Gauge Tool Set Quickly Determines Type of Clamp or Bracket Needed

The LMCurbs gauge tool set was designed to help customers save time and money by quickly determining the type of clamp or bracket that is needed for a metal roofing application. There are two styles, one for the S-5! Utility Clamps and one for the five different profiles of the S-5! RibBrackets.

With these gauges, contractors can instantly determine which clamp or RibBracket best fits the metal roof profile while at jobsite. These gauges will greatly reduce the need for shipping out samples to test fit. For the estimators and installers that need to provide a quick estimate and/or begin an expedited install, these gauges could easily save a day or two of back and forth trying to determine the correct product, according to the manufacturer.

Customized laser etching is available, allowing companies to hand them out to their customers with their contact information.

Applications and uses include:

  • ColorGard
  • Dual-Gard
  • LMCurbs IDS
  • LMCurbs SnowGuard
  • SnoRail/SnoFence
  • Solar
  • Solar Attachment 
  • Tools & Hardware
  • Utility
  • X-Gard

For more information, visit www.lmcurbs.com

IMPs Are Key to Construction of New Warehouse at Manufacturing Complex

The new warehouse at the Komatsu manufacturing complex in Longview, Texas, features insulated metal panels from Metl-Span in both the roof and wall systems. Photos: LMCurbs

When a warehouse at the Komatsu manufacturing complex in Longview, Texas, sustained extensive tornado damage, the company decided to build a new, state-of-the-art warehouse in its place.

Komatsu turned to a trusted business partner, Transet Co., a Longview-based design-build contractor, to demolish the old structure and construct its 81,438-square-foot replacement. The new warehouse features insulated metal panels (IMPs) from Metl-Span in both the roof and wall systems, as well as a permanent rooftop walkway system from LMCurbs, which was installed to facilitate ongoing maintenance of the rooftop HVAC units.

According to Dale Pickard, project manager for Transet Co., the IMPs not only made for smooth construction, but they helped the warehouse meet building envelope energy requirements.

Challenges on the project included a tight schedule, unseasonably rainy weather and accommodating nearby manufacturing facilities that were continuously operational.

The LMCurbs Roofwalk System was installed to facilitate ongoing maintenance of the rooftop HVAC units and protect the roof.

The scope of work included the removal of the previous structure and subgrade remediation. After the footings and slab were in place, the Pre-Engineered Metal Building (PEMB) was erected. The system was supplied by Houston-based Mid-West Steel Building Co. and erected by Cannon Steel Erection Co., located in Tyler, Texas.

After the metal frame and roof purlins were in place, Cannon Steel Erection installed the IMPs to complete the wall and roof systems. “You basically go in sequence from left to right with the IMP roofing panels,” Pickard explains. “You just start at one end, work to the other end, and then come back and install the panels on the other side. It’s basically a straight line process from one end to the other.”

The roofing panels were 42 inches wide and 4 1/2 inches thick and incorporated a standing seam. “The panels attach at the purlin with a concealed fastener clip,” says Pickard. “The IMP has a finished skin on the upper and lower sides.”

The seams were hand crimped and then mechanically seamed. At the eave, a gutter system was installed after the roof and wall panels were tied in together.

Workers on the roof were tied off with personal fall arrest systems and retractable lifelines attached to non-penetrating temporary anchor points. “All facets of construction safety were of paramount importance to Transet Co.,” Pickard states. “Safety was and is the first order of business for everybody.”

Completing the Roof Installation

The roof system features Kingspan skylights, which were installed using custom curbs supplied by LMCurbs, headquartered in Longview, Texas. LMCurbs also supplied curbs for the HVAC units, as well as the rooftop walkway system.

The LMCurbs Roofwalk System was installed using H90 clamps from S-5!

The walkway was installed after all of the HVAC equipment was in place and the roof system was completed. The LMCurbs Roofwalk System was designed to provide a safe way to access HVAC equipment while protecting the roof. “It’s basically a roof access area for the maintenance personnel to enter,” Pickard says. “It’s a railed walkway gated at one corner of the building for access, and it goes to each one of the rooftop units (RTUs). In all, there is more than 1,400 linear feet of walkway.”

The system was mounted using S-5! H90 clamps. “There were no penetrations in the roof,” Pickard points out. “It’s a durable system that will protect the owner’s investment in the roof.”

According to Aaron Combs, product manager at LMCurbs, the project was one of the first to use the company’s redesigned LMCurbs Roofwalk System with upgraded handrails. “It was designed to be both a better looking, more professional end product for the building owner, and a more user-friendly system for the installers in the field,” Combs says. “The new handrail assembly utilizes Speed-Rail fitting by Hollaender and is now down to four pieces — from 28— so the number of man-hours needed to install the system is drastically reduced. It also streamlined the warehousing and distribution process because the redesigned support plates eliminated multiple manufacturing processes. With this redesign and stackable plates, we are able to maintain better stocking levels and provide our customers with a faster shipping timeframe.”

Field installations often present unique and unforeseen obstacles. On this project, when the location of some HVAC units was adjusted from the initial layout, Combs was ready to help ensure the walkway would be installed correctly. “We are always available to offer advice and technical support, and that can be especially important with a first-time installer,” Combs says. “They can contact us any time and we can help walk them through it and assist with any issues that might arise.”

Work began in April 2019 and wrapped up February 2020. “We had a wet start, which made soil remediation difficult,” notes Pickard. “In the latter part of our project, we had an extremely wet January and February, and that presented challenges in erection and finish out. Despite the bad weather, the building came together ahead of schedule.”

Coordinating all phases of the project at an active manufacturing campus also posed some logistical hurdles. “The existing plant, of course, was in operation the entire time,” recalls Pickard. “The site where the new warehouse was being built was where the old warehouse facility was, and the existing loading dock had to remain in operation until they were in the new building. That encroached on the footprint of the new facility.”

Final touches included new loading docks, interior offices and restrooms. “This project shows our ability to deliver an outcome that meets the client’s needs from design to finished product — safely, under budget, and ahead of schedule,” notes Pickard.

“It demonstrates our ability to provide a first-class warehouse facility for the owner. We’ve been doing it a long time. Our company has been in business for 38 years. We are a safety-oriented company with vast experience in most phases of commercial, industrial, and institutional construction, and we are there for our customers.”

TEAM

Design Builder: Transet Co., Longview, Texas, www.transetco.com

Engineer: Johnson & Pace Inc.,Longview, Texas, www.johnsonpace.com

Steel Erector: Cannon Steel Erection Co., Tyler, Texas, www.cannonsteel.com

PEMB Supplier: Mid-West Steel Building Co., Houston, Texas, www.mid-weststeel.com

Rooftop Curb and Walkway Supplier: LMCurbs, Longview, Texas, www.lmcurbs.com

MATERIALS

Roof and Wall Panels: Insulated Metal Panels, Metl-Span, www.metlspan.com

Rooftop Curbs: LMCurbs, www.lmcurbs.com

Rooftop Walkway: LMCurbs Roofwalk System

Rooftop Walkway Clamps: H90 Clamps, S-5!, www.s-5.com

Skylights: Kingspan, www.kingspanlightandair.us

S-5! Offers Three Webinars on Solar and Snow Retention Topics

As part of the company’s mission to provide its customers with the highest level of service and customer care, S-5! is providing a series of informative webinars on a variety of solar and snow retention topics in March.

The S-5! webinars include: 

Rieles vs Fijación Directa Techos Metálicos – Spanish Only, Jueves 26 de marzo de 2020 a las 9:00 a.m. – 10:00 a.m. MST. Presentador: Juan Carlos Fuentes, Director Internacional de Ventas, S-5! Te invitamos a nuestro Webinar exclusivo por primera vez en Español. En estos complicados tiempos, S-5! Metal Roof Innovations está comprometido con nuestros clientes en el mercado Latinoamericano. Register Now

Best Practices to Install Solar on Metal Roofs, Thursday March 26, 12:00 p.m. – 1:00 p.m. MST. Presenter: Mark Gies, Northeast Sales Representative, S-5! NABCEP Approved Earn 1.5 JTA hrs. With the demand for sustainable power on the rise, building owners and homeowners alike are turning to solar power as a supplemental power generator. Choosing the right platform for solar panels is critical to the design process and can significantly impact both initial and long-term costs. This course will cover the various types of metal roofs, how they are constructed and their numerous advantages for solar installations. Various solar mounting systems and the myriad of roof attachments will be presented along with performance and cost comparisons. Finally, other fundamental aspects of solar installation on metal roofs are discussed. Register Now

Use of Snow Guard Devices: Science or Science Fiction, Friday March 27, 10:00 a.m. – 12:00 p.m. MST. Presenter: Rob Haddock, CEO and Founder, S-5! The force of snow and ice on rooftops can be significant, wreaking havoc on valleys, eaves, flashings and gutters. Slippery roof surfaces can result in the sudden release of snow buildup, dumping tons of the white stuff below. Snow guard devices of every description proliferate the marketplace. Misconceptions are promulgated through “technical” articles and sales claims that espouse conjecture and mythology in place of prudent science and logic when it comes to the control of snow and its effects on-and off-rooftops. Register Now

For more information, visit https://s-5.com

Illinois Manufacturing Facility Incorporates PV Panels With Roof Re-cover

McElroy Metal’s manufacturing facility in Clinton, Illinois. Photos: McElroy Metal

After completing successful solar panel installations with roof re-covers at plants in Peachtree City, Georgia, and Adelanto, California, McElroy Metal recently completed a third solar conversion at its plant in Clinton, Illinois.

The original R-panel metal roofing on the plant, constructed in the 1970s, was re-covered using McElroy Metal’s 238T symmetrical standing seam roofing. The 238T metal roofing panels were roll formed on site, run directly on to the roof and installed by Prairieland Roofing of Arthur, Illinois. After the new roof sections were complete, Inovateus Solar installed 1,116 Hanwha Q-Plus L-G42 350W panels on the facility using roof attachment solutions from S-5!

The large-scale, multifaceted solar installation at the Clinton plant required a two-pronged approach, as the facility consisted of two different metal roof types: a face-attached trapezoidal profile on one section of the facility and a standing seam profile on another.

S-5!’s engineering team collaborated with McElroy Metal to determine which clamps and brackets were most appropriate based on the two different types of roofs, their respective load capacities, resulting load distribution and best fit of mounting components. They analyzed roof-specific data and CAD drawings to determine precise attachment points across the massive solar array and to determine the bill of materials, including clamps, brackets and PVKITs.

This photo shows S-5!’s S-5-T Mini clamps and PVKIT 2.0 MidGrabs and EdgeGrabs mounted on a McElroy Metal 238T standing seam roofing system.

S-5-T Mini clamps were selected to attach the solar panels to the facility’s new 238T symmetrical standing seam roof system. Featuring a two-piece design to allow easy installation anywhere along the length of the panel seam, S-5-T Mini clamps are specifically designed to fit profiles with a T-shaped seam configuration like the 238T. Beyond the fit, this clamp, in tandem with all S-5! attachment solutions, was specifically load tested on the 238T in the gauge used for the project, enabling comprehensive system engineering specific to this project. This process is routine for S-5!, and the company has more than 500 individual load test results published and accessible on its website.

The solar installation on the facility’s existing Multi-Rib Panel roof system required S-5!’s RibBracket II. These brackets are specifically designed to attach to this type of roof profile. The RibBrackets offered the best fit and provided more than enough tested holding capacity for the dimensions of the rib.

In addition, the entire solar array was mounted using S-5!’s PVKIT 2.0 Solar Solutions, comprised of MidGrabs and EdgeGrabs, which enabled solar installers to mount the solar panels directly onto the clamps and brackets. The pre-assembled components reduced installation time and cost for PV mounting, eliminating the need for an elaborate rail system, while also providing better load distribution into the roof and substructure.

“As a leader in the metal construction industry, we have had the privilege of working alongside McElroy in many venues, industry trade groups and supply relationships, now spanning almost 40 years,” says S-5!’s Founder and CEO, Rob Haddock. “We are proud industry partners and look forward to continuing working together in expanding the use of solar.”

TEAM

Roofing Contractor: Prairieland Roofing, Arthur, Illinois

Solar Installer: Inovateus Solar, South Bend, Indiana, www.inovateus.com

MATERIALS

Metal Roof Panels: 238T, McElroy Metal, www.mcelroymetal.com

Solar Panels: Q-Plus L-G42 panels, Hanwha, www.hanwha.com

Clamps and Solar Attachments: S-5-T Mini clamps, RibBracket II, and PVKITs, S-5!, www.S-5.com

New Non-Penetrating Attachment Solution for Standing Seam Metal Roofs

S-5!’s new GripperFix technology ensures a secure and dependable attachment solution that preserves the integrity of the roof and avoids destructive corrosion. According to the company, this system is quick and simple to install, lasts the life of the roof, maintains roof warranties and is less expensive than other mounting methods. Gripper fix uses S-5 seam clamps or mini clamps to make a secure maintenance-free attachment to any standing seam metal roof using patented non-penetrating S-5 technology. 

Traditionally, mounting rooftop ancillary items using concrete blocks for ballast damages a roof and provides a temporary fix. Wooden dunnage causes early corrosion. According to the company, S-5!’s new GripperFix technology ensures a secure and dependable attachment solution that preserves the integrity of the roof and avoids destructive corrosion.  

S-5! will introduce its new GripperFix technology February 4-6 at the International Roofing Expo (IRE) in Dallas. Attendees are invited to stop by S-5! Booth #2622 to see firsthand its new universal GripperFix system, which makes mounting almost anything on standing seam and exposed-fastener roof profiles simple and easy.

For more information, visit www.s-5.com

S-5! Receives 2019 Industry Advocate Award From the Metal Building Manufacturers Association

S-5! announced it has been awarded the 2019 Gold Level Industry Advocate Award for outstanding service, participation and support of the Metal Building Manufacturers Association (MBMA).

Accepting on behalf of the S-5! team was CEO and Founder Rob Haddockat the MBMA annual meeting and awards presentation, held December 3 in Scottsdale, Arizona.

Haddock, a well-known metal roof consultant, author, speaker and inventor of the non-invasive clamps for fastening accessories to standing seam metal roofs, was awarded for his time, expertise and advocacy of MBMA and the entire metal building industry.

Among the seven companies who were presented with gold, silver and bronze level awards, S-5! Attachment Solutions earned gold recognition and was recognized for exceptional commitment to promoting and enhancing MBMA initiatives, including participation in MBMA committees, advocacy efforts to enhance the metal building systems industry, attendance at MBMA educational and promotional events, and safety program participation.

Haddock is no stranger to the metal construction industry. With now 48 years in the business, his unwavering confidence in metal roof superiority built S-5!’s strong foundation. His attachment solutions make metal the most user-friendly roof type on the market.

“I am honored to receive this award and to be part of such a great community of industry specialists and an organization that provides incredible resources to those who work in metal building systems,” said Haddock. “I am a big believer in participating in industry associations like MBMA where you can meet others who will mentor and encourage you along the way.”

For more information, visit www.S-5.com and www.mbma.com.

Marina’s New Roof Is Its Signature Design Element

When the former Morrow’s Marina first hit the Ridley Township, Pennsylvania, real estate market, it seemed like this last piece of the town’s open space might soon become a townhome development. But the township’s board of commissioners had a different idea for the tumble-down, 14-acre property, sited on Darby Creek, less than a mile from the entrance to the Delaware River. In addition to a new public recreation amenity, some on the board also saw a possible income opportunity too good for the township to pass up.

“I think, with good management, there could be a lot of revenue in the future,” says Bob Willert, who was then the board’s president, of the financial benefits the marina could offer.

Over the years, the town has made improvements to the marina, boosting its popularity with boaters. And, with the recent opening of a new $6 million restaurant, along with marina offices, right on the waterfront, that income potential is becoming a reality. Owned by the township and leased to a local restaurateur, the new Stinger’s Waterfront has quickly become a popular destination. It’s also easy to find, even without a GPS, thanks to a standout metal roof finished in an impossible-to-miss Copper Penny hue.

Choosing the Roof System

While the color is certainly eye-catching, it was the classic PAC-CLAD Snap-Clad profile that first caught the attention of Clarice Jones, project architect with Catania Engineering Associates, the restaurant’s Milmont Park, Pennsylvania-based design firm. She knew the standing seams on the 10,500 square feet of Snap-Clad roof panels — complemented by a matching 1,500 square feet of vented PAC-750 Soffit Panels — would emphasize the crisp lines of the building’s contemporary façade.

Crews from E.P. Donnelly installed 10,500 square feet of PAC-CLAD Snap-Clad roof panels in Copper Penny and 1,500 square feet of matching vented soffit panels. Photos: © hortonphotoinc.com

“The seaming is punched out — I saw a particular style,” she says. “I liked the way the seam looked in profile; it was a nice tight look.”

E.P. Donnelly Inc., of Warrington, Pennsylvania, installed the roof, and it was a complicated project. The sloped design is interrupted on both sides with three triangular window dormers, requiring complex detailing. And a multi-gabled cupola required similar attention, though at a smaller scale. Donnelly’s project manager, Gerry Campi, suggested Petersen’s PAC-CLAD product to the general contractor — J.S. McManus Inc. of Chester Heights, Pennsylvania — as a better fit for this demanding project.

“I told the GC that Petersen was a much better product, and the GC made the switch,” Campi says. “We use the Snap-Clad profile regularly. It snaps together the best. It’s a really nice product.”

For Jones, metal was the only roofing option that would work; any other option would have looked too residential. But, interestingly, the bright metallic finish wasn’t her first choice. Initially, her plans had called for a more neutral gray, but the town’s business manager opted for the definitely-not-neutral Copper Penny shade. “They wanted something bolder,” Jones says. “It’s like a flame; I’m glad they chose it. It sparkles like a diamond.”

Building a Landmark

The roof design features a multi-gabled cupola as well as triangular window dormers.

After winning the project, J.S. McManus Inc. needed to complete the building construction on a tight schedule. Michael McManus, vice president of J.S. McManus, coordinated the work of subcontractors and worked closely with the architect, owner, restaurant owner, and the other prime contractors. “I had my superintendent, Tim O’Connell, who was on site to handle the day-to-day operations,” McManus notes. “We kept our focus on getting the steel superstructure completed as soon as possible so that we could get the roof installed. As with all projects, once the roof is installed, then you can really expedite the project since you don’t have to worry about being impacted by the weather. It took a lot of hard work from my team, and we all stayed focused and worked diligently to complete the project on time.”

As soon as they could, crews from E.P. Donnelly tackled the challenging installation. Crew members were tied off 100 percent of the time to ensure safety. The architectural features called for extra care during detailing to ensure smooth lines, and crews worked carefully to make sure that all areas were fully sealed and waterproofed.

Snow Retention System

Despite Ridley Marina being located in snow country, no snow retention had been specified for the project. “We actually brought this up to the owner and architect that no snow guards were specified for the metal roof, which would create a serious safety concern,”says Campi.E.P. Donnelly recommended installing the S-5! ColorGard system, citing it as the only system the company installs.

A ColorGard engineered snow guard system was added at the recommendation of the roofing contractor on the project.

Sourcing the snow guard system was an easy decision because Campi had worked with a specific distributor since 2013. Brock and Associates Metal Resources, based in Pittsburgh, fulfilled the necessary bill of materials. Brock is a manufacturer and distributor of exterior metal cladding systems for commercial and industrial applications.

The project called for thirty 8-foot sections of unpunched ColorGard rail. To attach the rail, 290 S-5-S Clamps were employed. Then, 290 Sno-Clips II and 290 VersaClips were installed to complete the engineered snow guard system atop the marina’s new copper penny roof. Of course, ensuring aesthetics remained an important design goal, and matching the roof color was crucial. The product allows color-matched strips of the roof metal to be inserted into the ColorGard sections, providing the necessary holding strength while still maintaining a streamlined appearance.

Since its completion, the Ridley Township Marina project has become a stunning showpiece for the area, and all involved with the project point to the roof as its most stunning architectural feature. Campi notes that the roof has become a billboard, of sorts, for the marina, visible from a nearby interstate highway. “When you’re coming down I-95 through Philly, that Copper Penny roof really stands out,” he says.

TEAM

Architect: Catania Engineering Associates, Milmont Park, Pennsylvania, www.cataniaengineering.com

General Contractor: J.S. McManus Inc., Chester Heights, Pennsylvania, www.jsmcmanus.com

Roofing Contractor: E.P. Donnelly Inc., Warrington, Pennsylvania

Distributor: Brock and Associates Metal Resources, Pittsburgh, Pennsylvania, www.brock-assoc.com

MATERIALS

Metal Roof System: PAC-CLAD Snap-Clad Panels, Petersen, www.pac-clad.com

Soffit Panels: PAC-CLAD PAC-750 Soffit Panels, Petersen

Snow Retention System: ColorGard, S-5!, www.s-5.com

A Talented Team and the Right Products Secure Massive 1.32 MW Solar Array

Replacements, Ltd.’s facility in in Greensboro, North Carolina, is topped by a 200,000-square-foot array of photovoltaic panels. Photos: S-5!

Replacements Ltd., based in Greensboro, North Carolina, touts itself as the world’s largest retailer of china, crystal and silver. The company specializes in locating and supplying hard-to-find and discontinued patterns. Their flagship location houses approximately 12 million items from around 450,000 patterns, and their arena-sized warehouse spans eight football fields.

Always proponents of sustainability, Replacements Ltd. is also an avid practitioner of recycling throughout the facility. The company’s very business model, after all, is predicated on locating and preserving difficult-to-procure fine china and collectibles. Taking this green approach one step further, Replacements Ltd. embraced renewable energy by embarking on a solar panel project for the facility’s rooftop.

Replacements Ltd. had long considered solar power, so when the company expanded into a larger facility, the standing seam metal roof was designed to sustain the additional weight of solar panels.

The Solar Installer and the Distributor

Hoping to offset more than 30 percent of the facility’s total energy use, Replacements Ltd. sought out a company that specialized in large-scale rooftop PV array installation. Such an undertaking meant many qualified companies would be vying for the project. Ultimately though, the competition could not match the stellar reputation, high recommendations, and overall value of Yes Solar Solutions (YSS). The company won the contract.

S-5-H clamps from S-5! were used to support the racking system components and conduit lines on the rail system. The design of the non-penetrating clamp allows it to be installed anywhere along the length of the rib.

Kathy Miller, co-founder and CEO of Yes Solar Solutions in Cary, North Carolina, was enthusiastic about Replacements Ltd.’s plans for solar expansion. To Kathy and her husband Stew, this PV project was yet another opportunity for them to achieve what led them into this business in the first place: “preparing the next generation for a sustainable future.” It was also an opportunity to work side-by-side with a company as dedicated to the environment as they are. YSS fully understands the positive impact solar add-ons can have on companies and on their bottom line.

Never having worked with Replacements Ltd. before was no barrier to efficient operations. The team at Yes Solar includes experts in logistics, industry standards, and sourcing the highest quality materials and equipment. To ensure a smooth project timeline, Yes Solar enlisted the services of a distributor the company had successfully worked with on a number of prior occasions.

Design in hand, Yes Solar Solutions went to a trusted source for material acquisition. CivicSolar, with offices in California, Massachusetts, and Texas, offers a full selection of module, inverters, racking, and storage equipment for solar installation. Having partnered on other projects since 2016, Yes Solar’s director of operations, Rob Smith, reached out to CivicSolar looking for racking solutions for an extensive 1.32 MW rooftop project they had in the works. A solar project of this magnitude would require some logistics magic. Yes Solar arranged for all materials to ship directly to the jobsite. Mary Jane Gilliland, Account Manager from CivicSolar, worked closely with Yes Solar to ensure smooth shipments and consistent timelines.

Mounting the Solar Panels

Yes Solar Solutions provided a bill of materials for the project utilizing the IronRidge rail system and S-5! clamps. In order to provide the most advantageous quote for YSS, CivicSolar cooperated with S-5! and IronRidge to produce a pricing and logistical plan that steered Yes Solar towards success.

CivicSolar supplied all necessary metal roof attachment clamps to secure all racking system components and conduit lines for the rail system. During the installation, a plywood walkway was installed to protect the metal roof.

Coordinating lead times for large material quantities, Civic and Yes Solar Solutions worked closely to ensure smooth and predictable timelines on all deliveries involved in the project. All materials were shipped and delivered according to the anticipated timeline and the project was successfully installed on time. According to Stew Miller, co-founder and president of Yes Solar Solutions, “This project was a result of industry support, as the referral came from a utility scaled solar company. When we got the contract, there was a sudden shortage of solar modules, and another solar company helped us source the materials. It was a good example of how solar companies can work together to the benefit of a customer and the industry.”

The solar array on the Replacements Ltd. building needed an attachment solution that would not only ease installation, but also be low cost and lightweight. S-5! non-penetrating clamps achieved these requirements building a strong foundation of savings across the board for the entire project.

During clamp installation, a plywood walkway was also installed to help with crew safety as well as installation efficiency. By facilitating navigation, crews could inspect the roof, perform maintenance, and protect the existing metal roof.

S-5! clamps were selected because they met the demanding specs required by installation, and they have the rigorous testing data to back them up. The racking system components and conduit lines on the rail system are supported with S-5-H clamps. The clamps accommodate metal roof panels with a horizontal seam and do not penetrate the roof. The design of the clamp features two pieces, making it a perfect choice for this project, as it can be installed anywhere along the length of the rib.

Long-Term Outlook

The final result of Replacements Ltd. rooftop solar array project is a sight to see. Spanning three-quarters of the entire surface of the arena-sized shopping facility, or 200,000 square feet, the PV system will help the company save around $100,000 per year in electricity costs. The array is divided into four separate systems, all on the same roof. It is also the largest net-metered project in North Carolina, and excess power can be returned to the grid for credit.

TEAM

Owner: Replacements Ltd., Greensboro, North Carolina, www.replacements.com

Solar Installer: Yes Solar Solutions, Cary, North Carolina, https://yessolarsolutions.com

Distributor: CivicSolar, Boston, Massachusetts, www.civicsolar.com

MATERIALS

Clamps: S-5-H clamps, S-5!, www.s-5.com

Mounting System: IronRidge rail system, IronRidge, www.ironridge.com

Copper Dome Crowns Hancock Welcome Center at Liberty University

Hancock Welcome Center at Liberty University features a standing seam metal roof with a copper-clad dome in the center. Photo: NB Handy

When the Hancock Welcome Center at Liberty University was built, it was an ambitious new construction project with a very tight schedule. The three-story, 32,000-square-foot structure was designed and built by Glass & Associates of Lynchburg, Virginia. The Jeffersonian-style building features a standing seam metal roof with a copper-clad dome at the center. Finding a roofing contractor that could execute both systems on time was crucial.

Troy Brown, vice president and general manager of Craftsman Roofing in Lynchburg, Virginia, knew his company would be up to the challenge. At the time, the company was known as WA Lynch Roofing; the name was changed to Craftsman Roofing when it was purchased by its current president, Mitch Reaves.

Craftsman Roofing tackles all types of commercial roofing projects, including slate, metal, tile, and low-slope membrane systems, as well as some high-end residential work. According to Brown, the team at Craftsman thrives on unique, one-of-a kind projects, including new construction and restoration projects at churches and schools, so the company was uniquely suited for the challenges of the Hancock Welcome Center.

To meet the demanding schedule, crews worked on both roof systems at the same time, beginning the installation of the main standing seam roof while the dome was constructed on the ground. The standing seam roof system was manufactured from Sentriclad 24-gauge Galvalume in Dark Bronze, while the dome was comprised of 16-ounce copper flat-lock panels.

The Main Roof

According to Brown, the key to meeting the demanding schedule was the decision to erect scaffolding around the entire structure. Brown consulted with Darryl Glass, president of Glass & Associates, and they determined a fully scaffolded system would be the best way to ensure the safety of crews and speed the installation.

The eight-sided dome was completed on the ground and lifted into place after the flat-seam copper panels were installed. Photo: Craftsman Roofing

“The scaffolding was one of the big clinchers on this project,” Brown says. “Glass & Associates scaffolded the whole thing, and it allowed us to go much faster and work more efficiently on the roof.”

Coils of Sentriclad were supplied by NB Handy, and the snap-lock panels were roll-formed at the site. “We fabricated the panels on the ground and we had a lift bring them up to the scaffolding,” Brown says. “There was an extra bay where panels could be stacked. Each day, all of our material and gang box, drills and everything were right there, ready to go, so every morning we could just rock and roll.”

In addition to the scaffolding, the safety plan mandated that roofing crews on the sloped sections were tied off with safety harnesses. They worked strategically to get the roof system installed as efficiently as possible. “The roof is kind of a mirror image, both front and back,” Brown explains. “We worked from the outside edges to the inside, working on the front and back at the same time. Then all the gable ends started coming together so that where we ended was right at the dome.”

Crews left a narrow pathway around the dome so that portion of the project could be completed without damaging the panels. “The easy part was the roof,” notes Brown. “The hard part was the dome.”

The Dome

After a platform and the steel framing for the dome were erected on the ground, a separate crew installed the copper panels before the dome was lifted to the roof. The curving, eight-sided dome was covered with copper flat-lock panels. “There were transverse seams all the way up through it,” notes Brown. “You basically have an octagon, so at every corner you had to make sure you were at the same elevation all the way around. You had to get that right, and the framing guys had to have it right before we could even go to work.”

Photo: NB Handy

The interlocking flat-lock panels were custom fabricated from 16-ounce copper, as were the ridge caps. Work began on one side and continued on the exact opposite side, shifting from one side to the other until all eight sections were completed. “We shingled up to the top through the radius on each section, and those had to intersect left and right of each other, so that everything matched perfectly,” Brown recalls.

The dome was then lifted into place. “There is a hole at the top for the skylight, and they ran slings right down through it and lifted it with a crane,” Brown says. “They picked the entire copper bell up, hung it in the air, and Darryl Glass had a crew that would cut all of the steel out without burning the copper. We then dropped it into place, so we had to be on point with our flashing kits so everything would work out.”

Brown credits excellent planning and communication with the general contractor for the successful outcome. He commends Darryl Glass and his superintendent, Benny Tomlinson, for their expert use of scaffolding on the project, which aided roofing crews, as well as masons, painters and window installers. “They were really good with figuring out things scaffolding-wise, allowing us to have access with safety so we could move quickly and efficiently around the building,” Brown says. “We were committed to getting it done — to getting in, getting out, and getting out of the way so that other trades could get to work.”

Crews also installed an S-5! ColorGard snow retention system. The project was completed on schedule, and Craftsman Roofing is proud to have it in the company’s portfolio of successful projects. “We’re known in the area for doing a lot of standing seam, and we’re known for our ability to get things done,” Brown says. “We are also able to work with a team of general contractors, and they respect us for having a force that can get in there, solve issues that come up, and help get the project in on time with top-quality workmanship. We have changed names, but I’ve been with the company for 27 years, and we’ve demonstrated the same quality all of that time.”

TEAM

Architect and General Contractor: Glass & Associates, Lynchburg, Virginia, https://www.glass-associates.com

Roofing Contractor: Craftsman Roofing, Lynchburg, Virginia, www.craftsmanroofingva.com

Distributor: NB Handy, Lynchburg, Virginia, www.nbhandy.com

MATERIALS

Metal Roof System: Sentriclad 24-gauge Dark Bronze, Sentrigard, www.sentrigard.com

Copper Dome: 16-ounce copper flat-lock panels 

Snow Retention System: ColorGard Snow Rail, S-5!, www.s-5.com

Utility Mounting System for Metal Roofs

S-5! introduces the universal GripperFix utility system for standing seam, exposed-fastened, and trapezoidal metal roof profiles. Mount almost anything with this safe and cost-effective system that uses only struts, S-5! clamps or brackets and tabs. Install HVAC, satellite dishes, inverters, conduit, communication equipment, service walkways, light fixtures, and more without using improper materials that can compromise both the equipment and the integrity of the roof itself. Using concrete blocks for ballast is unsafe and causes destructive corrosion. According to the manufacturer, this all-aluminum and stainless system will last the life of the roof.

For more information, visit www.S-5.com