Project Profiles: Education Facilities

Maury Hall, U.S. Naval Academy, Annapolis, Md.

TEAM

Roofing Contractor: Wagner Roofing, Hyattsville, Md.
General Contractor: C.E.R. Inc., Baltimore, (410) 247-9096

The project included 34 dormers that feature double-lock standing-seam copper and fascia metal.

The project included 34 dormers that feature double-lock standing-seam copper and fascia metal.

ROOF MATERIALS

Wagner Roofing was awarded the complete replacement of all roof systems. These included an upper double-lock standing-seam copper roof system, a bullnose copper cornice transition, slate mansard, 34 dormers with double-lock standing-seam copper and fascia metal, eight copper hip metal caps and a continuous built-in gutter with decorative copper fascia. Each of the dormers also had a copper window well.

The upper standing-seam roof was removed and replaced with 24-inch-wide, 20-ounce copper coil rollformed into 1-inch-high by 21-inch-wide continuous standing-seam panels that matched the original profile. The eave bullnose, which also served as the mansard flashing, was removed and returned to Wagner Roofing’s shop where it was replicated to match the exact size and profile.

The 34 dormer roofs were replaced with 20-inch-wide, 20-ounce copper coil formed into 1-inch-high by 17-inch- wide continuous standing-seam panels. The decorative ornate fascia of the dormers was carefully removed and Wagner’s skilled craftsmen used it as a template to develop the new two-piece copper cornice to which the roof panels locked. The cheeks and face of the dormers were also re-clad with custom-fabricated 20-ounce copper.

The oversized built-in-gutter at the base of the slate mansard was removed and replaced with a new 20-ounce copper liner custom-formed and soldered onsite. The replacement included a specialty “bull-nosed” drip edge at the base of the slate and an ornate, custom-formed fascia on the exterior of the built-in gutter. The decorative copper fascia included 85 “hubcaps”, 152 “half wheels” and 14 decorative pressed-copper miters. The original hubcap and half-wheel ornaments were broken down and patterns were replicated. Each ornamental piece was hand assembled from a pattern of 14 individual pieces of 20-ounce copper before being installed at their precise original location on the new fascia. The miters were made by six different molds, taken from the original worn pieces, to stamp the design into 20-ounce sheet copper.

In all, more than 43,000 pounds of 20-ounce copper was used on the project.

Copper Manufacturer: Revere Copper Products

ROOF REPORT

Maury Hall was built in 1907 and was designed by Ernest Flagg. Flagg designed many of the buildings at the U.S. Naval Academy, including the Chapel, Bancroft Hall, Mahan Hall, the superintendent’s residence and Sampson Hall. His career was largely influenced by his studies at École des Beaux-Arts, Paris. Examples of Flagg’s Beaux-Arts influence can be found in the decorative copper adorning the built-in gutter on building designs.

Maury Hall currently houses the departments of Weapons and Systems Engineering and Electrical Engineering. The building sits in a courtyard connected to Mahan Hall and across from its design twin, Sampson Hall.

PHOTO: Joe Guido

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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

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.

SOPREMA Joins the Polyisocyanurate Insulation Manufacturers Association

The Polyisocyanurate Insulation Manufacturers Association announced that SOPREMA has joined the group as a manufacturing member.

“The addition of SOPREMA to the polyiso industry and the PIMA family reflects the continuing growth of polyiso as North America’s insulation product of choice,” says Jared Blum, president PIMA. “SOPREMA’s construction industry leadership role is well acknowledged, and the PIMA Board of Directors looks forward to the active involvement of the company.”

SOPREMA joins PIMA’s six manufacturing members: Atlas Roofing, Firestone Building Products, GAF, Hunter Panels, Johns Manville and Rmax.

SOPREMA is an international manufacturer specializing in the development and production of innovative products for waterproofing, insulation, soundproofing and vegetated solutions for the roofing, building envelope and civil engineering sectors. Founded in 1908 in Strasbourg, France, SOPREMA now operates in more than 90 countries.

With its first polyisocyanurate insulation plant in North America, SOPREMA will expand its presence in the construction market by offering complete roofing solutions to its clients, while managing all production phases.

“SOPREMA is proud to join PIMA and contribute to the energy performance of buildings and the reduction of greenhouse gases as a manufacturer of high-performance insulation boards,” says Richard Voyer, executive vice president and CEO of SOPREMA North America.

Firestone Building Products Recognizes 133 Firms with Partner in Quality Award

Firestone Building Products Co. LLC, a manufacturer and supplier of a comprehensive “Roots to Rooftops” product portfolio, recognized 133 firms across the U.S., Canada and Mexico with the 2015 Partner in Quality Award. The annual award honors an elite group of Firestone Building Products Red Shield Licensed Roofing Contractors for a high level of craftsmanship and the skill set required for superior roofing installations.

Firestone Building Products Red Shield Licensed Roofing Contractors are required to complete extensive product installation training. As a testament to their expertise, projects are backed by the Firestone Building Products Red Shield Warranty. Depending on the commercial roofing system, terms of the warranty can range from five years to 30 years. To qualify, winners had to:

  • Install a minimum of eight warranted roofs in 2014, and four warranted roofs per year for each of the prior four years.
  • Maintain at least 1 million square feet of Firestone Building Products roofs under warranty.
  • Achieve an annual Firestone Building Products Quality Incidence Rating (QIR) of 1.25 or less (QIR measures each contractor’s performance based on warranty repair incidences per million square feet under warranty).
  • As part of the program, winners are able to participate in the Firestone Building Products Community Service Program, which makes them eligible for a $1,000 annual credit to donate labor and materials for roofing projects in their respective communities.

“At Firestone Building Products, we recognize what it means to go above and beyond, and we hold our contractors to a high standard,” says Tim Dunn, president of Firestone Building Products. “The Partner in Quality Award gives these talented and hard-working contractors the praise they truly deserve.”

Please visit the Firestone Building Products website for a complete listing of Partner in Quality Award Winners.

A Green Roof Provides Residents of a Senior Housing Complex with an Improved View

The Findlay Teller Apartments provides affordable housing for low-income seniors in the Bronx, N.Y. The complex includes 32 one-bedroom and 131 efficiency units. Its 9,925-square-foot green roof is its most prominent green-building element and gives residents a welcomed view of green space.

Built in 1906, the dilapidated building was revitalized by three local Bronx organizations.

Built in 1906, the dilapidated building was revitalized by three local Bronx organizations.

“Many green roofs are on top of buildings where no one can see and enjoy them. The Findlay Teller green roof, particularly the sections installed on the terrace level and second-floor roofs, has many windows that look out on the [green roof sections],” says Antonio Freda, owner of Bronx-based Freda Design Associates Ltd., the architect for the apartment building’s renovation. “In fact, 90 percent of the apartments have a view of the green roof.”

RESTORING A NEIGHBORHOOD LANDMARK

Located at 1201 Findlay Avenue in the Morrisania neighborhood of the Bronx, the community landmark has a long history. The building was constructed in 1906. The Daughters of Jacob, a non-profit service organization, originally used the building as a hospital and nursery facility. It was renovated in 1920. The east and west wings were added in 1952.

Converted to subsidized senior housing under the U.S. Department of Housing and Urban Development (HUD) Section 202 program in 1978, and known as Findlay Plaza, the building deteriorated over the years. By December 2007, the apartments had a lowly score of 34 out of 100 on HUD’s Housing Quality Standards. Buildings must score at least 86 for their conditions to be rated healthy and safe. Eventually, HUD foreclosed on the property.

In 2009, three local organizations, the Citizens Housing and Planning Council, the Local Initiatives Support Corp. and the Belmont-Arthur Avenue Local Development Corp. (BAALDC), worked together to win the support of the building’s tenants and neighborhood leaders to acquire and rehabilitate the property.

Roofing workers spread the growing media on the roof.

Roofing workers spread the growing media on the roof.

BAALDC, which strives to prevent the deterioration, blight and abandonment of at-risk housing in the Bronx, established the Findlay Teller Housing Development Fund Corp. (Findlay Teller HDFC) to take on the challenge of assembling financing and renovating the building.

“The building was in a very sad state of disrepair,” notes Joe Cicciu, executive director of BAALDC and president of Findlay Teller HDFC. “We put together $20 million in funds from many different sources, including a major grant from JPMorgan Chase, to save and rehabilitate the building.”

GREEN BUILDING AND A GREEN ROOF

Notias Construction Inc., Flushing, N.Y., was the general contractor for the project. The firm managed the renovation according to Enterprise Green Communities Criteria, a program of Columbia, Md.-based Enterprise Community Partners, a non-profit dedicated to creating opportunity for low- and moderate-income people through affordable housing in diverse, thriving communities. Required by the New York City Department of Housing Preservation and Development, the criteria define standards for green-building practices applicable to affordable housing. Thus, the renovation included a new structural roof with two layers of insulation, high-efficiency boilers, replacement windows and new energy-efficient lighting. In addition to the green roof, permeable pavement in the parking area reduces stormwater runoff.

PHOTOS: XERO FLOR AMERICA

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Firestone Building Products Recognizes 189 Partner in Quality Award Winners

Firestone Building Products Co. LLC recognized 189 firms across the United States, Canada and Mexico with the 2014 Partner in Quality Award. The annual award honors an elite group of Firestone Building Products Red Shield Licensed Roofing Contractors for a high level of craftsmanship and the skillset required for superior roofing installations.

Firestone Building Products Red Shield Licensed Roofing Contractors are required to complete extensive product installation training. As a testament to their expertise, projects are backed by the Firestone Building Products Red Shield Warranty. Depending on the commercial roofing system, terms of the warranty can range from five years to 30 years.

To qualify, winners had to:

· Install four warranted Firestone Building Products roofs in each of the past five years.
· Maintain at least 1 million square feet of Firestone Building Products roofs under warranty.
· Achieve an annual Quality Incidence Rating (QIR) of 1.5 or less (QIR measures each contractor¹s performance based on warranty repair incidences per million square feet under warranty).

As part of the program, winners are able to participate in the Firestone Building Products Community Service Program which makes them eligible for a $1,000 annual credit to donate labor and materials for community roofing projects.

“At Firestone Building Products, we are committed to working with the best contractors in the industry to ensure the success of every Firestone roofing project,” said Tim Dunn, president of Firestone Building Products. “The Partner in Quality Award honors the expertise, skill and craftsmanship of our hard-working contractors.”

View a complete list of Partner in Quality Award Winners on Firestone Building Products’ website.

Firestone Building Products Releases Build My Roof App

Firestone Building Products Co. LLC's Build My Roof App

Firestone Building Products Co. LLC’s Build My Roof App

Firestone Building Products Co. LLC has made available its Build My Roof App for iPad and Android tablet devices. The app is available as a free download from iTunes and the Google Play Store. Starting from the deck and selecting additional components, contractors, sales reps and architects can construct a virtual roof using any of the Firestone Building Products roofing systems. The Build My Roof App intuitively narrows options to only those appropriate to the selected assembly. Users can create multiple projects, save plans and add construction notes. A convenient R-Value calculator is built in, making it easier to construct a roof that meets the necessary codes.

Projects: Offices/Manufacturing

Accident Fund Holdings Inc. Headquarters, Lansing, Mich.

Team

Roofing Contractor: Bloom Roofing, Brighton, Mich.
Construction Manager: The Christman Co., Lansing
Architect of Record: HOK, St. Louis
Construction Engineer: Ruby + Associates Inc., Farmington Hills, Mich.

Roof Materials

Accident Fund Holdings Headquarters features a white TPO roof. PHOTO: Image Michigan and The Christman Co.

Accident Fund Holdings Headquarters features a white TPO roof. PHOTO: Image Michigan and The Christman Co.


An insulated cool roof minimizes the building and surrounding area’s heat-island effect.
White TPO Roof: Firestone Building Products Co.
Polyurethane-foam Adhesive: OMG Roofing Products
Caged Roof-hatch Grab Bars: LadderPort

Roof Report

Accident Fund Holdings, the nation’s 13th largest workers’ compensation insurer and a subsidiary of Blue Cross Blue Shield of Michigan, has been headquartered in Lansing, Mich., for more than 100 years. When it outgrew its office, the firm’s leaders were determined to stay in Lansing.

By revitalizing the iconic Ottawa Street Power Station, which was built along the Grand River in 1939 but had been mostly abandoned since 1992, the company would have 9 stories and 122,000 square feet to grow into. To support Michigan’s economy, 106 of the 118 contracts and suppliers that participated in the project were Michigan-based firms and 54 of those were Lansing-based.

To remove existing building elements, including catwalks, elevator/ stair shafts, framing and platforms, the team cut two 40-foot-long by 20-foot-wide roof hatches so a crane operator could move about 8,900 pieces of steel in and out of the building while the floors were built from the bottom up.

Since Accident Fund moved into its new headquarters, the building has won numerous awards, including the Governor’s Award for Historic Preservation from the state of Michigan and an Excellence in Economic Development Award from the Washington, D.C.-based International Economic Development Council. [Read more…]

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