Planning and Teamwork Are Essential in Tackling Retail Project

Peach State installed a mechanically attached TPO system over the existing modified bitumen roof system on two buildings totaling approximately 75,400 square feet.

Peach State installed a mechanically attached TPO system over the existing modified bitumen roof system on two buildings totaling approximately 75,400 square feet.

Headquartered in Atlanta, Peach State Roofing Inc. has 15 branches and covers clients across the nation. The company specializes in commercial and industrial roofing, and excels at large-scale single-ply jobs. The goal of every branch is to provide the same level of service for clients no matter where they are in the country, as exemplified by a recent project at a large retail mall in South Carolina.

Peach State’s Charlotte branch is located in Rock Hill, S.C. The company has re-roofed three of the five roofs at Gaffney Premium Outlets in Gaffney, S.C., including two roofs completed this year in just two weeks. Anthony Wilkerson, the branch manager, and Blake Wideman, strategic accounts, shared their insights on the project.

Peach State’s Charlotte branch focuses primarily on re-roofing, service and maintenance work for existing customers and property managers. Most of the company’s work involves TPO, EPDM and PVC, but crews have to be able to handle almost every type of system on the market. “If there is a hotel with some shingles or metal on it, we want to be able to complete every facet of the job, but most of our work revolves around single-ply roofing,” Wilkerson states. “We are certified with every major single-ply manufacturer.”

Anthony Wilkerson (left) and Blake Wideman of Peach State Roofing’s Charlotte branch inspect the completed project at Premium Outlets in Gaffney, S.C.

Anthony Wilkerson (left) and Blake Wideman of Peach State Roofing’s Charlotte branch inspect the completed project at Premium Outlets in Gaffney, S.C.

According to Wilkerson and Wideman, Peach State’s strength lies in building relationships with its clients by providing quality workmanship and excellent customer service. “We do that through our project management, our expertise and our training,” says Wilkerson. “We put a lot into training our employees so that they know how to do the technical details that the manufacturers are asking for.”

Wilkerson believes Peach State offers the best of both worlds—flexibility at each branch and the depth of knowledge from the large corporate organization. “We’re independent, but I work with the corporate office every day,” says Wilkerson. “We have local representation around the country, but at the same time we have that teamwork, so you’re still getting the same quality from each office that you’re getting from the corporate office. We try to be as close to the way Atlanta does things—the Peach State Way—all across board, all over the country.”

Landing a Big One

In the case of the recent project at Gaffney Premium Outlets, the work was an outgrowth of the company’s previous successful projects, including a re-roofing job at the same complex last year. “Our bid was what they were looking for,” Wideman says. “We gave them the price they were looking for and the quality they wanted. That’s how we were awarded this project.”

This aerial view shows the five buildings of the Gaffney Premium Outlets mall. Peach State Roofing re-roofed the two buildings on the left this year, after completing work on the building at the far right last year.

This aerial view shows the five buildings of the Gaffney Premium Outlets mall. Peach State Roofing re-roofed the two buildings on the left this year, after completing work on the building at the far right last year.

The mall is made up of five buildings, and the company re-roofed two this year totaling approximately 75,400 square feet. Peach State installed a mechanically attached TPO system from Firestone over the existing modified bitumen roof system. “We came up with a plan to cover the old roof with a half-inch high-density cover board,” Wilkerson says. “Then we mechanically attached a Firestone 60-mil white TPO system over the cover board.”

The system was chosen for its durability, according to Wilkerson. “They were looking for a long-term solution,” he says. “We went with a re-cover because it was more cost-effective for their budget, but we could still offer them the same warranty and the same guarantee that the system would be just as effective if they had torn the old system off and started from scratch.”

The company used 8-foot rolls of TPO on the project for several reasons. “We went with 8-foot rolls on this project because it was easier to apply the rolls,” notes Wilkerson. “They are not as heavy as the 10-foot rolls. It’s easier to let the rolls relax when you roll them out and easier to keep them tight when you are securing them to the deck.”

Fasteners were installed every 12 inches on center at the edge of the TPO sheets, and the next sheet was heat welded over the top of the screws and plates, and then mechanically fastened at the other end.
Extra care had to be taken with the details, especially walls and curbs. “We tore all of the old membrane off the curbs and off the walls, and we used bonding adhesive to go up the walls,” Wilkerson explains.

At the walls, the field sheets were run up the wall 12 inches and mechanically attached. “We adhere a sheet to the wall, and we heat weld that to the field sheet,” explains Wilkerson, “At the top of that, we use a water cutoff behind the sheet, and we use a termination bar. The termination bar is installed 12 inches on center, and then we use a sealant at the top of the termination bar. We came back with a surface-mount counterflashing, which basically just goes over the top of the termination bar. It has a little kick-out on it, so once that’s attached, it gives you double protection where your membrane is terminated.”

Curbs were handled in a similar fashion. “With the curbs, you run the field sheet right up to the curb, and then you mechanically attach it 12 inches on center,” Wilkerson notes. “Then we use bonding adhesive to install a piece of membrane on each side of the curb. We don’t do one piece and wrap it all the way around. We use four separate pieces, and we adhere them to the curb. Then we heat weld those pieces to the field sheet. For the curbs, we use a flashing that goes underneath the curb itself, and we attach that 12 inches on center all the way around. That lets the water shed over the HVAC unit and then down onto the membrane past the flashing, so there’s nowhere for the water to penetrate.”

Meeting the Challenges

The sheer size of the project was a challenge, but Peach State is used to handling large-scale projects. Logistics and scheduling were also demanding due to customer activity at the mall. “It was a good project for us, but I’d say one of the biggest challenges was that the mall remained open the whole time we were doing the roof,” Wilkerson says. “We had to check in with each tenant in every building to make sure everything was OK from the night before.”

Extra care had to be taken with the details at walls and curbs. Bonding adhesive was used to install a piece of membrane on each side of the curb. Then those pieces were heat welded to the field sheet.

Extra care had to be taken with the details at walls and curbs. Bonding adhesive was used to install a piece of membrane on each side of the curb. Then those pieces were heat welded to the field sheet.

The project called for roofing specific sections each day to make sure the roof stayed watertight at all times. “We sealed the roof up every night 100 percent, so if it rained in the evening, it had to be like we had never been up there,” Wilkerson recalls. “If we took three air conditioners apart in a section that we did one day, at night before those guys went home the air conditioners were wrapped back up, the flashing was put back around the air conditioner and all of the edges of the roof were sealed to the old roof so everything was watertight.”

Safety was also a concern, especially with pedestrian traffic below. “We had to make sure all of our safety procedures were in place for our crews and for the members of the public going in and out of the doors,” Wilkerson says.

The crews used safety lines at the perimeter, and anyone outside the safety lines had to be tied off at all times. “We had to make sure we had a man strictly watching out for the safety of the crews. You have to make sure any little pieces of membrane don’t blow off the roof. You have to make sure all of that is being cleaned up steadily as the job is going on. You don’t want the public to see anything except the flag stands on the roof.”

Staging was complicated, but luckily the jobsite offered ample space for trucks and cranes to be moved between the buildings. The key was to tackle high-traffic areas early in the morning and move to less busy spots as the day wore on.

Proper staging is crucial to jobsite efficiency, notes Wilkerson. “We like to stage the material as we put it on so we’re not dragging it across the roof,” he says. “It’s all right there for them, laid out as they go.”

Support and teamwork are essential up and down the line. “We work really well as a team, so if anyone has any small questions, they can ask the superintendent and call me, so we can make sure we take care of it the Peach State Way.”

Flexing Their Muscles

The project went off without a hitch, says Wilkerson. The mall traffic was never disrupted. “Not one leak, not one complaint on this project,” he says. “Our project management on this project was spot on. Our superintendents held their own out there. And our guys—it’s the attention to quality and all the time we put into training our guys that allows them to do this and make it look almost seamless. It’s one of those situations where you want it to look easy while you’re doing it, but when you’re in the mix of it and you’re trying to get it all done, it’s not as easy as it looks.”

Customer service was crucial. It wasn’t just the property management company that had to be kept informed—it was each individual retailer in the building. “There were so many people to deal with,” notes Wideman. “Every manager of each of those units had to be kept informed of the process. Roofing is not as hard as people think, but keeping up with the owners, keeping people happy, letting people know ahead of time what’s going on is a big challenge. We had to make friends with everyone ahead of time and let them know where to call with any questions.”

“The project, as far as roofing goes, was pretty straightforward,” concludes Wilkerson. “The key is to keep up with everyone on a daily basis and let them know what’s going on so if there is a small problem, it doesn’t keep brewing until it’s a big problem.”

Photos: Peach State Roofing Inc.

Forecasters Predict Healthy Outlook for Construction Industry

After a strong 2015, there is a growing sense that the construction industry expansion will be more tempered over the next eighteen months. However, continued demand for hotels, office space, and amusement and recreation spaces will ensure continued growth in the overall construction spending market over this time period.
The American Institute of Architects’ (AIA) semi-annual Consensus Construction Forecast, a survey of the nation’s construction forecasters, is projecting that spending will increase less than six percent for 2016, with next year’s projection being an additional 5.6% gain.

INFOGRAPHIC: To see each of the panelist’s projections, click here.

“Healthy job growth, consumer confidence and low interest rates are several positive factors in the economy, which will allow some of the pent-up demand from the last downturn to go forward,” said AIA Chief Economist, Kermit Baker, PhD, hon. AIA. “But at the same time, the slowing in the overall economy could extend to the construction industry a bit – with the biggest drop off expected in the industrial facility sector over the next year and a half.”

Market Segment Consensus Growth Forecasts 2016 2017

Overall nonresidential building 5.8% 5.6%
Commercial / industrial 11.7% 6.5%
Hotels 17.9% 7.6%
Office space 14.7% 7.5%
Retail 7.4% 5.2%
Industrial facilities -2.1% 2.9%
Institutional 4.5% 5.8%
Amusement / recreation 10.0% 5.7%
Education 6.5% 6.3%
Healthcare facilities 2.3% 5.0%
Religious -0.4% 1.9%
Public safety -3.7% 3.3%

Baker added, “The issues that could derail continued expansion in the construction sector include: weak U.S. manufacturing output, struggling economies in key international markets, the ripple effect from the Brexit decision, and the typical uncertainty leading up to a U.S. presidential election that results in reluctant investors.”

Project Profiles: Retail

Sierra Nevada Brewery, Mills River, N.C.

About 58,000 pounds of copper were installed on the brewery.

About 58,000 pounds of copper were installed on the brewery.

TEAM

Roofing Contractor: The Century Slate Roofing Co., Durham, N.C.
Architect: Matthew Galloway of Russell Gallaway Associates Inc., Chico, Calif.

ROOF MATERIALS

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project. This was close to 750,000 pounds of slate, or 375 tons.

About 3,000 feet of custom copper gutters and downspouts, conductor heads and 100 squares of painted standing-seam panels were fabricated, and pre-built copper clad dormers and decorative copper cornices were installed.

The project also included 35 squares of copper standing-seam roofing, 25 squares of soldered copper flat-seam roofing and 115 squares of copper wall cladding. About 58,000 pounds of copper were installed on the brewery.

Everything on the building is oversized and that meant everything had to be built to support the heavy structural loads and live loads from wind and mountain snow. The large roof faces called for 10-inch custom copper gutters. When you have gutters that large in the mountains of North Carolina you have to consider the extraordinary weight of the annual snow.

In addition to snow guards being installed on the slate roof, custom 1/4-inch-thick copper gutter brackets fastened the gutter to the fascia. It is typical on steel-framed construction, particularly on this scale, that the framing is out of square and there is widely varying fascia and rake dimensions.

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project.

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project.

However, these items should not appear out of square or have varying dimensions. Great care had to be taken to measure and custom bend onsite all the detail flashings so everything appeared perfect. This took many skilled craftsmen, a great deal of time and the absolute drive to provide the highest quality work.

Slate Manufacturer: Evergreen Slate Co. Inc.
Copper Fabricator: K&M Sheet Metal LLC
Supplier of Underlayment, Copper Sheets and Coil, Insulation and Nailbase Sheathing: ABC Supply Co. Inc.

ROOF REPORT

The new-construction project began in November 2013 and was completed in September 2015.
The team completed the slate installation so well that The Century Slate Co. was awarded the 2015 Excellence in Craftsmanship Award by Evergreen Slate for the project.

PHOTOS: The Century Slate Roofing Co.

Pages: 1 2 3 4

Project Profiles: Retail/Mixed-use

Outlet Collection at Niagara Niagara-on-the-Lake, Ontario, Canada

Team

DEVELOPER: Ivanhoé Cambridge, Montreal

The largest open-air outlet mall in Canada features approximately 23,000 square feet of PTFE fiberglass membrane walkway canopies.

The largest open-air outlet mall in Canada features approximately 23,000 square feet of PTFE fiberglass membrane walkway canopies. PHOTO: Birdair

Roof Materials

The largest open-air outlet mall in Canada features approximately 23,000 square feet of PTFE fiberglass membrane walkway canopies. The membrane canopies exhibit a flying-mast cone design that provides relief from the elements and creates a signature look for the shopping center.

PTFE, or polytetrafluoroethylene, is a Teflon-coated woven fiberglass membrane that is durable and weather-resistant. PTFE fiberglass membranes can be installed in climates ranging from the frigid arctic to the scorching desert heat with a project life in some cases exceeding 30 years.

PTFE fiberglass coating is chemically inert, and the low-surface free energy of the material results in an electrical-grade fabric membrane that is readily rinsed by rain-water. It is also immune to UV radiation. This combination makes PTFE-coated fabric membrane ideal for projects requiring weather endurance and fire resistance.

PTFE fiberglass is ENERGY STAR- and Cool Roof Rating Council-certified. During scientific tests of its solar properties, it was discovered that PTFE fiberglass membranes reflect as much as 73 percent of the sun’s energy while holding just 7 percent on its exterior surface. Certain grades of PTFE fiberglass can absorb 14 percent of the sun’s energy while allowing 13 percent of natural daylight and 7 percent of reradiated energy (solar heat) to transmit through.

PTFE FIBERGLASS MEMBRANE DESIGNER, FABRICATOR, INSTALLER: Birdair

Roof Report

Located beside the Queen Elizabeth II Highway, less than 20 kilometers from the U.S. border, the 520,000-square-foot shopping center features 102 retailers, including Canada’s first Pandora outlet, White House Black Market outlet and Bass Pro Shops Outpost. Other sought-after brands at the center include a Kate Spade Outlet, NIKE Factory Store, Calvin Klein Outlet and Michael Kors Outlet.

The Niagara Outlet Collection was developed to attract shoppers and visitors who might have otherwise crossed the U.S. border to shop in the Fashion Outlets of Niagara Falls, the Walden Galleria or the Boulevard Mall. David Baffa, Ivanhoé Cambridge senior vice president of retail development, said the developer wants the new outlet collection to be part of the Niagara experience.

Outlet Collection at Niagara is committed to corporate responsibility and environmental sustainability and has a number of design features throughout the property to raise awareness of its green initiatives. Its canopies make the open-air concept possible, reducing energy consumption because the common areas do not need to be heated or cooled. Some of the public buildings, like guest services and the eatery, have been designed so that they can be opened to the outdoors in favorable weather, thus saving energy and connecting people to the outdoors.

Pages: 1 2

The BTI-Greensburg John Deere Dealership Installs Tornado-Resistant Daylighting Systems and Other Sustainable Materials

On the night of May 4, 2007, brothers Kelly and Mike Estes saw their BTI-Greensburg John Deere Dealership obliterated by an EF5 tornado nearly 2-miles wide (according to the Enhanced Fujita Scale, which rates the strength of tornados by the damage caused; view the scale on page 3). Astoundingly, 95 percent of their town—Greensburg, Kan.—was also destroyed that day. The tornado did much more than rip roofs off buildings and toss things around; it turned the entire community into what looked like kindling.

Rarely do communities get hit by an EF5 tornado, which can come about when air masses collide. Sometimes warm, humid air from the Gulf of Mexico rises above drier air from the Southwest deserts in the U.S. This can create unstable conditions resulting in thunderstorms and worse. A strong collision of air masses creates a strong storm. Additionally, wind patterns and the jet stream can magnify the storm, resulting in what people refer to as “the perfect storm”.

After being completely destroyed by an EF5 tornado, the BTI-Greensburg John Deere Dealership has been rebuilt in Greensburg, Kan., in a better, greener way.

After being completely destroyed by an EF5 tornado, the BTI-Greensburg John Deere Dealership has been rebuilt in Greensburg, Kan., in a better, greener way.

Despite the large-scale losses incurred by the entire town, 100 customers and friends of the Estes family showed up the morning of May 5 to help them salvage what remained of their business. Shortly after the tornado disaster, Kansas Gov. Kathleen Sebelius stated her wish that Greensburg become the “the greenest city in the state”.

As part of their commitment to their community, Kelly, Mike and their family decided to rebuild their business in a better, greener way. They wanted the new 28,000-square-foot prefabricated metal building to be the world’s greenest farm-machinery facility; attain a LEED Platinum rating from the Washington, D.C.-based U.S. Green Building Council; and use the least energy possible. One of the most important considerations was using building materials that could withstand future tornados.

DAYLIGHTING

To help achieve LEED Platinum and outlast any future high-velocity winds, they incorporated 12 Daylighting Systems in their retail area’s roof to showcase their merchandise; reduce lighting energy costs; and flood the area with natural light, a benefit for customers and employees.

The Daylighting Systems capture light through a dome on the roof and channel it down through a highly reflective tube. This tubing is more efficient than a traditional drywall skylight shaft, which can lose over half of the potential light. The tubing fits between rafters and installs with no structural modification. At the ceiling level, a diffuser that resembles a recessed light fixture spreads the light evenly throughout the room.

The dome is made from high-quality acrylic resin that is specifically formulated for increased impact strength, chemical- and weather-resistance, and high clarity (a polycarbonate inner dome is used for high-velocity hurricane zones). Domes are engineered to deflect midday heat and maximize low-angle light capture. The tubing is made from puncture-proof aluminum sheet coated with the highly reflective material for maximum light transfer. The units (independently tested by Architectural Testing in Fresno, Calif.) comply with various building codes including the 2009 International Building Code and 2010 Florida Building Code, including high-velocity hurricane zones.

“When our power went out one time for four hours, we were able to keep the shop open and operating due to daylight strategies, which includes the Daylighting Systems,” notes Mike Estes. “We didn’t anticipate this benefit but we’re really happy to have this bonus.”
PHOTO: SOLATUBE INTERNATIONAL INC.

Pages: 1 2 3

NCI Metal Depots Opens Raleigh, N.C., Location, Grand Opening Wednesday, Feb. 12

NCI Metal Depots, a national network of retail outlets providing metal buildings and roofing to everyone from homeowners to contractors, recently opened a store in Raleigh, N.C., at 5115 New Bern Ave.

Metal Depots offers a wide range of products ideally suited for residential, commercial and agricultural applications. The showroom offers consumers an opportunity to browse its many offerings as well as work in the design center to create the perfect roof for their home or a new building for their property.

Chris Pettis, vice president of Metal Depots, says, “Raleigh was the perfect site for us to open a new store. The market is here, and the people that we’ve worked with thus far have been fantastic, which gives us a positive outlook. We’re really looking forward to providing a unique shopping and buying experience for our customers, something that is not typical in our industry.”

Metal Depots is currently open to the public and will be having its Grand Opening on Wednesday, Feb. 12. Stop by during the hours of noon to 2 p.m. EST for a chance to win some great prizes.

NCI Metal Depots is an NCI Group Inc. company, which has headquarters in Houston. With 37 manufacturing facilities located throughout the U.S., Canada and Mexico, NCI is one of the largest designers, manufacturers and vendors of metal coatings, components and buildings in North America.