Meticulous Preparation Sets Up Restoration Project for Success

Photos: Debby Amador, Roma Police Department

Officials at Roma High School in Roma, Texas, knew they needed a new roof. The tile roof on the main complex was more than 25 years old, and some components were clearly failing. They didn’t realize that many of the leaks and resulting wall deterioration were caused by other problems as well. Luckily, they reached out to design and construction professionals who did their homework, diagnosed all of the key problems, and developed a plan to fix them. The crowning touch of the building envelope restoration plan was a beautiful standing seam metal roof, and the success of the project is proof that hard work pays off not only in the classroom, but on top of it.

The Consultant

As its building envelope consultant, Roma Independent School District chose Amtech Solutions Inc., headquartered in Dallas, Texas. The full-service architectural, engineering, and building envelope consulting firm has been in business since 1982. Working out of the company’s Rio Grand Valley (RGV) office located in Pharr, Texas, Amtech Solutions inspected and evaluated the entire site and reviewed legacy documents to identify the underlying issues.

They found quite a few, notes Michael Hovar, AIA, RRO, LEED AP, a senior architect and the general manager of the company’s RGV office. “They thought all they had was a roofing problem,” he notes. “But we saw right away that not properly managing water off the roof was the cause of wall deterioration, which then became leaks into the building. Our experience with the entire envelope and all facets of design and construction really helped us on this one.”

Roma High School in Roma, Texas, underwent a three-phase building envelope restoration plan in 2016-2017. After the walls were repaired and restored, the roof and mechanical equipemt were replaced. Photos: Debby Amador, Roma Police Department

Amtech Solutions put together a presentation for the school board to detail what they discovered and the plan they proposed to remedy the situation. The company also worked with the school district to help develop a budget.
The restoration plan was split up into three phases. The first phase focused on restoring the walls and windows. The second phase encompassed roof replacement and installing new mechanical equipment. The third phase involved improving drainage, grading and other site repairs.

Amtech Solutions decided not to bid the project out to a general contractor, but rather to bid each phase separately. “We decided to split it up into stages and do it logically, starting with the walls first,” Hovar says. “For the walls, we got restoration contractors who specialize in wall restoration work.”

Restoration Services Inc. (RSI) of Houston, Texas handled the first phase in the summer, as the wall repairs would be louder and more disruptive to students. The roof replacement project was scheduled for the fall. “Once all of the stuff on the ground was done, that allowed us to do the re-roofing work throughout the school year, which also helped the price,” notes Hovar. “Our experience has always been that if we have good cooperation with the contractors and the school staff, at the end of the job they end up being best friends. And that’s exactly what happened. At the end of the job, they were sad to see the roofers go.”

Amtech Solutions convinced the school district the plan would work. “It took some coordination, communication and cooperation, and it took a motivated owner that was willing to do this and trust us,” Hovar says. “They looked to us for guidance, and we said, ‘We do this all the time. We do roofing projects throughout the year, occupied and unoccupied, and we do it in a way that respects what the occupant’s needs are.’”

When it came time to specify the roof system, school board members were divided; one faction wanted to install a new tile roof, and the other wanted to go with metal. “The interesting thing is, for the historical architecture of the area, both of those roofs are appropriate, so from the standpoint of historical significance, either one works,” Hovar says. “In the end, it was quite a bit more expensive to utilize tile than it was to utilize a metal roof.”

The Roof Systems

The decision was made to go with a standing seam metal roof from McElroy Metal on the vast majority of the complex, including the main roof, the gymnasium, and two freestanding structures — the art and industrial arts buildings — that had been added over the years. The main tile roof was removed and replaced with McElroy’s 138T Panel, a 16-inch-wide, 24-gauge panel in Brite Red. McElroy’s 238T Panel, a 24-inch-wide, 24-gauge panel, was specified for the gym, as well as the art and industrial arts buildings. In a cost-saving measure, the color on the gym roof was changes to Galvalume Plus. In all, more than 233,000 square feet of metal roofing was installed.

Before

“The reason we picked this roof system is we’ve had a lot of great experience with it,” Hovar says. “We love that panel because they can actually bring the roll former to the jobsite. That gives the roofing contractor a lot more options on how he can load the roof and sequence the job. The other beauty of this panel is that it has unlimited movement. The panels itself slides back and forth over a fixed clip. It also flashes like a dream.”

Low-slope roof areas adjacent to the gym were replaced with a two-ply modified bitumen system from Siplast. CPI Daylighting manufactured a new skylight for the atrium.

As part of the roofing phase, gutters and downspouts were added. “There was nothing controlling the water before on this project,” Hovar says. “We designed a gutter system with expansion joints as per SMACNA guidelines. The contractor made absolutely beautiful shop-welded aluminum downspout boots.”

The most crucial detail was a custom-made saddle that solved the problem of water infiltration at the transition between the roof and walls on the wings. “This ultimately simple solution addressed one of the major design flaws that plagued the facility from the first days of occupancy,” Hovar notes. “We modeled the three-dimensional design of those saddles, and the contractor welded them in his shop. He fabricated them out of .080 aluminum and they were seamless. The restoration contractor had already installed all of the through-wall flashing, so all the roofer had to do was put counterflashing in and do his work around it. He was able to fly without being slowed down by a mason on the job.”

The Roofing Contractor

The roofing phase of the project was handled by Rio Roofing, headquartered in Harlingen, Texas. The company primarily installs low-slope and metal roofs, and its focus is on large commercial and institutional projects. ““We do nearly 90 percent public bonded work,” notes Hedley Hichens, vice president of Rio Roofing. “We found out that whether it’s a small job or a big job, the paperwork is still the same, so we try to make it worthwhile.”

The company worked on the Roma High School project for about a year, wrapping up the roofing phase of the project in November 2017.

After the structure’s main roof was removed, the tile was replaced with a standing seam metal roof featuring McElroy’s 138T Panel in Brite Red. Photos: Debby Amador, Roma Police Department

The decision was made to tackle the wings on the main roof first. “During the pre-con meetings, we met with the principal and the superintendent and asked, ‘Which wings are the worst?’” Hichens notes. “There was one wing that was the most problematic, so we started with that area first.”

Rio Roofing began by tearing off the existing tile roof. “There were about 1,925 squares of concrete tile we had to remove,” Hichens notes. “We had crews on the roof tearing off tile, crews on the ground palletizing the tile and storing it in the parking lot.”

As crew members removed the old tile and felt, others followed behind and installed polyisocyanurate insulation and Polystick MTS, a waterproofing underlayment designed for high-temperature applications. “We did 40 or 50 squares a day, moving down the wing,” Hichens says. “We dried in the whole school. Then we came back with the 138 panel.”

On top of the gym and other buildings that received the 238T panel, the existing metal roofs were left in place. “We put flute fill on top of the old panels. Then we screwed down 3/8-inch Securock, primed it and put the Polyglass underlayment down on top of that,” Hichens explains. “That 24-inch panel is a great panel to work with because every time you put one down, you’re 2 feet closer to finishing.”

Installing the New Roofs

The school’s main roof covers a central hub with eight wings coming off of its octagonal skylight. Where the wings tie together, access was limited.

“It was a tight squeeze,” Hichens says. “Getting in there and getting out was difficult. I think our fork lift only cleared one of the walkways by 2 or 3 inches. It’s a big campus, but the layout was difficult at the school.”

Once the wings were dried in, sheet metal crews installed the edge metal and 4,000 linear feet of gutters. They also started forming the panels.

Typically, Rio Roofing lifts the roll former to the roof edge, but it was difficult to get a large lift next to the building, so in this case the roll former was left on the ground. It was moved from wing to wing as the job progressed. “We used a New Tech roll former on this project,” Hichens says, “We would put the roll former parallel to each wing and store the panels on the ground in each area.”

Panels were hemmed and notched using a Swenson Snap Table Pro and lifted to the roof with a fork lift and a special cradle. Crews used a hand seamer to set temporary seams and followed up with a robotic seamer from D.I. Roof Seamers. “The panels are easy to install,” Hichens says. “You get about four guys 10 feet apart to engage the panels and clips and you just keep going. At the end of the day crews put the seam caps on.”

On the low-slope areas, Rio Roofing installed approximately 47,000 square feet of the Siplast two-ply SBS modified system, which was torched down over new lightweight concrete. “For their size, the low-slope areas had a ton of mechanical equipment and ductwork up there,” notes Hichens. “There were a lot of key details.”

Rio Roofing custom-manufactured numerous curbs and details, including the saddles over problem areas at the walls. “We have a full welding shop,” Hichens notes. “We have a full machine shop. We make all of our own curbs here, so there is no lead time for ordering curbs, and we are sure they’ll fit.”

Teamwork

Work on the project has now moved on to a fourth phase: installing translucent panels over the swimming pool. Hovar believes teamwork was the key to the project’s success. “We had such a good contracting team, we did good field work to begin with, and we had an understanding owner,” he says. “Designing it wasn’t easy, but thankfully our experience helped. We just had a really good team to execute it, all the way around. That’s what makes for a great, project, right? When everybody is invested in a good outcome, they always support everybody else.”

Communication was also essential, and Building Information Modeling (BIM) helped keep everyone on the same page. “We modeled the project on our BIM software, and it helped everyone understand the scope and challenges. The BIM model allowed the owner see exactly what the project would look like, and it helped the contractor understand the staging and logistical challenges before the project was bid,” Hovar says. “There were no surprises.”

TEAM

Architect and Consultant: Amtech Solutions Inc., Pharr, Texas, www.amtechsls.com
Roofing Contractor: Rio Roofing, Harlingen Texas
Wall Restoration Contractor: RSI-Restoration Services Inc., Houston, Texas, www.rsi-restorationservices.com

MATERIALS

Metal Roof System
Metal Panels: 138T panel (16 inches wide, 24 gauge) and 238T Panel (24 inches wide, 24 gauge), McElroy Metal, www.mcelroymetal.com
Underlayment: Polystick MTS, Polyglass, www.polyglass.us
Cover Board: Securock, USG, www.usg.com
Skylight: CPI Daylighting, www.cpidaylighting.com

Low-Slope Roof System
Modified Bitumen Membrane: Paradiene SBS, Siplast, www.siplast.com

Miami-Dade County Approves PolyPUF Foam Systems

Miami-Dade County Department of Regulatory and Economic Resources issued several Notices of Acceptance (NOA) for Polyglass’ PolyPUF Foam Systems, certifying the commercial roofing solution for use in high velocity hurricane zones.

“We are delighted to have the quality and safety of our Spray Polyurethane Foam System affirmed by Miami-Dade County, a Florida building code agency recognized nationally for its rigorous testing methods for building materials,” said Maury Alpert, codes and compliance manager at Polyglass U.S.A., Inc. “This certification allows us to provide roofing products and systems to roofers building in cities with extreme weather.”

PolyPUF is a closed cell sprayed in place polyurethane foam that acts as an air barrier, insulation and roofing system in a single application. The NOAsconfirm that PolyPUF (2.5, 2.8 and 3.0 lb densities) is designed and tested in accordance with Miami-Dade Product Control Section requirements and is approved for use over wood, steel, recover and concrete decks. Aside from its durability and long-term performance, PolyPUF offers a high R-value, which means greater potential for energy savings. To maximize the performance of PolyPUF apply Polyglass’ Miami-Dade approved PolyBrite 70, 90 or 95 roof coatings.

For more information, visit www.polyglass.us.

 

NRCA Announces Polyglass Has Joined One Voice Initiative

The National Roofing Contractors Association (NRCA) has announced Polyglass U.S.A., Inc., Deerfield Beach, Fla. has joined NRCA’s One Voice initiative, upgrading its associate membership to “partner member.”

In 2017, NRCA launched its One Voice initiative to unite the roofing industry and speak with one voice about matters critical to the roofing industry’s continued success.

To ensure all industry sectors are given an opportunity to participate, NRCA amended its bylaws to allow manufacturers, distributors, architects, engineers and consultants that choose to participate to become full members of the association, meaning they will be granted voting rights and eligible for leadership roles within the association. Previously, such rights were reserved only for contractor members.

“NRCA’s One Voice initiative offers a unique opportunity for the roofing industry to address the major issues we face. However, our work can only be accomplished with commitments from leaders from all sectors of this great industry,” says Reid Ribble, NRCA’s CEO. “Only together as a roofing community can we take this transformational approach to address our issues and concerns and achieve success in the future.”

Issues currently affecting the roofing industry include workforce development and certification; advancing the industry’s public policy agenda; building codes and insurance; and increasing professionalism throughout the industry.

“We are excited about the One Voice initiative, a great forum for enacting change in the roofing industry,” says Scott Lelling, director of strategic marketing for Polyglass U.S.A., Inc. “As industry leaders, our collective response can accelerate change and shape the future. We are committed to doing our part.”

For more information, visit www.nrca.net/onevoice.

Canadian Association Adds Polyglass Solutions to Roof Guarantee Program

Polyglass U.S.A. Inc. announced that its products are approved for the RoofStar Guarantee, a comprehensive program offered to Canadian building owners and is backed by both the contractor and the Roofing Contractors Association of British Columbia (RCABC).

According to the company, the inclusion of Polyglass’ solutions in the RoofStar Guarantee program recognizes the products as high-quality solutions. Established by the RCABC, the RoofStar Guarantee was introduced to ensure quality installations and acceptable standards for roofing materials. RCABC certifies that only the best materials are used for installations and also provides reputable contractors, well-trained installers, and independent inspections.

“We are excited about this achievement and look forward to providing more of our premium solutions to the Canadian roofing industry,” said Director of Sales, Technical and Customer Service Todd Homa. “As a member of the RCABC, we appreciate the standards in place to maintain quality and provide all parties in the process with peace of mind and security.”

For more information, visit https://polyglass.us.

Polyglass Achieves ISO 9001:2015 Certification

Polyglass U.S.A., Inc. announced that it has achieved ISO 9001:2015 certification. This accomplishment validates Polyglass’ commitment to manufacturing quality roofing and waterproofing products, enhancing customer satisfaction, and improving business performance.

“We are proud to receive ISO 9001:2015 for all of our Polyglass locations,” said Polyglass CEO Natalino Zanchetta.  “As a quality-focused company, implementing a Quality Management System is a natural step for Polyglass. It increases our reputation for quality products in the industry and builds trust and confidence in our brand.”

Certification to ISO 9001 requires an accredited registrar (third-party auditing organization) to thoroughly review the company’s policies, processes, and procedures to ensure that they are capable of consistently meeting customer, regulatory requirements and the intent of the ISO 9001:2015 standard.

The ISO 9001 standards are published by the International Organization for Standardization, an international agency composed of the national standards bodies of more than 160 countries. A new version of the ISO 9001 appears about every seven years to ensure organizations continue to adapt to the changing environment in which they operate. ISO 9001:2015 is the latest of the ISO 9001 international standards.

For more information, visit www.polyglass.us.

New Roof and Building Upgrades Provide Security for Florida Day Care Center

The Joseph Caleb Center

The Joseph Caleb Center received a building envelope upgrade that included a new modified bitumen roof for the low-slope sections and a new standing seam metal roof on steep-slope sections at the perimeter. Photos: Polyglass USA Inc.

The Joseph Caleb Center in Miami caters to a very young clientele, but the building housing the early childhood education center was definitely showing its age. The existing roof was failing, the concrete walls were cracked, and the window seals were broken. The restoration project was a complicated one, with several roof and wall systems that had to be tied in together. Luckily, that’s just the type of project Errol Portuondo likes. Portuondo is the owner of Florida Building & Supply in Miami, which focuses primarily on commercial restoration and re-roofing projects. The company restored the building, topping it with a new self-adhered, modified bitumen roof system and crowning it with a standing seam metal roof around the perimeter.

“We handle the whole envelope,” Portuondo notes. “That’s what sets us apart. That’s our niche. We like to go into these projects that have four, five, six items—the kind of projects other companies avoid. Most people like to handle the easy stuff—get in and get out. We like to tackle the harder type projects that require a lot of thinking.”

Complicated Scope of Work

The project required a roof system that was Energy Star rated and would comply with South Florida’s requirements for high velocity hurricane zones. Furthermore, the building would remain open during the roofing installation process, so the roof system could not give off any fumes or volatile organic compounds (VOCs). A self-adhered modified bitumen roof system from Polyglass USA Inc. was chosen for the flat roof sections because of its high reflectivity, durability, and ease of installation, as well as the lack of any odor.

The existing roof consisted of a mechanically attached modified system surrounded by a standing seam metal roof. Florida Building & Supply first removed the metal roof system, as it partially covered the flat roof. After the steep-slope sections were dried in with 30-pound felt and Englert MetalMan HT self-adhered underlayment, crews began to tear off the old modified system. Everything was removed down to the lightweight insulating concrete (LWIC) that had been installed over the metal deck.

The day care center

The day care center was open during the restoration project, so the safety plan included moving the children’s playground during the roof installation. Photos: Polyglass USA Inc.

The specification called for adhering polyiso insulation directly to the lightweight with OlyBond 500 adhesive from OMG Roofing Products, so making sure the LWIC was in good shape was crucial. Core samples were taken of the roof and subjected to a series of adhesion and compression tests required by the county. “We passed all of the tests and got all of the approvals regarding the lightweight, and we installed the insulation and the Polyglass system on top of that,” Portuondo says. “We like using that system because it is easy to install and allows us to salvage the lightweight. It also gives you really great uplift resistance.”

Crews installed tapered polyiso insulation manufactured by Hunter Panels to a custom-designed layout provided by ABC Supply Co. Insulation ranged in thickness from more than 5 inches to a minimum of 1 ½ inches. After the existing roof system was removed, Portuondo realized that the deck could not be penetrated without potentially damaging the structure, affecting the placement of emergency overflows. “Some of the existing buildings weren’t designed like they are today, so you have to work with the existing drains and make sure you can take care of the water through emergency overflows if any drains should get clogged,” he says.

After the insulation was installed, the 20,000-square-foot low-slope section was ready for the Polyglass three-ply, self-adhered modified bitumen roof system. Elastoflex SA V, a self-adhered SBS modified bitumen membrane, was used for the base and interply sheets. The surface layer consisted of Polyfresko G SA, a white, self-adhered APP modified bitumen cap sheet manufactured with CURE Technology, a thin-film technology designed to improve the membrane’s durability, UV and stain resistance, and granule adhesion.

“What we like about the self-adhered system is that you can move on the roof quick and clean,” Portuondo says. “Sometimes the intake of the mechanical units is up on the roof, and with a hot asphalt application, you have to be careful with any fumes. That’s not a consideration with the self-adhered system. It’s very clean and very fast, especially if you are about to get a rainstorm. You can get a barrier installed very quickly on the roof as opposed to hot asphalt or a torch system.”

Details, Details

Once the new low-slope roof was installed, work began on the new standing seam metal roof manufactured by Englert. Tying in the metal roof with the modified roof was relatively easy, according to Portuondo, but other details were more problematic.

The last steps included perimeter metal trim and gutters. “We work closely with the manufacturers based on their inspection process and when there are certain details,” notes Portuondo. “In this specific project, there were a lot of details.”

Waterproofing the skylights

Waterproofing the skylights was tricky, as the glass extended under the metal roof and ended just a few inches from the new modified bitumen roof system. In these sections, Polyflash 2C, an odor free, fluid-applied flashing system from Polyglass, was used. Photos: Polyglass USA Inc.

Florida Building & Supply also handled repairing and painting the perimeter of the building. Hairline fractures in the concrete block walls were repaired with epoxy injections prior to painting. Crews also re-caulked and waterproofed all of the windows and skylights, including glass walls that extended under the metal roof at the top and ended at the bottom just a few inches from the modified roof system.

“That tie-in was very difficult because by the time you ended your base flashings for the modified, you were right at the glazing,” Portuondo says. “For those areas, the only solution was the Polyglass Polyflash 2C kit.” Polyflash 2C is an odor free, fluid-applied flashing system that is UV-stable.

Setting up the plan of attack in advance was crucial, notes Portuondo, but with any older building, you have to be ready to adapt as the job progresses. “You don’t really know structurally what you’re going to run into until you start to tear off,” he says. “Sometimes what you find under the roof turns out to be different than you expected, and you have to make changes in the field.”

Safety is always the top concern for both employees and members of the public, notes Portuondo. “We moved the playground area and set up a safety perimeter fence,” he explains. “We made sure the children would not be harmed while we were installing the roof, so that was a logistical problem.”

The company is used to overcoming logistical problems. “Our forte is re-roofing existing buildings, and so they are always active,” he says. “We strive to do quality work and stay on top of everything. We’ve just been doing this for so long that we know what we’re doing.”

Hanley Wood Names Best Products from 2014 IRE

Hanley Wood Exhibitions has announced the selection of six products receiving recognition based on innovation, productivity and cost-effectiveness during the 2014 International Roofing Expo (IRE), held Feb. 26-28 at the Mandalay Bay Convention Center in Las Vegas. A panel of industry experts selected the “Best New Product” and “Best Sustainable Product” from selections found in the Product Showcase at the show.

The IRE Product Showcase, a 2,500-square-foot pavilion, featured 28 displays of the latest products focusing on safety and sustainability – as well as products made in the USA – in a direct, non-selling environment. Judges selected first, second and third place winners in each category.

Carlisle SynTec Systems of Carlisle, Pa., was awarded Best New Product for its Sure-Flex KEE HP PVC Membrane. ERSystems & Elastek of Irving, Texas, was awarded Best Sustainable Product for its ER One Step.

“The 2014 IRE was successful,” said Ryan Blad, Technical Service & Support for ERSystems & Elastek. “The biggest highlight would be OneStep winning the Best Sustainable Product Award.”

Second place in the Best New Product category was awarded to Galaxy Energy Americas of Aurora, Ontario, for its G7 universal standing-seam clamp, while third place was awarded to Metal Plus LLC of Winsted, Conn., for its Roofer’s Helper bracket.

Second place in the Best Sustainable Product category was awarded to Polyglass USA of Deerfield Beach, Fla., for its Polyfresko G SA, while third place was awarded to Freedom Supply of Wendell, N.C., for its Roofer’s and Paver’s Edge.

“We congratulate all six award winners,” said Tracy Garcia, CEM, IRE Show Director. “These companies deserve recognition for the innovative products they created and the significant impact each will have on the roofing industry.”

Other companies competing for the Best New Product award included AVM Industries, Benjamin Obdyke, DI Roof Seamers, Eco Chief Products, Epilay, ERSystems & Elastek, Insulation Solutions, Leister USA, Lifetime Tool and Building Products, MetalSafe Coatings, Polyglass USA, SafePro Guard, Tramex, Vector Mapping / IR Analyzers.

Competing for the Best Sustainable Product award were AVM Industries, Carlisle SynTec Systems, DaVinci Roofscapes, Eco Chief Products, Lifetime Tool & Building Products, Metal Plus and MetalSafe Coatings.

The 2015 International Roofing Expo will be held Feb. 24-26, at the Morial Convention Center in New Orleans. Online housing reservations can be made immediately and online registration will open in September.

Polyglass Offers Rewards, Donates to Red Cross

Deerfield Beach, Fla.-based Polyglass U.S.A. Inc. recently introduced its Polyglass Q Rewards program as a way of saying “thank you” to professional roofing contractors. There is no cost, no commitment and no catch. Simply purchasing eligible Polyglass products allows contractors to earn rewards points. Eligible purchases made on or after Sept. 1, 2013, will qualify. To learn more, visit .

In other news, Polyglass recently donated $25,000 to the Greater New York chapter of the American Red Cross, Washington, D.C. Serving Long Island and Metro NY North chapters, which encompass 13.5 million people, the Greater New York chapter continues to assist those who were affected by Sandy.

“We are thrilled we can contribute to the region affected by Sandy,” comments Scott Lelling, Polyglass’ senior manager of strategic marketing. “There is still a need to assist these communities in rebuilding and we hope to continue our participation in that process.”