Products
White Elastomeric Coating: AcryliTop from Firestone Building Products
Existing Polystyrene: Dow
After Years of Roof Leaks, a Laboratory That Produces Theatrical Equipment and Software Undergoes a Complex Reroofing
Founded in 1910, Rosco Laboratories is a multi-national producer of equipment, software and products for the theatrical, film, and television industries and architectural environment. As with every aging flat roofing system, water leakage was becoming a recurring problem at Rosco’s Stamford, Conn., facility. The severity of the leakage was further exacerbated by the lack of roof drainage (only two roof drains serviced the entire building) and poor deck slope conditions (less than 1/16 inch per foot).
Rosco representatives employed traditional methods to control and/or collect the moisture within the building by use of several water diverters. This technique was effective but Rosco representatives soon recognized this was not a viable long term solution as the physical integrity of the roof structure (deck) became a principal concern to the safety of the building occupants.
The Fisher Group LLC, an Oxford, Conn.-based building envelope consulting firm was retained by Rosco in March 2009 to survey the existing site conditions and determine the need for roofing replacement. The existing roofing construction, which consisted of a conventional two-ply, smooth-surfaced BUR with aluminized coating, exhibited numerous deficiencies (most notably severe alligatoring) and was deemed unserviceable. Construction documents, including drawings and specifications and a project phasing plan were developed by Fisher Group to address the planned roof replacement.
Bid proposals were solicited from prequalified contractors in June 2010, and F.J. Dahill Co. Inc., New Haven, Conn., was awarded the contract on the basis of lowest bid.
The building basically consists of a 1-story steel-framed structure constructed in the 1970s. It is a simple “box”-style configuration, which is conducive to manufacturing.
In conjunction with design services, destructive test cuts were made by Fisher Group in several roof sections as necessary to verify the existing roofing composition, insulation substrate, moisture entrapment, and substrate/deck construction. A total of four distinct “layers” of roofing were encountered at each test cut. The existing roofing construction consisted of alternating layers of smooth- and gravel-surfaced, multi-ply felt and bitumen built-up roofing. The bitumen contained throughout the construction was fortunately asphalt-based. Succeeding layers of roofing were spot mopped or fully mopped to the preceding layer (system). The combined weight of the roofing construction was estimated to be upwards of 20 to 22 pounds per square foot when considering the moisture content. This is excessive weight.
It is interesting to note that a minimal amount of roof insulation was present in the existing construction. Insulation was limited to a single layer of 1/2-inch-thick fiberboard. Additional insulation would need to be provided as part of the replacement roofing construction to increase the roof’s thermal performance and comply with the prescriptive requirements of the Connecticut State Energy Conservation Construction Code.
The structural substrate, or decking, is conventional in nature, comprised of poured gypsum roof decking. The roof decking incorporates 1/2-inch gypsum formboard loose laid between steel bulb-tee supports spaced about 32 inches on-center. The poured gypsum roof decking in this instance was utilized as the structural substrate and for insulating purposes. Poured gypsum roof decking has a minimal insulating value of perhaps R-2 to R-3, which is obviously considered to be minimal by present standards.
A representative number of bulk material samples were obtained by Fisher Group from the existing roofing construction as necessary to determine the material composition. The sampling included field membrane roofing plies, coatings and cements, and associated roof penetration and perimeter flashings. Laboratory analysis revealed that the second, third and, in some instances, fourth roofing “layers” (field membrane plies) contained varying amounts—5 to 10 percent—of asbestos (chrysotile) which would necessitate full abatement of the roofing construction.
PHOTOS: The Fisher Group LLC
As associate executive director of the Washington, D.C.-based EPDM Roofing Association (ERA), I focus a great deal of my time and energy on the codes and standards that regulate or guide the roofing business. In the current environment, driven by constant upgrades in technology, as well as the need to save energy, these codes—and the standards that often inform them—seem to be undergoing steady revision. Believe it or not—and the word “geek” does come to mind—I find participating in this process extremely interesting. In fact, following and sometimes influencing emerging codes and standards is among the most important responsibilities of my job.
I’ll be the first to admit that a detailed review of a standards manual is probably not anyone’s idea of exciting reading. But given the importance of codes and standards to the construction industry, we ignore them at our own risk.
For a start, what’s the difference between a code and a standard? Ask enough people in the roofing industry and you will get a variety of answers. But generally, codes are the “top-tier” documents, providing a set of rules that specify the minimum acceptable level of safety for manufactured, fabricated or constructed objects. They frequently have been enacted into local laws or ordinances and noncompliance can result in legal action. Standards, on the other hand, establish engineering or technical requirements for products, practices, methods or operations. They literally provide the nuts and bolts of meeting code requirements. If codes tell you what you have to do, standards tell you how to do it. Frequently, standards—especially “voluntary consensus standards”—are the precursors for what becomes law years down the road.
ERA has represented the manufacturers of EPDM roofing for more than a decade. Through the years, we have learned the importance of interfacing with standard-setting and regulatory bodies. One of our first, and most important, learning experiences was working with the Northeast and mid-Atlantic states when they issued regulations designed to achieve federally mandated air-quality standards. (See the article in Roofing’s September/October 2014 issue, page 58.) The initial regulations, which lowered the amount of VOCs in many roofing products, were based on those used in southern California and incorporated provisions that were effective in the climactic and market conditions of that state. But states in the affected areas, from Virginia to Maine, confronted a situation where the new regulations threatened to bring the roofing industry to a sudden halt. In some instances, no adhesives and sealants were available to meet the new standards. And the new products, when they became available, would need to be effective in very cold climates totally unlike those on the West Coast.
ERA worked with officials throughout the impacted areas, helping to create “phase-in” schedules that would give industry enough time to develop products to meet the new standards. In state after state, the local regulators welcomed our input. Our point-of-view was based on a deep understanding of the business needs of our industry. Just as important, we understood the science behind the proposed regulations and could work with the regulatory bodies to ensure the air-quality needs and the needs of the roofing industry were met.
This experience has informed our ongoing approach to code-setting and regulatory bodies. Since our work with the states setting VOC standards, we have invested staff time and resources to stay current with and even ahead of proposals that would impact our members and their customers. We have testified before the South Coast Air Quality Management District in California on its proposal to limit VOCs. ERA has organized an ad-hoc coalition to successfully oppose an unnecessarily stringent proposal to require reflective roofs in the Denver area. And our organization is currently providing input to Atlanta-based ASHRAE’s efforts to clarify its regulation regarding air leakage. This issue—of great importance to the roofing industry—relates to other work being done in ASHRAE working groups and subcommittees on thermal bridging, as well as the definition of walls and wall assemblies. ASHRAE has convened an “Air Leakage Work Group” whose charge is to review the pertinent sections of Standard 90.1 and make recommendations for revising it. ERA staff will be present at this group’s meetings and will once again provide input based on the expertise of our members.
When I work with code-setting and regulatory groups, I am reminded of that very familiar saying, “It’s not whether you win or lose, it’s how you play the game.” Based on our work at ERA, I’d like to revise that. Your skill at “playing the game” will definitely influence whether you win or lose. Our experience tells us that staying involved with regulatory groups and providing them with input based on firm science and field experience leads to a winning outcome for the roofing business.
Firestone Building Products Co. LLC, a manufacturer and supplier of a comprehensive “Roots to Rooftops” product portfolio, is celebrating the 35th anniversary of its trademark ethylene propylene diene monomer, RubberGard EPDM roofing system, which has helped cement its commercial roofing reputation for trust and confidence.
Firestone Building Products began its journey to become a global leader in the commercial roofing industry in 1980 with the installation of its first warranted EPDM roof in the small town of West Bend, Wis.
“At the beginning, none of us really knew the life expectancy of the EPDM roof,” says Clay Van Gomple, president of Spec Products, a sales representative for Firestone Building Products. “The Firestone Building Products professionals were very positive they had the formulation.”
Today, Firestone Building Products is internationally known to set the standard for quality rubber products, innovation and leadership. Its manufacturing plant opened in Prescott, Ark., in 1983 and has increased capacity to become the largest EPDM manufacturing facility in the world. Since 1980, approximately 6.5 billion square feet of Firestone Building Products RubberGard EPDM have been installed globally.
Throughout the years, Firestone Building Products has grown from one to 15 plants and expanded into multiple product lines, including EPDM rubber membranes, thermoplastic membranes, modified bitumen and polyisocyanurate insulation.
“Innovating new commercial building performance solutions is top of mind at Firestone Building Products because we understand and always consider the unique challenges of our contractors, architects and building owners,” says Tim Dunn, president of Firestone Building Products. “This 35th anniversary milestone demonstrates our commitment to those key stakeholders. Their trust is the reason we can confidently promise that, ‘Nobody Covers You Better.'”
The original EPDM formulation has held strong for more than three decades and still holds strong today. Firestone Building Products has built on that foundation of reliability, evolving its application to meet the needs of building owners, contractors and architects.
In 2015, Firestone Building Products introduced its revolutionary Secure Bond Technology, the next generation in fully adhered roof system application. Secure Bond Technology ensures adhesion coverage across the entire roofing membrane, establishing one of the most powerful bonds possible. RubberGard EPDM SA with Secure Bond Technology is the only EPDM SA available on the market today.