Illinois Manufacturing Facility Incorporates PV Panels With Roof Re-cover

McElroy Metal’s manufacturing facility in Clinton, Illinois. Photos: McElroy Metal

After completing successful solar panel installations with roof re-covers at plants in Peachtree City, Georgia, and Adelanto, California, McElroy Metal recently completed a third solar conversion at its plant in Clinton, Illinois.

The original R-panel metal roofing on the plant, constructed in the 1970s, was re-covered using McElroy Metal’s 238T symmetrical standing seam roofing. The 238T metal roofing panels were roll formed on site, run directly on to the roof and installed by Prairieland Roofing of Arthur, Illinois. After the new roof sections were complete, Inovateus Solar installed 1,116 Hanwha Q-Plus L-G42 350W panels on the facility using roof attachment solutions from S-5!

The large-scale, multifaceted solar installation at the Clinton plant required a two-pronged approach, as the facility consisted of two different metal roof types: a face-attached trapezoidal profile on one section of the facility and a standing seam profile on another.

S-5!’s engineering team collaborated with McElroy Metal to determine which clamps and brackets were most appropriate based on the two different types of roofs, their respective load capacities, resulting load distribution and best fit of mounting components. They analyzed roof-specific data and CAD drawings to determine precise attachment points across the massive solar array and to determine the bill of materials, including clamps, brackets and PVKITs.

This photo shows S-5!’s S-5-T Mini clamps and PVKIT 2.0 MidGrabs and EdgeGrabs mounted on a McElroy Metal 238T standing seam roofing system.

S-5-T Mini clamps were selected to attach the solar panels to the facility’s new 238T symmetrical standing seam roof system. Featuring a two-piece design to allow easy installation anywhere along the length of the panel seam, S-5-T Mini clamps are specifically designed to fit profiles with a T-shaped seam configuration like the 238T. Beyond the fit, this clamp, in tandem with all S-5! attachment solutions, was specifically load tested on the 238T in the gauge used for the project, enabling comprehensive system engineering specific to this project. This process is routine for S-5!, and the company has more than 500 individual load test results published and accessible on its website.

The solar installation on the facility’s existing Multi-Rib Panel roof system required S-5!’s RibBracket II. These brackets are specifically designed to attach to this type of roof profile. The RibBrackets offered the best fit and provided more than enough tested holding capacity for the dimensions of the rib.

In addition, the entire solar array was mounted using S-5!’s PVKIT 2.0 Solar Solutions, comprised of MidGrabs and EdgeGrabs, which enabled solar installers to mount the solar panels directly onto the clamps and brackets. The pre-assembled components reduced installation time and cost for PV mounting, eliminating the need for an elaborate rail system, while also providing better load distribution into the roof and substructure.

“As a leader in the metal construction industry, we have had the privilege of working alongside McElroy in many venues, industry trade groups and supply relationships, now spanning almost 40 years,” says S-5!’s Founder and CEO, Rob Haddock. “We are proud industry partners and look forward to continuing working together in expanding the use of solar.”

TEAM

Roofing Contractor: Prairieland Roofing, Arthur, Illinois

Solar Installer: Inovateus Solar, South Bend, Indiana, www.inovateus.com

MATERIALS

Metal Roof Panels: 238T, McElroy Metal, www.mcelroymetal.com

Solar Panels: Q-Plus L-G42 panels, Hanwha, www.hanwha.com

Clamps and Solar Attachments: S-5-T Mini clamps, RibBracket II, and PVKITs, S-5!, www.S-5.com

IMPs Provide Aesthetics, Durability for Houston Renovation

A 70-year-old manufacturing facility in West Houston was transformed into The Cannon, an entrepreneurial hub, office complex and event space. Photos: Metl-Span

Renovating and transforming a 70-year-old manufacturing facility into a contemporary office building with impressive amenities requires some imagination, careful planning and a lot of communication. The Cannon, an entrepreneurial hub in west Houston, also called for more than 90,000 square feet of insulated metal panels (IMPs) for walls and roofing.

The Cannon, a 120,000-square-foot modern, flexible workspace, provides innovators with everything they need to establish a home base for their companies. Home to more than 500 of Greater Houston’s most talented and accomplished entrepreneurs, creatives and small business owners, The Cannon includes 131 offices, 300 open and dedicated desks, a movie theatre, game room, event space, full-service kitchen, a health and wellness room, and a courtyard with outdoor seating. The facility is marketed as “a citywide ecosystem for Houston’s entrepreneurs, small businesses, freelancers and creatives.”

The renovation incorporated more than 90,000 square feet of insulated metal panels for walls and roofing.

Insulated metal panels from Metl-Span helped achieve the desired appearance, inside and outside. “We could have gone the conventional route, with insulation and drywall, but we really wanted to maintain some of the original look of the building,” says Ken R. Harry, AIA, NCARB, LEED AP, Principal of Abel Design Group of Houston. “With the insulated metal panels, we were able to leave the interior beams and columns exposed. Plus, we got the levels of insulation that were required for the roof and walls. Right from the start, it seemed like the logical way to go.”

The original building was stripped down to the steel structure. Some of the 70-year-old purlins and cross members had to be replaced. “We had to verify every dimension of all the beams so shop drawings could be accurate,” says David Baldwin, Sales Manager at FSR Services of Houston. “The beams were painted, and the insulated metal panels were installed. The bright blue beams against the white interior finish of the insulated metal panel is a very modern and clean look.”

The project called for approximately 67,775 square feet of Metl-Span’s CF42R insulated metal roofing panels, with 4 inches of urethane insulation, in the color of Burnished Slate. The exterior panels were 24-gauge Galvalume. The wall panels were two profiles and colors: 37,858 square feet of CF7.2 InsulRib in Burnished Slate and 9,437 square feet of CF36A in Chestnut, both with 22-gauge Galvalume exterior panels. All interior panels were 24-gauge Galvalume in Igloo White.

Baldwin says FSR needed 180 working days to install the IMPs, but crews ran into weather delays during the rainy Houston summer of 2019, which pushed back the original completion date approximately 90 days. The project was completed in August 2019.

“We were basically working in a mudhole all summer,” Baldwin says. “There were a lot of days we couldn’t get anything done. Our equipment was buried in the mud.”

The Cannon is the largest IMP project completed by FSR Services. Baldwin says his team, led by owner Steve Seibert and project manager Tommy Pavlicek, did its best to keep the project moving along. Seibert says it was a challenging project, retrofitting an existing structure, but the end product turned out amazing.

“Insulated metal panels are easy and quick to install,” Baldwin says. “The larger panels cover a lot of space in a single pass. It’s a lot easier than making several passes for the exterior system, interior system and insulation.”

TEAM

Architect: Abel Design Group, Houston, Texas, www.abeldesigngroup.com

IMP Installer: FSR Services, Houston, Texas, www.fsrservices.com

MATERIALS

Roof Panels: CF42R in Burnished Slate, Metl-Span, www.metlspan.com

Wall Panels: CF7.2 InsulRib in Burnished Slate and CF36A in Chestnut, Metl-Span

DEWALT Manufacturing Plant Produces 10-Millionth Tool

DEWALT Charlotte, N.C. manufacturing plant has celebrated a milestone, as the professional tool brand’s 10-millionth tool rolled off the production line. Company executives were on hand to build the 10-millionth tool, a 20V MAX XR Lithium Ion Brushless 3-Speed Hammer Drill (DCD996P2).

Across its seven U.S. manufacturing plants, the brand produced more than 90 million individual products made in the USA with global materials in 2016, an almost 50 percent increase from the 62 million individual products in 2015, just one year earlier. This is an accomplishment towards the brand’s effort to expand its domestic manufacturing using global materials, an effort that began in 2013. In addition to Charlotte, DEWALT operates manufacturing facilities in New Britain, Conn.; Greenfield, Ind.; Hampstead, Md.; Shelbyville, Ky.; Cheraw, S.C.; and Jackson, Tenn.

Frank Mannarino, president of DEWALT Professional Products Group says, “Year after year, DEWALT has increased its production of tools made in the U.S. with global materials. We have worked hard to drive productivity and efficiency at our manufacturing facilities, delivering products with the same guaranteed quality customers have come to know and expect from the brand. We are a global brand proud to have been founded in the U.S. and proud to continue to manufacture in the U.S.”

DEWALT understands that buying American products and building the American economy are important to its customers. Connie Grant, an employee at the Charlotte plant states, “It makes me proud to work for a company that values the American workforce.”

DEWALT is committed to crafting tools as strong as its American pride. Visit the website to learn more about DEWALT products.

ATAS International Inc. Program Expands Knowledge of Manufacturing, Career Opportunities

In celebration of Manufacturing Day 2016, ATAS International Inc. opened their doors on to area students to expand their knowledge of manufacturing.  Schools that were represented are Lehigh Career and Technical Institute, Schnecksville; Sacred Heart School, Allentown; Parkland School District, Allentown; and Career Institute of Technology, Easton.
 
This program was designed to expand knowledge of manufacturing and improve public perception of today’s manufacturing career opportunities.  Students were able to tour the ATAS facility to experience first-hand the processes in which metal components for the building envelope are manufactured.  They also viewed a panel discussion consisting of several ATAS employees, who spoke about their positions in departments that include production, marketing, sales, technical services and human resources. Students learned that every person within a manufacturing company must work together to produce a product and provide service to their customers.
 
Manufacturing Day is an annual national event executed at the local level supported by thousands of manufacturers as they host students, teachers, parents, job seekers and other local community members at open houses, plant tours and presentations designed to showcase modern manufacturing technology and careers.  Studies show that almost 80 percent of Americans believe manufacturing is important to our economic prosperity, standard of living, and national security.  Yet only 30 percent of those surveyed would encourage their children to go into manufacturing careers.  This is a trend that must be reversed and which Manufacturing Day seeks to address by giving people an opportunity to discover what modern manufacturing environments are really like.
 
“There is a demand for skilled professionals in the manufacturing sector who can design, program and operate technology”, says Jim Bus, executive vice president of ATAS International.  “The average age of a manufacturing employee is 56, and between now and 2020 there will be a shortage of skilled workers who will need to be replaced.”
 
Manufacturing Day is co-produced by the Fabricators & Manufacturers Association International (FMA), the National Association of Manufacturers (NAM), the Manufacturing Institute (MI), and the National Institute of Standards and Technology’s (NIST) Hollings Manufacturing Extension Partnership (MEP).  Partners include Edge Factor and the Science Channel and guest producer, Industrial Strength Marketing.

MBCI Houston Plant Hosts National Manufacturing Day

Congresswoman Sheila Jackson presents NCI a flag that was flown over the U.S. Capital building and a Certificate of Congressional recognition during National Manufacturing Day.

Congresswoman Sheila Jackson presents NCI a flag that was flown over the U.S. Capital building and a Certificate of Congressional recognition during National Manufacturing Day.

In celebration of National Manufacturing Day 2016, NCI Building Systems Inc. (NCI) opened three of its manufacturing facilities to the public, including its MBCI manufacturing facility in Houston.

More than 300 people participated in MBCI’s Manufacturing Day activities, which included facility tours, presentations from company and community leaders, a question-and-answer session and a catered lunch to participants as part of an ongoing effort to promote the strength of U.S. manufacturing and increase awareness of the outstanding career opportunities in the field. The tours showcased a working plant featuring MBCI designers, programmers and technology operators who each play a role in manufacturing the products our communities and industries rely on.

Students from Cold Springs – Oakhurst and Sealy ISDs, and professionals from The Lucas Group, Ernst & Young and The Welding School heard presentations given by NCI President, Don Riley and NCI Vice President of Manufacturing, Carlin Mueller, as well as Congressman Gene Green (TX-29) and Congresswoman Sheila Jackson-Lee (TX-18). The messages delivered focused on the career and growth opportunities available in manufacturing, with Jackson-Lee sharing her views on the role of the industry in building the US economy, saying “I am excited about that fact that you are, in essence, recognizing the importance of acknowledging to America that we need to make things with our hands.”

Further emphasizing the importance of the work done by manufacturing companies like MBCI, NCI was presented a United States flag that was flown over the U.S. Capital building and a Certificate of Congressional recognition on the occasion of National Manufacturing Day by Jackson-Lee.

SOPREMA Expands Manufacturing Facility to Accelerate Services

SOPREMA expands its Gulfport, Mississippi manufacturing facility in an effort to increase product offerings and expedite production. The expansion comes as a solution to continued growth that the Gulfport operations team has experienced and will further accelerate service to the market.

The Gulfport facility completes a 21,250 square foot addition, with its location situated on SOPREMA’s campus which encompasses manufacturing, product testing, distribution and a training facility. The expansion is used for both additional product offering and warehouse of product and materials in various stages of the production process.

“The expansion is an opportunity to continue to support the SOPREMA growth initiatives as our business grows,” said Kent Furcron, Gulfport plant manager, SOPREMA. “We are proud that our facility is now able to produce more product and provide additional jobs in the region.”

Metl-Span Starts Production at Canadian Manufacturing Facility

Metl-Span, a manufacturer of insulated panels, has started production at the recently acquired plant in Hamilton, Ontario, Canada.

To better serve customers in the Canadian and Northeastern U.S. markets, Metl-Span is producing Mesa, Light Mesa, Striated and Fluted panels at the 24,000-square-foot manufacturing and warehouse facility. The Hamilton plant was acquired in October 2015.

“Our team has successfully completed the installation of technology and equipment to supply insulated metal panels to our customers,” says Steve Zirkel, Metl-Span president. “The market demand remains strong as architects and building owners continue to recognize the benefits of our wall systems.”

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.”

Dura Coat Products Completes Expansion of Manufacturing Facility

Dura Coat Products Inc. announced that the expansion of the Huntsville, Ala., manufacturing plant is now complete.

Dura Coat Products Inc. announced that the expansion of the Huntsville, Ala., manufacturing plant is now complete.

Mike Hong, president and CEO of Dura Coat Products Inc., announced that the expansion of the Huntsville, Ala., manufacturing plant is now complete. The factory has been undergoing construction recently to add 35,000 square feet of paint manufacturing capability.

The plant was originally built in 2002, designed from the ground up specifically for paint manufacturing. It was located to serve customers in the southeast and offer next day delivery within a 500-mile radius. Built next to the Wheeler Wild Life Refuge, a 35,000-acre preserve along the Tennessee River and habitat for wintering and migrating birds in the eastern U.S., Dura Coat adheres to stringent environmental restrictions and upholds some of the highest air quality, wastewater and hazardous waste management standards.

Because of increasing demands, the factory needed to expand and has now approximately doubled its manufacturing capacity.

Duro-Last Completes PVC Extruder

Duro-Last Inc. announced the completion of a PVC extruder located in its Saginaw, Mich. manufacturing facility.

The announcement was made by Duro-Last CEO Tom Saeli and Mildred Burt, wife of founder John R. Burt, during a company-wide meeting. This investment comes as part of Duro-Last’s commitment to continue to manufacture high-quality roofing systems.

“Duro-Last has been a manufacturer of PVC roofing systems since our inception in 1978. We have built a new PVC sheet extruder to allow us to handle increased demand for our products,” says Saeli. “We are enthusiastic about making this investment here in Saginaw and believe that investing in technologically advanced manufacturing in the U.S. is the right thing to do.”

Duro-Last is the material of choice for high-quality, low-slope roofing. Our PVC roofing membranes are durable, serviceable, flame-resistant, highly flexible and recyclable. Duro-Last manufactures and sells complete PVC roofing systems with a broad range of products to satisfy all types of low-slope roof requirements. Duro-Last has manufacturing operations in Michigan, Mississippi, Texas, Iowa, and Oregon, and distribution centers in New York and Ontario.