Complex Metal Roof Replacement Becomes Award-Winning Project

The main roof on the historic Dilley-Tinnin home was made up of multiple roof planes and featured an internal gutter. Photos: Texas Traditions Roofing

Located just outside of Austin in Georgetown, Texas, the historic Dilley-Tinnin home dates back to 1879. When it was struck by lightning, the main roof was damaged beyond repair. The original soldered, flat panel roof would have to be removed and replaced as part of a restoration project that posed numerous challenges.

The roof was made up of some 20 roof planes and included an internal gutter system, numerous penetrations, and multiple low-slope transitions. The new metal roof would have to be watertight and durable — and meet strict guidelines for historical accuracy.

Crews from nearby Texas Traditions Roofing were up to the challenge. They removed the damaged sections of the existing roof and installed a striking red standing seam metal roof manufactured by Sheffield Metals.

Michael Pickel, vice president of Texas Traditions Roofing, was called in to assess the damage. The original roof had a standing seam look to it in some sections, but it was comprised of metal panels that were soldered together. “It was metal 100 percent, from the fascia, to the gutter, to the flat portion, all soldered together into one piece,” he notes.

Crews from Texas Traditions Roofing removed the damaged sections of the existing roof and installed a red standing seam roof manufactured by Sheffield Metals.

The entire main roof area would have to be replaced, while the gray metal roof system on one wing was left in place. The main roof was comprised of multiple roof areas with slopes ranging from completely flat to pitches of 3:12 and 4:12. “It really wasn’t that steep, and that’s what caused us to recommend the double-lock panels,” Pickel says. “Given all of the soffits and all of the transitions, the slope required us to use a double lock.”

The Texas Traditions team worked for eight months with the local historical committee to ensure that the new roof would meet its guidelines. The committee approved the 2.0 Mechanical Standing Seam roof manufactured by Sheffield Metals, and the roof restoration work began.

The metal panels of the original roof were removed, along with most of the internal gutter. “The home was leaking pretty bad,” Pickel recalls. “There was some significant damage to the integral gutter, and we had to rebuild at least 80 percent of it. It was flat, and we added slope to it. It was a beast. We tore the whole thing off and came in with all manufacturer approved products: high-temp synthetic underlayment, high-temp ice and water, and the metal panels and butyl sealant.”

The existing roof was damaged by lightning. The soldered, flat panel roof had to be removed and replaced.

Most of the deck was in good shape, but the fascia needed extensive repairs. Extreme care had to be taken to protect the custom carpentry just below the eaves. “It was a crazy custom fascia,” Pickel notes. “We’ve never seen anything like it before.”

After the internal gutter was rebuilt, it was lined with a 60-mil TPO membrane from GAF. “We did a metal fascia, and it was also lined with TPO. It ran about 18 inches up behind the field panels to give it some added security. It was also lined with ice and water shield.”

The metal panels were roll-formed on the site. “Due to all the different lengths, we took measurements, rolled them on site, and applied them one at a time,” Pickel explains. “All of the trim and accessories were manufactured in our metal shop and brought to the site.”

Panels were lifted into place with a rope-and-pulley system and installed over Viking Armor synthetic underlayment and GAF StormGuard leak barrier. The re-roofed area was approximately 2,500 square feet, but the project was a labor-intensive puzzle. “It was a small project, but it was really cut up,” Pickel says.

Crew members were tied off 100 percent of the time at the eave and while installing the metal panels. “The nice part was it wasn’t too steep, and the lip of the integral gutter added another layer of safety as well,” Pickel explains. “From a safety standpoint, it was pretty basic; the steepest section was 4:12, and a lot of the work was done on the flat area.”

In the flat area, crickets were used provide adequate slope beneath the metal panels. The transitions made for some tricky details. “When you hit the low slope on metal — and that’s really 2:12 or less — you start to be more concerned about making sure you’re doing everything you can to get that water off that roof,” Pickel says. “If the water moves slowly, you have to do all you can to make sure that roof is fully sealed and ensure it just won’t leak.”

Crews tackled the challenges one at a time. “Just like any project, once you start to move on it, it gets a little bit easier,” Pickel says. “We learned a lot as we progressed. Each section made the next section a little bit easier.”

Texas Traditions submitted the project to Metal Roofing Alliance (MRA) for its Best Residential Metal Roofing Project competition, and MRA selected Texas Traditions Roofing and Sheffield Metals as the first-quarter winners in the category.

“When we got the news, we were just ecstatic,” Pickel says. “I think roofers are very proud of the work they do, and to get that recognition is fun and exciting. It also gets the team fired up.”

Pickel credits his company’s success to a simple formula: quality craftsmanship by talented and experienced crews. “One of our owners has been in construction for 40-plus years,” he says, referring to his father, Mike Pickel. “He handled multi-million-dollar commercial projects for a very large general contractor. His experience and ability to manage our jobs, educate our crews, and educate our superintendents helps out gain knowledge beyond the roof. There’s more to it than just the roof, and being mindful of the entire building is a huge advantage.”

For more information about how to enter MRA’s “Best Metal Roofing” competition for the trades, visit www.metalroofing.com.

TEAM

Roofing Contractor: Texas Traditions Roofing, Georgetown, Texas, www.texastraditionsroofing.com

MATERIALS

Metal Roof: 2-inch mechanical lock panels in Cardinal Red, Sheffield Metals, www.sheffieldmetals.com

Underlayment: Viking Armor synthetic underlayment, VB Synthetics, www.vbsynthetics.com

Leak Barrier: GAF StormGuard, GAF, www.gaf.com

Contractor Has the Right Prescription for Medical Office Building

Texas Traditions Roofing installed the metal and TPO roofs on the Pflugerville Parkway Medical Office Building, as well as the metal wall panels, soffit, fascia, gutters and downspouts. Photos: Texas Traditions Roofing

The Pflugerville Parkway Medical Office Building features a metal roof, a TPO roof, metal wall panels, soffit, fascia, gutters and downspouts. The new construction project was perfect for Texas Traditions Roofing, which prides itself on its versatility and quality craftsmanship.

Headquartered in Georgetown, Texas, the company handles a variety of commercial and residential work. “Residentially we do replacements and custom home new construction,” says Michael Pickel, estimator, Texas Traditions. “On the commercial side, we do mostly new construction, but we also do commercial repair and replacement as well.”

Pickel was the estimator on the project, but he feels the term “estimate” doesn’t begin to cover what his job entails. “We want to be the experts and provide all of the information for the general contractor, rather than just throwing an estimate at them,” he says. “We take that responsibility very seriously, whether it’s residential or commercial. We don’t necessarily like the word ‘estimate’ because it sounds like you’re guessing and just hoping it’s right. We understand that commercial new construction involves an estimate, but what we try to do is just be very specific and clearly define what we’re going to be doing, how we’re going to be doing it, and what the manufacturer and what the NRCA recommends us to do. That way nothing is incorrect, it’s not going to leak, obviously, and you have the backing of the manufacturer because it was installed properly.”

Multiple Systems

The scopes of work included two sections of metal roofing — a peaked section in the middle of the main roof and a shed roof off to one side of the building. A TPO roof system was applied over the main roof on either side of the metal roof in the center. “We started with the metal roofing panels on the top first, and then worked our way down to the lower section on the side,” Pickel notes. “Shortly after that, we came back and installed the TPO roof. It was pretty open, so it was fairly easy to put that down.”

The low-slope roof sections were covered with a 60-mil TPO system manufactured by GAF. Photos: Texas Traditions Roofing

The metal roof system manufactured by Sheffield Metals features 1.5-inch Snaplock 450 Panels in Ash Grey. Approximately 4,000 square feet of roof panels were installed over two layers of 2.2-inch polyiso insulation, which was mechanically attached. The underlayment used was Viking Armor from Viking Barriers.

The 6,000-square-foot low-slope roof was topped with a 60-mil TPO system manufactured by GAF. First, two layers of 2.2-inch polysio were mechanically attached to reach R-25. A tapered insulation system was then fully adhered across the entire roof to ensure proper drainage.

The safety plan utilized a Raptor safety cart, which was lifted to the roof with a SkyTrak. “The Raptor system was either on the left or right side of the roof, depending what side we were working on,” Pickel says. “Any time workers were on the roof, they were tied off.”

After the roofs were completed, the focus shifted to the wall panels. Berridge Vee Panels in Charcoal Grey were installed using a man lift. “We put Z-purlins down horizontally over the vapor barrier,” notes Pickel. “Then we installed the 1-inch, four-by-four mineral wool insulation, and attached our panels over that.”

Metal crews also installed 11-inch fascia across the entire edge of the roof, including both the metal and TPO sections. “There are some tricks involved with that because it was a fully tapered TPO system, so your height differences can vary,” Pickel explains. “Making sure the fascia wrapped smooth and properly, and was the proper height, was a little tricky.”

Gutters were not originally specified, but they were added at the suggestion of Texas Traditions. “We talked to the G.C. about talking to the owner because we felt they were going to want gutters,” Pickel recalls. “They came back to us and said they wanted gutters, so we issued a change order for it.”

The company installed 6-inch box gutters and four-by-four downspouts matching the metal roof.

A Challenging Schedule

The jobsite was relatively open, accessible and easy to navigate, so some typical problems that can crop up with new construction projects weren’t a big issue. The HVAC units were installed on a pad within a fenced-in area on the ground, minimizing roof penetrations as well as foot traffic on the roof. Crews were able to focus on doing the job right — and doing it safely. “Installation-wise, it wasn’t too tricky,” Pickel notes. “We just had to ensure that everything was installed to the manufacturer’s requirements.”

Manpower and scheduling posed the toughest hurdles, notes Pickel, but the general contractor, Lott Brothers of Austin, Texas, did a great job of keeping everyone on the same page. “We had weekly mandatory meetings that were set up by the G.C., and it was very helpful for us and other trades as well,” Pickel says. “Having to coordinate multiple trips is very common with new construction, unfortunately, but it’s great that we are able to do so much work. We did everything down to the gutters and downspouts — the full system — but it takes a lot of coordination and scheduling of the crews, especially when you have other jobs as well.”

One advantage of the multiple scopes of work was that Texas Traditions crews didn’t have to worry about coordinating transition details with crews from other companies. “It’s also nice for the owner,” Pickel adds. “If they have any issues or if they have any questions, they know the roofer did every bit of the metal on this job, and all of the TPO roof, and they know who to contact.”

Versatility is one of the company’s strengths, and for that Pickel credits the experience of the company’s owners, including his father, co-owner Mike Pickel, who has more than 30 years of experience in the construction industry, including 20 years working for a general contractor.

“He understands the complexity of coordinating multiple trades because he did it for so long from a G.C. perspective,” Pickel says. “His ability to know what needs to be done when allows us to be more effective and more efficient with our time. It allows us to be the expert in front of a general contractor because he was a general contractor. He worked with superintendents. He worked with multiple trades. His ability, knowledge and expertise within our company allows us to be the roofing expert.”

Texas Traditions strives to make the best use of that wealth of knowledge. “Each job is treated with care,” Pickel says. “It’s treated with expertise because it’s not just another job — it’s someone’s home, it’s someone’s office. We do apartment complexes, we do office buildings, we do residential homes, we do churches. Mike treats it with care, and it trickles down to everyone else to treat it with care as well.”

TEAM

Architect: Tim Brown Architecture, Austin, Texas, www.timbrownarch.com

General Contractor: Lott Brothers Construction, Austin, Texas, www.lottbrothers.com

Roofing Contractor: Texas Traditions Roofing, Georgetown, Texas, www.texastraditionsroofing.com

MATERIALS

Low-Slope Roof: 60-mil TPO, GAF, www.GAF.com

Metal Roof Panels: Snaplock 450 Panels, Sheffield Metals, www.sheffieldmetals.com

Underlayment: Viking Armor High-Temp, Viking Barriers, www.vikingbarriers.com

Metal Soffit Panels: FWP non-vented Soffit Panels, Sheffield Metals

Metal Wall Panels: Berridge Vee Panels, www.berridge.com

Sheffield Metals Offers New Color Visualizer

Sheffield Metals International (SMI) announced the launch of its new and improved Color Visualizer. The user-friendly tool allows home or property owners, contractors, architects, manufacturers, and other members of the industry to create detailed digital mock-ups of their projects. 

Users can choose from one of the sample pictures provided in the tool, or they can upload a photo of their actual home or property. From there, they can select between a wide variety of Sheffield Metals’ product options, including seam types, profiles, thicknesses, and colors, and apply each one to the defined metal roof, wall, and trim areas of the photo. 

Not only does the Color Visualizer protect a consumer’s investment, but it provides a realistic representation of the finished project. “We heard feedback from customers and others within the industry that they wanted a more advanced and interactive styling tool beyond small paint samples and color cards,” said Adam Mazzella, Vice President of Sheffield Metals. “With the new Color Visualizer, you can get a much clearer idea of what the roof, wall, or trim will look like as a specific color, rather than just imagining the result.” 

Users have the option to save, download, share, and print their project choices to help when comparing amongst different styles. Plus, unlike other color visualizing services, the Sheffield Metals Color Visualizer is entirely free to use. 

For more information and a walk-through tutorial, visit https://www.sheffieldmetals.com/Resources/Color-Visualizer.

Sheffield Metals International Launches New AIA Accredited Course

Sheffield Metals International, a member of Mazzella Companies and a distributor of coated and bare metal coil and sheet products, recently launched a new American Institute of Architects (AIA) accredited course for the architectural and design community. The Continuing Education (CE) course, titled “Portable Rollforming, Applicable Engineering & Installation Details,” provides design professionals with in-depth insights into the benefits of portable rollforming in standing seam metal roof and wall applications, including efficiency, flexibility, and sustainability.

Learning objectives include: 

  1. Define the benefits of portable rollforming. 
  2. Describe how to achieve a UL 90 Wind Uplift Classification or rating. 
  3. Explain the difference between when a metal panel manufacturer provides written test reports from a qualified testing and inspecting agency representing Underwriters Laboratories, Inc. (UL) versus providing a listing of the UL Construction Number(s). 
  4. Correctly specifying applicable uplift testing requirements based upon the project’s deck assembly. 
  5. Recognize the appropriate, cost-effective installation details to apply, based upon job-specific conditions. 

The presentation is hosted as a video on the Sheffield Metals website, lasts approximately one hour, and delivers one Learning Unit hour that includes teaching relevant to HSW (Health, Safety, Welfare) for both AIA members and non-members. All attendees will have their attendance recorded with the AIA and have the Learning Unit Hour applied to their record. The course is also applicable to state MCE (mandatory continuing education) licensure. 

“In addition to the online course, we’re offering a ‘Face-to-Face’ program that teaches the same topic to architects, designers, specification writers, project managers, and beyond who want us to come to their city,” said Lori Reynolds Morrow, Architectural Project Manager at Sheffield Metals. “The ‘Face-to-Face’ program offers the same Learning Unit hour and serves as a fantastic opportunity for firms to receive a more interactive, high-energy, and personalized presentation.” 

A Certificate of Completion is provided to “Face-to-Face” program attendees and to online participants who achieve an 80 percent or higher on the brief 10 question quiz at the end of the course. 

For more information, visit https://www.sheffieldmetals.com/ce.

Sheffield Metals Launches New Website

The Sheffield Metals website now suits PC and mobile users with a reactive interface design.

The Sheffield Metals website now suits PC and mobile users with a reactive interface design.

The Sheffield Metals website now suits PC and mobile users with a reactive interface design. The new website contains valuable information and documentation for architects, contractors, builders and homeowners. It also features a more comprehensive product line, including Coils and Sheets (COOLR Metal Roofing), Engineered Standing Seam Metal Roof and Wall Systems, Specialty Coil and Sheet Products (Zinc, Copper, Weathered Series, WeatherXL SMP and Vintage), Valspar Products, Rollforming Machines, Sheet Metal Fabrication Equipment, Accessories and Components, and more.

Features:

  • Reactive interface design allows easy navigation for PC and mobile users.
  • Revamped Engineering section features access to all of the available engineering for Sheffield Metals Standing Seam Metal Roofing and Wall panel profiles without a login.
  • Paint warranty request form allows the user to easily submit warranty requests direct from the site or via PDF.
  • Roof Color Visualizer features Sheffield Metals’ 50-plus colors and finishes.
  • Brochure downloads throughout the site.
  • Enhanced Resources page with videos, color cards, profile cut sheets, calculators and more.
  • Social media connectivity with Sheffield Metals and the Mazzella Co. family on Facebook, Twitter, LinkedIn and YouTube.
  • Careers page link featuring all the available positions at Sheffield Metals and the Mazzella Co.