Forty Years of Roof Leaks Solved with Standing-seam Copper

Because the show must go on, what served as a canopy-style roof at the Miller Outdoor Theater, Houston, needed repairs in short order. Byrne Metals, Humble, Texas, installed more than 18,000 square feet of copper 238T standing-seam panels during the five-month off season by calling in the rollformer from McElroy Metal that runs panels right onto the roof deck.

Improvements included replacements of the east and west wings, a new soffit for the main sloped roof and the new 20-ounce copper standing-seam roof.

Improvements included replacements of the east and west wings, a new soffit for the main sloped roof and the new 20-ounce copper standing-seam roof.

“Everyone else who had tried to fix the problems focused on trying not to change the appearance,” says Karl Schaack, P.E., president of Price Consulting, Houston. “We realized providing a leak-free solution required some change in the appearance. We got a little pushback at first, but when we explained our design, they were just happy to know it wasn’t going to leak anymore.”

“It was a very challenging job,” says Neil Byrne, president of Byrne Metals. “This is an iconic structure in Houston, originally built in 1968. At the time, it won several awards for its design.”

Unfortunately, right from the start, the design didn’t hold up against the Texas rains. For more than 40 years, anyone who was hired to fix the problem, failed.

Schaack chose 238T symmetrical panels from McElroy Metal for the project. “It’s rigid and it meets high-wind requirements,” he says. “The 238T is symmetrical so if a panel gets damaged, you only have to replace one panel.”

BEFORE: The multi-million dollar renovation in Hermann Park served to correct canopy deficiencies that caused leaks above the stage and audience.

BEFORE: The multi-million dollar renovation in Hermann Park served to correct canopy deficiencies that caused leaks above the stage and audience.

The multi-million dollar renovation in Hermann Park served to correct canopy deficiencies that caused leaks above the stage as well as the audience, putting a real damper on the theater’s cultural and educational event offerings.

Byrne Metals went to work as soon as the 2013 season concluded in early November. Improvements included replacements of the east and west wings, a new soffit for the main sloped roof and the new 20-ounce copper standing-seam roof. The profile was McElroy Metal’s 238T symmetrical standing-seam panel. “Using copper helped the new roof blend in with the original framework,” Schaack says. “Especially as it ages, it will look great, like it’s been there all along.”

Changes in design to the updated roof, as well as a watertight standing seam installation, will help prevent future leaks.

Using copper helped the new roof blend in with the original framework. The profile was McElroy Metal’s 238T symmetrical standing-seam panel.

Using copper helped the new roof blend in with the original framework. The profile was McElroy Metal’s 238T symmetrical standing-seam panel.

The roof area between the existing Corten superstructure was framed with purlins, a metal deck was installed on top of the purlins, then a 1 1/2-inch nail base was installed over the deck along with ice and water shield. A giant reverse-slope diverter was built at the intersection, where the sloping roof connected to the stage wall. Valleys were lowered below the roof plane and there was a slight change in pitch that was overcome by rounding the insulation/plywood over the pitch change.

McElroy Metal’s job-site production equipment simplified the process of installation and made the job site safer. The rollformer was hoisted to the eaves on a scissor lift where panels were conveniently run onto the roof. Not only did this method eliminate the need for an expensive crane to get panels on the roof, it was safer as some of the panels were up to 110-feet long. Because of the unique shape of the roof, panels were cut to fit on the roof.

“We specialize in the unique and difficult,” Byrne says. “This is the kind of job we like. We generally have about 20 to 30 projects under contract at any one time, but this one required a lot of personal attention from our upper management, myself included. We had as many as 30 crew members onsite, working 10-hour days and some weekends, when necessary.”

A rollformer was hoisted to the eaves on a scissor lift where panels were conveniently run onto the roof.

A rollformer was hoisted to the eaves on a scissor lift where panels were conveniently run onto the roof.

As with all Byrne Metals jobs, safety was a major consideration during the evaluation and installation. “There are three things we consider important to staying in business,” Byrne says. “Safety, quality and productivity. We have a fulltime safety person on staff making sure we’re working safely on all jobs. This job required us to take into consideration some other factors like guys working long days, getting fatigued and the speed at which we had to work to complete the job on time. We enjoy a good challenge and Miller Outdoor Theater falls into that category.”

PHOTOS: McElroy Metal

McElroy Metal’s Shingle Recover System Brochure Is Available for Download

McElroy Metal’s 138T Shingle Recover System brochure is now available for download.

McElroy Metal’s 138T Shingle Recover System brochure is now available for download.

McElroy Metal’s 138T Shingle Recover System brochure is now available for download. The 138T symmetrical standing-seam panel offers ease of installation, the ability to replace individual panels, wind-uplift resistance and improved weather tightness. The system does not require tear-off and disposal of the existing roof or underlayment while yielding reduced utility expenses, leading to a quicker return on investment for the building owner.

Install Standing Seam over Shingles

McElroy Metal has introduced a method for installing standing-seam metal roofing directly over asphalt shingles without a tear-off.

McElroy Metal has introduced a method for installing standing-seam metal roofing directly over asphalt shingles without a tear-off.

McElroy Metal has introduced a method for installing standing-seam metal roofing directly over asphalt shingles without a tear-off. The system is designed around the patent-pending 138T Shingle Recover Clip and 138T symmetrical standing-seam panel. The main challenges when installing a metal roof directly over shingles with no underlayment are clip alignment and abrasion on the underside of panels. The 138T Shingle Recover Clip is long enough to sit on two shingles, aligning the clip into the plane of the roof. The clip has eight holes so the installer can align the fasteners through the ends of the shingle tabs. The clip’s 3/4-inch height holds the panel up so it does not touch the surface below but allows a contractor to walk on the roof without damaging the clips or panels.

McElroy Metal Moves into Manufacturing Plant and Service Center in Southeast Texas

McElroy Metal operations in Houston moved into a manufacturing plant and attached service center to better serve its large customer base in southeast Texas.

McElroy Metal operations in Houston moved into a manufacturing plant and attached service center to better serve its large customer base in southeast Texas.

McElroy Metal operations in Houston moved into a new manufacturing plant and attached service center to better serve its large customer base in Southeast Texas.

“We were able to improve efficiencies and increase capacity with the layout in the new manufacturing facility,” says Matthew Edwards, plant manager. “Ultimately, we’re able to turn around orders substantially quicker.”

The new manufacturing plant is 30,000 square feet and the service center is a 9,000-square-foot facility. The move was completed in early 2015 and the company celebrated with an open house.

Edwards says McElroy Metal customers doing business at the Houston Service Center are installing residential and architectural roofing as well as working on commercial projects. To serve these customers, the new service center, managed by Bill Harris, features most McElroy Metal profiles, including the 138T and 238T symmetrical standing seam profiles. The service center stocks large quantities of 24-gauge flat sheets in 29 colors, hardware and accessories and is set up to service walk-in customers of small, medium and large operations. With the convenience of being attached to the plant, large orders can be produced and delivered quickly.

The Houston facility also offers onsite roll forming with its purpose-built, fully self-contained truck, “Straight Shooter.” Designed to site form panels directly onto the roof, Straight Shooter can reach eave heights upwards of 30 feet and run continuous length panels up to 200 feet long. This unique service offers the 138T and 238T symmetrical standing seam panels, as well as 2-inch Maxima standing seam panels, a wide service area and the additional option of onsite curving.

McElroy Metal Updates Metal Roofing Panel Profile Brochure

McElroy Metal has updated the brochure on one of its most popular through-fastened metal roofing panel profiles, Max-Rib.

McElroy Metal has updated the brochure on one of its most popular through-fastened metal roofing panel profiles, Max-Rib.

McElroy Metal has updated the brochure on one of its most popular through-fastened metal roofing panel profiles, Max-Rib.

Available in four options, Max-Rib provides options for project needs, depending on desired longevity, aesthetic appeal and budget.

Max-Rib Ultra is manufactured from a Galvalume substrate with a PVDF coating for performance in a light-gauge panel. It combines the long-life performance of a Galvalume steel substrate with a fade- and chalk-resistant PVDF-based Fluropon paint system. Max-Rib II has a Galvalume substrate with a siliconized polyester coating to provide a multi-purpose metal panel. Max-Rib 100 features a galvanized G100 substrate with a siliconized polyester coating and Max-Rib Commodity is a non-warranted economical panel, ideal for basic shade and shelter applications.

Recover Metal Building Roofs with Metal

McElroy Metal has received patents on two frameless systems to recover the most prevalent metal roof panels in open-frame metal buildings.

McElroy Metal has received patents on two frameless systems to recover the most prevalent metal roof panels in open-frame metal buildings.


McElroy Metal has received patents on two frameless systems to recover the most prevalent metal roof panels in open-frame metal buildings: exposed fastener R-panels and 3-inch-tall trapezoidal standing seam. Both systems weigh about 2 pounds per square foot. The recover systems use tall clips, fasteners and insulation. With these solutions, a high-end standing-seam roof can be installed for about the same price or as little as 25 percent more as coating and single-ply alternatives. The new roof will have no end laps because the panels can be site-formed in continuous lengths, using one of McElroy’s job-site production vehicles. (There are different steps for recovering trapezoidal and R-panel systems.)

MiaSolé and McElroy Metal Partner to Sell Thin Film Solar Modules

MiaSolé Hi-Tech, a subsidiary of Hanergy, announced a partnership with McElroy Metal to sell MiaSolé FLEX series, thin film solar modules as part of McElroy Metal’s solar panel solutions. The MiaSolé thin film modules carry a 15.5 percent efficiency rating with a simple peel-and-stick application method that reduces balance of system costs by 20 percent. McElroy will offer MiaSolé modules factory laminated directly to its metal roof panels to create a lightweight, low-profile solar energy solution durable in extreme, high-wind and seismic zones and on buildings with limited load bearing roofs.

McElroy also markets a complete solar kit for McElroy standing seam, low-slope, storage unit and carport metal roofs. By providing square footage and location, McElroy can provide a complete, pre-engineered solar package with MiaSolé modules, inverter and balance of system components.

The MiaSolé and McElroy Metal partnership combines many advantages for architects, developers, builders and contractors. The 25-year—or more—power output of the MiaSolé FLEX series modules compliments the long service life of metal roofs. Options for factory-applied FLEX modules to metal panels can further reduce onsite installation costs and contribute to consistent quality.

“Today, solar is becoming a standard part of the building envelope,” says Ken Gieske, vice president of marketing for McElroy Metal. “Our partnership with MiaSolé expands our support of green building initiatives and the growing demand for renewable energy as an industry standard.”

Anil Vijayendran, head of product management at MiaSolé, adds: “We are excited to partner with McElroy Metal. With a high efficiency rating for thin film, the MiaSolé FLEX series modules enable roof manufacturers to install a renewable energy solution on roofs and structures previously restricted by wind, seismic and weight limited building structures.”

McElroy Metal Updates Its Architectural Colors Chart

Just in time for the busy building season, McElroy Metal has released its updated Architectural Colors chart.

The four-page chart, available on the McElroy Metal website, highlights the standard architectural colors, the updated “Deep Tone Premium” colors, as well as the company’s metallic color offerings. The back page of the chart features color specifications: reflectivity, emissivity and solar reflective index.

“The updated Architectural Colors chart conveniently packages all of the options available to architects, roofers and building owners, while providing them with all the information they need to select the right color for their project,” says Mark Lawson, vice president of sales for McElroy Metal.

To have a hard copy of the brochure mailed to you, email a request. To obtain a PDF online, visit McElroy Metal’s website and click on the “downloads” menu at the top of the page.

Projects: Offices/Manufacturing

Accident Fund Holdings Inc. Headquarters, Lansing, Mich.

Team

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

Roof Materials

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

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


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

Roof Report

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

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

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

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

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McElroy Metal Updates Product Brochure

McElroy Metal has just released its updated company product brochure. The 36-page brochure features the entire McElroy line of construction products and components for the architectural metal construction industry, including up-to-date information on its most recent product addition, the 138T and 238T standing seam systems. These symmetrical standing seam systems offer many advantages including unsurpassed strength, individual panel replacement capabilities and reduced installation/labor costs.

“For more than 50 years, McElroy Metal has worked hard to provide its customers with the most innovative building products,” says Ian McElroy, the company’s third-generation president. “We believe our continuing growth is a reflection of the success of our customers who take advantage of our ever-growing line of top quality products.”

The new brochure also includes information on retrofit options. McElroy Metal offers a variety of engineered systems to adapt to an existing roof’s structural support system, whether constructed of steel, concrete or wood. Among the other newer company offerings featured include insulated metal panels under the name of Green Span Profiles, a joint venture IMP manufacturing company.

The brochure highlights the company’s proven standing seam systems, concealed fastener wall panels, exposed fastener roof and wall panels as well as soffit and fascia offerings.

To have a hard copy of the brochure mailed to you, email a request to info@mcelroymetal.com.