McElroy Metal Moves into Manufacturing Plant and Service Center in Southeast Texas

McElroy Metal operations in Houston moved into a manufacturing plant and attached service center to better serve its large customer base in southeast Texas.

McElroy Metal operations in Houston moved into a manufacturing plant and attached service center to better serve its large customer base in southeast Texas.

McElroy Metal operations in Houston moved into a new manufacturing plant and attached service center to better serve its large customer base in Southeast Texas.

“We were able to improve efficiencies and increase capacity with the layout in the new manufacturing facility,” says Matthew Edwards, plant manager. “Ultimately, we’re able to turn around orders substantially quicker.”

The new manufacturing plant is 30,000 square feet and the service center is a 9,000-square-foot facility. The move was completed in early 2015 and the company celebrated with an open house.

Edwards says McElroy Metal customers doing business at the Houston Service Center are installing residential and architectural roofing as well as working on commercial projects. To serve these customers, the new service center, managed by Bill Harris, features most McElroy Metal profiles, including the 138T and 238T symmetrical standing seam profiles. The service center stocks large quantities of 24-gauge flat sheets in 29 colors, hardware and accessories and is set up to service walk-in customers of small, medium and large operations. With the convenience of being attached to the plant, large orders can be produced and delivered quickly.

The Houston facility also offers onsite roll forming with its purpose-built, fully self-contained truck, “Straight Shooter.” Designed to site form panels directly onto the roof, Straight Shooter can reach eave heights upwards of 30 feet and run continuous length panels up to 200 feet long. This unique service offers the 138T and 238T symmetrical standing seam panels, as well as 2-inch Maxima standing seam panels, a wide service area and the additional option of onsite curving.

Galvalume-coated Metal Roofs Will Last at Least 60 Years with Minimal Component Repair

The term “infrastructure sustainability” continues to gain importance because of rapidly increasing building infrastructure components around the country needing major repairs and/ or replacements. Consequently, roof maintenance or replacement materials and methods must last at least 60 years; consider LEED v4 from the Washington, D.C.-based U.S. Green Building Council. For more than 30 years, millions of square feet of Galvalume-coated roofs have resisted the atmospheric conditions to which they are exposed with little or no maintenance and are well prepared to continue protecting building interiors for more than 30 additional years. Material science and professional project engineering and installation prove Galvalume-coated metal standing-seam roofs will perform for that period of time.

This is a nine-year-old painted Galvalume roof in Alabama.

This is a nine-year-old painted Galvalume roof in Alabama.

MATERIAL SCIENCE

The first standing-seam metal roof was introduced by Armco Steel Corp., Middletown, Ohio, at the 1932 World’s Fair in Chicago. Armco Steel ceased doing business many years ago, but its standing-seam metal roof design has been adopted by all manufacturers in today’s commercial metal roofing market. The second longest-lasting introduction into this market was in the early 1970s when Bethlehem, Pa.-based Bethlehem Steel introduced a Zinc/Aluminum coating—now known as Galvalume—for carbon-steel metal roofs. This coating, applied to both sides of the steel coil, has been successfully used for the majority of metal standing-seam roofs ever since.

Since Galvalume was introduced, there have been several evaluations, reports and predictions as to how this product would “weather” the test of time. In 2012, the Chicago-based Metal Construction Association (MCA) and Olympia, Wash.-based Zinc Aluminum Coaters Association (ZAC) commissioned a study to perform forensic tests at 14 existing Galvalume standing-seam metal roof sites throughout the country in varying climates and precipitation pH. The average age of these roofs was more than 30 years at the time of testing.

Initially, the sites were selected based on temperature and humidity zones throughout the U.S. As the field results were processed, however, it became apparent the expected lives of these roofs were directly dependent on the precipitation pH levels with very little correlation to temperature and humidity. The building sites chosen were located in the following states:

  • Massachusetts (2 sites)
    This Galvalume roof in Missouri is nine years old.

    This Galvalume roof in Missouri is nine-years old.


    Ohio (3 sites)
    South Carolina (2 sites)
    Georgia (1 site)
    Colorado (1 site)
    New Mexico (1 site)
    Arizona (1 site)
    Oregon (1 site)
    Wyoming (2 sites)

The study was directed by MCA and three independent consultants and their firms, which managed and performed the field work: Rob Haddock of Metal Roof Advisory Group, Colorado Springs, Colo.; Ron Dutton of Ron Dutton Consulting Services LLC, Annapolis, Md.; and me and my firm Metal Roof Consultants Inc., Cary, N.C. This group, plus Scott Kriner, MCA’s technical director, authored the actual report, which was issued by MCA and ZAC in November 2014 and is available online.

The team harvested and analyzed actual field samples of Galvalume-coated metal standing-seam roof panel materials and sealants and examined all the individual roofs’ ancillary components. Finally, it created an experienced assessment of the roofs’ conditions and associated costs to replace.

PHOTOS: METAL ROOF CONSULTANTS INC.

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Fall-protection Attachment for Standing Seam

Fall Protection Distributors LLC has released its SSRA1, a patented, non-penetrating life-saving device.

Fall Protection Distributors LLC has released its SSRA1, a patented, non-penetrating life-saving device.


Fall Protection Distributors LLC has released its SSRA1, a patented, non-penetrating life-saving device. It consists of a solid 6061-T6 aluminum body with 12 stainless-steel set screws. The standard assembly also includes a 5,000-pound certified d-ring for single-man attachment. The SSRA1 weighs 4 1/2 pounds and installs with basic hand tools. It can be used for temporary or permanent attachment without penetrating standing-seam panels. The design, which works on more than 500 standing-seam panel profiles, allows for attachment of devices from various fall-protection manufacturers.

Union Corrugating Has Added Standing Seam Manufacturing Capabilities

As part of its strategy to continuously improve service levels and lead-times, Union Corrugating has added standing seam manufacturing capabilities to their Orange, Va. manufacturing facility. The new equipment makes Union’s Advantage-Lok II, SL 150 and ML 150 profiles.

“We have redefined our mission statement to be the most convenient metal roofing supplier in the industry, and as a result, we are investing heavily in expanding production capabilities at our plant locations to improve lead-times,” says Keith Medick, Union’s CEO. “The new machinery will significantly reduce lead-times for our customers in Virginia, West Virginia, Maryland and Delaware by eliminating the need for shipments from our Fayetteville, N.C. plant. Customers can now expect lead-times for standing seam to be only a few days, a significant improvement from the one to two weeks in the past.”

The profiles are popular in residential and light commercial applications and Union has experienced strong growth with these products in recent years. Below is a description of the profiles being manufactured:

  • Advantage-Lok II – 1-inch rib screw flange standing seam
  • SL 150 – 1.5-inch rib snap lock standing seam
  • ML 150 – 1.5-inch rib mechanically seamed standing seam

Projects: Office

DPR Construction, Phoenix

Eighty-two Daylighting Systems were installed in the renovated 16,533-square-foot building.

Eighty-two Daylighting Systems were installed in the renovated 16,533-square-foot building.

Team

Roofing contractor: Arithane Foam, Corona, Calif.
Architect/engineer: SmithGroupJJR, Phoenix
Daylighting systems distributor: Norcon Industries, Guadalupe, Ariz.

Roof Materials

Eighty-two Daylighting Systems were installed in the renovated 16,533-square-foot building, formerly an abandoned retail boutique at the corner of 44th Street and Van Buren in Phoenix.

“The use of the Daylighting Systems was an integral part of our sustainability and lighting energy savings plans for the renovated space,” says Dave Elrod, regional manager of DPR Construction, Phoenix. “The products are a cost-efficient solution to provide lighting since they nearly eliminate the need for artificial daytime lighting.”

In addition, the roof is composed of foam with an R-25 insulation value (approximately 4-inches thick) over plywood sheathing.

Daylighting systems manufacturer: Solatube International Inc.
Foam roofing manufacturer: Quik-Shield from SWD Urethane

Roof Report

DPR Construction is a national technical builder specializing in highly complex and sustainable projects. In less than 10 months, the design-build team researched, designed, permit-ted, and built a highly efficient and modern workplace with numerous innovative sustainability features.

In addition to natural daylighting, the office features an 87-foot zinc-clad solar chimney, which releases hot air from the building while drawing cooler air in; shower towers that act as evaporative coolers to regulate building temperatures; 87 operable windows designed to open and close automatically (based on indoor/outdoor temperatures); and two “vampire” shut-off switches to keep electrical devices (radios, cell-phone chargers, microwaves) from using plug energy when no one is in the office.

Access to the building was limited during construction. Spray foam roofing, which took about seven days to complete, had to be done in small quadrants because of the tight schedule as work was progressing in the other sections. The roofing workers were challenged by the barrel-shaped roof, which created footing difficulties, and the many penetrations that had to be flashed, including all PV support legs, Solatubes, skylights and HVAC penetrations. Work was completed in the middle of winter, so additional protections and efficiencies were required.

The circa-1972 building has been officially certified as a Net-Zero Energy Building by the Seattle-based International Living Future Institute through its Living Building Challenge program. It also has received LEED-NC Platinum certification from the U.S. Green Building Council, Washington, D.C.

PHOTOS: Ted Van Der Linden, DPR Construction

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A Standing-seam Roof Protects a Bank and Its Offices for the Long Term

Located on a high-traffic, signature intersection in Taylorville, Ill., Palmer Bank sought a timeless design that would visually represent its strength and stability to the community of just more than 11,000 people.

Design for the project was provided by The Redmond Co., Waukesha, Wis. The design team blended extensive detailing and profiling of the metal roof with a masonry façade to create an attractive prairie-style look.

Design for the project was provided by The Redmond Co., Waukesha, Wis. The design team blended extensive detailing and profiling of the metal roof with a masonry façade to create an attractive prairie-style look.

Design for the project was provided by The Redmond Co., Waukesha, Wis. The design team blended extensive detailing and profiling of the metal roof with a masonry façade to create an attractive prairie-style look.

“We clearly wanted to take advantage of the great location with a strong, timeless design,” says Andy Young, The Redmond Co.’s director of project development and construction manager on the project. “We presented two options to the bank regarding the roof … It was pretty unanimous that everyone liked the standing-seam profile look. We also liked the life-cycle cost of the roof since the bank plans to be the owner of this building for the long term.”

Installation of the standing-seam roof was completed by E.L. Pruitt Co., Springfield, Ill.

Installation of the standing-seam roof was completed by E.L. Pruitt Co., Springfield, Ill.

Installation of the standing-seam roof was completed by E.L. Pruitt Co., Springfield, Ill. The crew, which consisted of six tied-off workers, installed fascia, gutters, downspouts and soffit. Flashing components were custom-fabricated in E.L. Pruitt’s shop.

The metal is coated with ENERGY STAR-approved colors and is vented for optimal airflow, which greatly in-creases the roof’s longevity and energy efficiency. The metal was installed over roof-deck protection and a self-adhered underlayment.

The metal is coated with ENERGY STAR-approved colors and is vented for optimal airflow, which greatly in-creases the roof’s longevity and energy efficiency.

The metal is coated with ENERGY STAR-approved colors and is vented for optimal airflow, which greatly in-creases the roof’s longevity and energy efficiency.

According to Dallas Stephenson, E. L. Pruitt’s project manager, the roofing job took about six weeks to complete. He explains: “The most difficult part was doing all the seam layout because the product requires a progressive install, which means you can’t really start in the middle of the roof and work both directions. You have to start in a corner and work out of a corner and then work into a corner and then work back out of the corner.”

The metal was installed over roof-deck protection and a self-adhered underlayment.

The metal was installed over roof-deck protection and a self-adhered underlayment.

Stephenson notes symmetrically lining up seams on the bank’s dormers and then across the roof was challenging. “Once we got all that figured out—took all the measurements on the job site and confirmed them—it went fairly smoothly,” he says.

“We knew the many hips and valleys would be somewhat of an installation challenge, but the installer did a terrific job,” Young notes.

Stephenson is quick to return the compliment: “Scott Brooks, site superintendent, and Andy Young from The Redmond Co. did an excellent job of picking a good team to build Palmer Bank. Everything just worked out great!”

PHOTOS: Petersen Aluminum Corp.

Team

Roofing installer: E.L. Pruitt Co., Springfield, Ill.
Designer: The Redmond Co., Waukesha, Wis.

Roof Materials

Approximately 9,000 square feet of 24-gauge, 16-inch Snap-Clad panels and 2,200 square feet of PAC-850 Soffit Panels were utilized to meet the design objectives. The Snap-Clad panels were finished in Charcoal and the 0.032 PAC-850 Panels were finished in Slate Gray.
Panels’ manufacturer: Petersen Aluminum Corp.
Roof deck protection manufacturer: Deck-Armor from GAF
Underlayment manufacturer: Grace Ice and Water Shield

Sustainable Home Features a Metal Roof for Durability and Energy Efficiency

A Metal Sales roof system has been chosen to top an ambitious Net-Zero building. Ronda and Nigel Farrar chose to work with Metal Sales on their 3,000-square-foot home in Escondido, Calif. The home overlooks Lake Hodges and was designed to be a model for green design by utilizing commercially available green building products.

The Farrar's dream of achieving a Net-Zero energy design was realized with help from Metal Sales Manufacturing Corp.

The Farrar’s dream of achieving a Net-Zero energy design was realized with help from Metal Sales Manufacturing Corp.

The Farrars are the owners of the new home and its surrounding sustainable farm. The home is one of San Diego County’s first LEED Platinum homes and is ENERGY STAR qualified. Their dream of achieving a Net-Zero energy design was realized with help from Metal Sales Manufacturing Corp.

“We chose a metal roof for our home because it was a sustainable material with a long life expectancy,” explains homeowner Rhonda Farrar. “Compared to other non-metal roofing materials, a metal roof is more durable and lighter, resulting in structural savings when building. Metal roofing also makes our home safer in the event of an earthquake or fire. Due to the reflectivity and energy efficiency of the metal, the roof contributes to a comfortable, energy-efficient living space.”

The home features 5,000 square feet of 24 gauge Magna-Loc standing seam roof panels in Antique Patina from Metal Sales. More than 100 panel colors from Metal Sales are listed with ENERGY STAR and improve energy efficiency by reflecting sunlight. This provides an energy savings by reducing the amount of energy needed for cooling the home. The steel panels are also 100 percent recyclable and contain a high percentage of recycled material. Each of these factors contributes to the home’s LEED Platinum certification.

"We chose a metal roof for our home because it was a sustainable material with a long life expectancy," explains homeowner Rhonda Farrar. "Compared to other non-metal roofing materials, a metal roof is more durable and lighter, resulting in structural savings when building."

“We chose a metal roof for our home because it was a sustainable material with a long life expectancy,” explains homeowner Rhonda Farrar. “Compared to other non-metal roofing materials, a metal roof is more durable and lighter, resulting in structural savings when building.”

“The longevity, reflectivity and energy-efficient qualities of a metal roof make it an ideal choice for a sustainable home,” says Drew Hubbell, owner of Hubbell & Hubbell Architects. “The cool metal roof reflects heat, reducing cooling needs and allowed for easy installation of the photovoltaic panels without penetrating the roof. The standing seam roof also fit the architectural style of the home with an antique patina finish. The simple lines of the roof fit in with the modern design of the home and complements the home’s exterior.”

The project team consisted of homeowners Rhonda and Nigel Farrar; architect Hubbell & Hubbell Architects, San Diego; general contractor Gaitaud Construction, San Diego; and roofing contractor Victor Contracting & Roofing, Escondido. For more information about the Farrar Green Home and Sustainable Farm, visit the Farrar Green Home website.

One-piece Clamp Fits Standing-seam Panels with Horizontal Seams

The S-5-H90 is a one-piece clamp that was developed to accommodate metal roof panels with a horizontal seam greater than 0.65 inch.

The S-5-H90 is a one-piece clamp that was developed to accommodate metal roof panels with a horizontal seam greater than 0.65 inch.

The S-5-H90 is a one-piece clamp that was developed to securely and cost‑effectively accommodate metal roof panels with a horizontal seam greater than 0.65 inch.

Turning the clamp 90 degrees so that the bolt hole side is facing up, slip the clamp on the seam and tighten the setscrews. Go to the S-5! website for information about properly attaching S-5! clamps. After the clamp is installed, affix ancillary items using either of the two threaded bolt holes and bolt provided. The S-5-H90 is perfect for use with S-5! ColorGard and X-Gard snow retention systems and other heavy-duty applications.

The S-5-H90 Mini is a bit shorter than the S-5-H90 and has one setscrew and one threaded bolt hole rather than two. The mini is the choice for attaching all kinds of rooftop accessories: signs, walkways, satellite dishes, antennas, rooftop lighting, lightning protection systems, solar arrays, exhaust stack bracing, conduit, condensate lines, mechanical equipment—just about anything!*

The S-5-H90 and S-5-H90 Mini clamps are each furnished with the hardware shown to the right. Each box also includes a bit tip for tightening setscrews using an electric screw gun. The structural aluminum attachment clamp is compatible with all common metal roofing materials excluding copper. All necessary stainless steel hardware is included. Please visit www.S-5.com for more information including CAD details, metallurgical compatibilities and specifications.

The S-5-H90 clamp has been tested for load-to-failure results on a variety of horizontal standing seam roof profiles from leading panel manufacturers. The independent lab test reports can be found on the company’s website.

Metal Roofing Resembles Shake, Slate and More

Quality Edge has launched Matterhorn Metal Roofing, which is made from steel and available in four profiles: Shake, Slate, Tile and Standing Seam.

Quality Edge has launched Matterhorn Metal Roofing, which is made from steel and available in four profiles: Shake, Slate, Tile and Standing Seam.

Quality Edge has launched Matterhorn Metal Roofing, which is made from steel and available in four profiles: Shake, Slate, Tile and Standing Seam. A two-year development process resulted in carefully crafted splits, cracks and grains that mimic each profile’s natural counterpart. The shake profile features 21 individual shake designs to enhance the natural overall effect. In addition, Matterhorn’s patented fourpoint fastening system conceals the overlapping metal panels on slate and shake. All profiles have been tested to withstand hurricane-force winds up to 130 mph.

Research Study Shows Certain Metal Roofs Can Last at Least 60 Years

The Metal Construction Association (MCA) has released new research findings that conclude that certain metal roof systems can last at least 60 years, meaning they do not require replacement during a commercial building’s service life.

“This study is a breakthrough for the metal construction industry because it finally provides third-party, scientific data that backs up the long held stance that 55 percent Al-Zn coated steel standing seam roofing systems are very durable, economic, and can be better for the environment,” said Scott Kriner, Technical Director, Metal Construction Association. Most non-metal roofing systems require one or more full replacements within a typical building’s 60-year service life, which is costly and often adds to the solid waste stream in landfills.

The study, sponsored by MCA and the ZAC Association, was conducted with oversight of three independent consulting firms which analyzed low-slope, unpainted 55% Al-Zn coated steel standing seam roofing, in a wide range of environments across the U.S.

This type of roof material is known by many trade names throughout the world, principally GALVALUME and Zincalume in the United States. It is very common on low rise commercial buildings such as warehouses, schools, distribution centers, shopping centers, exposition halls and other facilities. Experts estimate that the market size for this type of low slope roofing in the U.S. is over 350 million square feet.

The study incorporates the results of multiple field inspections, independent laboratory analyses of metallic corrosion of the roof panels, components and sealants, and includes assessment of all integral ancillary components that impact the end of roof service life.

The research team selected 14 building sites in five climate regions of various geographies in the continental United States, exhibiting a spectrum of climates related to heat and humidity including Hot-Dry, Hot-Humid, Cold-Dry, Cold-Humid, and Moderate-Acid. The precipitation acidity also varies considerably from one site to the next over this broad geography.

The research study concluded that the expected service life of an unpainted 55 percent Al-Zn coated steel standing seam roof constructed today in a wide range of environments using best practices can be expected to be in excess of 60 years, a value that equals the assumed building service life as described in the USGBC’s Leadership in Energy and Environmental Design building rating program, version 4.

In the study, the steel panel roofs experienced corrosion rates that conservatively project service lives well beyond the service life of most buildings. The range depends on the climate and the local precipitation pH.

The study also confirmed that these types of metal roofs resist corrosion even in “weak” spots, such as sheared edges and panel profile bends. Inspections showed an absence of significant red rust after up to 35 years, indicating exceptional corrosion resistance in areas susceptible to exhibiting the first signs of corrosion.

The study acknowledges that all roof systems require a regular maintenance program (at least annually) to clean off debris and to inspect the condition of the roof in order to achieve the kind of service lives shown in this study. While low-slope steel standing seam roof systems were projected to last up to 60 years, ancillary components (such as fasteners) may need to be replaced during the roof life, but this represents significantly less than 20% of a total roof replacement cost.

“We are planning to conduct more studies on different types of metal roofing, and in some cases we expect similar or even better results in terms of roof service life,” adds Kriner. “We think these studies will help to motivate building owners and architects to specify metal roofing more often.”

The report was authored by Ron Dutton, Ron Dutton Consulting Services LLC; Rob Haddock, Metal Roof Advisory Group; Chuck Howard, Metal Roof Consultants and Scott Kriner, Metal Construction Association. The report was also peer reviewed by Morrison Hershfield laboratory in Canada.