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

New Samco Website Highlights All of the Company’s Capabilities

Samco Machinery, a manufacturer of custom roll-forming and material handling equipment, has launched a new website to fully showcase the company’s capabilities.

“Our website had run its course,” said Steve Kagan, Marketing Specialist at Samco Machinery. “So, we’ve created a dynamic and professional user-friendly website that loads quicker and is easy to navigate with fewer drop-down menus. We’ve also upgraded the responsiveness of the site to be easier to use on a wide range of devices.”

Kagan noted the new Samco Machinery website places more emphasis on videos and imagery showcasing the company’s capabilities and the industries in which they serve. 

The site will be updated on a regular basis with company news, product activity, upcoming events, and latest articles. Visitors are encouraged to explore the website and sign up for direct emails from the company. 

For more information, please visit the new Samco Machinery website.

Atas Adds Roofinox Stainless Steel Roofing Products to Product Catalog

ATAS International Inc. has expanded its three-year partnership with Roofinox America with the addition of the company’s stainless steel roofing products to the 2016 ATAS complete product line catalog.  
 
The Roofinox product line consists of Roofinox Classic brush-rolled stainless steel, Roofinox Pearl bead-blasted stainless steel, Roofinox Plus ribbed stainless steel, Roofinox Chroma mirror-rolled stainless steel and Roofinox Tin-plated (Terne), the only tin-plated stainless steel roofing product specifically developed and manufactured for roll forming and fabricating. Designed to offer long-term sustainability and corrosion-resistance for wall-cladding, flashing, rainware, interior design and virtually all forms of roofing applications, each Roofinox product is also easy to seam, while offering superior aesthetics and reducing machine and tool wear.
 
“We are always looking to support our customers ranging from builders to appliance and toy manufacturers with the highest quality products available in the marketplace today,” says Gary Miller, ATAS’ OEM manager. “Roofinox supports this goal in two distinct areas. Their Tin-plated (Terne) is not only ideal for roll forming and fabricating, its popularity has grown with architects that enjoy the grey patina look these products achieve over time. We have found Roofinox stainless steel products to be more ductile and offer less spring back than similar products, in addition to providing excellent corrosion protection.”
 
“ATAS is a great partner,” says Dave Rowe, vice president at Roofinox America. “They know the market well and are striving to expand their customer base with products for architects and contractors. We are thrilled to be featured in the latest ATAS product line catalog and made available to their growing list of national clients.”
 
Originally developed to withstand the harsh climatic conditions found in Central Europe, the complete Roofinox stainless steel product line is ideal for applications ranging from rural, urban and light industrial areas to historic and commercial sites and extreme coastal environments. Available in coil or sheet, materials can be ordered by themselves so customers can do their own forming or products can be prefabricated by distributors like ATAS.  
 

Roofinox Displays Its Line of Stainless Steel Roofing Products to Contractors and Architects

Roofinox displays its line of stainless steel roofing products to contractors and architects attending the Moon in June Machinery Show in Lynchburg, Va. The annual exposition is specifically developed to showcase the latest advancements in roofing machinery and materials by N.B. Handy Company, HVAC equipment and supplies.

“We appreciate Roofinox’s participation in this year’s event,” says Paul Seufer, general manager of the N.B. Handy Machinery Group. “Our goal is to spotlight sheet metal fabrication machinery and materials available in the marketplace. This includes the interactive display of services in an environment where customers can experience processes and benefits first-hand. Roofinox’s stainless steel roofing products offer forming characteristics that run through our equipment.”

“It is a privilege to work alongside N.B. Handy,” says Dave Rowe, vice president at Roofinox America. “This event provides a wonderful opportunity for building professionals to interact with experts, ask questions and actually witness how our products work with their equipment under in-field conditions.”

Roofinox provides a range of tin-plated (Terne) products designed to offer sustainability and corrosion-resistance for wall-cladding, flashing, rainware, interior design and virtually all forms of roofing applications. Roofinox Tin-plated (Terne) is specifically developed and manufactured for roll forming and fabricating.

Developed to withstand climatic conditions found in Central Europe, the Roofinox Stainless Steel product line is ideal for applications ranging from rural, urban and light industrial areas to historic and commercial sites and coastal environments. With ongoing exposure to the elements, Roofinox Tin-plated (Terne’s) surface will develop an elegant matt grey patina finish over time.

A substitute for lead-coated copper, zinc/tin-zinc coated copper, Terne-coated materials, galvalume and lead, Roofinox Tin-plated (Terne) is available in coil or sheet. Materials can be ordered by themselves so customers can do their own forming or prefabricated by a Roofinox distributor.

Rollforming Line Performs at Variable Speeds up to 60 Feet per Minute

Samco Machinery introduces the Hands-Free Multi-Product Roll Forming Line, a high-performance line engineered for the specific needs of customers producing multiple profiles.

Samco Machinery introduces the Hands-Free Multi-Product Roll Forming Line, a high-performance line engineered for the specific needs of customers producing multiple profiles.

Samco Machinery introduces the Hands-Free Multi-Product Roll Forming Line, a high-performance line engineered for the specific needs of customers producing multiple profiles.

Samco Machinery’s latest innovative rollforming line is designed to produce products for “Just-in-Time” production. This machine has the ability to perform at variable speeds up to 60 feet per minute, depending on the punching pattern and part lengths. Very much a “hands-free” machine, the entire process is automated from the moment coil leaves the uncoiler until finished product exits the cut-off.

Features include:

  • 10K double-ended uncoiler with hydraulic mandrel expansion.
  • Universal Bottom Driven Roll Former with side-by-side tooling for “Just-in-Time” production.
  • Auto Pre-Punch/Notch Press Selection System with guiding system and AMS controller as required by “Just-in-Time” production.
  • Closed Loop Length Control Systems to maintain sufficient coil stock in the line.
  • Stop-and-Go Cut-Off Hydraulic Press mounted on the roll former base includes three sets of cut-off dies with auto-die change system.
  • Sweep unit with adjustable sweep with roller straightener dedicated for specific profile(s).
  • Just 2 feet of prevailing scrap on leading and trailing ends of coil.

Brock Associates Partners with Roofinox to Sell Roofing and Rollforming Products

“When Follansbee closed its doors, removing its TCS II from availability a few years ago, it left a serious hole in the market for architectural stainless steel,” says Allan Brock, president of Brock Associates of Pittsburgh, Pa. “Architects still need TCS-II and many are still specifying it for their designs. So we decided to satisfy this market by bringing Roofinox into our product line.”

Brock Associates is now sourcing material for its commercial roofing and siding/ACM applications from Roofinox America, the U.S. arm of Roofinox International, Europe’s supplier of quality stainless steel specifically designed for roofing and rollforming.

Allan Brock says: “Over recent years, we have seen the market for metal in roofing, siding and paintable flashing, increasing, especially in the high-end applications, in our market area of Pennsylvania, Ohio, West Virginia, New Jersey and Virginia. When we saw an opportunity to re-introduce stainless into the market with Roofinox, we went for it, and we have not been disappointed.”

“We are extremely pleased about Brock’s decision to go with Roofinox,” notes Dave Rowe, vice president of Sales, Roofinox America. “Roofinox Tin Plated stainless offers a great replacement for the old TSC II, along with a rich architectural appearance.

He continues: “The good news, is it is 20 percent more malleable than any other stainless products on the market making it easier than ever to roll-form. The strength and malleability of our product coupled with our unique surface textures provides our clients with a desirable product.”

Roofinox America has been providing Roofinox Classic, Roofinox Plus .0157 and Roofinox tin-plated (Terne-coated) material to American fabricators, roofing contractors and metal roofing distributors for more than two years.