Orlando Airport Project Necessitates Custom Fabrication, Precise Installation

 

Work on the first phase of the Orlando International Airport expansion project includes the South Airport Intermodal Terminal Facility and APM Complex, which features a standing seam metal roof

Architectural Sheet Metal Inc. has been in servicing the Orlando area for more than 23 years, specializing in commercial metal roofs and wall systems, primarily new construction. When Matthew Leonard, the company’s vice president, found out that the Orlando International Airport was proposing a new terminal project with a metal roof, he jumped at the chance to submit a bid.

He wanted to land the job because it would be the largest project the company has ever tackled, and one of its most prominent. He also wanted it for another reason—he knew he’d see it every time he drove to the airport. “For many years now, we’ve specialized in standing seam metal roofs. It’s our bread and butter,” he says. “We’ve done lots of schools, government building, military bases. It’s just something we enjoy doing. When this project came around, right here in our backyard, we knew we wanted to take it on. It’s larger than anything we’ve ever done, but it’s our specialty.”

The South Airport Intermodal Terminal Facility and APM Complex is a new construction project that coordinates mass transit for the airport, including regional rail systems and the Automated People Mover (APM). It’s part of the first phase of an ambitious $2 billion plan to almost double the size of the airport.

Architectural Sheet Metal installed the Berridge standing seam metal roof system, as well as internal aluminum gutters and a custom-fabricated aluminum bullnose that runs along the perimeter of the roof

The building encompasses approximately 200,000 square feet, and the structure is primarily covered with a standing seam metal roof. The scope of work for Architectural Sheet Metal included installing the metal roof system and internal aluminum gutters. It also included custom fabrication and installation of an aluminum bullnose that runs along the perimeter of the roof. “Every roof is radiused, and some sections have compound double raiduses,” Leonard notes. “The trickiest part of the project is probably the bullnose because all of the gable ends of the roof are radiused, and the large bullnose has to be welded on in 30-foot sections.”

Another tricky thing about the project is that the work was divided into two different contracts with two different construction managers. On one side of the building, which houses the monorail and parking garage, the project is overseen by Hensel Phelps, and on the other side, which handles the train lines, the construction is overseen by a Turner-Kiewit joint venture. The dividing point is a building expansion joint that runs across the middle of the roof. “We’re one of very few subcontractors out here that has a contract with both of the construction managers,” Leonard says. “They both have their own agendas, their own timelines, and their own completion dates, and it was a delicate balancing act working with the two of them.”

Installing the Roof

The roof system was designed to unify the elements of the structure and tie the building together. Some sections of the roof cover the building, while others serve as canopies, so there are two types of metal deck on the building. “The area we call the spine has a 3-inch-thick acoustical deck,” Leonard explains. “That was interesting because before we could put our 6 inches of polyiso on, we had to install batten insulation in the flutes. The acoustical decking is perforated, so you can see through it. That’s a little different, when you’re so high up. It spooked the guys at first to be able to see right through it.”

Crews dried in the entire roof with a waterproofing underlayment from MFM Building Products specifically designed for high-temperature applications.

The other sections were comprised of standard type B metal deck. Sections covering the interior were insulated, while canopy sections were covered with 5/8-inch DensDeck from Georgia-Pacific.

Crews from Architectural Sheet Metal dried in the entire roof with a peel-and-stick waterproofing underlayment from MFM Building Products specifically designed for high-temperature applications, MFM Ultra-HT. “It’s easy to install,” notes Leonard. “That’s our go-to underlayment for metal projects.”

After the underlayment was applied, the welded aluminum gutters were installed. “The longest piece was 78 feet,” says Leonard. “We fabricated the sections, water-tested them and shipped them out. We used a crane to lift them to the roof.”

The roof system was supplied by Berridge Manufacturing, and the 24-gauge galvalume metal panels were roll formed at the site. “Berridge has a ZEE-Lock double-lock standing seam panel,” Leonard says. “We own one of their portable roll formers, and we have it on site here. We pick it up with a crane, and lift it up to the edge of the roof, and we actually roll form our largest panels straight out to the roof. The guys just catch the panels as they come out of the roll former.”

Metal roof panels were roll formed at the site. For most roof sections, the roll former was hoisted by a crane, to the edge of the roof, and crew members stacked the panels as they come out of the roll former.

Panels were stacked in piles of 10 for installation. There were 12 different roof surfaces, so as the roll forming crew moved along, other crews would start installing the panels. “Every stack was tied down with strapping to ensure that it wasn’t susceptible to wind,” Leonard points out. “With a hurricane in the forecast, we were very careful about that.”

The panels in the spine area had a tighter radius, so those panels were formed on the ground using separate curving machine. Lining up the panels perfectly was critical. “With a radiused roof, it’s sometimes harder to find things to measure off to ensure your panels are straight. This panel is a left-to-right system. It’s a male-female overlay with a continuous clip that Berridge manufactures. The panels are hand-crimped together, and then you do the first and second stage of the double-lock panels with an electric seamer. You just turn it on and it goes up and over.”

Details, Details

Fall protection posts were installed during the framing process, which helped with safety planning but posed problems when it came to detailing. “It’s nice to have permanent fall protection points to tie into, as everyone had to be 100 percent tied off, but there are close to 200 fall protection posts on the project that we had to cut around and flash,” Leonard says. “I’ve never seen so many posts on a roof like that.”

The aluminum bullnose was constructed after precise measurements were taken at the site. After they were custom painted to match the roof, the 30-foot sections were lifted into place and installed.

Because the posts were tied into the structural steel and couldn’t be moved, the company designed and manufactured a welded aluminum flashing detail to ensure they all looked the same no matter where they landed in the panel profile. “We set up a welded aluminum flashing that should last forever, and it’s welded, so it shouldn’t leak. We try to go above and beyond in our flashing details.”

Leonard points to his company’s fabrication experience as a key to its strength. “We try to be more than just a roofing company,” he says. “We try to be a custom metal fabrication company that fabricates the panels to precise specifications determined by the site. We custom fabricate metal and then, as roofers, we install it. We like to have that double whammy. Not many people have that ability to do both.”

The company’s expertise came in handy on the bullnose. “The bullnose was originally bid as 22-gauge metal,” he says. “We looked at it and we didn’t like it. It’s a large, 9-inch radius, and we felt the thin, light-gauge metal would shake in the wind. Every 10 feet would be a lap joint with caulk, which would be susceptible to wind damage. We came up with the idea of using a welded piece of .080 aluminum. Once it was approved, we purchased a 100-ton press brake with a custom die to fabricate this bullnose.”

The bullnose was constructed from precise measurements taken at the site. “We took the radius off of the building and created jigs in our warehouse,” Leonard explains. “We welded pieces together in 30-foot sections, and we shipped them to a local painter who coated them with baked-on Kynar to match the roof.”

The bullnose was designed to hook into the gutter strap and wrap around onto the fascia, where it is screwed into the framing. In areas where there is no gutter, sections of the bullnose are equipped with a larger flange with an S-hook built into it to attach it to the roof. Corner pieces tie it all together.

Watching Out for Irma

Dealing with two different GCs was challenging, in part due to changes in the schedule. “Originally, we were supposed to finish one side first and then start the other side, but both phases of the project ended up starting around the same time,” says Leonard. “This doubled the manpower we needed on the job.”

Photos: Aerial Innovations

For changes like the bullnose, Architectural Sheet Metal had to make sure RFIs were submitted and approved by both sides. “Sometimes it was hard to keep track of who we submitted it to, but it worked to our benefit at times. Once it was approved by one side, it was easily approved by the other.”

The schedule had the crews working in hurricane season, and precautions were taken to make sure the job site was prepared for high winds. “When Hurricane Irma was approaching, I checked every single weather update every day until it made landfall,” Leonard recalls. “It hit on a Monday, and a full week ahead of that we were cleaning the roofs and preparing the gutters. We removed all debris on the jobsite because any trash on the roof could clog the downspouts. We added more and more men to the process throughout the week, and we shut the jobsite down on Wednesday. We took all of the material we had, stacked it, bundled it together, and we were able to move it all inside the building. We were pretty well complete on the Hensel-Phelps side, and Turner Kiewit brought in 40-foot Conex boxes for us to put our material in and secure it. They tried really hard to make sure the jobsite was secure.”

As the storm progressed, it deviated from the projected path, and no one could be certain which direction the winds might be coming from. “We just had to start battening everything down,” Leonard recalls.

Photos: Architectural Sheet Metal Inc.

Stacks of panels on the roof that were not yet installed were strapped every 2 feet on center. The entire state was in emergency mode, making things difficult. “For four or five days before the storm even hit, we couldn’t find water, rope and extension cords. Grocery stores were running out of supplies. Gas stations were running out of gas.”

After the storm passed, Leonard breathed a sigh of relief. The roof wasn’t damaged. The panels that had already been installed were in great shape, and the uninstalled panels weren’t harmed.

Elements like the weather are beyond anyone’s control, and Leonard notes his company tries to control as many variables as it can. “We have full control over the actual fabrication of the material and the quality of it,” he says. “When I call something in, I talk to our guy who works with me. Our company oversees it. Every morning I stop by the shop and follow up on the process on the way to the job site. We install it. I can make sure everything is OK.”

The project is nearing completion, and Leonard can’t wait to finish a landmark project he’ll see every time he makes a trip to the airport. “You can’t miss it,” he says. “It’s huge.”

TEAM

Architect: HKS Architects, Orlando, Florida, HKSinc.com
General Contractors: Hensel Phelps, Greeley, Colorado, HenselPhelps.com; and a joint venture between Turner Construction, Orlando, Florida, Turnerconstruction.com, and Kiewit, Sunrise, Florida, Kiewit.com
Metal Roofing Contractor: Architectural Sheet Metal Inc., Orlando, Florida, ASMfl.com

MATERIALS

Standing Seam Metal Roof: Berridge Zee-Lock Double-Lock, Zinc-Cote, Berridge Manufacturing, Berridge.com
Underlayment: MFM Ultra-HT Wind & Water Seal, MFM Building Products, MFMbp.com
Cover Board: DensDeck, Georgia-Pacific, Buildgp.com

METALCON 2017 Wraps Up Successful Show in Las Vegas

METALCON 2017 was held in Las Vegas Oct. 18-20, and according to show management, exhibitors at the largest international event for the metal construction industry networked with more than 5,000 attendees, including designers, builders, developers, contractors, fabricators and suppliers from more than 50 countries.

“This is one of the unique venues in the world where we have access to our entire value chain,” said Mark MacDonald of Valspar. “We see everyone from coil coaters all the way down to building product suppliers, regional roll formers and even roofing contractors. It gives us an opportunity to network with our current customers, talk about new business opportunities, as well as meet our future customers. There really isn’t another venue quite like this, and we are happy to be here.”

“It’s been an incredible attendee show,” said Scott Cosens of Samco Machinery, manufacturers of custom metal roll-forming equipment. “We have never seen this type of volume of people. We were running out of paper on our leads. All I can tell you is, if you are not coming to METALCON, you are missing out, and what’s even more amazing, I am finding that still again, all of these suppliers and providers are coming from all over the world, not just the U.S. and Canada. We are never not going to be here. We have been here for well over two decades, and we are already back for next year.”

A newcomer to METALCON this year was DuPont Tyvek Protec, a synthetic roofing underlayment product. “We couldn’t be more excited to be here,” said Roofing Segment Leader Susan Homan. “Honestly, after the first day, our expectations have been exceeded. The quality of the crowd here is really great. We have had really great engagement with contractors and other professionals alike, so we are really glad to be at METALCON.”

Another new exhibitor was Stubai, an Austrian manufacturer of roofing and metalworking tools. “We decided to come to METALCON because we can meet our final customers who actually work with our tools,” said Sites Manager Lukas Braun. “It is interesting for us to get to know how they use the products, but we can also get in touch with decision makers, new retailers, and existing retailers. For us, the U.S. is a very big country so it is more convenient for us to meet all of our customers here.”

Geoff Stone with MetalForming Inc., a provider of high-tech sheet metal component manufacturing machines, has attended all 27 METALCON shows. “This was an absolutely terrific show,” said Stone. “The marketplace is in great condition. There’s lots of folks spending money. I think we probably did somewhere in the neighborhood of $3 or $4 million dollars’ worth of business as a result. As usual, METALCON is our most important show, and we’ve really enjoyed being here.”

Lee Ann Slattery, sales support manager for ATAS International Inc., manufacturers of metal panels, has also attended METALCON for many years. “This year, especially, seems to be a very busy show for us,” said Slattery. “We’ve had a lot of attendees come by our booth, a lot of questions being asked and a lot of different types of people attending. We have talked to contractors, building owners, international folks and facility mangers, so it really has drawn a wide variety of people, and that’s one of the reasons we like doing this show.”

Ken Buchinger of MBCI, manufacturers of metal roofing and wall panels, has been in the industry for more than 40 years and has attended every METALCON. “I have seen this industry grow over the years,” said Buchinger. “I have also seen it become much more complex from the standpoint of product offerings, product installation and the details on roofs, so installers need good information and training. The Metal Construction Association (MCA) and METALCON provide quite a few training programs to help contractors, both with installation and how to run their businesses.”

“The show itself is great because you have the opportunity to meet different manufacturers and contractors, learn from each other and learn about ancillary products available to integrate into your offerings,” said Buchinger. “Its’s a great opportunity for contractors, whether you have been one for just a few years or for many years; there is always something to learn at METALCON.”

“2017 has been an incredible year for METALCON,” said Jonathan Rider, an MCA Board Member and Chief Administrative Officer with D. I. Roof Seamers, manufacturers of roof seaming tools. “This year we broke all kinds of records with attendance and pre-registration, with booth sales and even with on-site sales. It also offered a whole new take on our education track with incredible success and amazing new topics such as drone services for roof inspections, marijuana laws and new litigation affecting the work force. We are going to continue developing the education track in conjunction with the AIA to adapt to the industry’s needs and the way our needs are changing in the field.”

“This year’s attendees were from all over the world,” said Rider. “We are really branching out as METALCON is becoming truly an international show, and we had a lot of incredible feedback from our exhibitors on how great the international attendance was. In addition, local attendance was fantastic. So many local erectors and builders left their job sites and came out on to the show floor to join us. They were elated with the technology and new innovations offered on the show floor by exhibitors.”

“2018 promises to be the biggest year in recent history for METALCON,” said Rider. “Charlotte is an amazing city. You can expect a bigger show, more attendees and the newest technology available.”

This year’s metal roofing games, another sold-out event, awarded a total of $8,500 to its winners. Six teams of two competed in five “competitions,” inspired by this year’s theme “Aces of Las Vegas.” Each competition paid $500 to the winning team. Top awards each day included a Daily Points Award of $750. The winner on Wednesday was Joe Arnold and Paul Kulb of Thomas Phoenix International. On Thursday, Matt Cox and Justin Hopta, also of Thomas Phoenix International, were the winners. On Friday, both teams came together in a face-off where Cox and Hopta were victorious in taking home the MCA METALCON National Metal Roofing Championship and $2,000. Next year’s teams will be able to pre-register for the Charlotte games beginning in February 2018.

“Las Vegas was the best show for us in years,” said Claire Kilcoyne, METALCON Show Director. “Business is back! The aisles were packed, and exhibitors were thrilled with the traffic, leads and sales. We saw an increase in international attendance, successfully raised $4,000 for the America’s Fund and once again, enjoyed a full house for the MCA Triumph Awards. We are already gearing up for Charlotte, which promises to be another great show.”

METALCON is produced by PSMJ Resources Inc. and sponsored by The Metal Construction Association. For more information, visit www.metalcon.com.

Logistics Create Challenges on Metal Roof Installation for Kentucky High School

When the design for Logan High School in Russellville, Ky.

When the design for Logan High School in Russellville, Ky., called for metal panels measuring 161 feet, 2 inches in length, the decision was made to roll form them on the job site. Photos: Morin, a Kingspan Group Company

The design for the metal roof on Logan High School called for panels on one side of the roof to measure more than 160 feet. That posed logistical problems, to be sure, but the project proved there’s more than one way to deliver roof panels.

Morin, a Kingspan Group Company, recently introduced an onsite roll-forming process that runs panels to the eaves, where they are gathered and stacked for installation. Logan High School in Russellville, Ky., was the first project that put the method to the test. Panels on one side of the roof were 46 feet long, while panels on the other side measured 161 feet, 2 inches in length.

According to the company, the on-site process offers the benefit of producing panels of almost any length without lapping them. This is especially useful when restrictions on the length of delivery trucks and their loads do not allow for panels to be delivered via truck.

On this project, 89,000 square feet of SymmeTry Roof Series panels in Regal White were installed. “For the longer panels, we had 11 men on the roof,” says Basil Slagle, production manager and roll former operator for Morin. “We also had three separate scissor lifts between the roll former and the eave, with men on them to guide the panels to the roof because that’s as close as we could get with the roll former.”

The SymmeTry Roof Series is a mechanically seamed structural roof system that is both symmetrical and hydrostatic by design. Slagle produced 18-inch wide panels with 2 1/2-inch legs from the 22-gauge, pre-painted Galvalume.

The start of the project was delayed by heavy rains, notes Slagle. “And that Kentucky red clay, if you’d walk on it wet, you’d sink into the clay up to your shin. They had trucks with four-foot tires getting stuck in the wet clay.”

Tough Field Conditions

When the rain stopped, Slagle got to the jobsite on a Monday and realized he would not be able to drive his 10-ton vehicle into place. “They had to build us a 300-foot gravel road so we could pull the machine into place, get it where we needed it to be,” he says. “We finally got set up that Thursday morning.”

Eastern Corp. installed the roof system

Eastern Corp. installed the roof system, using crews ranging from 12-17 workers at a given time. Panels for the shorter side of the roof had to be transported over the ridge and stacked by hand. Photos: Morin, a Kingspan Group Company

Once the roll former was in place—about 100 feet from the roof eaves—the three scissor lifts were rolled into place in line between the roll former and the roof edge. Slagle then ran a “sacrifice panel” to use as a bridge, of sorts, from the roll former to the roof. Panels going on to the roof would slide across the sacrificial panel to the roof, where crew members would carry them to a staging spot on the roof. The sacrificial panel, almost 100 feet long, was eventually recycled.

Slagle ran the shorter panels first so crew members could haul them across the ridge to the opposite side of the building. Then the longer panels were produced and set up on the near side of the building. The Regal White panels were all covered with plastic film to protect them from the red clay on the boots of the installers, who had to walk on the panels to install the batten over the seams. After the battens were installed and seamed, the plastic film was removed. (Failure to remove the plastic film in a timely fashion will eventually lead to damage on the panels when the film is removed.)

“The installation went great,” says Nancy Mullins, senior project manager for Eastern Corp., of Norcross, Ga. “We had anywhere from 12-17 crew members at the site at a given time. The challenges were the logistical hurdles like getting the scissor lifts in place and getting the panels to the roof and stacking them.

On this project, 89,000 square feet of SymmeTry Roof

On this project, 89,000 square feet of SymmeTry Roof Series panels by Morin were installed. Photos: Morin, a Kingspan Group Company

“We install all the panels and then come back to install the seam cap and do the seaming. We always wait to make sure everything is where it needs to be, in regard to any penetrations. We really had no issues.”

After the panels were in place, the battens were installed and seamed around the 2 1/2-inch legs of each pan. The battens were cut to 46 feet to match the panel length for the shorter roof. To batten and seam the 161-plus foot panels, the battens were cut to 81 feet and lapped near the center. Slagle ran panels for four buildings at the school, one attached to the main school building and three outbuildings still under construction.

Eastern also installed 1,100 linear feet of a snow retention system, the iBeam from Sno Gem. The iBeam is installed near the eaves on both sides of the roof, with the longer panels hosting a second row nearer the center of the roof.

TEAM

Architect: JKS Architecture, Hopkinsville, Ky., JKSae.com
General Contractor: A&K Construction Inc., Paducah, Ky., AKconstruction.com
Roofing Contractor: Eastern Corp., Norcross, Ga., Easterncorpus.com
Metal Roof System Manufacturer: Morin, a Kingspan Group Company, Morincorp.com

North Carolina Middle School Generates More Energy Than It Uses

Sandy Grove Middle School in Hoke County, N.C.

Sandy Grove Middle School in Hoke County, N.C., was designed to be an energy-positive building. It generates 40 percent more energy than it consumes. Photo: Mathew Carbone Photography

When Robbie Ferris first presented the idea of a school building that generates more energy than it uses, people were skeptical. Now he can point to Sandy Grove Middle School in Hoke County, N.C., as proof that a high-performance school building can go well beyond net zero and generate 40 percent more energy than it consumes.

Ferris is the president of SfL+a Architects and manager at Firstfloor, a development company that specializes in public-private partnerships and design-build-operate agreements. “We designed the building, we own it and we lease it to the school district,” he says. “We monitor all of the systems remotely. One of the reasons we do that is because when you put really high-performance systems in buildings, you have to make sure they are operating at peak efficiency. It can take time to make sure everything is optimized.”

Three years after completion, Sandy Grove Middle School is outperforming its energy models, and the building continues to win accolades. It recently received Energy Star 100 Certification and has been recognized as the nation’s most energy positive school.

“Sandy Grove Middle School is a perfect example of a high-performance facility,” says Ferris. “With the public-private lease-back model, everyone wins. The students receive a quality school, it fits in to the school system budget, and it is energy efficient to help both total cost and our environment.”

The building’s systems were designed to be as energy-efficient as possible, and that includes the roof, which features an array of photovoltaic (PV) panels to generate electricity. “We wanted a roof that would last 30 years,” Ferris notes. “We’ve had a tremendous amount of success with TPOs, and metal roofs as well. This particular client wanted a metal roof look from the front, but they were very open to a membrane roof on other parts of the building. We made the decision to put the metal roof on the front of the building and a TPO on the wings at the back of the building.”

On this project, the warranties were important considerations, along with durability and energy efficiency. SfL+a specified a standing seam metal roof system manufactured by Dimensional Metals Inc. and a TPO system manufactured by GenFlex. “Obviously, if you’re putting a couple of million dollars’ worth of solar panels on your roof, you want to make sure you have a roof that is going to be problem free.”

A Smooth Installation

The installation was a challenging one, but everything went smoothly, notes Aaron Thomas, president and CEO of Metcon Inc. Headquartered in Pembroke, N.C., Metcon is a full-service general contractor that specializes in energy positive commercial buildings, so it was perfectly suited to serve as the construction manager on the project.

Photovoltaic panels were installed

Photovoltaic panels were installed on both the standing seam metal roof and the TPO system. The systems on the low-slope roof sections are fully ballasted, and both sections were installed without penetrating the roof system. Photo: SfL+a Architects

Thomas and Ryan Parker, senior project manager with Metcon, coordinated the work of subcontractors on the job, including the Youngsville, N.C. branch of Eastern Corp., which installed the TPO and metal roofs, and PowerSecure, the solar installer on the project, based in Wake Forest, N.C.

The roof systems covered 85,000 square feet, and Sharp PV panels were installed on both the metal roof and the TPO system. Solar panels were also installed on freestanding structures called “solar trees.” Each solar tree is 20 feet tall, 25 feet wide and weighs 3,200 pounds.

“The TPO roof system was upgraded to an 80-mil product due to solar panels being added to the roof,” Parker notes. “It was 100 percent ballasted on the low-slope sections, with slip sheets being used below the racking on the TPO roof.”

On the metal roof, clips manufactured by S-5! were used to affix the solar racking to the seams. “There are no penetrations for the frames, and penetrations for the electrical wiring went through vertical walls, not the roof,” Parker says. “There were no penetrations anywhere in the roof system, which made all of the warranties that much easier to keep intact.”

The biggest challenges on the project, according to Parker, were coordinating the different scopes of work and ensuring all of the manufacturers’ warranty considerations were met. “We had two different kinds of roofs, both coupled with solar panels,” Parker says. “Like any rooftop with photovoltaic products, there had to be special attention paid to the warranties of all parties involved. Both Genflex and DMI were closely involved in coordinating details to ensure that the owner achieved a great roof free of defects.”

The building’s systems were designed for energy efficiency

The building’s systems were designed for energy efficiency, and the roof features an array of photovoltaic panels to generate electricity. Photo: Mathew Carbone Photography

One key was developing a detailed schedule and keeping everyone on it. “We would meet once a week and huddle up on how it was progressing and what else needed to be done,” Parker recalls. “We found that by using a collaborative submittal sharing platform, all of the varying parts and pieces could be checked by all parties to ensure compatibility.”

There were multiple safety concerns associated with combining solar panels to the roofing system, so everyone had to be on the same page. “The roofing subcontractor and the solar subcontractor performed a joint safety plan that utilized common tie off points,” Parker notes. “The job had zero lost time.”

“Everyone coordinated their work and it was a great team effort,” Ferris says. “It was one of the smoothest jobs I’ve ever seen. We have not had a single leak on that project—not a single problem.”

Proof Positive

For Ferris, the greatest obstacle on energy-positive projects convincing members of the public and governmental agencies of the benefits. “The biggest challenges had nothing to do with construction; they had to do with just doing something new and different,” he says. “The toughest challenge was getting the school board, the county commissioners, the public and the review agencies on board. It took a very long time—and lots of meetings.”

Photo: SfL+a Architects

Now Ferris can point to Sandy Grove as an example of just how a high-performance school building can pay huge dividends. “As soon as you see it in real life, you’re on board,” he says. “It’s very exciting for people to see it. If we can get people to the school, they’ll walk away convinced it is the right thing to do.”

With Sandy Grove, the school district has a 30-year lease with an option to purchase. Ferris believes the lease model is the perfect solution for educators. “We’re responsible for any problems for the life of the lease,” he says. “If a problem does come up, we usually know about it before the school does because we monitor the systems remotely online.”

“In their world, buildings are a distraction from educating kids,” Ferris concludes. “This is one building that is not a distraction.”

TEAM

Building Owner: Firstfloor, Inc., Winston-Salem, N.C., Firstfloor.biz
Architect: SfL+a Architects, Raleigh, N.C., Sfla.biz
Construction Manager: Metcon Inc., Pembroke, N.C., Metconus.com
Roofing Contractor: Eastern Corp., Youngsville, N.C.
Photovoltaic Panel Installer: PowerSecure, Wake Forest, N.C., Powersecure.com
Metal Roof System Manufacturer: Dimensional Metals Inc., DMImetals.com
TPO Roof System Manufacturer: GenFlex Roofing Systems, GenFlex.com

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

Liberty University Taps Experienced Team for Indoor Practice Facility

Liberty University

Photo: Leah Seavers. Copyright Liberty University

While he was a student in the 1970s at Liberty Baptist College in Lynchburg, Va., Craig McCarty took a job with a roofing company to help him pay his way through school. One of his business courses required students to set up a model business, so McCarty set up a fictional roofing company.

When a recession forced his boss to close down the company where he worked, McCarty turned his classroom project into reality. He got his contractor’s license and formed his own roofing business at the age of 20. More than 40 years later, he is installing roofs on the same campus he once took classes for a college now known as Liberty University.

McCarty is the president of McCarty Roofing, headquartered in Lynchburg, Va. This year the company installed the standing seam metal roof on Liberty University’s new indoor football practice facility, the fourth building the company has worked on at the school. McCarty has always been fascinated by metal roofs, and he estimates that 70 percent of the company’s business comes from the metal segment of the market. “It’s our passion, and we’re really good at it,” he says.

Liberty University’s new indoor practice facility encloses an entire regulation football field.

Liberty University’s new indoor practice facility encloses an entire regulation football field. The structural metal roof system is made of panels that run the entire width of the building.

He’s found a great place to ply his trade in Liberty University, which has made roofs manufactured by Fabral Metal Wall and Roof Systems into something of a signature architectural style. Other Fabral roofs at the university include those on Williams Stadium, Hancock Welcome Center, Jerry Falwell Library, and the LaHaye Recreation and Fitness Center.

According to Jerry Wandel, Fabral’s Mid-Atlantic territory manager, based in Richmond, Va., Fabral and distributor NB Handy in Lynchburg have partnered to provide architectural metal enclosure systems for 13 buildings on the campus since 2010.

The new practice facility encloses an entire regulation football field, and the design for the structural metal system on the vaulted barrel roof called for panels—many as long as 240 feet—that would run the entire width of the building.

Fabral’s Stand’N Seam 24-gauge panels in Dark Bronze were specified for the project. According to Wandel, the product features a unique stainless-steel clip design and double lock-seamed side joints that allow panels to expand and contract throughout their entire length. The system had been installed successfully on indoor practice facilities at other colleges, including Georgia Tech, the University of Virginia, Virginia Tech and Virginia Military Institute.

“When you run a panel that long, clearly one of the biggest concerns is expansion and contraction,” Wandel says. “Our Stand’N Seam product just lends itself to a project that has 240-foot panels. This one was right in our wheelhouse.”

Riding the Curve

The first task for McCarty Roofing was drying in the metal deck. Crews installed two layers of 2 ½ inch polysio and covered the insulation with Blueskin, a self-adhering underlayment manufactured by Henry.

The metal panels were fabricated on the site. Fabral supplied the roll former and brought in Ray Berryhill to operate the equipment. “Ray has done all of these jobs for us,” notes Wandel. “We want to make sure the contractor is in position to have a quality installation. Ray has so much knowledge about these jobs. He was the perfect person to execute this one.”

The panels were fabricated on the site.

The panels were fabricated on the site. The roll former was lifted into place at the edge of the roof by crane, and panels were rolled directly onto the roof and stacked for installation.

A crane was used to lift the roll former into place at the edge of the roof. “We were able to set the front two feet of the roll former in the built-in steel gutter, and then drop the back end of the machine down to the proper angle so we could roll the panels right onto the roof,” McCarty explains. “About every 15 or 20 feet up the roof we would stack some insulation, so the panel would float across the roof. Once it hit the top and went down the other side, it could just ride the roof down.”

The original plan was to install the panels as they came off the roll former, but McCarty decided it would be more efficient to run all of the panels, stack them on the roof, and install them once all of the panels were fabricated. “We had a large crane on site that was costing us money, and we had the people from Fabral there,” he recalls. “I went to the construction manager and said, ‘It’s going to make a lot more sense if we get all of the panels for the project up on the roof as quickly as possible.’”

The 4,000-pound metal coils typically supplied enough material for 8-10 panels, so Berryhill would run 8-10 panels at a time as crews from McCarty Roofing stacked them. When the roll former was lowered to the ground to load another coil, workers would strap the panels into place, figure out how much area the panels would cover, and set up again another 20 feet or so down the roof to receive the next batch. “We had a series of 15 or 20 straps for each bundle of panels,” says McCarty. “We had to be careful, but with eight people, you could pick up the panel and gently set it down.”

After the roll forming crew was done, the panels were pulled off of the stacks and installed. “It was a pretty extreme radius, but the panels just laid down on the roof perfectly,” McCarty recalls. “The design worked out really well.”

Liberty University

Photo: Joel Coleman. Copyright Liberty University

The built-in gutter gave crews a good location to set the bottom edge of the panels. “At the eaves, the roof pitch was very steep—maybe 12:12—and it was almost flat at the top,” notes McCarty. “We had to be tied off 100 percent of the time. We used retractables, but the safety equipment still limited our movement. It was pretty difficult for the guys working the first 30 or 40 feet.”

The roof featured large skylights, which made the metal panel layout critical. The design also featured upper and lower sections that stepped down around large windows, which made for some tricky details. “At the gable ends, we had to make the cuts at an angle,” McCarty notes. “We cut the panels in place with drill shears and hand turned them with tongs to lock then onto a cleat.”

The schedule was tight, and weather was also a concern. “It was in the dead of winter,” McCarty recalls. “We started laying panels in January. Fortunately, we had a mild winter, but at times it was like a wind tunnel. You’re not going to pick up a 240-foot panel in 35 mile-an-hour winds, so there were days we just weren’t able to work.”

The project was wrapped up at the end of May, and McCarty credits the decision to stack the panels as one of the keys to meeting the deadline. “It was the right call,” he says. “The time we saved made up for the lost days due to the weather and helped us complete the job on time.”

TEAM

Architect: VMDO Architects, Charlottesville, Va., VMDO.com
Construction Manager: CMA Inc., Lynchburg, Va., CMAinc.us
Roofing Contractor: McCarty Roofing Inc., Lynchburg, Va., McCartyroofing.net
Distributor: NB Handy Co., Lynchburg, Va., NBhandy.com
Metal Roof System Manufacturer: Fabral Metal Wall and Roof Systems, Fabral.com

Pre-Notched Trims and Flashing Components Save Time at the Jobsite

ATAS pre-notched trims and flashing are consistent dimensionally and provide an aesthetically pleasing final installation.

ATAS pre-notched trims and flashing are consistent dimensionally and provide an aesthetically pleasing final installation.

ATAS International Inc. has expanded its line of pre-notched trims and flashing components.  Trims and flashing are often critical elements of metal roof, wall and soffit installations.  They provide weather resistance of the installed system, as well as aesthetic value of the finished building.  ATAS can provide solutions that address both of those elements which can help to control costs.  
 
Common problems that occur in metal panel trim and flashing installation include maintaining the correct overlap distances.  As well, heavier gauges and multiple bends or complex shapes may make field notching difficult.  The quality of workmanship in creating trims and flashings in the field are not as easily controlled compared to factory fabrication, and the time to perform this operation in the field is typically longer.
 
ATAS trims and flashing are consistent dimensionally and provide an aesthetically pleasing final installation.  The use of these components eliminates unknown field costs and results in an efficient installation, which saves the contractor time and money. 

Silicone Sealant Repairs Roofs, Masonry and Sheet Metal

The 100 percent Silicone Sealant seals and repairs roofs, masonry, architectural sheet metal, and metal roof seams and fasteners.

The 100 percent Silicone Sealant seals and repairs roofs, masonry, architectural sheet metal, and metal roof seams and fasteners.

Mule-Hide Products Co. has added 100 percent Silicone Sealant choices to its Silicone Roof Coating System, expanding the color offering to include clear and the packaging options to include 10-ounce tubes.
 
100 percent Silicone Sealant is a mastic version of the Mule-Hide 100 percent Silicone Roof Coating. It is a moisture-cure silicone sealant designed for use in sealing and repairing roofs, masonry, architectural sheet metal, and metal roof seams and fasteners. 
 
The addition of clear sealant allows contractors to complete projects that would otherwise require color-matching. It is available packaged in tubes only.

In addition to clear, the tubes are available filled with white sealant. The plastic cartridges are an option for use in smaller applications or when precision is required. They also can be submerged under water to repair roof leaks, gutters and downspouts.
 
100 percent Silicone Sealant provides adhesion to concrete, masonry, polyurethane foam, EPDM membranes, TPO membranes, aged PVC membranes, aged acrylic coatings, granular cap sheets, wood, metals, Kynar finishes and most other building materials. When using 100 percent Silicone Sealant with a TPO roof membrane, Mule-Hide Si TPO Primer must be applied first. 
 
The sealant has minimal odor, making it contractor- and building-occupant-friendly. Its volatile organic compound (VOC) content of less than 10 grams per liter makes it acceptable for use in areas with VOC restrictions. It does not corrode metals.
 

Project Profiles: Hospitality & Entertainment

B.O.B., Grand Rapids, Mich.

Roof Materials

The double-sided green wall surrounds guests with nature and provides fresh ingredients for the food they enjoy.

The double-sided green wall surrounds guests with nature and provides fresh ingredients for the food they enjoy.

The B.O.B.’s 900-square-foot Sky Patio was completed in August 2015 when its signature green wall was installed. The distinctive double-sided green wall surrounds guests with nature and provides fresh ingredients for the food they enjoy.

“Our living wall on the Sky Patio is a vivid symbol of our commitment to sustainability and support of the local environments where our restaurants are located,” says Alice Jasper, director of sustainability, the Gilmore Collection. “It greens up the exterior and interior of the rooftop patio, contributing to the beautification of downtown, making the patio more inviting from the street below and enhancing the dining experience of our guests.”

The two-sided green wall totals 608 square feet. Three exterior sections (48 inches in height) are attached to the outside of the fencing that surrounds the patio. Facing out to the street, these sections frame the Sky Patio on three sides with flowering annuals and perennials. There are five interior sections (45 1/2 inches in height), three on the inside of the perimeter fence, two on the back wall of the building. In addition to flowers, the interior sections include vegetables and herbs used in the kitchen.

The two-sided green wall totals 608 square feet.

The two-sided green wall totals 608 square feet.

“Local sourcing of ingredients is one of our main sustainable hospitality practices,” says Barbie Smith, the Gilmore Collection’s gardener. “With the green wall at the B.O.B., we grow ingredients right near the tables where our guests dine. You cannot get more local than that.”

“What chef wouldn’t want a garden with fresh herbs and produce right in their restaurant? A green wall makes it practical,” adds Mick Rickerd, chef at Bobarino’s. “We utilize the herbs in all our everyday dishes and the vegetables, like Swiss chard and rainbow carrots, in daily features. Our mixology team incorporates fresh basil, mint, lemongrass and thyme into special summer cocktails.”

Green Wall Manufacturer: LiveWall

Roof Report

The B.O.B. is the Gilmore Collection’s most ambitious project, and it exemplifies the company’s commitment to sustainability. The B.O.B. is an acronym for Big Old Building; the 70,000-square-foot, 4-story, red brick building was constructed in 1903 as a grocery warehouse. It stood vacant for decades before the Gilmore Collection saved it from demolition and began its transformation into a landmark hospitality destination in downtown Grand Rapids. The B.O.B. offers multiple venues, including bars, restaurants, comedy and nightclubs, as well as the rooftop Sky Patio, which is accessible through Bobarino’s restaurant on the second floor.

Photos: LiveWall

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MBMA Welcomes New Membership

The membership ranks of the Metal Building Manufacturers Association (MBMA) are continuing to expand. MBMA recently welcomed Panasonic Corp. of North America (Panasonic) as its 60th Associate member, and Package Steel Systems Inc. as a Building Systems member.
 
Panasonic will be represented by Jon Downey, who serves as the company’s housing and construction market development manager. Package Steel Systems will be represented by Bob Fisette, who serves as the company’s president.
 
“Our members are vital to MBMA’s continued success and influence in the building and construction industry,” says Dan Walker, PE, associate general manager of MBMA. “Each company’s unique contributions help us to advance the acceptance of metal building systems as the building solution within the low-rise commercial construction market.”
 
Based in Newark, N.J., Panasonic Corporation of North America manufactures consumer and industrial products, including building insulation solutions and products for metal roofs and gutters. The company is a subsidiary of Osaka, Japan-based Panasonic Corp., founded in 1918.
 
Package Steel Systems is located in Sutton, Mass. The metal building manufacturer serves customers in the Northeastern region of the U.S.
 
The MBMA is comprised of metal building system manufacturers and their suppliers who fabricate or manufacture materials for the industry, as well as architecture and engineering firms and service providers.