Shear Cuts Metal while Conserving Materials and Costs

Kett Tool Co.’s KD-400 18-Gauge Double-Cut Shears help manufacturers and contractors conserve materials and cut costs. The shears deliver precision cuts in cold rolled (C.R.) mild steel, stainless steel, aluminum, plastic and Formica without warping or bending the original material or the finished piece.

Kett Tool Co.’s KD-400 18-Gauge Double-Cut Shears help manufacturers and contractors conserve materials and cut costs.

Kett Tool Co.’s KD-400 18-Gauge Double-Cut Shears help manufacturers and contractors conserve materials and cut costs.

The Double-Cut Shears’ dual blades transfer any distortion produced in cutting to a small 7/32-inch waste strip, leaving behind material edges that are not hardened or burred to allow maximum use of sheet material. The blades’ swiping action also seals edges of coated metals.

Kett’s KD-400 shears use a 5-amp, variable speed, 2,500 RPM electric motor to produce straight or contoured cuts in C.R. mild steel (up to 18-gauge), most grades of stainless steel to 20-gauge, aluminum to 0.080 inches, and plastic or Formica up to 3/32 inches thick—all at speeds of up to 300 inches per minute. The lightweight, maneuverable shears easily follow a scribed line, capable of cutting a radius as small as 6 inches.

The KD-400 Double-Cut Shears are also available with a contour cutting blade 60-21C to cut tighter curves and the HS blade 60-21HS for cutting foam filled doors. All shear heads are precision made in the U.S. featuring A2 tool steel blades for prolonged durability.

The KD-400 Double-Cut Shears are available through authorized dealers.

MCA Recognizes Eight Building Projects at Awards Show

Selected by a panel of professional architects, eight building projects from across the country have been recognized by the Metal Construction Association (MCA) at the 2017 Chairman’s Awards show.

Announced at the MCA’s winter meeting held in Weston, Fla., the Chairman’s Awards are given to the year’s most exceptional building projects involving MCA member companies. Awards are based on overall appearance, significance of metal in the project, innovative use of metal, and the role of metal in achieving project objectives.

The MCA Chairman’s Awards were given in eight categories: overall excellence; residential; metal roofing; education, primary and secondary schools; education, colleges and universities; institutional; municipal; and commercial/industrial.

The 2016 Chairman’s Award winners in each category were:

Recipients for these awards are selected each year from projects submitted by MCA members to “Metal Architecture Magazine’s” annual Design Awards Program. The honorees were chosen by a panel of professional architects, which included Mark Dewalt, AIA, principal, Valerio Dewalt Train Associates, Chicago; Mark Horton, FAIA, principal, Mark Horton/Architecture, San Francisco; Brent Schipper, AIA, LEED AP, principal, ASK Studio, Des Moines, Iowa.

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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METALCON Returns to Baltimore

METALCON 2016, the metal construction industry’s international event for metal construction products, technologies and solutions, returns to Baltimore for its 26th annual tradeshow and conference.

Designers, builders, developers, contractors, fabricators and suppliers from more than 50 countries attend this event each year. Industry experts from 275 companies exhibit the latest products and technology while sharing their knowledge with attendees. Industry specialists present key topics in the show’s highly-rated, education program.

METALCON 2016 is scheduled for Oct. 26-28, 2016 and takes place at the Baltimore Convention Center, 1 W. Pratt St., Baltimore, MD 21201.

Garland Releases Metal Solutions Brochure

To help customers find the perfect metal solutions for their job, Garland developed a Garland Metal Solutions brochure. This new tool gives architects, building owners, facility managers and other design professionals full access to Garland’s comprehensive offering of long-lasting, durable and eco-responsible metal building solutions.

Not only does this brochure cover Garland’s full line of metal options like R-Mer Shield, R-Mer Span, R-Mer Wall Pan, R-Mer Loc, and high-performance edge metal systems, it also highlights the vast metal color selection.

“This brochure is a great showpiece to highlight the wide array of high-performance metal options that we offer. The best part is that we have a solution to suit everyone, and our engineering team can provide the service behind each metal system to make sure every individual customer is satisfied,” says Tom Diamond, senior product manager with Garland.

CIDAN Machinery Joins the Metal Construction Association

The Metal Construction Association (MCA) welcomes CIDAN Machinery to its membership roster. The company has joined the association’s ranks of about 75 member companies with specialties in the metal construction industry.

CIDAN Machinery has manufactured machines since 1907 and is a well-established company within the sheet metal industry. The company manufactures and markets the brands CIDAN and Göteneds at its factory in Götene, Sweden.

“CIDAN Machinery is excited to participate in networking and stay current with the metal construction industry,” says Larry Chandonnet, CIDAN’s president.

MCA member companies benefit from participation in association activities that focus on research, codes and standards, market development, and technical programs. The association works to increase the use of metal materials in construction by educating the building and design communities about the benefits of metal.

MCA members represent a broad scope of companies including metal roof, wall panel, shingles and coatings manufacturers, coil coaters and metal producers, distributors, equipment and accessories manufacturers, energy insulation system manufacturers, and MCM fabricators. Membership information kits for each industry segment are available on MCA’s website.

METALCON Helps Veterans in Local Community

The metal construction industry’s international event for metal construction products, technologies and solutions gives back to the local community during its 25th annual METALCON tradeshow and conference taking place Oct. 14-16 at the Tampa Convention Center in Tampa, Fla.

METALCON is partnering with the America’s Fund, a non-profit organization dedicated to helping U.S. armed forces’ veterans, to raise money for military veterans in need of care at Tampa’s Polytrauma Rehabilitation Center.

METALCON is no stranger to the local community. At METALCON 2006 in Tampa, U.S. Army Staff Sgt. Paul Russell ‘Russ’ Marek of Satellite Beach, Fla., was awarded a new, ADA-compliant accessible home through METALCON’s annual giving back program. Marek who was severely injured in 2005 while serving in Iraq spent more than a year recuperating at Tampa’s James A. Haley Veterans’ Hospital, which opened its Polytrauma Rehabilitation Center in 2014—this year’s recipient of METALCON’s giving back program.

The Tampa Polytrauma Rehabilitation Center is one of five facilities in the U.S. designed to provide intensive rehabilitative care to veterans and servicemembers who have experienced severe injuries.

Staff Sgt. Marek suffered serious injuries when his tank was destroyed by enemy fire. His right arm and leg were severed, in addition to parts of his right ear and left hand. He also suffered severe head trauma and burns to more than 20 percent of his body. “To date, Russ has made amazing progress in his recovery and soon is expected to be walking without assistance,” says Russ’ father, Paul Marek Sr.

METALCON Show Director Claire Kilcoyne was incredibly moved by Staff Sgt. Marek’s courage and determination to move forward. Having maintained a strong relationship over the years with Marek and his family, they look forward to joining together at METALCON’S 25th anniversary celebration.

Knowing many more young military heroes exist, Kilcoyne announces METALCON’s giving back program will continue to benefit the America’s Fund throughout each year, assisting military in all branches of the U.S. armed forces.

“Going forward we want to ensure METALCON’s giving back efforts benefit those brave individuals who’ve put their futures on the line to make all of us safer and able to enjoy all of the freedoms we have,” says Kilcoyne. “By affiliating with America’s Fund, we open the door for more recipients and donations on an ongoing basis, not just at our annual event.”

Donations can be made to America’s Fund throughout the year and can be applied to specific programs or veterans upon request.

America’s Fund is a program created to direct urgently needed resources and financial support to injured and critically ill members of the U.S. armed forces and their families. It is a self-funded program of the Semper Fi Fund. Since its inception in 2004, the Semper Fi Fund has provided more than $100 million in support to veterans and their families.

“We are honored to be chosen as the official charity of METALCON; their support will make a difference in the lives of so many service members and their loved ones,” says Karen Guenther, CEO and president, Semper Fi Fund.

Contributions to the America’s Fund can be made on the METALCON website or in the exhibit hall at The Deck, booth 973. Army Staff Sgt. Marek, along with America’s Fund representatives and METALCON management will be available for comment at the booth on Wednesday, Oct. 14.

MCA Celebrates 25th Anniversary of METALCON

As part of the 25th anniversary celebration of METALCON, the Metal Construction Association (MCA) is reinvigorating its presence on the show floor, including a new educational theater and displays at the association’s newly designed booth (#1831), as well as the annual Chairman’s Awards presentation, and expanded Metal Roofing Championship Games.

This year, MCA’s councils, which serve various segments of the metal construction industry, are represented through informative displays and educational sessions held daily in a theater at the booth. The 20-minute sessions will highlight the advancements that MCA and its members are making together to benefit the industry. Sessions include:

  • Benefits of Insulated Metal Panels (IMPs) Council – Understand how getting involved with the IMP Council helps members grow their business.
  • Industry Case Studies on Retrofit – Explore the advantages of installing new metal roofs over old roofs, and learn how the Retrofit Council works to grow market share in commercial, industrial and residential renovation construction.
  • Service Life Study – Learn about the groundbreaking study conducted by MCA and the ZAC Association that shows that some metal roofs can last as long as the buildings they cover: typically 60 years or more.
  • Seaming Guide – Hear first-hand from industry leaders about best practices for metal roof seaming, and other initiatives that the Accessories Council has under way
  • Value of MCA Meetings and Membership Benefits – Discover the benefits from MCA membership. The association is offering 50 percent off membership dues for the remainder of 2015. Learn about networking opportunities available with industry leaders at MCA’s Winter and Summer Meetings.
  • Growth and Trends in Metal Construction – Get a sneak-peak at market analytics, typically only available to members, and learn about trends and growth opportunities for metal roof and wall panels.
  • Fastener Selection Guide – Find out how to choose the correct fastener from experts from MCA’s Accessories Council.
  • Benefits of Exhibiting at METALCON – Learn how to take full advantage of all the opportunities available when your company exhibits at METALCON.
  • Metal Roofing Contractor Benefits – Discover how metal roofing contractors can get to the next level through the MCA.
  • Roofing Installation Manual and White Papers – Get the edge by learning new techniques from the installation manual and white papers put together by industry experts from MCA’s Roofing Council.

These projects and others will be brought to life by new displays, highlighting the many ways that MCA is advocating and supporting the metal building industry. Actual mock-ups illustrating best practices will be on display, as will case studies, white papers and technical bulletins highlighting the latest industry trends.

A schedule of presentations at the booth is as follows:

    Wednesday, Oct. 14

    • 12:30 p.m. Benefits of the IMP Council
    • 1:30 p.m. Industry Case Studies on Retrofit
    • 2:30 p.m. Service Life Study (1 hour presentation)
    • 4 p.m. Seaming Guide
    • 4:45 p.m. Value of MCA Meetings and Member Benefits
    • 5:30 p.m. Chairman’s Awards Presentation

    Thursday, Oct. 15

    • 12:30 p.m. Growth and Trends in Metal Construction
    • 1:30 p.m. Fastener Selection Guide
    • 2:30 p.m. Service Life Study (1-hour presentation)
    • 4 p.m. Benefits of Exhibiting at METALCON
    • 4:45 p.m. Value of MCA Meetings and Member Benefits

    Friday, Oct. 16

    • 10:30 a.m. Metal Roofing Contractor Benefits
    • 11:30 a.m. Roofing Installation Manual and White Papers

MCA will also unveil the 2015 prestigious Chairman’s Awards at METALCON on Wednesday, Oct. 14, at 5:30 p.m.

The Chairman’s Awards are an annual designation given to outstanding building projects involving MCA member companies. Recipients for these awards are selected each year from projects submitted to Metal Architecture Magazine’s annual Design Awards Program. The honorees are chosen by a panel of professional architects, which included Elaine Tisovec Fitzgerald, AIA, CCS, ArchiTech Consulting Inc., Mount Prospect, Ill.; Michael Fitzgerald, AIA, Principal, OKW Architects, Chicago; and Ted Haug, AIA, LEED AP, Legat Architects, Chicago.

The MCA Chairman’s Awards are given in nine categories: commercial/industrial; education, colleges and universities; education, primary and secondary schools; institutional; metal roofing; municipal; and residential. The judges also recognize projects with an award for overall excellence.

Award recipients are determined based on overall appearance, significance of metal in the project, innovative use of metal, and the role of metal in achieving project objectives. Photos and descriptions highlighting the winning projects will be on display in the MCA booth after the awards ceremony.

In addition, MCA has added a new challenge to the MCA/METALCON Metal Roofing Championship Games, which will take place in booth #109. This year’s theme is ‘Battle by the Bay’ and will include five different competitions where contractors can compete to win cash prizes in challenges that include the proper use of screw guns and seamers, as well as installing retrofit sub-framing, standing seam roof panels, snow retention and other common rooftop accessories.

The games will be held on each of the three days of the show, during exhibit hall hours, and each of the challenges has a $100 cash prize for the winner or winning team.

METALCON will be held Oct. 14-16, 2015 at the Tampa Convention Center in Tampa, Fla.

Triangle Fastener Releases Market Specific Product Catalogs for the Metal and Low-slope Roofing Industries

Triangle Fastener Corp. has released its Market Specific Product Catalogs for the metal roofing/building, low-slope roofing, and the interior/drywall construction industries.

Triangle Fastener Corp. has released its Market Specific Product Catalogs for the metal roofing/building, low-slope roofing, and the interior/drywall construction industries.

Triangle Fastener Corp. has released its Market Specific Product Catalogs for the metal roofing/building, low-slope roofing, and the interior/drywall construction industries. The catalogs provide information about a variety of fasteners, sealants, flashings, tools and contractor accessories, as well as technical information and installation tips. They are available for download on the Triangle Fastener website.

A Metal Roof Crowns a Residential New-construction Project

When Charles Callaghan purchased the two vacant lots next to his home in Ponte Vedra Beach, Fla., he thought they would form the perfect location for his family’s dream home. A team comprised of architects, contractors and manufacturers worked together to bring his ideas to life in the form of a new 7,500-square-foot residence. The building’s crowning feature is a metal roof system that was designed to complement the aesthetics of the home and stand up to the harsh oceanfront environment for decades to come.

The roof of the Callaghan residence in Ponte Vedra Beach, Fla., features 12,000 square feet of Petersen Aluminum’s Snap-Clad in Slate Gray.

The roof of the Callaghan
residence in Ponte Vedra
Beach, Fla., features 12,000 square feet of Petersen Aluminum’s Snap-Clad in Slate Gray.

“With the larger lot, we thought we could do something unique to the neighborhood,” Callaghan says. “When we first met with the architect, there were a few keys we wanted to stress. First, we didn’t want a boxy-looking house. We also wanted shingle-style siding and a metal roof. We like the look of the metal roof, we like the durability, and we thought it would be a good way of complementing the shingles on the house.”

At every phase of the project, the team of construction professionals ensured the project was executed with precision, down to the last detail of the metal roof.

THE DESIGN

The house was designed by Jaycox Architects & Associates, Jacksonville, Fla. According to William R. Jaycox, principal, the plan made the backyard pool the home’s focal point. “They wanted to do a casual, shingle-style beach house that wasn’t like everyone else’s house,” Jaycox notes. “We designed the house so it was mostly single-story and spread it out around the pool, which made for an interesting roof design. It’s all in small modules.”

The L-shaped home features a master-bedroom suite on one side while the other side contains the living room, dining room, kitchen, family room and guest bedroom. “This one also has a four-car garage under the main roof, and, because the house wraps continuously around the pool, you get a fun little foyer in the front with a little cupola up above, you get the dormers for the bedrooms in the attic, and the master suite is a little pod unto itself,” Jaycox adds. “The back has a pool pavilion separate from the house. When you put all of those elements together, you get a very interesting structure, and the metal roof was perfect because it accentuates the lines.”

The roof system specified included 12,000 square feet of aluminum panels in the cool-color Slate Gray. “This house is only a few blocks from the ocean, and in those cases we typically use aluminum,” Jaycox says. “We’ve had great success with that system. It’s absolutely bombproof from a corrosion standpoint with stainless fasteners, heavy-gauge aluminum and the Kynar finish.”

Thorne Metal Systems installed a high-temperature, self-adhered underlayment beneath the metal roof, as specified.

Thorne Metal Systems installed a high-temperature, self-adhered underlayment beneath the metal roof, as specified.

When applied by a certified installer, the system can qualify for a 20-year Oceanfront Finish Warranty from the manufacturer. In addition, the roof meets all Florida’s tough building-code requirements. The system, consisting of 0.040-gauge aluminum, 16-inch-wide panels with fastening clips spaced at 24-inches on-center, carries a Miami-Dade NOA with a -110 PSF uplift. (The UL 90 uplift is -52.5 PSF.)

THE INSTALLATION

The roofing contractor on the project was Thorne Metal Systems of Middleburg, Fla. Owner Bill Thorne has been installing metal roofs since 1989. He formed his own company 13 years ago, and it has become the go-to metal roof installer for Jaycox Architects
& Associates and the general contractor on the project, C.F. Knight Inc., Jacksonville.

Thorne has a lot of experience installing this particular aluminum roof system. “The system is a very easy system to install,” he says. “It’s very user- friendly. The panels have male and female joints that snap together and are held in place with stainless-steel clips.”

PHOTOS: Petersen Aluminum Corp.

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