New Construction Project Tests Contractor’s Mettle

Photos: Lynn Cromer Photography, Ferris, Texas

Photos: Lynn Cromer Photography, Ferris, Texas

Independence High School in Frisco, Texas, was conceived as an impressive new construction project on a tight schedule. The standing seam metal roof of the building was a key component in the architectural planning, as it was designed to provide aesthetic appeal for the massive structure while minimizing the view of mechanical equipment for passers-by on the ground.

The roof also was comprised of several low-slope sections, which were covered with a modified bitumen system. Both the metal and modified systems contributed to the building’s energy efficiency, helping the project achieve LEED Silver status.

The roof systems were installed by the Duncanville, Texas, branch of Progressive Roofing Services. Randy Dickhaut, the company’s general manager, indicated the project was completed in approximately one year—an ambitious schedule for a job of this size. “It was a challenging new construction job,” he says. “There were a lot of logistics involved, but in general, the job went very well.

A Tale of Two Roofs

The first goal of the project was drying in the metal decking. A two-ply, hot–mopped modified bitumen system manufactured by Johns Manville was installed on 24 decks totaling approximately 195,000 square feet of low-slope roof area. The system was applied over two layers of 2 1/2-inch polyiso insulation and 1/2-inch JM Securock cover board. The system was topped with an Energy-Star rated cap sheet, DynaGlas FR CR.

Photos: Lynn Cromer Photography, Ferris, Texas

Photos: Lynn Cromer Photography, Ferris, Texas

In the nine sections where the 88,000 square feet of metal roofing was installed, two layers of 2 1/2-inch polyiso insulation were attached, along with plywood decking and self-adhering TAMKO TW Tile and Metal underlayment. The standing seam metal roof system was manufactured by McElroy Metal, and the company provided the manpower and equipment to roll form the panels on the job site. Roof panels were the company’s 22-gauge Maxima 216 panels in Weathered Galvalume. These panels were complemented by 24-gauge Flush panels on walls and soffits.

The roll former was mounted on a scissor-lift truck. The eaves of the building were approximately 36 feet off of the ground, so a sacrificial panel was used to create a bridging effect to help guide panels to the roof. “Basically, the roll former went right along with us,” Dickhaut recalls. “We would pull 30 or 40 squares of panels, then drop the machine and move to the next spot. We were able to roll the panels right off the machine and lay them in almost the exact spot they would be installed.”

Photos: Lynn Cromer Photography, Ferris, Texas

The length of some of the panels posed a challenge, and as many as 12 crew members were needed to guide them into place for installation. In the steep-slope sections, crew members had to be tied off 100 percent of the time, so retractable lanyards were used to help keep safety lines out of the way.

The roof was mechanically seamed using a self-propelled industrial roof seamer manufactured by D.I. Roof Seamers. “We call it walking the dog,” notes Dickhaut. “One man can operate the equipment, and he just walks it every inch of every seam.”

The metal roof was designed to hide the mechanical equipment for the building, and Progressive Roofing completed work on two deep mechanical wells before the HVAC equipment was installed. “In the wells, we used McElroy’s Flush panels for the vertical surfaces and transitioned to the metal roofing,” notes Dickhaut. “In the bottom of the mechanical wells, we installed the Johns Manville modified roof and flashed the curbs.”

Rising to the Challenge

Dickhaut points to a few challenges on the job, including the length of the panels and the weather. “Overall, the job went really well,” he says. “The architects did a great job on the design, and McElroy has really good details. It was a pretty straightforward process. There was a lot of wind and rain we had to cope with. When you have a 100-foot panel that you can’t kink or scratch, it can get kind of tricky. You just have to be very careful.”

Photos: Lynn Cromer Photography, Ferris, Texas

Photos: Lynn Cromer Photography, Ferris, Texas

The Texas weather made the schedule unpredictable. “We were on that job over a year, so we caught all four seasons,” he says. “Weather had a huge impact. We dealt with extreme heat, humidity, snow, ice, mud, monsoon-type rains. Texas throws anything and everything at you.”

Whatever the conditions, Progressive Roofing was ready. “We show up locked and loaded,” Dickhaut says. “We attack it. We have seasoned veteran roofers that lead the pack. On that particular project, we had an architect, roofing consultants, an owner’s rep, and a general contractor. We would also bring in the McElroy and JM reps periodically for consultation. It’s really a team effort.”

TEAM

Architect: Corgan Associates Inc., Dallas
General Contractor: Lee Lewis Construction Inc., Dallas
Roofing Contractor: Progressive Roofing Services Inc., Duncanville, Texas

Johns Manville Partners With Logistics Lighting

Johns Manville announced the company has formed a partnership with Logistics Lighting to create the Johns Manville skylight program. The skylight program was established to allow JM to integrate skylights into clients’ projects and incorporate a seamless process for including a complete system with the roofing package. This program includes various skylight products with different brands in order to provide the most cost-effective option, with up to a 20-year warranty. The products offered through the program include skylights, smoke vents, tubular skylights, safety screens, burglar bars and roof curbs. There are also several services offered through the JM skylight program, including design and layout of skylights, energy savings calculations, specification review, submittal packages, and project specific meetings with designers and contractors.

This program has allowed JM to broaden the company’s offering and create more opportunities for customers to diversify based on their needs. The goal of the partnership was to combine Logistics Lighting’s extensive knowledge of skylights with the expertise that JM brings to roofing, creating real value for the consumers. According to JM, this partnership provides consumers with quality products, a competitive price, and a guarantee that is backed by a trusted company.

The JM skylight program includes a skylight warranty, issued by JM, as an addendum to the 20-year roof guarantee. The 20-year guarantee is only available on Velux and Kingspan products. The other two brands that are offered are Sunoptics and Wasco, and those have up to five and 10-year warranties, depending on the product.

President of Logistics Lighting Eric Huffman stated, “We are proud to be a part of the Johns Manville skylight program. We are honored to serve Johns Manville clients and sales team, and to provide the finest skylight and smoke vent options for their projects, combined with the best warranty available. The skylight program allows JM to help their clients to cost-effectively meet their daylighting and sustainability goals, and serve as a single source for the entire roof guarantee.”

For more information about the skylight program, contact Huffman at EHuffman@LogisticsLighting.com or call (307) 633-9696.

Re-Roofing of Shopping Center Poses Logistical Challenges

Southgate Shopping Center: Sebring, Florida

The re-roofing project of the shopping center totaled 79,556 square feet.

The re-roofing project of the shopping center totaled 79,556 square feet.

Roofing contractors often find themselves tackling re-roofs at shopping centers in piece-meal fashion, doing sections over the years as the budget allows. When property manager Southern Management and Development decided to remodel the entire Southgate Shopping Center in Sebring, Fla., in conjunction with Publix Markets’ replacement of their existing store at the location, they looked to Advanced Roofing to get the job done.

The scope of work included re-roofing three large sections of the retail plaza and a drugstore on the property. The roofing portions totaled 79,556 square feet.

Roof System

The roof specified was a two-ply modified bitumen system from Johns Manville. In the three large sections of the plaza, the existing built-up roof was completely torn off, while the drugstore was a re-cover project, notes Andrew Vik, estimator and project manager with Advanced Roofing’s Tampa branch, which operates under branch manager Michael Landolfi.

Roofing work started in November 2016 and was completed in February 2017. After the existing roof was removed, crews installed 2-inch polyiso to the steel deck. “We mechanically fastened that with a half-inch USG SecuRock cover board through the steel deck,” notes Vik. “The two plies of modified bitumen were then torch applied, a smooth base sheet and a white granulated cap sheet.”

On the drugstore, the roof was vacuumed, and the cover board and two plies were installed over the top of the old roof system.

In addition to the roofing scope, Advanced Roofing’s HVAC division installed and removed heating and air conditioning units and replaced some obstructive ductwork. “We had our own HVAC people working with our roofing crews, so it was easy to coordinate everything,” notes Vik. “We had HVAC installations on three of the buildings, and we remounted existing units on two of the buildings. There was also a lot of demolition on the south building, as there were several derelict units that
had been sitting there for quite some time. Those had to be hoisted off there and taken out.”

A Challenging Project

In addition to the roofing scope, Advanced Roofing’s HVAC division installed and removed heating and air conditioning units and replaced some obstructive ductwork.

In addition to the roofing scope, Advanced Roofing’s HVAC division installed and removed heating and air conditioning units and replaced some obstructive ductwork.


Logistics are often a challenge with a shopping center that remains open to the public, notes Vik. “You have to load and unload multiple levels of the roof at different times,” he says. “Customer relations is also a challenge; you have to keep everyone happy and ask a lot of questions. The construction manager has to do a lot of P.R. when he’s there.”

Demolition portions of the project were done at night and application during the day, so business at the mall was never disrupted. Traffic in the parking area was also a key concern.

“Setup areas had to be barricaded and marked off while we were loading and unloading,” Vik says. “There was even a drive under bridge connecting two buildings that had to be re-roofed, so we always had to be mindful of people below.”

Parapet walls did not surround all portions of the roof, so safety precautions included a safety perimeter; employees outside the perimeter had to be harnessed and tied off to a portable fall protection anchor system by Raptor.

The project went off without a hitch, according to Vik. “The mall was 100 percent open during the entire project,” he says. “Things went very smoothly— especially for everything that was involved. One of our mottoes is, ‘The harder the job, the better.’ We like a challenge. We take on a lot of projects other companies shy away from.”

The keys to his company’s success are coordination and versatility, states Vik. “We do it all,” he says. “We didn’t have to get anybody from outside the company to work on the project. We did all the roofing, all of the HVAC, and all of the hoisting was done in-house. We’ve also got lightning protection inhouse, and we have a solar division. We have a great team. Everyone does their part to get the bids out and get the jobs done. It’s the best team I’ve ever worked with.”

Team

Roofing Contractor: Advanced Roofing Inc., Tampa, Fla.
Consultant: CBA Roof Consulting LLC, Lake Worth, Fla.
Roof System Manufacturer and Technical Support: Johns Manville, Denver

Johns Manville Roofing Innovations to Be Featured on Episode of TV Show

Johns Manville (JM) will be featured in an episode of “Office Spaces” during its third season. “Office Spaces” reports on innovations in commercial construction and design spaces to explore cutting-edge products and technologies that impact the way we live, work and play. The segment featuring JM, titled “Meet the Innovators behind Johns Manville Commercial Roofing: Innovations for Efficiency & Longevity,” will air July 9 at 5 p.m. ET on FOX Business Network.

Aside from its initial broadcast on FOX Business, the footage and reporting from JM manufacturing plants will be made available for syndication to more than 100 stations across the country.

“Johns Manville started as a roofing company nearly 160 years ago and has a long history of innovation,” said Joe Smith, SVP and GM of Roofing Systems. “We look forward to highlighting our products and the people who make them on ‘Office Spaces.’ This is a great opportunity to tell our story and to showcase why Johns Manville is a leader in the markets we serve.”
 

Reflective Granulated Cap Sheet Is for BUR Systems

The reflective granulated cap sheet may be used as a cap or flashing sheet in built-up roof systems.

The reflective granulated cap sheet may be used as a cap or flashing sheet in built-up roof systems.

Johns Manville has introduced a highly reflective granulated cap sheet called GlasKap CR G, which may be used as a cap or flashing sheet in built-up roof systems. The CR G membranes are surfaced with white reflective minerals and can be installed using standard granulated cap sheet installation methods. GlasKap CR G joins the larger offering of JM cool roof membrane solutions. These products are approved by FM Global and UL. They are also listed with CRRC and meet current Title 24 requirements. GlasKap CR G provides an additional option for customers who want a reflective cap sheet as part of a reliable BUR system.

Johns Manville Announces Leadership Changes

Johns Manville recently announced that Tommy Knappich, Vice President of Sales for Roofing Systems, has been promoted to General Manager of Building Insulation in JM’s Insulation Systems business. The company named Jennifer Ford-Smith as its new Director of Sales for Roofing Systems.
 
“While Tommy’s contributions to Roofing Systems are too numerous to list, and he will be missed, I think we all agree that his promotion is a great and well-deserved opportunity,” says Joe Smith, Senior Vice President and General Manager, Roofing Systems. “In that same spirit, I am pleased to announce that Jennifer Ford-Smith is our new Director of Sales, Roofing Systems. Jennifer will lead the Contractor and Distributor channels for the business. The National Account and Specifier Services organization will continue to be led by Brad Burdic.”
 
According to the company, Ford-Smith joined JM 13 years ago, and she became Director of Marketing and Single Ply Product Management for Roofing Systems in 2012. Prior to joining JM, she held various marketing positions with Hunter Douglas. She earned a bachelor’s degree from Regis University in Marketing and Communications.

“We look forward to her continued contributions to the roofing business,” Smith notes. “Jennifer and I worked closely together for many years in Roofing Systems before 2012 to strengthen our single-ply offering while protecting our bituminous heritage. We expect to build on the current momentum and look forward to a great 2017.”

Project Profiles: Retail

Sierra Nevada Brewery, Mills River, N.C.

About 58,000 pounds of copper were installed on the brewery.

About 58,000 pounds of copper were installed on the brewery.

TEAM

Roofing Contractor: The Century Slate Roofing Co., Durham, N.C.
Architect: Matthew Galloway of Russell Gallaway Associates Inc., Chico, Calif.

ROOF MATERIALS

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project. This was close to 750,000 pounds of slate, or 375 tons.

About 3,000 feet of custom copper gutters and downspouts, conductor heads and 100 squares of painted standing-seam panels were fabricated, and pre-built copper clad dormers and decorative copper cornices were installed.

The project also included 35 squares of copper standing-seam roofing, 25 squares of soldered copper flat-seam roofing and 115 squares of copper wall cladding. About 58,000 pounds of copper were installed on the brewery.

Everything on the building is oversized and that meant everything had to be built to support the heavy structural loads and live loads from wind and mountain snow. The large roof faces called for 10-inch custom copper gutters. When you have gutters that large in the mountains of North Carolina you have to consider the extraordinary weight of the annual snow.

In addition to snow guards being installed on the slate roof, custom 1/4-inch-thick copper gutter brackets fastened the gutter to the fascia. It is typical on steel-framed construction, particularly on this scale, that the framing is out of square and there is widely varying fascia and rake dimensions.

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project.

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project.

However, these items should not appear out of square or have varying dimensions. Great care had to be taken to measure and custom bend onsite all the detail flashings so everything appeared perfect. This took many skilled craftsmen, a great deal of time and the absolute drive to provide the highest quality work.

Slate Manufacturer: Evergreen Slate Co. Inc.
Copper Fabricator: K&M Sheet Metal LLC
Supplier of Underlayment, Copper Sheets and Coil, Insulation and Nailbase Sheathing: ABC Supply Co. Inc.

ROOF REPORT

The new-construction project began in November 2013 and was completed in September 2015.
The team completed the slate installation so well that The Century Slate Co. was awarded the 2015 Excellence in Craftsmanship Award by Evergreen Slate for the project.

PHOTOS: The Century Slate Roofing Co.

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

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

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

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

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

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

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

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

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

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.

NRCA Aims to Increase Awareness During National Roofing Week

Roofs are one of the most important parts of our homes, schools and businesses. But they’re often ignored until in need of repair or replacement. During National Roofing Week, July 5-11, the National Roofing Contractors Association (NRCA) aims to increase awareness about the importance of hiring professional roofing contractors and making informed decisions about maintaining or replacing any roof system.

“National Roofing Week is about raising the public’s awareness about not only how vital a roof is, but also the importance of professional roof installation and maintenance to ensure safe, long lasting roof systems,” says Bill Good, CEO of NRCA. “Professional roofing contractors raise the bar for quality roof system work, and National Roofing Week helps homeowners and business owners make educated decisions when choosing a roofing professional.”

In honor of National Roofing Week, NRCA and King of Texas Roofing (Dallas) hosted a community service project, replacing the roof of Momentous Institute, owned and operated by the Salesmanship Club of Dallas. Momentous Institute is a nationally acclaimed lab school that provides therapeutic services to children and families in need in the Dallas area.

NRCA manufacturer members RMax (Dallas) OMG Roofing Supplies (Agawam, Mass.), Johns Manville (Denver), H&E Equipment Services (Dallas), Roofing Supply Group (Dallas) and Jim Whitten Roof Consultants (Austin, Texas) donated materials and labor for the project.

King of Texas Roofing re-covered 26,000 square feet of the nearly 20-year-old roof with 1-inch polyiso insulation and a 60-mil, white thermoplastic polyolefin (TPO) roof system. To celebrate National Roofing Week, NRCA is encouraging professional roofing contractors to participate in roofing or non-roofing related community service projects.

“In honor of National Roofing Week, we want to promote the good deeds of the roofing industry and emphasize the value of professional roofing contractors to the communities where they live and work,” says Good. “The best way to do that is through community service projects. We encourage all professional roofing contractors to engage with their communities and help in any way they can.”

During National Roofing Week, NRCA will recognize the winners of its annual Children’s Art Contest that was open to children in grades one through eight who are relatives of NRCA members and their employees. Contest winners will have their artwork featured on all 2015 National Roofing Week materials and displayed at industry events throughout the year.