Roofing a Resort in Paradise Took Great Design and Better Planning

Photos: Timbers Kauai

The Hawaiian Islands epitomize paradise with sandy beaches, crystal clear waters, warm days and balmy nights. Some are blessed to call the islands home, while others are lucky visitors. Both groups come together at Timbers Kauai — Ocean Club & Residences at Hokuala, an oceanfront destination nothing short of spectacular.

Opened in June 2018, Timbers Kauai exudes luxury island living. Located on Kauai’s picturesque southeast coast, the destination offers short- and long-term residents breathtaking unobstructed views of the Pacific Ocean and Hau’pu mountain range as well as immediate access to an unparalleled shoreline.

The design aesthetic of Timbers Kauai is inspired by the naturally distinct Hawaiian paradise surrounding it. All materials and finishes were deliberately selected for the richness and longevity they provide, from the cladding and windows, to roofing, luxe interior finishes and lush landscaping. Elements combine naturally, providing seamless easy connections between indoor and outdoor spaces.

“Key Hawaiian-inspired design elements were incorporated into the public indoor and outdoor spaces and main lobby,” says Gary Ross, director of architecture for Timbers Resorts. “Examples include the wave patterned fascia panels, nautical inspired backlit entry panels and the lobby’s Kappa inspired floor tile patterns.”

The Timbers Kauai features Hawaiian-inspired design elements throughout. Materials and finishes were selected for the richness and longevity they provide.

When considering roofing options for the resort, architects aimed for a durable, resilient material that complemented the sophisticated island design theme. They ultimately turned to Irvine, California-based Boral Roofing, specifying Saxony 900 Slate Appalachian Blend, a high-performance concrete roofing system with earthy stone hues replicating the natural look of real slate.

Since concrete tile is a high-quality, durable roofing solution that lasts much longer than some other competing roofing options, it is an ideal solution for the resort. The low maintenance tile also allows for localized repair areas should damage ever occur.

Sustainability is a major selling point of the concrete roof tile. Manufactured using naturally occurring and abundant geologic materials, the tile incorporates no chemical preservatives and is 100 percent recyclable at the end of its life on the roof. Concrete tile also provides the resort with substantial energy efficiency benefits, rendering significant reductions in the ongoing energy costs associated with heating and cooling the property as the seasons shift.

Fighting Unpredictable Weather

Another core consideration in the selection of the roof was storm resistance. The subtropical weather on Kauai can be trying for a roof. Hot, humid weather is common and torrential rainfall, fierce wind and hail occur as well. To protect the resort from these harsh weather variables, the architects sought a roofing material able to withstand the elements. Boral Roofing’s tile not only provided a complementary aesthetic, but also the weather resistance attributes required on Kauai.

Architects chose a high-performance concrete roofing system from Boral Roofing that replicates the look of natural slate.

 “We were able to specify a product that not only met the stringent wind and rain conditions of building in Hawaii, but also provided the style and elegance required of this project,” says Chris Ridings, partner at Poss Architecture + Planning of Aspen, the design firm retained by Timbers Resorts for the project.

Concrete roof tile also notably scores high in fire resistance. The Timbers Kauai roof is non-combustible, helping prevent ignition from occurring. The tile offers a Class A fire rating, the highest fire resistance rating for roofing.

Challenging Installation

Those involved in construction in Hawaii understand shipping can be a challenge. Many building materials must be delivered from the mainland. With most projects on strict timelines, delays in shipping can be troublesome and even costly. Thus, it is important that logistics, lead times, packaging, and fulfillment of orders are correct. With the roof installation, these factors came in to play.

Installation of the roof was led by Honolulu Roofing & Waterproofing, one of Hawaii’s first-established roofing companies. A project comprising three large buildings and 600 squares, the installation occurred over a three-month period. “We had to deal with adverse weather, primarily rain, but also hurricane warnings,” says Dan Jaeger, vice president. “Kauai didn’t end up getting hit with a hurricane, but because of the warnings, the materials already in transit had to return to their shipping origin and then be re-shipped. It took a bit longer than we would have liked.”

Despite weather delays, the Honolulu Roofing team completed the installation seamlessly once it got started. Jaeger points out that Boral Roofing was onsite during installation and contributed to the project’s success. “It’s really great to see a manufacturer present putting that level of effort into providing guidance during an installation,” Jaeger says.

The roof included all Boral components, but the attachment used for this project was the Polyfoam instant set adhesive, which is compatible with Boral Tile Seal underlayment.

Honolulu Roofing was able to install more than 580 squares of roof tile using one crew of eight men, with each member assigned a specific task on the roof, all overseen by Jaegar. He flew in daily from Honolulu before sunrise to make sure the job ran smoothly, even getting in a morning walk to the job site for exercise.

Honolulu Roofing also provided waterproofing for the low-slope portion of the project as it was critical that the roof tile installation tied into the low slope system properly. All told, the installation of the roof tile was completed ahead of schedule despite weather-related shipping delays.

Built to Entice and Endure

Timbers Kauai – Ocean Club & Residences at Hokuala is designed to offer an unparalleled experience for those who visit. Built from rich materials that last, the resort encourages luxury island living along a breathtaking stretch of coast. The island retreat offers residents and visitors alike a thoughtfully curated collection of services including access to a full-service restaurant with progressive approach to farm-fresh Hawaiian food, an oceanfront infinity-edge swimming pool, a separate ohana pool with a beach entry, and water features that form the heart of the resort. These are just a few of the onsite amenities set within the quality-crafted resort built of exceptional materials. No doubt, Timbers Kauai is designed to endure.

About the author: Ann Iten is the director of marketing for Boral Roofing, a manufacturer of durable and energy-efficient new and retrofit roofing systems. Visit Boral Roofing online at www.boralroof.com, and contact Ann at Ann.Iten@boral.com

TEAM

Architect: Poss Architecture + Planning, Aspen, Colorado, www.billposs.com, and Gary Ross, Director of Architecture, Timbers Resorts

Roofing Contractor: Honolulu Roofing & Waterproofing, Honolulu, Hawaii, www.honroof.com

MATERIALS

Concrete Roof Tile: Saxony 900 Slate Appalachian Blend, Boral Roofing, www.boralroof.com

Underlayment: Boral Tile Seal, Boral Roofing

Contractor Overcomes Challenging Logistics to Re-Roof 16-Story Westin Savannah

The Westin Savannah site posed logistical challenges, as it is bordered by the Savannah River, a canal and the Savannah Convention Center. Photo: SOPREMA

Were you to visit Savannah, Georgia, the Westin Savannah Harbor Golf Resort and Spa would be tough to miss. This landmark property, known for its 18-hole PGA golf course, secluded beach access and on-site spa, is the tallest building in the city at 16 stories. The aura of luxury surrounding the building was threatened, however, when Hurricane Matthew moved through the region, inundating the city with rainwater and causing the aging Westin Savannah roof to fail. With leaks resulting in the closure of a major portion of the hotel’s upper floor, it was clear the building owners would need to move quickly to restore a waterproof seal atop their building.

The job would not be easy. The Westin Savannah is surrounded by the Savannah River on one side, a canal on another and the Savannah Convention Center on a third. The only feasible area left to stage and load the roofing material onto a crane was the front parking loop and valet area — an area that would typically be avoided with any other roofing project. “We only had one spot where we could set up, and that was the biggest challenge,” says Larry Hoffman, the superintendent who oversaw the installation of the roof at the Westin Savannah on behalf of Whitco Roofing, the Westin’s chosen contractor. “We were very limited with regard to any mobility around that hotel, not to mention the fact that we had to get materials onto a roof that was 270 feet from the ground.” 

Envisioning an Approach

The Whitco Roofing team also had to deal with challenging application conditions, given that the roof had many penetrations due to the presence of air conditioning units, towers, exhaust vents, lighting, walkways, ladders, staircases and other equipment. Special care would have to be given to the installation of the flashing to ensure no opportunities for leak formation remained after the roofing job was done. Recognizing that the use of a liquid flashing material was the best bet to keep the roofing layer monolithic despite all the penetrations, the Whitco Roofing team set about selecting the right compatible materials for the job.

SOPREMA’s SENTINEL P150 60-mil PVC-based roofing membrane was selected for the projectbecause we wanted a durable roofing product that was compatible with a liquid flashing material for difficult base flashings encountered during this project,” explains Henri Brickey, director of business development for Whitco Roofing. “We recommended the SOPREMA PVC membrane for several reasons, the first of which is the superior chemical and UV resistance PVC offers over TPO. Since we also intended to wrap the large quantity of concrete and metal support column bases with SOPREMA’s ALSAN RS 230 Flash polymethyl methacrylate (PMMA) liquid resin, we made sure the PVC membrane was compatible and that we could include those areas under the roof’s warranty.” 

The Installation Commences

The complex coordination required for a successful roofing installation began on the ground. One week’s worth of material was staged at a time, then a crane was brought in to upload materials to the roof on the same day trash was being downloaded from the old roof tear-off process. All debris had to be carefully bagged and secured with tarps to avoid pollution in the nearby Savannah River, and the delivery and removal of four dumpsters at a time had to be carefully coordinated so that no dumpster was left on the premises overnight, blocking entry to the building. “You had to be out of there by five o’clock with everything, and it had to be done in a particular sequence, further complicating matters,” explains Hoffman.

On the rooftop, existing asphalt-based roofing materials were stripped down to the concrete deck. SOPREMA SOPRA-ISO3.5-inch polyisocyanurate insulation was adhered using SOPREMA DUOTACK 365 foam adhesive to provide improved R-value to the building. Next, the PVC membrane was bonded onto the insulation, providing both a reliable waterproofing layer and a reflective white finish that would help diminish heat absorption compared to the older materials. The liquid resin coating was then applied to prevent water intrusion at all exposed concrete column bases — extending up and coating metal base plates — and at vertical flashing points where air handling units tied into the building’s walls. New tapered crickets were also installed between drains, improving the overall flow of water on the roof and reducing the opportunity for ponding water.

Safety and Communications Prioritized

Throughout the project, OSHA guidelines had to be followed carefully on the rooftop and on the ground to ensure both workers and bystanders entering and exiting the hotel were safe. Flagging and ground guides were used around the staging area, and strict adherence to timelines for deliveries and mobilizations were also critical to the safe execution of the project. The Whitco Roofing team worked closely with the hotel management throughout the process to prevent interference with hotel operations and to minimize risks to guests. 

The building now benefits from a superior roofing membrane that is Energy Star-compliant, upgraded insulation, a strong foam adhesive that helps resist uplift pressure during storms and a monolithic waterproofing layer thanks to the liquid flashing installed around all penetrations. “SOPREMA’s single-ply membranes have a reputation for strength and durability,” notes Brickey, “and especially with the inclusion of the liquid flashing system to deal with difficult flashing details, we were able to provide a long-lasting, warranted waterproofing solution for the Westin.”

In all, more than 14,000 square feet of roofing material was replaced over the course of roughly a month by a large team of installers. In part because the hotel staff was so pleased with the way the job was planned, managed and executed, Whitco Roofing was brought back to install a new roof on a lower section of the building as well. That project was recently completed, positioning the Westin Savannah to resist the elements while serving as a relaxing getaway for the foreseeable future.

TEAM

Roofing Contractor: Whitco Roofing, Atlanta, Georgia, www.whitcoroofing.com

MATERIALS

Roof Membrane: SENTINEL P150 PVC, SOPREMA, www.soprema.us

Insulation: SOPRA-ISO, SOPREMA

Adhesive: DUOTACK 365, SOPREMA

Liquid Flashing: ALSAN RS 230 Flash, SOPREMA