Outfitter’s New Roof Is Designed to Look Great, Withstand the Elements

When the owners of the Bass Pro location in Pearl, Mississippi, looked for a new roof, they initially considered the spruce green color shared by many of the company’s other outlets, but the existing fascia boards inspired them to choose Colonial Red from Petersen’s palette of stock colors. Photos: hortonphotoinc.com

Bass Pro Shops brands itself as a supplier of performance products designed to endure the great outdoors, but at its Pearl, Mississippi, store, the roof was falling short of that standard. The roof’s mix of membrane and metal roof systems was damaged during a severe weather event, which prompted a re-roofing initiative.

“They had a hailstorm come through and they wanted to upgrade,” says Roman Malone, president of the installing firm, E. Cornell Malone Corp., based in nearby Jackson, Mississippi. In addition to installing a new membrane roof, the project including replacing the existing bare Galvalume steel panels with 59,000 square feet of Petersen’s Snap-Clad roofing panels Kynar-finished in PAC-CLAD Colonial Red. The panels form the highly visible sloped portions of the roof, along with a canopy overhang over the building’s storefront walkway and entrance.

After the metal roof system was installed, crews completed Firestone TPO roof on the low-slope section.

The 100,000-square-foot store was a founding anchor retailer in the 150-acre-plus Bloomfield Development. It shares the title with Trustmark Park, home of the Atlanta Braves’ minor-league baseball team, the Mississippi Braves. People visit the retailer for more than just shopping — the facility includes a large aquarium, shooting gallery and 3-D archery range along with a bar and restaurant. Since its 2005 opening, the surrounding development has grown to include The Outlets of Mississippi, the state’s largest outlet center, which welcomes almost 4.5 million visitors every year.

The metal portion of the re-roofing effort included removing the existing panels along with the ice and water shield below, while the existing plywood decking and insulation remained in good shape. For the roofing pros from E. Cornell Malone, the heavily trafficked surroundings proved a greater challenge than the roof itself. “We had to keep the front door open,” Malone recalls. “The flagpole and the tallest part of the standing seam roof are right over the main entrance. There was a period of time when we had to work there, and we had to use the exit door as an entrance and block off that area for safety reasons. We had to move as fast as we could to minimize the disruption. We also had to use cranes to get the material up to the roof and the demolished material off the roof.”

Eye-Catching Color

While the profile of the standing-seam roof remained similar to its original appearance, the Colonial Red finish certainly creates a major pop for the building. Malone says store managers initially were considering the spruce green color shared by many of the company’s other outlets, when they happened upon Colonial Red in Petersen’s palette of stock colors. “The fascia boards just happened to be the same color as the roof — so, when they saw the Colonial Red, it was an obvious color choice for them,” Malone says. “We didn’t paint that fascia, and it just matched perfectly. I believe this is the first Bass Pro Shop in the country to use this color on their roof. It looks really good.”

E. Cornell Malone Corp. installed approximately 59,000 square feet of Petersen’s Snap-Clad roofing panels on the project.

Crews installed the metal roof system first, and then completed the installation of the single-ply roof on the low-slope section. “We had to use the flat roof as a work platform to reach the high part of the metal roof. We protected what was there, and then came back and put the TPO roof on. That way, we wouldn’t damage it during the installation of the metal roof.”

Crews mechanically attached a Firestone 60-mil TPO system over 1/4-inch DensDeck cover board. “The TPO portion of the project was pretty straightforward,” Malone says. “The highlight of this project is really the metal roof. You can’t see the TPO roof from the ground, but it complemented everything else, brought everything under warranty and got them up to date.”

An interesting detail on the project involved the large flagpole on the metal roof over the entrance. The safety system incorporates shock absorbing anchors, S-5! clamps, and a 100 feet of stainless steel line with hands-fee Unigrab Travelers and dedicated lanyards. “We worked with a safety company, Rooftop Anchor, to engineer a safety system so people could manage the flag and be safe,” Malone says. “Before that, the owners used to hire us to come out and raise and lower their flag. Now that they have a safety system in place, they can manage the flag themselves.”

Feedback on the new roof has been very positive, notes Malone. “The customers are ecstatic about the roof. It has totally transformed the building — it’s definitely an upgrade.”

TEAM

Roofing Contractor: E. Cornell Malone Corp., Jackson, Mississippi, www.ecmalone.com

MATERIALS

Metal Roof: Snap-Clad roofing panels Kynar-finished in PAC-CLAD Colonial Red, Petersen, www.pac-clad.com

Low-Slope Roof: 60-mil TPO, Firestone Building Products, www.firestonebpco.com

Cover Board: DensDeck, Georgia-Pacific, www.buildgp.com

Flagpole Safety System: Rooftop Anchor, Heber City, Utah, www.rooftopanchor.com

Standing Seam Clamps: S-5!, www.s-5.com

The Calcaire House Meets Strict Energy Codes — and Does it in Style

The residential compound is made up of five interconnected buildings and features both gabled standing seam metal roofs and low-slope TPO roofs. Photos: S-5!

The Calcaire House is a 15,000-square-foot modern Colorado single-family residential compound consisting of five interconnected buildings. Floor-to-ceiling glass connects the interior space to the exterior landscape, offering spectacular views of the Boulder Flatirons. A combination of exposed timber, stone and steel structural design elements, and exposed custom roof trusses complement the gabled standing seam metal roof.

Boulder Roofing Company and The Solar Revolution were charged with installing a metal roof and solar array with more than 60 kilowatts of solar dispersed over multiple rooftops. Boulder Roofing installed both standing seam metal and TPO roof systems on the project. Crews installed approximately 12,000 square feet of 14-inch, 24-gauge panels from Drexel Metals in traditional black over Titanium PSU30 high-temp peel and stick underlayment.

They also installed 3,000 square feet of 60-mil Versico TPO over low-slope areas. The TPO was adhered to quarter-inch DensDeck Prime over tapered EPS insulation. Boulder Roofing fabricated and installed custom flashings and coping, and also installed an S-5! snow-guard system incorporating the S-5! ColorGard bars, S-5-S Mini clamps, SnoClip IIs, and VersaClips.

The Energy Challenge

The city of Boulder has strict energy codes in place and requires all new construction to meet a certain level of efficiency. The requirements are based on the square footage of the home and are more stringent on larger homes — the larger the home, the more efficient it needs to be. The goal is to have a net-zero home, not taking energy from the grid, and the only way for a larger home to achieve this is with solar. A modest home or small addition might only require about 2 kilowatts. A large home might require 20-30 kilowatts.

The most optimal rooftops for solar were also the most visually prominent, and the homeowner was concerned about aesthetics. These concerns were alleviated after seeing a small-scale mock-up of the S-5! PVKIT 2.0 solution combined with an all-black solar module.

In addition, the area is considered a high-wind area and would require a study to account for windspeeds, as the solar installers could only rely on the roof itself and its attachment to the wood sheeting when attaching solar panels using S-5!’s zero-penetration system.

Another difficulty was finding a viable path to route the energy created by the solar panels back to the point of connection with the home’s distribution. The Solar Revolution worked with the builder and the architect, and analyzed photos and design plans to find ways to conceal the conduits. They ultimately found a viable path that was aesthetically pleasing, code compliant and cost-effective.

The Solution

The Solar Revolution installers utilized S-5!’s PVKIT 2.0 to build the solar array. The installation team started at ground level prepping S-5! PVKIT MidGrabs and EdgeGrabs. Another team member prepared the solar modules by installing the power optimizers and managing the various wires. By completing this work on the ground, the roof crew could focus on setting modules, and it minimized their time in harnesses on a steep metal roof. The solar installers prefer to install modules starting with the bottom row and working up. Extra care is taken when aligning the first row. This precision allows for subsequent rows to drop into place on the S-5! PVKIT MidGrabs.

The Solar Revolution installed a solar array that provides more than 60 kilowatts of power.

“The Solar Revolution has been utilizing the S-5! PVKIT 2.0 solution since it first hit the market,” says Doug Claxton, CEO of The Solar Revolution. “Hands down, it is the best solar mounting solution for metal roofing of any description. At first, we were a little worried about wire management and installing in landscape, but those worries were overcome with our first installation. It’s a piece of cake.”

Long-Term Outlook

With the S-5! PVKIT 2.0, the Calcaire House was able to meet the city code requirements for solar and establish itself as an energy-efficient, net-zero home. Because the PVKIT comes in black, it matched the roof nicely, pulling together all of the design elements in an aesthetically pleasing, cost-effective manner — saving the customer time and money on installation and materials.

TEAM

Architect: Surround Architecture, Boulder, Colorado, www.surroundarchitecture.com

General Contractor: Harrington Stanko Construction, Niwot, Colorado, www.harringtonstanko.com

Engineer: Anthem Structural Engineers, Boulder, Colorado, www.anthemstructural.com

Roofing Contractor: Boulder Roofing Company, Boulder, Colorado, www.boulderroof.com

Solar Installer: The Solar Revolution, Boulder, Colorado, www.thesolarrevolution.com

MATERIALS

Metal Roof: 175SS 14-inch, 24 gauge panels, Drexel Metals, www.drexmet.com

Underlayment: Titanium PSU30, Owens Corning, www.owenscorning.com

TPO Roof: 60-mil Grey TPO, Versico, www.versico.com

Cover Board: DensDeck Prime, Georgia-Pacific, www.buildgp.com

Solar Attachment: S-5! PVKIT 2.0 in black with S-5-S Mini Clamps, www.S-5.com

Snow Guards: S-5! ColorGard, S-5-S Mini Clamps, SnowClipIIs and VersaClips

Roof System Protects Health Care Facility in Northern Saskatchewan

The roof system specified for the William Charles Health Centre was a two-ply modified bitumen roofing system manufactured by IKO. Photos: IKO

When the $11.5 million William Charles Health Centre was built north of Prince Albert, Saskatchewan, durability and longevity were key considerations in the design and construction. The facility provides a variety of health care programs to meet the needs of the Montreal Lake Cree Nation.

The roof and walls were designed to last, even in tough weather conditions. The roof system specified was a two-ply modified bitumen roofing system manufactured by IKO. IKO’s Aquabarrier AVB was selected as an exterior peel-and-stick air and vapor barrier to support the facility’s exterior insulated wall system.

Oakwood Roofing& Sheet Metal Co., headquartered in Winnipeg, Manitoba, installed both the roof and wall systems. Founded in 1977, Oakwood Roofing is a full-service roofing and sheet metal contractor handling all types of commercial and residential projects including new construction, roof replacement, service and maintenance. The company also has a Building Division.

“We do all types of roofing and repairs,” notes Brett Laing, an estimator and project manager with Oakwood Roofing. “We do infrared scans, roof reports and assessments, budget pricing for new and re-roof projects, as well as metal cladding and composite panels. We also provide custom roof maintenance programs for companies, property owners and property managers.”

The company was invited to bid on the William Charles Health Centre installation by NDL, the construction manager on the project, and emerged as the low bidder. The roof on the new construction project was approximately 18,500 square feet. On either side of a slight peak, the metal deck slopes to the exterior, where gutters were installed for drainage. The slope on one side of the roof was 13.9 percent, and on the other it was 21.8 percent.

“The roofing wasn’t too difficult,” says Laing. “It’s a conventional two-ply mod bit system, but some of the components are not used that frequently. We use Z-girts to hold the insulation in place in high-wind applications.”

The first step was mechanically fastening 5/8-inch DensDeck Prime to the steel decking. Then a vapor barrier was torch-applied to the cover board. Two 4-inch layers of IKOTherm insulation were installed using Z-girts. Oakwood Roofing fabricated the Z-girts in the company’s sheet metal shop and installed them spaced 24 inches on center. The two layers of insulation and Z-girts were installed perpendicular to each other.

The insulation layers were topped with a layer of half-inch DensDeck Prime. “We used torch tape on all the laps, and ultimately torched the TP 180 FF base sheet from IKO over the top, and then torched the cap sheet to that.”

Oakwood Roofing also installed the wall systems. “We also installed the vapor barrier and longboard siding on this project,” says Laing. “It was a pretty good project for us.”

The remote location posed some difficulties, as crews stayed near the site. Weather is always a concern, and it can be even more problematic when crews are working remotely, but there were no delays on the project. The weather was mild and coordination of trades at the jobsite was excellent, according to Laing.

“NDL was the construction manager on the project, and they are very well organized with their scheduling,” he notes. “It was nice to work with such a professional team, and there were no issues. Everything went smoothly.”

The roof system was specified for its durability and ability to withstand severe weather conditions. “IKO put their name behind it and warranted the roofing system for 15 years,” Laing says. “They came out and made sure it was installed by us to their requirements. The project qualified for a no dollar limit warranty for 15 years, so that says it all right there about how durable the system is.”

Safety First

The fall protection plan incorporated warning lines at the perimeter and personal fall arrest equipment. “Everyone was tied off at all times on the roof,” Laing says.

For torch-down applications, the company’s policy it to institute a two-hour fire watch every time a torch is turned off. “We basically go around and test areas with a thermal gun,” Laing says. “Obviously, if temperatures are dropping, then we are headed in the right direction. We want to ensure that no hot spots are getting hotter, there is no fire risk, and that everyone is safe.”

Oakwood Roofing bears a Certificate of Recognition (COR), a nationally trademarked and endorsed program instituted by participating members of the Canadian Federation of Construction Safety Associations (CFCSA). “We are COR certified at Oakwood Roofing, so we hold our degree of standing to the highest for everyone involved — the workers, the owners of the building, the other trades,” Laing says. “Safety is at the very top of our list when we get into a project.”

For Oakwood Roofing’s experienced crews, this project was just another day at the office — even if the jobsite was 11 hours from home. “We’ve done a lot of work in the Prairie Provinces, in Ontario and into the Northwest Territories,” says Laing. “We are a special company. We wouldn’t have survived for 44 years if we weren’t. We’ve developed special skills and methods to overcome any obstacles that come our way, including extreme weather.”

TEAM

Architect: Patrick R. Stewart Architect, Chilliwack, British Columbia

General Contractor: NDL Construction Ltd., Winnipeg, Manitoba, www.ndlconstruction.com

Roofing Contractor: Oakwood Roofing& Sheet Metal Co., Winnipeg, Manitoba, www.oakwoodroofing.com

MATERIALS

Cap Sheet: Torchflex TP-250-CAP Heat Welded Cap Sheet, IKO, www.iko.com 

Base Sheet: Torchflex TP-180-FF-Base Heath Welded Base Sheet, IKO

Insulation: IKOTherm Commercial Roof Insulation, IKO

Wall Vapor Barrier: IKO AquaBarrier AVB Vapour Barrier, IKO

Cover Board: DensDeck Prime, Georgia-Pacific, www.buildgp.com

Shirley Ryan AbilityLab Features a Striking Standing Seam Metal Roof

The roof of Shirley Ryan AbilityLab incorporates striking V-shaped sections of standing seam metal panels and a tapered EPDM system. Photos: AJBROWNIMAGING.COM

The Shirley Ryan AbilityLab provides rehabilitation services to help patients recovering from severe conditions including traumatic brain injury, spinal cord injury, strokes, and cancer. The organization’s new 25,000-square-foot outpatient facility in Burr Ridge, Illinois, features a unique, uplifting roof design incorporating angled, V-shaped sections of standing seam metal roofing.

The low points in the center of each section and other low-slope areas are covered with an EPDM roof system. At the building’s perimeter, the roof and walls frame clerestory windows that allow natural light to flood the interior.

It took a talented team of construction professionals to execute the design conceived by architects in HDR Inc.’s Chicago branch. Willie Hedrick, Division Manager of All American Exterior Solutions, Lake Zurich, Illinois, notes that he and his team worked closely with the architect and the general contractor, Krusinski Construction of Oak Brook, Illinois, at each phase of the roof installation process.

“Initially the architect had specified a very nice but very expensive Terne-coated stainless steel panel,” notes Hedrick. “The project had budget issues, so we offered the Petersen prefinished steel panel as a value engineering option. The mechanically seamed Tite-Loc panel could handle the low-slope application and also came in a variety of colors. We also offered a 20-year watertight and finish warranty. For approval, we built a mockup for the architect and owner to review and also provided several references for completed projects around the Chicagoland area that they could visit to see finished examples of the proposed panel and color.”

Three different sections of the facility sport the Petersen’s V-shaped PAC-CLAD metal roof, with the wedges on each side sloping down to a valley in the center. Within the valley, the Carlisle SynTec EPDM roof system was installed over tapered insulation to ensure water would flow properly to the roof drains.

“The EPDM was an appropriate selection on the balance of the roof,” Hedrick says. “The workability of EPDM with tight, intricate details worked well throughout the project but especially within the gutter troughs between metal panel wedges.”

After the building’s metal deck was topped with half-inch DensDeck Prime and a self-adhered vapor barrier, crews from All American Exterior Solutions installed tapered polyisocyanurate insulation and 5/8-inch DensDeck Prime cover board. They then fully adhered 8,600 square feet of 60-mil EPDM.

All American then installed 21,500 square feet of 24-gauge steel PAC-CLAD Tite-Loc standing seam panels. The metal panels were installed over Carlisle WIP 300 HT underlayment, which topped 5/8-inch fire-rated plywood and 7 inches of polyisocyanurate insulation. Finishing touches included 3,800 square feet of Petersen .032 aluminum PAC 750 soffit panels and PAC 2000 prefinished Kynar column covers.

Installation Challenges

The weather was a concern, as the roof installation began in November and typical Midwest winter weather was looming. “The metal roof would be a time-consuming installation, so initially we focused on getting the building watertight for the GC by installing the EPDM roof and the metal roof underlayment, including insulation and plywood,” Hedrick explains. “The WIP 300HT allows for a 180-day exposure time to UV, so it gave us ample time to install the metal roof while ensuring watertightness in the space being finished below.”

Communication between all of the trades involved on the project helped ensure everything went smoothly. “There were trade coordination meetings with both the carpenter and the plumber,” Hedrick explains. “With the carpenter, we had to coordinate blocking heights to accommodate the tapered insulation. Also, due to the limited height to work within the gutter troughs and because the deck came down to a true V in the valley, we did an in-place mockup with the plumber to see how low the drain bowl could physically be set. Based on that elevation, we ordered custom EPS tapered edge panels to offset the V shape and provide a flat base to begin our tapered insulation system.”

Other details needed to be refined, including roof-to-wall transitions. “We worked with the GC and other trades to modify the detail for superior performance,” notes Hedrick.

Safety was always top of mind on the project. “Fall protection was the biggest safety concern,” Hedrick says. “We set up warning lines 6 feet from the edge creating a controlled access zone. Any work outside of the warning lines required workers to have 100 percent fall protection. All of the fascia and rake trim pieces were installed from an aerial lift.”

The installation was a complicated one, but All-American Exterior Solutions was up to the challenge. “We take pride in our ability to offer a range of products with a quality installation,” Hedrick says. “Our experience with multiple systems and manufacturers gives us the knowledge to be able to advise the design team on an appropriate product based on performance expectations balanced with budget.”

“Personally, I enjoyed the complexity and challenge that came with this project,” Hedrick concludes. “By no means is it a typical application; it required some critical and ‘outside the box’ thinking. I also enjoyed the collaborative nature a project like this requires. It was really a team approach between All American Exterior Solutions, the architects, the general contractor, and the other trades. The final product really shows that.”

TEAM

Architect: HDR Inc., Chicago, Illinois, www.hdrinc.com

General Contractor: Krusinski Construction Company, Oak Brook, Illinois, www.krusinski.com

Roofing Contractor: All American Exterior Solutions, Lake Zurich, Illinois, www.aaexs.com

MATERIALS

Metal Roof: PAC-CLAD Tite-Loc Plus Panels, Petersen, www.pac-clad.com

EPDM Roof: 60-mil EPDM, Carlisle SynTec, www.carlislesyntec.com

Underlayment: CCW WIP 300, Carlisle WIP Products, www.carlislewipproducts.com

Cover Board: DensDeck Prime, Georgia-Pacific, www.buildgp.com

Planning Ahead Sets Up Warehouse Re-Roofing Project for Success

Citizens Service Center is the primary document storage facility for El Paso County, Colorado. When the roof had to be replaced, protecting the interior of the facility was critical. Photos: Exterior Solutions Group

The most crucial decisions on a project are often made before work even begins. According to Ken Flickinger Jr., president of Exterior Solutions Group, that was the case with the recent Citizens Service Center re-roofing project in Colorado Springs. Owned and managed by El Paso County, the building is the primary document storage facility for the county. The building’s historic documents — some dating back to the 1800s — were under threat of damage due to an active roof leak. The existing roof also had extensive hail damage, so the roof replacement project was put out for bid.

With offices in Colorado, Iowa and Oklahoma, Exterior Solutions Group does all types of roofing work, but its focus is primarily on commercial roofing, both re-roofing and new construction. Flickinger, who heads up the location in Parker, Colorado, was definitely intrigued by the project.

The scope of work involved removing old HVAC equipment on the roof, which would be done by a separate party in coordination with the roofing contractor. The HVAC equipment was obsolete; it had been replaced and relocated a few years earlier. “It was an interesting project because there was equipment everywhere on this roof,” he says. “It looked like an automotive manufacturing plant. For us, we like those types of projects. We like ones that are a bit out of the ordinary and require a little bit higher level of project management. So, that’s what drew us to bidding the job.”

Tim Hicks, the salesperson at Exterior Solutions who sold the job, explains that the original spec called for white EPDM, with TPO as an accepted alternate. “Oddly enough, they didn’t require you to do the base bid to bid the alternate,” he notes. “We chose to just bid the TPO. We ended up being the low bidder on that, and that’s how we got the project.”

After obsolete HVAC equipment was removed, crews from Exterior Solutions Group installed a TPO system from Johns Manville.

The logistics of the removal and roof replacement would be complicated, and it became obvious that access to the roof would also be an issue, as it was a high-security building. “This is a multi-story building, and the amount of security we would have to go through to enter the building and get up to the roof hatch would’ve created all kinds of problems,” Hicks explains. “So, we suggested putting a stair tower up and giving us complete access from the outside. We’d never have to enter the building. They had never even considered that option, but as we walked them through it and said, ‘This is how we’d like to set the job up,’ they replied, ‘We love it.’”

The next step involved coordinating equipment removal with the HVAC contractor. Again, a suggestion from Exterior Solutions helped increase efficiency and cut costs. The HVAC contractor’s original plan called for roofing crews to take out the roof system around the HVAC units, allowing HVAC crews to cut out sections of the steel decking below the equipment. The deck sections would have to be replaced before temporary roofs could be installed to keep the building watertight. The team at Exterior Solutions pointed out that there was no need to remove the decking. Instead, the equipment supports could be cut off as close to the deck as possible, and the ends of the supports could be buried in the insulation of the new roof system.

Equipment Removal

In the end, that’s the plan they executed. A fire watch was set up inside the building as equipment was removed. Crews from Exterior Solutions removed the existing roof to give the HVAC crews access. “We basically created a hole in the roof for them so they could see what they were doing,” Hicks explains. “We would slice the existing TPO back and take out the insulation. They would put down welding blankets in the area and then use cutting torches to cut the I-beam and L-beam steel supports off. Our roofers were on site to make sure supports were cut down to the proper length. As soon as the supports were cut off, we basically filled the hole.”

The deck was left intact, making it much faster and easier to patch the existing roof. It was critical to ensure the roof was weathertight every night to protect the documents inside the building. “We put the insulation back, we replaced the membrane, and we used an Eternabond product or welded a small cover strip around it, depending on the size of the hole,” notes Hicks.

The HVAC equipment was taken off the roof with a crane. Once the equipment was removed from one side of the roof, crews began installing the new system.

Roof Installation

With the equipment gone, the rest was clear sailing. “In all honesty, the roof was easy,” Flickinger says.

The existing roof system was torn off down to the deck and a TPO system from Johns Manville was installed. New polyiso insulation was topped with a fully tapered system to ensure proper drainage. After DensDeck cover board was installed, the 60-mil TPO membrane was adhered into place.

“We worked from one side to the other,” Hicks says. “The high point of the roof with the tapered system was in the center, and water is pushed to both sides where there are internal drains and overflow scuppers. We started at the low point and roofed up the hill to the center on one side, and then turned around and did the exact same thing on the other side.”

Details were minimal — just a few penetrations and a curb around the roof hatch. The edge metal installed was the Anchor-Tite system manufactured by Metal-Era. “We offered an upgrade on the metal edge,” notes Hicks. “Instead of a shop-fabricated metal edge, we recommended Anchor-Tite all the way around. After all, the area is subject to high winds. We felt that was a better way to go.”

The TPO system installed was ideal for the project, according to Flickinger. “I’ve been a thermoplastic guy my entire career,” he says. “I’m a big believer in heat-welded seams. We thought the heat-welded seams and adhered walls offered a better approach. We think it’s a very good-looking roof, and with the addition of a cover board — which the original roof didn’t have — it would definitely improve its hail performance.”

Hicks credits the manufacturer for assistance on the project. “Manville was very supportive,” he says. “They were local, and their technical support is excellent. We thought that for a project like this, to have a partner who was right there with you was important.”

The project was completed in less than a month, and Flickinger believes the key to executing the job efficiently was the decision to set up the stair tower. “That was the suggestion of our project manager,” says Flickinger. “Our company likes using stair towers, especially when we’re talking about long ladder runs. For us, it’s partly about safety for our own people, but because the building was secured, and as they talked to us about the steps we would have to take on a daily basis to just get access to the roof, we realized it was just going to kill us on production. We were going to waste so may man-hours on a weekly basis just getting to and from the roof. That was one of the driving factors that got the owner to agree to the stair tower, and we got a change order for it.”

The cost of the change order was minimal compared to the time and money it saved. “We have some really bright people,” says Flickinger. “They are all really good at looking at something and seeing if there is a better way. One of our strengths is we are really good at creative solutions, whether it’s something as simple as avoiding the grief of going through a secured building or taking a step back and asking, ‘Why cut holes in the deck? Why can’t we just cut these supports off above the deck because we are burying them in 6 inches of insulation anyway?’”

“The other piece for us is that we focus on the safety side of it, not only for our own people, but also the site safety and the safety of the people inside the building,” Flickinger continues. “We are very aware of that as we set our jobs up and decide where to set our materials and those types of things.”

The last component of a successful project is top-quality workmanship. “We focus on doing it right the first time,” Flickinger says. “Getting that customer satisfaction, not only at the end of the job with a great roof, but also during the project by trying to minimize the pain that an owner typically goes through in a roofing project, that’s one of our strengths that this project demonstrates.”

TEAM

Roofing Contractor: Exterior Solutions Group, Parker, Colorado, www.exteriorsolutionsgroup.com

MATERIALS

Roof Membrane: 60-mil TPO, Johns Manville, www.jm.com

Cover Board: DensDeck Prime, Georgia-Pacific, www.buildgp.com

Edge Metal: Anchor-Tite, Metal-Era, www.metalera.com

Sensitive Re-Roofing Project Necessitates Durable System, Flawless Execution

The 250,000-square-foot Pepper River data center project would pose challenges including a tight schedule and difficult weather conditions. Utah Tile and Roofing Inc.

Utah Tile and Roofing Inc. prides itself in its ability to tackle difficult projects. When Okland Construction approached the company to help prepare budgets for a bid on a roof replacement on a building that would become a data processing center, they immediately knew this one would fit the bill.

Founded in 1948 in Price, Utah, Utah Tile and Roofing (UTR) relocated to Salt Lake City in 1966. The company handles all types of commercial roofing projects, as well as waterproofing, sheet metal, and wall panels. The current owners are Paul and Andrew Seppi, who took over from their father, founder Herman Seppi, in 1977. According to J.C. Hill, vice president, the company continues to build a reputation for craftsmanship as it works on some of Utah’s iconic buildings. “We’ve done a lot of high-end work here in the state of Utah,” Hill says. “A lot of the architectural gems here locally have our fingerprints all over them. The higher-end, more difficult work is where we’ve found our niche.”

The Aligned Energy data facility known as Pepper River in West Jordan, Utah, would also have its challenges, including a tight schedule and difficult weather conditions. Approximately 250,000 square feet of existing roof would have to be removed and replaced, but the sensitive nature of the building would require not only a durable temporary roof to keep everything dry during construction, but a resilient, long-lasting finished roof to protect the equipment below. The answer was a hybrid roof system from Sika with a vapor barrier set in hot asphalt. It would be topped with insulation, a cover board, and an 80-mil Sarnafil PVC membrane.

The design for the roof system was developed by UTR in conjunction with the architect, roof consultant, general contractor, and the manufacturer. “The vapor barrier would be set in hot asphalt as a temporary roof. The insulation and the tapered insulation would also set in hot asphalt,” Hill says. “That gave them some redundancy, which is a term those tech guys like.”

Roof Removal

The building’s original gravel-surfaced built-up roof had been covered over at some point with a mechanically attached white TPO roof on one side and a mechanically attached black EPDM roof on the other.

“We had to keep the building watertight as we tore it off,” says Hill. “We put the temporary roof down and crews would do a nightly seal to keep everything watertight as they progressed across the building.”

The existing roof systems included the building’s original gravel-surfaced built-up roof. It was cut into sections and pried off the metal deck.

Work was done in sections, beginning on one half the roof and then finishing up on the other. The expansion joint in the center of the building was the dividing line.

The safety plan included a perimeter flag system, and those outside the warning line were tied off 100 percent of the time. A scaffold stair tower was built to provide safe access to and from the roof.

Debris from the tear-off was removed using chutes and dumpsters. First the roof membrane was sliced up into manageable sections, rolled up, and deposited into a dumpster, along with the cover board. Then the built-up roof was cut into 3-foot-by-3-foot squares and pried off the metal deck.

The deck was swept clean of debris and inspected. Some of the decking had to be replaced, including sections where skylights were eliminated. A 5/8-inch DensDeck cover board was then screwed down to the metal deck. The vapor barrier sheets were unrolled and allowed to relax in the hot sun, and then set in hot asphalt. “We were able to do about 2,000 or 2,500 square feet a day with the tear-off and dry in,” notes Hill.

One unusual obstacle was a Canadian goose that had set up her nest in the expansion joint. “We had to leave that section undisturbed while she was waiting for her chicks to hatch,” says Hill. “Actually, there was a pretty good-size section of the roof in the middle that we weren’t able to address until she left. Luckily there was plenty of roof to work in, and we didn’t want to disrupt her. Even after she left with her chicks, she would come back and chase the guys around every once in a while.”

After the temporary roof was installed, the existing parapet walls were raised. The durable temporary roof allowed carpenters other trades to work on the roof without excessive fear of damage. After the trades completed their work, the finished roof system was installed right over the temporary roof.

The PVC System

First a layer of polyiso insulation was set in hot asphalt. Next the tapered insulation layer was also set in hot asphalt, followed by another layer of insulation to achieve R-30. Half-inch DensDeck Prime was then set in low-rise adhesive and the white PVC membrane was fully adhered.

To provide the durability the project needed, a hybrid roof system from Sika was specified. It included a vapor barrier set in hot asphalt and an 80-mil Sarnafil PVC roof system.

“We actually had two crews for that phase: a hot crew and a single ply crew,” Hill states. “The hot crew would be laying the insulation out in front, and then the single-ply crew would lay the cover board in the low-rise foam and start fully adhering that membrane down. It took a coordinated effort with the guys we had out there to make sure that there was no asphalt contamination of the PVC membrane and that white roof remained clean.”

As work continued on the second half of the roof, cold weather set in. Due to the temperature limitations of the membrane adhesive, the decision was made to switch to a self-adhered membrane. “We were having production issues with the cold weather, and we went back to Sarnafil and they recommended putting the SA down,” notes Hill. “It was the first time we had ever installed the self-adhered membrane. It saved our production, and we were able to install nearly as much as we were doing in the better weather days.”

The last steps on the project included installing edge metal. “We did a Sarnafil high-wind edge detail with their clad metal and a pre-finished metal fascia plate over the top,” says Hill. “It gave the building a nice finishing touch from the ground and also from the roof side.”

Meeting the Challenges

The biggest challenge on the first phase of the project was the tight schedule. “We had to get that first phase operational so they could get the data hall up and running,” says Hill. “We had to get the first section dried in so the trades — electricians, drywallers, painters, and tech guys — could get in there and do their work.”

Work began in April of 2019 and wrapped up in December of the same year. After the first phase was completed, the weather posed the greatest difficulties. “The winter was quite heavy,” Hill says. “We had to remove snow quite often to be able to go back to work.”

In the last phase of the project, cold weather and heavy snow affected the schedule.

Hill credits the teamwork between all of the principals and the excellent craftsmanship of job foreman Rudolfo Garcia and his crew for the success of the project. He also cites durability of the temporary roof and the extra protection the hybrid system provides as critical components in the design. “With carpenters and steel guys working over that temporary roof, the typical peel-and-stick vapor barriers simply wouldn’t have been durable enough,” he says. “This building has to remain dry. That temporary roof with a cap sheet over the top of it could have been a completed system, so it gave them the backup that they needed. If there ever is a problem on the top layer with that single ply, there is still that temporary roof underneath to keep them dry.”

Utah Tile and Roofing received first place in the 2019 Sika Sarnafil Project of the Year Awards in the Low-Slope Re-Roof category. “The award is a testament to how good our guys in the field are,” Hill says. “Because we have such good field mechanics, we are able to take on these tougher projects that take more critical thinking and more experience. They are the best at what they do, the engine that drives this thing. They are the ones that make it happen.”

TEAM

Architect: HKS Inc., Salt Lake City, Utah, www.hksinc.com

General Contractor: Okland Construction, Salt Lake City, Utah, www.okland.com

Roofing Contractor: Utah Tile and Roofing Inc., Salt Lake City, Utah, www.utahtileandroofing.com

MATERIALS

Roof Membrane: Sarnafil G410 80-mil PVC, Sika, https://usa.sika.com/sarnafil/

Insulation: Sarnatherm ISO, Sika

Vapor Barrier: HA-87 SBS Ply Sheet, Sika

Cover Board: DensDeck Prime, Georgia-Pacific, www.buildgp.com

Talented Team Designs and Installs Multiple Roof Systems for Dickies Arena

Dickies Arena in Fort Worth, Texas, hosts the Fort Worth Stock Show and Rodeo as well as concerts and sporting events. Photos: Trail Drive Management Corp.

The new Dickies Arena in Fort Worth, Texas, was designed to echo the iconic Will Rogers Memorial Center, a historic landmark built in 1934. The site of the Fort Worth Stock Show and Rodeo as well as other concerts and sporting events, Dickies Arena was designed to provide a modern entertainment experience and configurable event spaces that would stand the test of time. The multiple roof systems on the project — including the plaza deck surrounding the arena — were essential in delivering on these goals.

Dickies Arena features a domed main roof with a cupola at the top that pays homage to its historic neighbor. “One of the major themes, especially of the dome roof structure itself, was to have a kind of throwback to the original Will Rogers Center, which is still there,” says Eric Nelson, AIA, RID, CCCA, vice president at HKS, the architect of record for Dickies Arena. “The Will Rogers Center was one of the first buildings of its type to have a long-span steel truss roof system. We used that existing structure as the inspiration for the roof structure inside the arena. We have these very thin, elegant looking trusses that are very art deco.”

The new structure’s domed roof is surrounded by low-slope roofs and complemented by two towers topped with metal roofs. Dickies Arena also features a pavilion with a standing seam metal roof, which sits on a plaza deck that serves as an outdoor event space as well as a giant roof system covering exhibit space and areas for housing rodeo livestock. The venue is also designed to provide excellent acoustics for concerts and features luxurious millwork and finishes throughout to provide a touch of elegance. “I like to say that it’s a rodeo arena, but it’s designed like an opera house,” Nelson says.

It took an experienced team of design and construction professionals to envision and execute the project, including HKS, the architect of record; David M. Schwartz Architects, the design architect; The Beck Group, the general contractor; Jeff Eubank Roofing Co., Inc., the roof system installer; and Sunbelt Building Services LLC, the insulation distributor and installer of the plaza deck.

The Dome

The roof system specified for the dome featured an 80-mil PVC system with decorative ribs manufactured by Sika Sarnafil. “The roof system is one that we use pretty regularly on our large sports projects, the Feltback PVC,” notes Nelson. “It’s a lot more durable than other single-ply roof membranes, so we really like it a lot. Dickies Arena is an arena that wasn’t just built for the next 20 years; it’s meant to be there for the next 100 years, so we wanted to make sure we used nothing but the highest-quality materials, especially with all of the hailstorms that we can get out there in Fort Worth.”

The pavilion has a Fabral double-lock standing seam roof system.

The roof system installer, Jeff Eubank Roofing Co., Inc. of Fort Worth, Texas, tackled the dome roof first, followed by the low-slope sections and the metal roofs. Work on the dome roof began in July of 2018. “The project progressed pretty quickly,” says Jeff Eubank, vice president of Jeff Eubank Roofing Co. “The dome in and of itself was like two different projects. The top half of the dome is pretty workable and walkable, and the bottom 40 percent of the dome is almost vertical.”

The Sarnafil Decor system was installed over an Epic acoustical deck, which posed some logistical and safety challenges. “We had to engineer special anchors because a typical tie-off anchor could not be used,” Eubank explains. “Before we could set foot on the job, we had to engineer special tie-off anchors which nested into the acoustical deck.”

Eubank and a structural engineer worked with Epic Deck to construct anchor points that would meet requirements for fall arrest. The half-inch aluminum, F-shaped anchors were designed to rest in the flutes of the acoustical deck and featured a ring provide a tie-off point. They were set in place using a crane.

Safety concerns included the Texas weather. “Our biggest challenge came with the heat,” says Eubank. “Summers in North Texas are brutal enough, but at the end of last summer, a high pressure system just stalled over Fort Worth. We were in the middle of a drought, with temperatures up to 110 degrees. You’re up on a deck with nowhere to hide, and with it was pushing 200 degrees up there. From a life safety standpoint, we ended up pushing the dome installation to night work.”

The main roof on the arena’s dome was topped with an 80-mil PVC system with decorative ribs manufactured by Sika Sarnafil.

Crews applied approximately 250,000 square feet of material on a near vertical application at night, with lighting provided by six tower cranes. The project required 100 percent tie-off of men and equipment.

The original plan for the dome was to work top to bottom, but as work began, the cupola was incomplete, so the safety and logistical plans had to be radically changed. “We ended up basically making two rings around the dome, doing the near-vertical portion — the bottom 30 or 40 percent — first,” Eubank says. “We moved up and did another 360-degree loop around the top half of the dome once the cupola was done.”

The roof system was installed over the acoustical deck and loose-laid filler. After a 5/8-inch DensDeck Prime substrate board was installed, crews mechanically fastened two layers of Sarnatherm polyiso and 1/4-inch DensDeck Prime. They adhered the Sarnafil G-410 20 Feltback membrane, which was produced in a custom color called Agreeable Gray.

After the membrane was installed, the PVC ribs were heat welded into place to give it the look of a standing seam roof. “We installed over 16 miles of custom-color Decor ribbing,” notes Eubank.

The Logo on the Roof

The dome roof also prominently features the Dickies Arena logo, which took some advance planning. “We left an area of the ribs out on the east side anticipating the logo up there,” Eubank says. “That’s in another custom color. Sarnafil ran the custom color and templated the letters. The logo is roughly 130 feet by 10 feet, so we received a giant D, a giant I, a giant C, and so forth. Once these things are installed, there is no pulling them up — your only option is to tear the roof off. So, imagine working with a 10-foot letter, 200 feet up in the air, on a slope, and making sure it’s level.”

Eubank Roofing came up with a plan to use a section of 60-mil PVC membrane as a backer sheet. “We laid out this big backer sheet in Agreeable Gray and stenciled all of the letters across it,” Eubank explains. “We took the backer sheet up, got it lasered and leveled, and installed the solid backer sheet on the dome. It already had the stencils on it, so we were able fall back and install the individual letters. We didn’t need to line them up — we just had to fill in the blanks.”

The last steps in the dome installation included installing ribs in a second custom color to go through the letters. Helicopters also brought in three large Dickies signs, which were placed atop concrete pedestals treated with a Sarnafil liquid membrane.

Flat Roofs and Metal Roofs

On the low-slope sections that surround the dome, the Sarnafil G-410 Feltback was installed over structural concrete and fully tapered polyiso. “There is a tremendous amount of masonry work on this project, and it is gorgeous,” Eubank notes. “It was important, though, on the low-slope portions to let the brick work and stone work wrap up before any roofing membranes were installed.”

The design of the arena echoes the iconic Will Rogers Center, which was the inspiration for the thin, elegant steel trusses.

A vapor barrier was installed over the structural concrete deck. After masonry work was completed, crews installed a fully tapered polyiso system in ribbons of OM Board adhesive, then adhered 1/4-inch DensDeck Prime and the 80-mil PVC membrane.

The complex also features two different metal roof systems from Fabral. On the north side of the building, the two towers were capped with a flat-seam panel. Down at the plaza level, the pavilion was topped with a double-lock standing seam roof system featuring Fabral 24-gauge Galvalume Power Seam panels.

According to Nelson, an area underneath the pavilion serves as a warm-up arena for horses during the rodeo, so the design was meant to evoke a rustic effect. “The cladding on that building is all quarter-inch steel with rivets on it,” Nelson points out. “Galvalume is finished to look like galvanized sheet steel, but it won’t tarnish or turn white or black like galvanized steel would — which is why they selected it — but it still has that kind of throwback look of a barn.”

Out of the Gate

Dickies Arena is now open to the public and is gearing up to host its first rodeo. The experienced team that built it has moved on to other projects, but they look back on their work on the new landmark venue with pride.

“I’m very proud of the people that I work with and the thought and care that they put into the project and the time that we take,” Eubank says. “A lot of our work is negotiated re-roofing, and I think that’s in large part because we take the time to think through a problem and come up with the best solution. I think that’s really highlighted here. You’ve got to take your time and do it right — and do it efficiently.”

Eubank commends the general contractor, H.C. Beck, for a smoothly operating jobsite. “The job was very well managed from a safety standpoint,” Eubank says. “The general contractor did a fabulous job of manipulating trade work and making sure no one was working overtop of anyone else.”

Nelson agrees, crediting the teamwork at every phase of the project for the successful outcome. “The partnership with David M. Schwartz as the design architect really worked very smoothly from our side,” Nelson says. “We worked very well with a talented team of consultants and who specialize in sports design. It’s a one-of-a-kind type of project.”

“My family has been in Fort Worth for five generations, and this is a project I’m just tickled to death about for the city,” says Eubank. “To be part of its install means a lot.”

TEAM

Architect of Record: HKS Inc., Dallas, Texas, www.hksinc.com

Design Architect: David M. Schwartz Architects, Washington, D.C., www.dmsas.com

General Contractor: The Beck Group, Dallas, Texas, www.beckgroup.com

Roofing Contractor: Jeff Eubank Roofing Co., Inc., Fort Worth, Texas, www.eubankroofing.com

MATERIALS

Dome Roof

Roof Membrane: Sarnafil G-410 20 Feltback PVC with Sarnafil Decor ribs, Sika Sarnafil, https://usa.sika.com/sarnafil

Acoustical Deck: Epic Metals, www.epicmetals.com

Cover Boards: 5/8-inch DensDeck Prime and 1/4-inch DensDeck Prime, Georgia-Pacific, www.buildgp.com

Low-Slope Roof

Roof Membrane: Sarnafil G-410 20 Feltback PVC, Sika Sarnafil

Cover Board: 1/4-inch DensDeck Prime, Georgia-Pacific

Metal Roof

Standing Seam Panel: 24-gauge Galvalume Power Seam, Fabral, www.fabral.com

Underlayment: Fabral HT, Fabral

Plaza Deck

Waterproofing Membrane: TREMproof 6100, Tremco, www.tremcosealants.com

Insulation: Foamular 600, Owens Corning, www.owenscorning.com

Brick Pavers: Hanover, www.hanoverpavers.com

At The Star, Durable Roof Systems Safeguard Buildings at Multi-Use Facility

Photos: KPost Roofing & Waterproofing

About 13 years ago, the original Dallas Cowboys Stadium in Irving, Texas, needed a new roof coating. KPost Roofing & Waterproofing of Dallas won the job; not too much later a partnership was born, and multiple roofing projects were the result, include The Star in Frisco, Texas.

Founded in 2004 by Keith Post, Steve Little, and Jayne Williams, with a core group of 11 roofing professionals, KPost now employs more than 400 people, including more than 60 specialized crews. Primarily a commercial roofing company, a residential division was opened four years ago to increase reach and service area. With a dedicated focus on safety, quality, and value, the company has amassed a portfolio of 1,240-plus projects and 60,000 work orders valued at more than $541 million, including multiple highly visible projects in the last several years like the headquarter buildings for Liberty Mutual, Toyota, and Charles Schwab; the Irving Music Factory; the Omni Dallas; the Statler Hotel; Texas Rangers Globe Life Field; and many more.

A longtime partnership with the Dallas Cowboys meant that when the team’s new indoor practice facility/mixed-use development was going under construction, KPost stepped in.

The Star

The mixed-use facility known as The Star is located on 91 acres in Frisco, Texas, and includes the Dallas Cowboys World Headquarters and domed practice facility, the Baylor Scott and White Health Sports Performance and Healthcare Center, The Star District shopping area, the Ford Center (a state-of-the-art 510,000 square foot indoor athletic facility shared by the Dallas Cowboys, the City of Frisco, and area high schools), and the beautiful Omni Frisco, which is nestled in the southeast corner of the complex.

The Star in Frisco is a mixed-use complex that includes the Dallas Cowboys World Headquarters, a domed practice facility, the Ford Center, and the Omni Frisco Hotel.

With a wide variety of building conditions throughout the complex, project architects selected roof assemblies that would meet the individual criteria of a high-rise hotel roof, a mid-level mixed-use space roof, and the domed roof of the Cowboys indoor practice facility. Various manufacturers and system assemblies were considered, and the use of a premium coverboard was always front of mind.

“The Omni Frisco roof levels 16 and 17 included a large amount of rooftop mechanical and lighting systems that require regular maintenance and a durable surface from which to work,” explains Chris Evans, chief estimator with KPost. “Additional details included the sheathing on the parapet walls and, of course the dome over the indoor practice facility.”

Evans’s job with KPost is that of leading the team with technical brainstorming and quality control in accomplishing project pricing and proposals.

“The use of a cover board was always part of the design,” continues Evans. “The architect opted for a single-ply roof at all roof areas. Single-ply roof membranes typically perform better when placed over a solid substrate. If not, there is an increased risk for premature wear, tear, and puncture. We needed to choose an option that would help the roof membrane perform to its full potential.”

Additionally, Frisco is located in the midst of the hail belt, which upped the ante for additional durability and protection against puncture.

Why Use a Cover Board?

Using a cover board is important for multiple reasons:

  • To preserve membrane integrity: Cover boards provide a smooth substrate to support the waterproofing membrane with the right balance of strength and flex.
  • To protect the insulation: Insulation compression causes material degradation, which lowers R-values. The polyiso insulation boards are typically the most expensive component in a commercial roof assembly, and critical in achieving target R-value. Cover boards are well-equipped for heavy loads and will protect the insulation and membrane beneath from being smashed by heavy equipment.
  • To increase durability: Puncture and impact resistance ensures product longevity. Impact resistance to foot traffic equals less maintenance, fewer repairs over time, and an extension of the life of the roofing assembly.
  • To provide weather protection: Wind and hail can wreak havoc on roofing assemblies, but a cover board helps maintain structural integrity during both the storm and the post-storm inspection.

The cover board is a team player; it not only protects the assembly and building from damage — it supports the performance of other assembly materials and the mechanical assets that call the roof home.

The Right Materials for the Project

Carlisle’s single-ply roofing membranes were chosen for the project, with Sure-Weld TPO specified for lower roof areas and Sure-Flex PVC for the dome roof. DensDeck Prime roof boards were incorporated in the submittals, with products provided by CSL Materials of Frisco. Evans and his team chose Georgia-Pacific’s DensDeck Prime Roof Board with EONIC Technology as the cover board for The Star — and offered multiple reasons why.

“It is clear that DensDeck and GP, along with their trade partners, are committed to testing a large amount of assembly types and material configurations. This commitment by GP has resulted in an ample amount of approved and tested assemblies, which allows us to find the right answer for pretty much any roof area,” says Evans.

“Fact is, DensDeck has become one of our key components used on most roof systems,” says Aileen Struble, senior estimator with KPost. “Between the testing, the ease of use, and the durability, DensDeck consistently offers the best protection.”

The most senior estimator on the KPost team, Struble has been with the company since the doors opened. She works on multi-system projects, including both new construction, remedial work and large historical renovations. She is KPost’s go-to estimator when faced with technically challenging and complicated projects, and she has received four ABC National Eagle Awards on her projects. An estimated 300,000 square feet of DensDeck Prime Roof Board was used on The Star.

When it came to the challenging logistics of the domed roof covering the indoor practice facility, the DensDeck Prime Roof Board passed with flying colors — literally, as the roof board was integral to the overall system, which was flown into place via helicopter.

“It’s all about consistency,” concludes Evans. “One of the greatest benefits with DensDeck is the fact that we receive the exact same product every single time we order it. This incredible level of consistency affords us the ability to deal with other challenges of construction because we know how DensDeck will behave under multiple conditions, and at the end of the day this consistency minimizes our overall risk. Partnering with consistency is necessary for success.”

“We like to call DensDeck the Goldilocks of the roof board industry: some options are too dense, and with some the dimensional stability just isn’t there,” says Struble. “GP and DensDeck has figured it out, because their roof board is just right.”

TEAM

General Contractor: Manhattan Construction Company, Dallas, Texas, www.manhattanconstructiongroup.com

Roofing Contractor: KPost Roofing & Waterproofing, Dallas, Texas, www.kpostcompany.com

MATERIALS

Roof Membranes: Sure-Weld TPO and Sure-Flex PVC, Carlisle SynTec, www.carlislesyntec.com

Cover Board: DensDeck Prime, Georgia-Pacific, www.buildgp.com

Living Roof Helps Orcas Island Home Blend into the Landscape

This residence on Orcas Island is crowned with an extensive green roof from XeroFlor.
Photos: Terra Firma NW LLC

Orcas Island is a horseshoe-shaped island in the northwest corner of the state of Washington. With an area of 57 square miles, it’s the largest of the San Juan Islands, and accessible only by ferry. When a client approached him about building a custom home on the island, Justin Paulsen jumped at the chance. Paulsen is the owner of Terra Firma NW LLC, a general contractor located in nearby Eastsound, Washington. “We were hired directly by the owners to build the project from the ground up,” Paulsen notes.

The 3,400-square-foot home features 3,850 square feet of roof area, which is crowned with a living roof. The system specified for the project was a XeroFlor extensive green roof, which was installed on top of a PVC membrane roof manufactured by Versico.

The green roof system consists of a root barrier with a drainage composite, 1-1/4 inches of growing medium, and pre-vegetated sedum mats. The system was installed in the late fall in 2018, so many of the plants were dormant. Photos: Terra Firma NW LLC

“The roof system works well for the home, which is designed in the style of the Bauhaus school of design,” notes Paulsen. “The home features many linear design elements, and the green roof gives it a sense of blending in with the natural surroundings.”

It was only the second green roof Paulsen had been involved with, so he made sure to do his homework. He knew from experience that work on the island would pose logistical challenges, so he tapped a talented to team to help design and execute the project.

The Roofing Contractor

Paulsen wanted a skilled roofing contractor to install the waterproof layer beneath the green roof system. The Versico rep in the area, Ken Stillwell, recommended All Weather Rooftop Solutions, headquartered in Everett, Washington. The company, owned by partners Todd Severson and Greg O’Neill, typically focuses on commercial work, but this project was right in their wheelhouse. Severson knew the company had to plan ahead to ensure the everything went smoothly.

Crews from Terra Firma NW installed the green roof system. The sedum mats arrived on a pallet and were unrolled on top of the growing medium. Photos: Terra Firma NW LLC

“Working on the island was the biggest challenge of the whole project,” Severson notes. “We wanted to complete the project in one week, so we had to make sure we had everything ready to go. Everything had to be transported by ferry, so we had to schedule all of the trucks and make sure all of the material landed at one time. We just had to make sure we had all of the material and manpower on that ferry.”

The PVC roof system was installed over a plywood deck. Crews first installed two layers of 3.3-inch insulation to achieve an R-value of 38. Tapered insulation system was then added to ensure proper drainage. The insulation was topped with half-inch DensDeck Prime cover board, which was mechanically attached. A gray 60-mil PVC membrane from Versico was then fully adhered over the entire assembly.

All Weather crews also installed OMG SpeedTite roof drains with Vortex-breaker technology, as well as Solatube light tubes. The large skylight was installed by the manufacturer, CrystaLite.

All Weather Rooftop Solutions installed the PVC membrane to provide a waterproof barrier beneath the green roof. Photos: Terra Firma NW LLC

The sheet metal work was completed by All Weather on a second trip, with a smaller crew returning to complete the flashing and edge metal. The roofing portion of the project went smoothly. “Justin from Terra Firma was great work with, and our superintendent, Jeff Gale, did a great job quarterbacking it on our end,” Severson notes. “Everything went off without a hitch. It’s a pretty unique little structure.”

Paulsen agrees. “They did a great job installing the insulation and the membrane,” he notes. “The biggest thing we had to deal with after that was protecting the membrane from other trades. Our stonemason had to go back up on the roof and complete the chimneys.”

To preserve the integrity of the membrane after it was installed, Terra Firma crews cut a 20-mil pond liner pond liner into sections that were used to protect areas of the roof that had to be accessed by other trades.

Installing the Green Roof

After all the other work was completed on the rooftop, crews from Terra Firma installed the green roof system in the late fall of 2018. Paulsen had heard about XeroFlor from another contractor and did some research. He then contacted Clayton Rugh, director of XeroFlor America, to design and specify the system.

“I thought it was really top-notch system,” Paulsen notes. “I went to Clayton to document some other examples that had been installed in the area, and I pitched it to our client. Clayton did all of the functional engineering work on the green roof system and determined the soil requirements. The plantings by XeroFlor were sourced very close to the project site, which helps to ensure successful future growth.”

Photos: Terra Firma NW LLC

The extensive green roof system consists of a root barrier with a drainage composite, which is an open-flow zone of polymer coils with a bonded fleece fabric sheet. The drainage material was topped with 1-1/4 inches of growing medium, followed by 1-inch-thick pre-vegetated mats, which contained a mix of sedum succulents.

The pre-vegetated mats are installed just like sod. “They arrive rolled up on a pallet,” Rugh notes. “You just align the roll adjacent to the previously installed roll, abutting it tightly, and roll it into place.”

Terra Firma also installed the edge metal and rock ballast around the perimeter. “I was amazed at how simple it was to accommodate the green roof portion of the project,” Paulsen says. “Once the membrane was down, we knew we were rock solid and the house was well protected. The green roof portion was easy to install. I’d definitely do one again.”

Paulsen is proud to have this project under his belt. He can’t wait to see it in the spring, when the green roof is in its full glory.

“Terra Firma NW thrives on jobs that have complex and unusual requirements,” Paulsen says. “This job, from foundation all the way through the roof, presented numerous design challenges. We have a $2 million-dollar house under this roof. If I had to give advice to anyone doing a green roof, my advice would be: Don’t cut corners.”

TEAM

Architect:  Harlan Pedersen AIA, Orcas, Washington

General Contractor: Terra Firma NW LLC, Eastsound, Washington, www.tfnwllc.com

Roofing Contractor: All Weather Rooftop Solutions, Everett, Washington, www.allweatherroof.net

MATERIALS

Extensive Green Roof System: XeroFlor XF + GM Assembly, XeroFlor North America, www.xeroflornorthamerica.com

Roof Membrane: 60-mil PVC, Versico Roofing Systems, www.versico.com

Cover Board: DensDeck Prime, Georgia-Pacific, www.densdeck.com

Skylight: CrystaLite, www.crystaliteinc.com

Daylighting: Solatube, www.solatube.com

Roof Drains: SpeedTite roof drains, OMG Roofing Products, www.omgroofing.com

Recreation Center’s Innovative Roof and Wall Systems Provide Added Durability

Indian River County Intergenerational Recreation Center hosts recreational and competitive sporting events and other community activities. Photos: Borrelli + Partners

Indian River County Intergenerational Recreation Center was designed to be the hub of its community, a venue that hosts recreational and competitive sports and other activities, including educational, social and philanthropic events.

The new $10.4 million facility, branded by the county as the “iG Center” and often referred to as “Big Red,” consists of two adjoining main buildings: the two-story gymnasium and a long, single-story wing that houses various multi-purpose rooms, a concession area, a game room and a catering kitchen.

The site’s location near the oceanfront in Vero Beach, Florida, is susceptible to hurricanes and other extreme weather events, and making sure the complex would stand up to the elements was a key consideration for officials and residents in the county. This concern prompted a focus on the design of the building’s exterior envelope. In the end, a metal roof and metal wall panels were the key to meeting the building’s design goals.

Design Criteria

When county officials spoke with the architects at Borrelli + Partners, they had a strict set of criteria in mind for the building, including the ability to withstand high wind speeds and 100-year rainstorms. “They mandated a sloped roofing system,” notes Dan-Michael Trbovich of Borrelli + Partners. “They wanted a minimum 20-year warranty, and they said they were looking for a ‘50-year roof.’ This affected the roof design and the wall design.”

The new $10.4 million facility was designed to stand up to hurricanes, torrential rains and extreme fluctuations in temperature. Photos: Atlantic Roofing II of Vero Beach Inc.

A key goal of the team at Borrelli + Partners was to specify a watertight metal roof system that would also allow unlimited thermal movement to cope with extreme temperature fluctuations. They found what they were looking for in a standing seam metal roof and wall system manufactured by IMETCO.

The 37-acre site and open park setting also provided the opportunity to explore interesting aesthetic elements. The building would be highly visible, and goals included a dynamic exterior design that would allow the park and the building complement each other. In the end, the decision was made to go with bright red and white metal panels that would stand against the blue sky to create what Trbovich calls an “All-American design.”

In one of many daring design elements, sections of the red roof panels were folded over and brought down to the ground to serve as wall panels. A custom detail was devised to make the transition impervious to water penetration.

“Our criteria included a kneecap—a premanufactured fixture that would be put over the entire thing,” Trbovich says. “IMETCO was the only manufacturer we knew that offered that, and it was absolutely critical in the design.”

Areas in which the panels were turned over included the south-facing wall, which was no coincidence. “We wanted to make sure the south-facing wall didn’t get too much heat, so what you’re essentially doing is creating a vented roof decking system that protects the vertical surface on the south side,” notes Trbovich.

High summer temperatures and afternoon rains in Vero Beach can cause a lot of expansion and contraction, so HVAC and plumbing systems were rerouted to avoid the roof. “There is not a single roof penetration,” Trbovich says. “We wanted to make sure that roof would be able to move and slide. We wanted to make sure there were no contraction points that would hang it up, therefore we went with a design that would not allow roofing penetrations, whether it was a vent pipe, air duct or air-handling unit.”

Detailing was meticulous and consistent throughout, according to Trbovich. Flashing details were all designed to have a 6-inch overlap. “We went to extreme levels of detailing, whether it was in section cuts or in isometric cuts, to make sure that each and every one of those flashing details had that same 6-inch overlap. We required those be uniform across the facility on all corners, so that we essentially matched rake, eave jamb and corner flashing details.”

Installation Challenges

To ensure the details were correctly installed in the field, the architect and manufacturer worked closely during construction with the general contractor, KAST Construction, and the installer, Atlantic Roofing II of Vero Beach Inc.

The building’s exterior envelope features a metal roof system and metal wall panels manufactured by IMETCO. Photos: Borrelli + Partners

Atlantic Roofing IIapplied the standing seam roof system and metal wall panels, as well as a small single-ply roof on a flat section near the entryway. IMETCO Series 300 panels in Cardinal Red were installed on both the roof and walls, while white IMETCO Latitude panels were also installed on the walls.

The metal roof system was installed over the structure’s metal deck. It included 3 inches of polyiso insulation, 5/8-inch DensDeck and Aqua-Block 50 peel and stick, high-temperature underlayment.

The absence of penetrations simplified the metal roof installation, notes Steven Cottrell, project manager and chief estimator for Atlantic Roofing II. “The panels were rolled right on the site, and the longest ones up there are 168 feet long,” he says.

The roll former was stationed on the ground, and panels were lifted to the roof with a special cradle. “IMETCO brought out the metal and provided the machinery to roll them out, and the panels were placed onto giant spacer bars and loaded onto the roof,” Cottrell explains. “It was a bit of a challenge. We had 20 men up on the roof unloading them.”

The flat roof sections connecting the two buildings and the entryway were covered with a Seaman FiberTite KEE membrane, which was fully adhered over 3 inches of polyiso, tapered insulation and 5/8-inch DensDeck.

The roof system features a large internal gutter, which was lined with the same FiberTite roof system. Metal panels drop into the gutter and pick up on the other side, so it was crucial to ensure the area would be watertight and the panels would line up perfectly. “We worked closely with the architect and manufacturer on that,” notes Cottrell. “We used their eave detail and high eave detail, and it worked very well.”

Elegant Solutions

According to Cottrell, the roof and wall installations went smoothly and the roof is performing well — despite a hurricane and a 100-year rainstorm. “We’ve had no leaks, zero callbacks,” he says.

Photos: Borrelli + Partners

As the building was completed, Borrelli + Partners worked with the county to design the landscaping around the structure. “Our architects and interior designers work very closely with the landscape crew,” Trbovich notes. “We’re concerned about the physical space — external, internal, architectural and throughout. It’s a real holistic design approach, and you don’t see that with most architectural firms.”

The result is a project that Cottrell and Trbovich point to with pride. “It’s a unique structure,” says Cottrell. “It was a challenging project, but we rose to the challenge and banged it out. It’s like a little star for us on the fridge, if you know what I mean.”

For Trbovich, what stands out the most is the marriage of form and function in the many details. “While the building looks interesting with the awning and the striking form of the red standing seam roof, what’s crucially important is all the things we just talked about that are embedded in that design — the solutions themselves.”

TEAM

Architect: Borrelli + Partners, Orlando, Florida, www.borrelliarchitects.com
General Contractor: KAST Construction, West Palm Beach, Florida, www.kastbuild.com
Roof System and Wall System Installer: Atlantic Roofing II of Vero Beach Inc., Vero Beach, Florida, www.atlanticroofing2.com

MATERIALS

Metal Roof Panels: Series 300 in Cardinal Red, IMETCO, www.imetco.com
Metal Wall Panels: Series 300 in Cardinal Red and Latitude in White, IMETCO
Underlayment: Aqua-Block 50, IMETCO
Cover Board: 5/8-inch DensDeck Prime, Georgia-Pacific, www.densdeck.com
Single-Ply Membrane: 50-mil FiberTite XT KEE, Seaman Corporation, www.fibertite.com