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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Denver International Airport Is Reroofed with EPDM after a Hailstorm

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?

The storm created concentric cracks at the point of hail impacts and, in most cases, the cracks ran completely through the original membrane.

The storm created concentric cracks at the point of hail impacts and, in most cases, the cracks ran completely through the original membrane.

Nick Lovato, a Denver-based roofing consultant, most likely runs through a similar checklist before each flight. But there’s one other important thing he does every time he walks through DIA. As he crosses the passenger bridge that connects the Jeppeson Terminal to Gate A, he always looks out at the terminal’s roof and notices with some pride that it is holding up well. Fifteen years ago, after a hailstorm shredded the original roof on Denver’s terminal building, his firm, CyberCon, Centennial, Colo., was brought in as part of the design team to assess the damage, assist in developing the specifications and oversee the installation of a new roof that would stand up to Denver’s sometimes unforgiving climate.

HAIL ALLEY

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.

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.

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.

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.

In some areas adjacent to the airport’s clerestory windows, the membrane received much more solar radiation than other areas of the roof.

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.

LONG-TERM SOLUTION

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.”

PHOTOS: CyberCon

Roof Materials

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

Choose Sustainable, Durable and Geographically Appropriate Roofs

Carlisle SynTec Systems has made available its RoofEd eBook for download through iTunes and Google Play.

Carlisle SynTec Systems has made available its RoofEd eBook for download through iTunes and Google Play.

Carlisle SynTec Systems has made available its RoofEd eBook for download through iTunes and Google Play. The first chapter of RoofEd focuses on EPDM roofing systems and their attributes. RoofEd contains videos, articles, case studies and photos, all of which are designed to give readers a deeper understanding of their commercial roofing system options. RoofEd can also be used as an on-the-road sales tool to help building owners choose the most sustainable, durable and geographically appropriate roof for their buildings.

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).

The gypsum decking was cut out within the limits of the entire framing “bay” and infilled with galvanized metal decking. The longitudinal deck panel edge was seated atop the horizontal leg of the bulb-tee section (visible in the center of the photograph) and mechanically fastened using self-tapping screws. The ends were supported by the steel purlins. The underside of the decking was prepainted to match the ceiling finish. Supplemental structural support consisting of strips of 14-gauge galvanized sheet metal were attached to the bottom of each bulb-tee section contiguous to the repair to provide additional support for the adjacent gypsum roof decking segment.

The gypsum decking was cut out within the limits of the entire framing “bay” and infilled with galvanized metal decking. The longitudinal deck panel edge was seated atop the horizontal leg of the bulb-tee section (visible in the center of the photograph) and mechanically fastened using self-tapping screws. The ends were supported by the steel purlins. The underside of the decking was prepainted to match the ceiling finish. Supplemental structural support consisting of strips of 14-gauge galvanized sheet metal were attached to the bottom of each bulb-tee section contiguous to the repair to provide additional support for the adjacent gypsum roof decking segment.


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.

Existing Conditions

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.

The roof insulation panels were set into ribbons of low-rise polyurethane foam insulation adhesive. The adhesive was applied in a continuous serpentine bead, spaced 6 inches on-center throughout the field of the roof.

The roof insulation panels were set into ribbons of low-rise polyurethane foam insulation adhesive. The adhesive was applied in a continuous serpentine bead, spaced 6 inches on-center throughout the field of the roof.


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

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You Can Influence Codes and Standards

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 Celebrates 35 Years of Its EPDM Roofing System

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.

Firestone Building Products Announces Master Contractor Award Winners

Firestone Building Products Co. LLC, a manufacturer and supplier of a comprehensive “Roots to Rooftops” product portfolio, announced the 263 firms that earned the 2016 Master Contractor Award. The top-tier companies were selected from a network of more than 3,000 Firestone Building Products Red Shield Licensed Roofing Contractors for delivering exemplary installation, quality of work and customer service.

The Master Contractor Program presents three distinct industry honors annually: The Master Contractor Award, Inner Circle of Quality Award and President’s Club Award. The program’s 2016 winners collectively installed more than 309 million square feet of warranted Firestone Building Products roofing systems on new and reroof projects during 2015.

“Our annual Firestone Building Products Master Contractor Program recognizes top-tier firms for their commitment to excellence and superior workmanship,” says Tim Dunn, president of Firestone Building Products. “Ultimately, the winners’ attention to detail during all installation phases helps ensure long-term roofing system performance. Master Contractor, Inner Circle of Quality and President’s Club award winners represent our best partners in the industry. We are proud of all they have accomplished and look forward to continuing to see them achieve.”

The program’s 2016 award categories and parameters include:

  • Master Contractor
    Master Contractor Award recipients were selected based on the total square footage installed and quality points accumulated for outstanding inspection ratings on systems covered by the Firestone Building Products Red Shield Warranty. Those include: RubberGard EPDM, UltraPly TPO, asphalt and metal roofing systems.

    Master Contractors were also eligible to earn points in the sustainability category. The program recognizes Firestone Building Products’ SkyScape Vegetative Roof System and SunWave Daylighting System.

    To meet the 2016 award requirements, a contractor had to complete a minimum of eight Red Shield warranted jobs during the 2015 calendar year, be in good financial standing with Firestone Building Products, and have a Preferred Quality Incidence Rating (QIR) that did not exceed three times the average QIR for Red Shield Licensed Roofing Contractors. QIR is determined by the annual number of quality incidents per million square feet of roofing under warranty.

  • Inner Circle of Quality
    Master Contractors were eligible for the Inner Circle of Quality Award by installing a minimum of eight warranted Firestone Building Products roofing systems each in 2014 and 2015; and four roofs per year for each of the prior three years. They were also required to maintain at least 2 million square feet of Firestone Building Products roofs under warranty and achieve an annual Quality Incidence Rating (QIR) of 1.0 or less.

  • President’s Club
    Master Contractors who have accrued the highest number of quality points for superior inspection ratings and total square footage of Firestone Building Products Red Shield warranted roofing system installations completed during the past year earned the distinguished President’s Club Award.

Johns Manville Plans to Build Second Production Line at Its Alabama Manufacturing Facility

Johns Manville (JM), a global building and specialty products manufacturer and a Berkshire Hathaway company, announced plans to build a second production line at the company’s Scottsboro, Ala., manufacturing facility. The new line will increase production capacity for JM TPO (thermoplastic polyolefin).

“This significant investment continues JM’s long-standing commitment to our customers, the industry, our employees and the communities in which we serve,” says Mary Rhinehart, JM’s president and CEO.

State and local officials in Alabama welcomed the announcement. “Alabama workers make all kinds of great products, and I am honored that Johns Manville has decided to expand its plant in Scottsboro with new capital investment that means more jobs for Alabama residents,” Gov. Robert Bentley says. “Creating jobs and opportunity in the state is my No. 1 priority, and we are committed to helping Johns Manville achieve success with this project in Jackson County.”

“JM has been an important member of our community for eight years,” says Scottsboro Mayor Melton Potter. “Their recent capacity expansion and the announcement of adding a second line shows JM’s confidence in our workforce to produce the best TPO in the industry. I thank JM for choosing to make this investment in Scottsboro and Jackson County.”

In October 2008, JM’s commitment to single ply manufacturing was solidified with the opening of a state-of-the-art TPO facility in Scottsboro. JM furthered its investment in single ply in 2012 with the opening of an EPDM (ethylene propylene diene monomer) manufacturing plant in Milan, Ohio.

The new TPO production line will bring JM’s total investment in commercial roofing over the past eight years to approximately $200 million. Together with putting money back in the American economy and bringing more than 175 jobs to the manufacturing sector, JM’s continued investments allow growth in the industry and extend JM’s areas of roofing expertise and available products.
To meet recent demand for JM TPO, JM began a capacity expansion project in March 2015 at the Scottsboro plant. Construction was completed in May, and now work will begin to construct the second production line.

“The plant expansion was a huge success and made our Scottsboro facility what is, in our view, the most productive and efficient TPO facility in the U.S., enabling us to meet our customers’ needs for the foreseeable future,” says Jennifer Ford-Smith, JM’s director of Marketing and Single Ply. “This new line will give JM the ability to supply our customers with even more JM TPO than was previously available.”

Senior vice president and general manager Robert Wamboldt says, “We’re proud to be a part of the commercial roofing industry, and we believe our 157-year history demonstrates that we are here to stay. This new production line will help JM meet customer demand and remain a supplier of choice in our industry.”

Creating Visual Impact with Copper and Silver Roofing Membranes

Whether you’re re-roofing a historic building that needs to maintain its aesthetics or you’re working on a new roof construction that has to make a statement, there are many instances in which a building owner would want his or her roof to generate a specific architectural appeal. The most difficult part of this is balancing durability and beauty with cost. Roof systems today have evolved to solve this conundrum. Now, copper and silver synthetic PVC membranes are being used to achieve the desired appearance of a metal standing-seam roof at a fraction of the cost without sacrificing performance.

Alternatives to Metal Roof Systems

Michigan State University replaced the existing slate roof system with SOPREMA SENTINEL Copper Art to provide the desired appearance and required long-term performance.

Michigan State University replaced the existing slate roof system with SOPREMA SENTINEL Copper Art to provide the desired appearance and required long-term performance.


Copper and silver synthetic membranes are great cost-effective alternatives to metal roofs. As flexible synthetic systems, these roof membranes are economical and easy to install by conforming to complex geometries.

Certain synthetic PVC roof membranes on the market today are offered in a variety of colors, some of which can mimic the look of metal roofing. While these roof membranes offer the proven long-term performance of flexible polyvinyl chloride (PVC), they provide the metal appearance via the addition of pigments that can chalk or fade as the pigmented membrane ages, therefore losing the desired aesthetic feature.

Conversely, SOPREMA SENTINEL Copper and Silver Art PVC membranes incorporate copper or aluminum metallic powder into the PVC formulation, producing an enhanced metallic look. Unlike pigmented membranes, SENTINEL Copper Art provides the same weathering capabilities as traditional standing seam copper—the SENTINEL Copper Art will patina as a traditional copper roof would. Silver Art is unique because the color will not fade due to the addition of metallic powder, and its surface layer is factory embedded with an acrylic shield treatment to resist dirt pickup and chalking. Copper Art and Silver Art membranes provide the long-lasting aesthetic appearance and waterproofing abilities of a metal roof.

Applications for Copper and Silver Membranes

Copper and silver roof membranes are often used on buildings where aesthetics are important. Historic buildings, churches, schools, government buildings and army bases are a few examples of where this type of roof membrane has been installed. These buildings may require a particular appearance or designers may simply wish to update the appearance or provide some panache. Mansards or other areas of visible existing light-gauge metal roof systems may be present on these buildings and flexible copper and silver roof membranes may be used as an alternative aesthetic solution.

SENTINEL Silver Art met Glenside Public Library’s leak-free and architectural needs, plus the roofing contractor liked that the SENTINEL membrane was easy to install and looked great upon completion.

SENTINEL Silver Art met Glenside Public Library’s leak-free and architectural needs, plus the roofing contractor liked that the SENTINEL membrane was easy to install and looked great upon completion.

For example, since 2007, the slate roof of the Snyder-Phillips residence hall at Michigan State University had been leaking. The university needed to replace the existing slate roofing system with a new system that would meet the aesthetic requirements of the historic building. SOPREMA SENTINEL Copper Art was installed as a cap sheet to provide the desired appearance and the required long-term performance.

In addition, the Glenside Public Library had an existing standing-seam roof that was tied-in to a low-slope ethylene propylene diene monomer (EPDM) roof. The tie-in between the two materials was problematic and continuously leaked. The library wanted to preserve the standing-seam appearance, but the noise created by wind and rain on the metal roof was a concern.

SOPREMA SENTINEL Silver Art was selected because it could provide the desired look while eliminating the tie-in issues between the steep- and low-slope roofing materials. SENTINEL Silver Art met the library’s leak-free and architectural needs, plus the roofing contractor liked that the SENTINEL membrane was easy to install and looked great upon completion. In addition to its aesthetic appeal, SENTINEL Silver Art also offered the benefit of significant noise reduction when compared to the former metal roof system.

Roofing Technology Advancements

As roofing technology advances, the options for creating a desired aesthetic have evolved. SENTINEL PVC Copper and Silver Art are high-performance roof membranes that provide the appearance of metal with the flexible, long-term performance of PVC, without the weight, expense or complexity of a traditional metal roof.

With Today’s ‘New Age’ Roofs, Removing All System Components May Not Always Be Required or in the Clients’ Best Interest

Years ago, reroofing design involved removing all roof-system components down to the roof deck and rebuilding a new roof system up from there.

PHOTO 1: This EPDM roof’s service has been extended for nine years and counting, approaching 30 years in-situ performance. Here, the restoration of perimeter gravel- stop flashing and lap seams, as well as detailing of roof drains, penetrations and roof curbs, is nearing completion.

PHOTO 1: This EPDM roof’s service has been extended for nine years and counting, approaching 30 years in-situ performance. Here, the restoration of perimeter gravel- stop flashing and lap seams, as well as detailing of roof drains, penetrations and roof curbs, is nearing completion.

Although that is still a viable option and often performed, the coming of age of many single-membrane roofs has altered the method of installing a new reroof system. Options now include EPDM roof restoration; removal of the roof membrane and the addition of new insulation and roof membrane; using the existing roof membrane as a vapor retarder and adding new insulation and roof membrane; removal of the roof cover and installation of new, leaving all the existing insulation in place.

When I first moved into roof-system replacement design some 35 years ago, the dominant roof systems being removed were bituminous, specifically gravel-surfaced asphaltic and coal- tar-pitch built-up roofs. As they aged, their surfaces often started to blister, crack and undulate with ridges—surfaces often unsuitable for roof recover. The bitumen often was deteriorating because of ultraviolet-light exposure; when that occurred, the deterioration of the felts was not far behind. The insulation was mostly perlite or high-density wood fiber; the amount was minimal (low thermal value) and, more often than not, flat or with very minimal slope. Drains were erratically placed, tapered insulation was not often the case and roof edges were predominately gravel stops. In the Midwest, many roof decks were cementitious wood fiber. The roof covers were often patched again and again, even as water infiltrated the system.

PHOTO 2: The re-flashing of roof curbs is an integral part of the restoration of EPDM roof membranes.

PHOTO 2: The re-flashing of roof curbs is an integral part of the restoration of EPDM roof membranes.

When replacement was necessary, the roof-edge sheet metal was removed; the entire existing roof system was removed down to the roof deck; and a new roof system was designed, often incorporating vapor retarders/temporary roofs so the removal of multiple layers of roofing could be accomplished, roof curbs raised, and enhancements of roof drains, curbs and roof edge could occur prior to the installation of the new roof cover. Tapered insulation designs be- came common; this would often require realignment of the roof drains to simplify the tapered design and installation. To accommodate the new insulation thickness, the roof edge had to be raised as did roof curbs, RTU curbs, plumbing vents and roof drains via extensions. Roof membranes changed from bituminous to those classified as “single plies”: EPDM, PVC, CPE, CSPE.

These new roof-system replacement designs resulted in superior roofs—85 percent of all the reroofs I have designed are still in place, still performing, still saving the owner money. Life cycles have moved from eight to 12 years, up to 18 to 25 years and longer. They certainly were more expensive than the original installation and, if a roof designer didn’t have a handle on costs to provide the owner with estimated costs of construction, were often shocking. But these roof systems were good for the client, economy, environment and public.

PHOTO 3: When restoring EPDM roof membranes, the removal of roof penetration flashings and installation of new with target patches will provide another 20 years of watertight protection.

PHOTO 3: When restoring EPDM roof membranes, the removal of roof penetration flashings and installation of new with target patches will provide another 20 years of watertight protection.

Over the years, codes and standards have changed, especially in the past decade, requiring increased insulation values and roof-edge sheet-metal compliance with greater attention to wind-uplift resistance. As the new millennium arrived, these “new age” roofs came of age and owners started to look at their replacement—often with increased costs stifling their budgets.

LEAN THINKING

A factor that increased the performance of many roof systems in the past 20 years was the emergence and growth of the professional roof consultant, often degreed in architecture or engineering, educated in roofing, tested and certified. These professionals brought a scientific approach to roof-system design. Raleigh, N.C.-based RCI Inc. (formerly Roof Consultants Institute) was the conduit for this increased level of knowledge, professionalism and the growth in quality roof-system design and installation.

PHOTO 4: On this roof, the existing loose-laid membrane was removed, open insulation joints filled with spray-foam insulation and new insulation added to meet current code requirements. A new 90-mil EPDM membrane was installed and existing ballast moved onto it to 10-pounds-per-square-foot coverage.

PHOTO 4: On this roof, the existing loose-laid membrane was removed, open insulation joints filled with spray-foam insulation and new insulation added to meet current code requirements. A new 90-mil EPDM membrane was installed and existing ballast moved onto it to 10-pounds-per-square-foot coverage.

As these professionals started to examine the older “new age” roofs, those whose first responsibility was doing what was best for the client saw greater opportunity than just a costly full-roof replacement. Although many roofs today still need to be fully removed, prudent professionals see other opportunities, such as the following:

ROOF RESTORATION
EPDM membrane ages with little change in physical characteristics as opposed to its built-up roofing predecessor; therefore, EPDM membranes often can be “restored” in lieu of removing and replacing the roof. (Studies to support the lack of change in EPDM’s physical characteristics while it ages include Gish, 1992; Trial, 2004; and ERA, 2010.)

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