Synthetic and Peel-and-Stick Underlayments for Metal Roofing

HydraShell MAX and HydraShell Supreme SA are McElroy Metal’s new underlayments. HydraShell MAX is the standard synthetic underlayment and HydraShell Supreme SA is a peel-and-stick underlayment. HydraShell MAX has a four-layer construction and can be used under all types of finished roofing materials, including steel roofing and is suitable for roof pitches as low as ½:12. HydraShell MAX requires significantly fewer fasteners than competitive products and provides a durable deck cover. HydraShell Supreme SA is the best choice in high-temperature, self-adhering applications. The SBS modified asphalt provides excellent pliability and the cool gray surface reduces heat build-up. 

For more information, visit www.mcelroymetal.com.

Granulated Self-Adhered Roofing Underlayment Features Slip-Resistant Surface

RhinoRoof Granulated Self-Adhered Roofing Underlayment The RhinoRoof brand of synthetic roofing underlayment now includes comprehensive roof deck protection. Comprised of the most advanced formulations for self-adhered roofing technology, new RhinoRoof Granulated Self-Adhered Roofing underlayment features a granulated, slip-resistant surface. The new synthetic underlayment offering complements contractors’ safety programs by providing a slip-resistant surface material on roofs of varying slopes. When paired with RhinoRoof U20 synthetic underlayment, the Granulated Self-Adhered Roofing Underlayment provides a system approach to protecting the entire roof deck against ice dams and wind-driven rains.

“RhinoRoof Granulated Self-Adhered Roofing Underlayment provides protection in the most vulnerable areas of the roof such as eaves and valleys,” said Jim Stange, Product Manager for Self-Adhered Underlayment. He noted the “peel and stick” product offers excellent adhesion across a broad temperature range. “The new granulated self-adhesive underlayment has been tested for adhesion at 40F and 75F and exceeds D1970 standards,” he said. The product can be left exposed for up to 30 days. Even at cold temperatures, the RhinoRoof® Granulated Self-Adhered Roofing Underlayment adheres to the roof deck, supporting flexible installation during seasons when temperatures can fluctuate widely.

Accroding to the company, multiple features contribute to the performance of RhinoRoof Granulated Self-Adhered Roofing Underlayment. The granulated surface features a 3-inch taped selvage edge and a polymer modified asphalt backing. The split sheet peel-away release liner facilitates easy installation on a broad range of roof designs. The product is packaged in a shrink-wrapped poly-sleeve, making it less susceptible to damage from the elements and easy to carry on the jobsite.

For more information, visit www.eavetopeak.com.

Metal Roof and Wall Panels Capture the Spirit of Shakespearean Theater

The Otto M. Budig Theater is the home of the Cincinnati Shakespeare Company. The new theater was designed by GBBN Architects in Cincinnati. Photos: Petersen Aluminum Corp

For many new arenas and theaters, the sheer size and scope of the project can pose the biggest hurdles. At the new Otto M. Budig Theater, home of the Cincinnati Shakespeare Company, the problem was the reverse. The intimate theater was shoehorned into an existing space up against an adjacent building, so logistics were tight. But that didn’t mean the roof system couldn’t be striking. Designed by GBBN Architects in Cincinnati, the building’s exterior features daring angles and multi-colored metal roof and wall panels that combine to help capture the spirit of the Shakespearean theater.

Matt Gennett, senior project manager and vice president of Tecta America Zero Company in Cincinnati, oversaw the roofing portion of the new construction project in the Over the Rhine section of Cincinnati on the corner of Elm Street and 12th Street. “This building was plugged in downtown, and they fit everything in real tight,” he says.

Approximately 5,400 square feet of PAC-CLAD 7/8-inch, 24-gauge Corrugated Panels from Petersen Aluminum Corp. were installed on the metal roofs and walls. Tecta America Zero Company installed the metal roof systems, as well as a TPO roof manufactured by Carlisle SynTec over the main structure and mechanical well. Work began in January of 2017 and the roofing portion of the project was wrapped up in late August.

The Metal Roof System

The building features two different metal roof systems. The roof on the Elm Street side is comprised of three intersecting triangle-shaped sections in two colors, Champagne Metallic and Custom Metallic Bronze. “There were several unique angles on the roof,” Gennett explains. “On the top, there was a second metal roof, a shed roof that went down to the 12th Street side.”

The theater’s roof and walls feature approximately 5,400 square feet of PAC-CLAD 7/8-inch Corrugated Panels from Petersen Aluminum Corp. in two colors. The wall panels are perforated. Photos: Petersen Aluminum Corp.

The metal roof systems were installed over a 2-inch layer of polyisocyanurate insulation and a 2-1/2-inch nail base from Hunter Panels, H-Shield NB. The nail base is a composite panel with a closed-cell polyisocyanurate foam core, a fiber-reinforced facer on one side and, in this case, 7⁄16-inch oriented strand board (OSB) on the other. The nail base was topped with Carlisle WIP 300 HT waterproofing underlayment to dry in the roof.

Crews also installed two rows of snow guards on the metal roof using the S-5! CorruBracket. “The snow guard was a little different,” Gennett says. “It was specifically designed for a corrugated roof.”

The TPO Roof System

The main roof and mechanical well were covered with the TPO roof system, which totaled approximately 8,300 square feet. After Carlisle VapAir Seal725 TR self-adhering air and vapor barrier was applied to the metal deck, crews installed two layers of 2-inch iso. Tapered insulation was applied over the top to ensure proper drainage. The insulation was covered with a 1/2-inch sheetrock and the 60-mil TPO was fully adhered.

Two large smoke hatches manufactured by Bilco were installed over the stage area. The ACDSH smoke hatches measured 66 inches by 144 inches, and are designed for theaters, concert halls and other interior applications that require limiting noise intrusion.

The Installation

The initial focus was to get the roof dried in so work could progress inside the building. The jobsite conditions posed a few challenges. The structure abutted an existing building, and the space was tight. The schedule necessitated multiple trips to the site, which can be a budget-buster on a small project. “We had a lot of trips in and out to accommodate the schedule and get everything dried in so they could meet the interior schedule,” notes Gennett. “We were sort of on call. We made three or four trips out to roof this small project, so it took a lot of coordination because it was completed in pieces.”

Crews tackled the TPO roof sections first. The mechanical well section provided several challenges. Changes in the mechanical well layout necessitated moving some curbs and making adjustments to the tapered insulation. “They were trying to get lot of equipment into a small space,” Gennett explains. “We had to make sure we could get the water to the low spots and route it around all of that equipment. That was probably the biggest challenge on the project.”

Staging material was also problematic, as traffic was heavy and parking space was at a premium. Material was loaded by a crane, which had to be set up in the street. “It’s a postage stamp of a site,” says Gennett. “This is a main thoroughfare, and there is a school right across the street. We had to work around school hours, and we couldn’t be working when the busses were coming in. We usually came in after school started, around 8 a.m., to load materials.”

When it came time to load the metal panels, the cramped jobsite actually paid off. “It was very convenient,” Gennett recalls. “We were able to load the panels onto the adjacent roof and just hand them over. We had a nice staging area for cutting, so all in all it wasn’t bad.”

The corrugated panels were installed with matching edge metal. “It’s not a complicated panel to install, and they look really nice,” Gennett notes. “On the Elm Street side, to the right of the valley was one color, and to the left was another, so we had to match the color with our coping. There were some interesting transitions with our metal. We also had to really pay attention to how the siding was being installed so we could match the metal to the siding and follow the transitions from color to color.”

The perforated wall panels were installed by ProCLAD Inc. of Noblesville, Indiana. “Once the walls were done, we came in and did the transition metal,” Gennett says. “We just had to make sure everything lined up perfectly.”

Planning Ahead

Ensuring a safe jobsite was the top priority for Tecta America Zero and Messer Construction, the general contractor on the project. “Both Messer Construction and Tecta America take safety very seriously. That’s why we’re good partners,” Gennett says. “We had PPE, high-visibility clothing, hard hats, safety glasses for the whole project. All of the guys were required to have their OSHA 10. Anyone outside of the safety barriers had to be tied off 100 percent of the time.”

Planning ahead was the key to establishing the safety plan and meeting the schedule while ensuring a top-quality installation. “This job had a lot of in and out, which is tough in the roofing business,” Gennett says. “But we planned ahead, we made sure everything was ready for us when we mobilized, and we did a good job of coordinating with the other trades. It took a lot of meetings and discussions — just good project management.”

Gennett credits the successful installation to a great team effort between everyone involved, including the general contractor, the subcontractors, and the manufacturers. “We pride ourselves on our great, skilled crews and our great field project management,” he says. “Our superintendents are there every day checking the work and making sure the guys have everything they need. Messer Construction is great to work with, and obviously having the manufacturer involved the project and doing their inspections as well helps ensure the quality meets everyone’s standards and holds the warranty.”

The theater is now another exciting venue in the Over the Rhine neighborhood. “It is really cool spot,” Gennett says. “It’s an up-and-coming neighborhood that’s grown in leaps and bounds in the last seven years. There is a ton going on in Cincinnati. It’s just another part of the city that makes it really fun to go downtown.”

TEAM

Architect: GBBN Architects, Cincinnati, Ohio, www.gbbn.com
General Contractor: Messer Construction, Cincinnati, Ohio, www.messer.com
Roofing Contractor: Tecta America Zero Company, Cincinnati, Ohio, www.tectaamerica.com
Wall Panel Installer: ProCLAD Inc., Noblesville, Indiana, www.procladinc.com

MATERIALS

Metal Roof:
Roof Panels: PAC-CLAD 7/8-inch Corrugated Panels, Petersen Aluminum Corp., www.pac-clad.com
Wall Panels: PAC-CLAD 7/8-inch Corrugated Panels, Petersen Aluminum Corp.
Nail Base: H-Shield NB, Hunter Panels, www.HunterPanels.com
Snow Guards: CorruBracket, S-5!, www.S-5.com
Waterproofing Underlayment: Carlisle WIP 300 HT, Carlisle SynTec, www.CarlisleSyntec.com

TPO Roof:
Membrane: 60-mil grey TPO, Carlisle SynTec
Waterproofing Underlayment: Carlisle WIP 300 HT, Carlisle SynTec
Smoke Hatches: ACDSH Acoustical Smoke Hatch, The Bilco Co., www.Bilco.com

Striking Asphalt Shingle Roof Tops the Restored Music Hall in Cincinnati

Originally designed by Samuel Hannaford in the 19th Century, the Music Hall first opened its doors in 1878. The Music Hall Revitalization Company coordinated the restoration of the 139-year old Cincinnati landmark, which just reopened to the public Oct. 6, 2017.
Photos: CertainTeed

The Cincinnati Music Hall is considered one of the largest and most beautiful concert halls and theaters in the world. It has played host to iconic performances and events for more than a century, from the 1880 Democratic National Convention to performances that helped shape the American arts scene.

A vision and product of 19th century architect Samuel Hannaford, Music Hall—as it’s known across the Queen City—first opened its doors to the public in 1878. Yet the doors on the 225,000-square-foot facility have been closed since May 2016 to allow for a complex interior and exterior restoration effort that would propel the aging building into the modern era while also preserving its beautifully unique characteristics.

The Charge

Restoring the beauty of Hannaford’s showpiece was more than a simple facelift. According to the Music Hall Revitalization Company, the nonprofit coordinating and leading the renovation, engineers investigating the building discovered structural deterioration beyond what one would expect in a 139-year old building, and recommended actions secure the Music Hall’s long-term viability.

The $135 million Music Hall renovation began in the spring of 2016, with the Cincinnati Center City Development Corporation (3CDC) overseeing construction. Following a rigorous request for proposals, 3CDC chose Imbus Roofing to install the new roof.

The Music Hall has been traditionally adorned with high-end shingles, and Grand Manor luxury asphalt shingles from CertainTeed were chosen to replicate the slate aesthetic and stand up to the elements. Photos: CertainTeed

Principal Daniel Imbus and his team were more than up to the task. Not only had Imbus Roofing performed the bulk of the roofing work at Music Hall over the past few decades, they have a rich legacy in the greater Cincinnati area. Among the other high-profile projects with connections to Imbus roofing are the Proctor & Gamble Twin Towers, the Walnut Hills Copper Dome, Paul Brown Stadium and the original Riverfront Stadium.

The team at Imbus worked closely with 3CDC, PWWG Architects and local distributor Midwest Roofing Supply to nail the aesthetic and capture the original essence of Music Hall.

“The roof replacement was a big part of the project, not only for protecting all the interiors that were being restored or replaced, but for the overall look of the building,” Imbus explains. “With the older building and the amount of other work being performed, just getting around the building and scheduling work around other trades such as painting, masonry, HVAC, etc., required a lot of planning.”

The Installation

Imbus partnered with Seth Dorn, branch manager at Midwest Roofing Supply, to find the appropriate materials to for the front towers, Corbett Tower, and Opera House portions of the roof. According to Dorn, the Music Hall has been traditionally adorned with high-end shingles, so they chose Grand Manor luxury asphalt shingles from CertainTeed to replicate the slate aesthetic and endure the wind, rain, snow and other elements typical to Cincinnati. To recreate the distinctive striped pattern of the roof, crews installed approximately 600 squares of Grand Manor shingles in two colors, Stonegate Gray and Brownstone.

The roof’s distinctive striped pattern was recreated with 600 squares of Grand Manor shingles in two colors, Stonegate Gray and Brownstone. Photos: CertainTeed

“We serviced Imbus Roofing with all potential materials for the project,” Dorn notes. “In addition to the shingles, we supplied DiamondDeck and WinterGuard underlayments from CertainTeed to further enforce weather protection.”

A large part of the roof replacement was the Main Hall, which sits above lower sections of the building and has a steep slope. To perform this installation, the Imbus Roofing team had to build scaffolding along the full gutter lines to provide safe and secure roof access and work platforms.

“With the steep slope of the roof, the shingles are an integral part of the exterior look of this historic building,” says Imbus. “It’s an introduction to the amazing interior renovation and exterior restoration.”

The Reopening

The project, more than seven years in the making, was completed on Oct. 1, 2017. The doors officially re-opened on Oct. 6 to kick off a weekend of events that included an opening night gala, a community Open House, and a pair of concerts featuring the Cincinnati Symphony Orchestra.

“It looks awesome,” reflects Dorn. “We will spotlight this job for all of our contractors and customers.”

“We had a great experience with this project,” Imbus adds. “It was a quick schedule with a lot of work to a signature building of Cincinnati. It is great being a part of a successful project that I think will impress everyone in the community.”

TEAM

Developer: Cincinnati Center City Development Corporation (3CDC), Cincinnati, 3CDC.org
Architect: PWWG Architects, Pittsburgh, PWWGgarch.com
Project Coordinator: Music Hall Revitalization Company, Cincinnati, Musichallcincinnati.org
Construction Manager: Messer Construction, Cincinnati, Messer.com
Roofing Contractor: Imbus Roofing, Wilder, Kentucky, Imbusroofing.com
Local Distributor: Midwest Roofing Supply, Cincinnati, Midwestroofingsupply.com

MATERIALS

Steep-Slope Roof System: Grand Manor luxury asphalt shingles, CertainTeed, CertainTeed.com
Underlayments: DiamondDeck and WinterGuard, CertainTeed

Orlando Airport Project Necessitates Custom Fabrication, Precise Installation

 

Work on the first phase of the Orlando International Airport expansion project includes the South Airport Intermodal Terminal Facility and APM Complex, which features a standing seam metal roof

Architectural Sheet Metal Inc. has been in servicing the Orlando area for more than 23 years, specializing in commercial metal roofs and wall systems, primarily new construction. When Matthew Leonard, the company’s vice president, found out that the Orlando International Airport was proposing a new terminal project with a metal roof, he jumped at the chance to submit a bid.

He wanted to land the job because it would be the largest project the company has ever tackled, and one of its most prominent. He also wanted it for another reason—he knew he’d see it every time he drove to the airport. “For many years now, we’ve specialized in standing seam metal roofs. It’s our bread and butter,” he says. “We’ve done lots of schools, government building, military bases. It’s just something we enjoy doing. When this project came around, right here in our backyard, we knew we wanted to take it on. It’s larger than anything we’ve ever done, but it’s our specialty.”

The South Airport Intermodal Terminal Facility and APM Complex is a new construction project that coordinates mass transit for the airport, including regional rail systems and the Automated People Mover (APM). It’s part of the first phase of an ambitious $2 billion plan to almost double the size of the airport.

Architectural Sheet Metal installed the Berridge standing seam metal roof system, as well as internal aluminum gutters and a custom-fabricated aluminum bullnose that runs along the perimeter of the roof

The building encompasses approximately 200,000 square feet, and the structure is primarily covered with a standing seam metal roof. The scope of work for Architectural Sheet Metal included installing the metal roof system and internal aluminum gutters. It also included custom fabrication and installation of an aluminum bullnose that runs along the perimeter of the roof. “Every roof is radiused, and some sections have compound double raiduses,” Leonard notes. “The trickiest part of the project is probably the bullnose because all of the gable ends of the roof are radiused, and the large bullnose has to be welded on in 30-foot sections.”

Another tricky thing about the project is that the work was divided into two different contracts with two different construction managers. On one side of the building, which houses the monorail and parking garage, the project is overseen by Hensel Phelps, and on the other side, which handles the train lines, the construction is overseen by a Turner-Kiewit joint venture. The dividing point is a building expansion joint that runs across the middle of the roof. “We’re one of very few subcontractors out here that has a contract with both of the construction managers,” Leonard says. “They both have their own agendas, their own timelines, and their own completion dates, and it was a delicate balancing act working with the two of them.”

Installing the Roof

The roof system was designed to unify the elements of the structure and tie the building together. Some sections of the roof cover the building, while others serve as canopies, so there are two types of metal deck on the building. “The area we call the spine has a 3-inch-thick acoustical deck,” Leonard explains. “That was interesting because before we could put our 6 inches of polyiso on, we had to install batten insulation in the flutes. The acoustical decking is perforated, so you can see through it. That’s a little different, when you’re so high up. It spooked the guys at first to be able to see right through it.”

Crews dried in the entire roof with a waterproofing underlayment from MFM Building Products specifically designed for high-temperature applications.

The other sections were comprised of standard type B metal deck. Sections covering the interior were insulated, while canopy sections were covered with 5/8-inch DensDeck from Georgia-Pacific.

Crews from Architectural Sheet Metal dried in the entire roof with a peel-and-stick waterproofing underlayment from MFM Building Products specifically designed for high-temperature applications, MFM Ultra-HT. “It’s easy to install,” notes Leonard. “That’s our go-to underlayment for metal projects.”

After the underlayment was applied, the welded aluminum gutters were installed. “The longest piece was 78 feet,” says Leonard. “We fabricated the sections, water-tested them and shipped them out. We used a crane to lift them to the roof.”

The roof system was supplied by Berridge Manufacturing, and the 24-gauge galvalume metal panels were roll formed at the site. “Berridge has a ZEE-Lock double-lock standing seam panel,” Leonard says. “We own one of their portable roll formers, and we have it on site here. We pick it up with a crane, and lift it up to the edge of the roof, and we actually roll form our largest panels straight out to the roof. The guys just catch the panels as they come out of the roll former.”

Metal roof panels were roll formed at the site. For most roof sections, the roll former was hoisted by a crane, to the edge of the roof, and crew members stacked the panels as they come out of the roll former.

Panels were stacked in piles of 10 for installation. There were 12 different roof surfaces, so as the roll forming crew moved along, other crews would start installing the panels. “Every stack was tied down with strapping to ensure that it wasn’t susceptible to wind,” Leonard points out. “With a hurricane in the forecast, we were very careful about that.”

The panels in the spine area had a tighter radius, so those panels were formed on the ground using separate curving machine. Lining up the panels perfectly was critical. “With a radiused roof, it’s sometimes harder to find things to measure off to ensure your panels are straight. This panel is a left-to-right system. It’s a male-female overlay with a continuous clip that Berridge manufactures. The panels are hand-crimped together, and then you do the first and second stage of the double-lock panels with an electric seamer. You just turn it on and it goes up and over.”

Details, Details

Fall protection posts were installed during the framing process, which helped with safety planning but posed problems when it came to detailing. “It’s nice to have permanent fall protection points to tie into, as everyone had to be 100 percent tied off, but there are close to 200 fall protection posts on the project that we had to cut around and flash,” Leonard says. “I’ve never seen so many posts on a roof like that.”

The aluminum bullnose was constructed after precise measurements were taken at the site. After they were custom painted to match the roof, the 30-foot sections were lifted into place and installed.

Because the posts were tied into the structural steel and couldn’t be moved, the company designed and manufactured a welded aluminum flashing detail to ensure they all looked the same no matter where they landed in the panel profile. “We set up a welded aluminum flashing that should last forever, and it’s welded, so it shouldn’t leak. We try to go above and beyond in our flashing details.”

Leonard points to his company’s fabrication experience as a key to its strength. “We try to be more than just a roofing company,” he says. “We try to be a custom metal fabrication company that fabricates the panels to precise specifications determined by the site. We custom fabricate metal and then, as roofers, we install it. We like to have that double whammy. Not many people have that ability to do both.”

The company’s expertise came in handy on the bullnose. “The bullnose was originally bid as 22-gauge metal,” he says. “We looked at it and we didn’t like it. It’s a large, 9-inch radius, and we felt the thin, light-gauge metal would shake in the wind. Every 10 feet would be a lap joint with caulk, which would be susceptible to wind damage. We came up with the idea of using a welded piece of .080 aluminum. Once it was approved, we purchased a 100-ton press brake with a custom die to fabricate this bullnose.”

The bullnose was constructed from precise measurements taken at the site. “We took the radius off of the building and created jigs in our warehouse,” Leonard explains. “We welded pieces together in 30-foot sections, and we shipped them to a local painter who coated them with baked-on Kynar to match the roof.”

The bullnose was designed to hook into the gutter strap and wrap around onto the fascia, where it is screwed into the framing. In areas where there is no gutter, sections of the bullnose are equipped with a larger flange with an S-hook built into it to attach it to the roof. Corner pieces tie it all together.

Watching Out for Irma

Dealing with two different GCs was challenging, in part due to changes in the schedule. “Originally, we were supposed to finish one side first and then start the other side, but both phases of the project ended up starting around the same time,” says Leonard. “This doubled the manpower we needed on the job.”

Photos: Aerial Innovations

For changes like the bullnose, Architectural Sheet Metal had to make sure RFIs were submitted and approved by both sides. “Sometimes it was hard to keep track of who we submitted it to, but it worked to our benefit at times. Once it was approved by one side, it was easily approved by the other.”

The schedule had the crews working in hurricane season, and precautions were taken to make sure the job site was prepared for high winds. “When Hurricane Irma was approaching, I checked every single weather update every day until it made landfall,” Leonard recalls. “It hit on a Monday, and a full week ahead of that we were cleaning the roofs and preparing the gutters. We removed all debris on the jobsite because any trash on the roof could clog the downspouts. We added more and more men to the process throughout the week, and we shut the jobsite down on Wednesday. We took all of the material we had, stacked it, bundled it together, and we were able to move it all inside the building. We were pretty well complete on the Hensel-Phelps side, and Turner Kiewit brought in 40-foot Conex boxes for us to put our material in and secure it. They tried really hard to make sure the jobsite was secure.”

As the storm progressed, it deviated from the projected path, and no one could be certain which direction the winds might be coming from. “We just had to start battening everything down,” Leonard recalls.

Photos: Architectural Sheet Metal Inc.

Stacks of panels on the roof that were not yet installed were strapped every 2 feet on center. The entire state was in emergency mode, making things difficult. “For four or five days before the storm even hit, we couldn’t find water, rope and extension cords. Grocery stores were running out of supplies. Gas stations were running out of gas.”

After the storm passed, Leonard breathed a sigh of relief. The roof wasn’t damaged. The panels that had already been installed were in great shape, and the uninstalled panels weren’t harmed.

Elements like the weather are beyond anyone’s control, and Leonard notes his company tries to control as many variables as it can. “We have full control over the actual fabrication of the material and the quality of it,” he says. “When I call something in, I talk to our guy who works with me. Our company oversees it. Every morning I stop by the shop and follow up on the process on the way to the job site. We install it. I can make sure everything is OK.”

The project is nearing completion, and Leonard can’t wait to finish a landmark project he’ll see every time he makes a trip to the airport. “You can’t miss it,” he says. “It’s huge.”

TEAM

Architect: HKS Architects, Orlando, Florida, HKSinc.com
General Contractors: Hensel Phelps, Greeley, Colorado, HenselPhelps.com; and a joint venture between Turner Construction, Orlando, Florida, Turnerconstruction.com, and Kiewit, Sunrise, Florida, Kiewit.com
Metal Roofing Contractor: Architectural Sheet Metal Inc., Orlando, Florida, ASMfl.com

MATERIALS

Standing Seam Metal Roof: Berridge Zee-Lock Double-Lock, Zinc-Cote, Berridge Manufacturing, Berridge.com
Underlayment: MFM Ultra-HT Wind & Water Seal, MFM Building Products, MFMbp.com
Cover Board: DensDeck, Georgia-Pacific, Buildgp.com

Ultra-Steep Slope Roof Poses Challenges in Historic Church Re-Roofing Project

Century Christian Church is a landmark building in Owensboro, Kentucky. Completed in 1963, the church is included on the Kentucky Historic Register and recognized for its unique architectural style.
Photos: Owens Corning

At Century Christian Church in Owensboro, Kentucky, it is not the steeple that points toward the heavens above, but rather the entire roof. The church’s 50/12 pitch roof has become one of the most distinguishing features in the local landscape.

Completed in 1963, Century Christian Church is included on the Kentucky Historic Register and recognized for its unique architectural style. In fact, the roof is so eye-catching that it has been incorporated into the church’s website message which reads, “Our roof reaches up; our hearts reach out.” The roof ascends 40 feet and is divided into four quarters or “bows,” with each symbolizing one of the four Gospels in the Bible.

In 2016, the church’s building committee realized it was time for a new roof. Located in an open field apart from other structures, the roof had been struck by lightning on several occasions. The protective cable that ran down the sides of the church as a conduit for lightning strikes had been eroded and just one section of cable was intact. The building’s location also presented airflow challenges. Storms and strong winds crossing the field had caused shingles to loosen and fly off the building.

According to Harold King, a member of the Century Christian Church building committee, the church considered several criteria when selecting All American Home Improvement, LLC in Evansville, Indiana, to complete the re-roofing project. “We wanted a reputable company who was experienced in doing steep slope work, had an excellent safety record, and had a workforce equipped to meet the needs of this labor-intensive job,” he says, adding that the

The roof ascends 40 feet and is divided into four quarters or “bows,” with each bow symbolizing one of the four Gospels in The Holy Bible. Photos: Owens Corning

company’s Owens Corning Roofing Platinum Contractor certification provided additional confidence. “Our Owens Corning area sales manager, John Sabbak, explained the warranty for the re-roofing project and that was very important for us in selecting the materials for the project,” King says, noting that Sabbak also stopped by at different times during the installation to check in on the progress.

A Daunting Task

What were the challenges the roofing contractor faced in tackling the project? “What wasn’t a challenge?” asked Josh Long, Western Kentucky Sales Manager at All American Home Improvement. The metal capping required to protect the building from lightening, and the scorching summer heat during the installation were just a few of the challenges. By far, however, the two most daunting challenges were the safety concerns associated with the pitch and the wind issues that challenged shingle adhesion.

To help foster safety on the steep slopes, teams were assigned to cover each of the four “bows” comprising the roof. The teams used a precisely calculated system of ladders and walkboards to safely navigate and scale the roof. “Roofers getting home to their families safely every night will always be a top priority at Owens Corning,” says Sabbak, noting that All American Home Improvement teams were outfitted with personal protection equipment and participated in advance walk-through processes to safely tackle the project.

Installation teams from All American Home Improvement participated in advance walk-throughs to ensure everyone was well versed in the safety plan. Photos: Owens Corning

The building committee at Century Christian Church also wanted to avoid the safety and aesthetic concerns associated with shingle fly-off. That’s where Owens Corning SureNail Technology and Duration Shingles came into play. Developed to provide exceptional wind resistance, the system can qualify for a 130-mph wind warranty. “The Duration shingle delivered both the performance and the warranty we needed for a job with this kind of pitch and exposure to airflow,” says Long. According to Long, the shingles were also hand sealed as required by Owens Corning for the building’s pitch. “The SureNail Technology made it easy for the teams to install the shingle correctly because the white strip in the middle of the shingle leaves no doubt as to where the nail should go and facilitated a smooth installation,” he says.

As the roofing project progressed, so did public interest. The local newspaper stopped by to capture photos of residents watching the re-roofing spectacle from lawn chairs on the church lawn. The combination of re-roofing a challenging structure, improving the aesthetics of a historic building and scaling a very steep roof made it a memorable project according to Long. “It was a very unusual project from our daily jobs, and the challenges were part of what made the project so fun,” he notes.

TEAM

Roofing Contractor: All American Home Improvement, LLC, Evansville, Indiana, 1shingleatatime.com

MATERIALS

Steep-Slope Roof System: Duration Shingles with SureNail Technology, Owens Corning
Underlayment: ProArmor, Owens Corning

Steep-Slope Projects: Risks, Considerations and Best Practices for Contractors

Photos: Atlas Roofing

Photos: Atlas Roofing

Many contractors treat residential roofing as routine. However, whether a re-roof or new construction, each project can be infinitely complex and should be addressed as such by always accounting for weather and safety issues, as well as proper installation and customer service.

One of the most prominent and popular elements of residential architecture is a steep-slope roof. According to the Occupational Safety and Health Administration (OSHA), steep-slope roofs have slopes greater than 4:12 and range from 18.5 degrees to 45 degrees or more. While the process of installing a roof with these angles isn’t necessarily much different from a low-slope roof, it can pose more risks and considerations for workers.

Weather Woes

Weather plays an important role in every roofing project, but staying on top of potential issues from Mother Nature is especially crucial during steep-slope jobs.

Photos: Atlas Roofing

Photos: Atlas Roofing

In high temperatures, workers may fall victim to heat cramps, heat exhaustion, heatstroke or worse. The best way to beat the heat is to start early and get as much done as possible before the temperature peaks. Starting early in the summer—specifically in the South—can allow work to be completed before daily rain showers roll in. Proper hydration and attire are also important.

Cold temperatures can create even more complications because some manufacturers advise against installing their products in weather below 45 degrees Fahrenheit and certain equipment is susceptible to freezing. Furthermore, workers have to pay extra attention to the grip of their shoes to avoid slipping and falling. Not to mention, freezing-cold hands and feet may cause an otherwise adept worker to become clumsy. Wearing the proper clothing is key during cold-weather jobs, and workers should be advised to keep an eye out for the first signs of frostbite, including cold skin, redness, tingling and numbness.

Safety Considerations

In 2015, falls were the leading cause of private-sector work deaths in the construction industry, accounting for nearly 40 percent of worker fatalities, according to OSHA. In addition, OSHA reports nearly 90 percent of fatal falls happen due to the lack of a fall-protection system.

Photos: Atlas Roofing

Photos: Atlas Roofing

When working on a roof slope greater than 4/12, OSHA requires additional safety measures, which include either a guardrail system with toeboards, safety net systems or personal fall arrest systems. Yet, many contractors—especially residential roofers—choose to forgo protective devices because they feel they are not feasible or create a greater hazard. In such cases, OSHA does allow the use of alternative fall-protection methods in residential construction, as long as contractors develop a written, job-specific fall-protection plan that complies with OSHA regulations.

Proper Installation

During the installation process, roofers should keep a few things in mind whether they’re applying shingles to a steep-slope or low-slope structure.

  • Valleys
Photos: Atlas Roofing

Photos: Atlas Roofing

Valleys are a critical part of proper roof installation because they experience the most water flow during rainstorms and can be potential leak points.

In an open valley, a piece of aluminum, copper or other type of metal is used to help keep rainwater flowing off the roof. Open valleys are often used when a homeowner wants a showier look, such as on a Colonial-style home.

Closed valleys—the most common valley installation method—use asphalt shingles and offer a more traditional look. When properly installed, they keep water from getting trapped in the valley and allow for proper drainage.

In addition to open and closed valleys, contractors also have the option to create a weave valley, which alternates shingles through the valley from both sides, creating a braid-like effect.

Laminate/architectural shingles should not be used for weave valleys. Because laminate shingles aren’t one-dimensional, they do not create the flat surface needed for a weave valley, which should only be used with three-tab shingles.

When using laminate shingles, be sure to follow instructions on the wrapper for either an open or closed application.

Contractors also need to be extremely careful around obstacles such as chimneys and skylights, which require their own flashing and water divergence methods. For instance, more flashing may be needed in these areas to divert water and prevent leaks.

  • Starter Shingles

Starter shingles allow the first course of shingles to properly seal down, protecting the edge of the roof and providing anchoring power for high-wind resistance at the critical eave and rake areas. They further protect the roof by filling in spaces under the cutouts and edges for the first course of exposed shingles, preventing wind uplift.

Photos: Atlas Roofing

Photos: Atlas Roofing

The most common mistake when installing starter shingles or modifying traditional three-tab shingles is putting them on backward or upside-down.

Additionally, the overhang should be no more than three-quarters of an inch to prevent wind from penetrating beneath shingles, as well as to keep shingles from curling or cracking.

In addition, many manufacturers caution against double-stacking pallets of starter shingles, which can cause the bottom shingles to warp. Be sure to read all storage and handling instructions prior to installation.

  • Underlayment

Underlayment is an important part of the roofing process and is required by code for residential properties to meet Class A fire requirements. Serving as a secondary barrier, underlayment protects rakes, eaves and critical flashings from water infiltration. Most warranties also require underlayment for the roof to be ASTM compliant. However, some contractors still opt not to use it because they want to save time on a project or their customer balks at the cost.

Photos: Atlas Roofing

Photos: Atlas Roofing

Another frequent error during underlayment installation is incorrect overlaps. On low-slope roofs (slopes between 2:12 and 4:12), underlayment should have double coverage. And while traditional installation is fine on steep-slope roofs, always follow manufacturer instructions for overlaps from course to course.

Last but not least, be sure to keep underlayment from wrinkling, which can cause ripples in the shingles. While trying to keep underlayment as flat as possible, avoid pulling it too tight because it has a natural expansion and contraction. If underlayment gets wet, be sure it adequately dries out before continuing the installation process.

  • Shingles and Nails

Shingles should be installed with the manufacturer’s recommended offset, which will help prevent leak points and also properly align the shingles across the roof. Once all of the shingles are aligned, only the shingles themselves should be exposed—not the nails.

Because the common bond area is the strongest part of a shingle, manufacturers require nails be placed there to achieve the advertised wind performance. Nails should not be too high or too low, or unevenly spaced. If nails aren’t positioned correctly, the manufacturer’s wind warranty may not be valid.

Customer Service Follow-Up

Providing excellent customer service is key to every roofing job. Homeowners who have a good experience are more likely to share positive reviews and opinions.

Photos: Atlas Roofing

Photos: Atlas Roofing

Before starting a steep-slope project, be sure to discuss the entire process with homeowners to ensure that they know what to expect, as well as the types of warranties they will receive with their new roof. In addition, prepare the surrounding property, such as windows and landscaping, to prevent damage during the installation process.

During the job, be sure workers are vigilant about not dropping nails anywhere on the jobsite. After the job, walk the property with the homeowners to ensure all debris and materials were cleaned up; magnets can be used to double-check for stray nails. If the homeowners are happy with the finished product and their experience, don’t be afraid to ask them to write a nice review on the company website, Angie’s List, Yelp or other customer referral app.

Most of the best practices for steep-slope roofing can be applied to any type of roofing project. However, steep-slope work can pose additional challenges that other projects may not. Always follow manufacturer’s instructions and OSHA guidelines on all roofing jobs, but especially on steep-slope projects, when one minor slip could turn into major consequences for all involved.

About the Author: Paul Casseri is the product manager of the Roofing Shingles and Underlayment Division for Atlas Roofing Corp., www.atlasroofing.com. He is responsible for all areas of product management, including product initiation, feasibility, design, development and testing. He is a graduate of Penn State University with more than 20 years of experience in the building products industry.

 

IKO PRO4 Plus Roofing Components System Promotion Awards New Truck

Idaho-based contractor KD Roofing is the recipient of a Dodge RAM 1500 Tradesman pickup truck as well as $22,500 in cash bonuses, thanks to its performance in the IKO PRO4 Plus Roofing Components System Promotion.

The initial PRO4 promotion was first introduced to encourage contractors to experience the benefits of working with a roofing system by offering rebate incentives. It was upgraded to the PRO4 Plus Promotion in 2016 to include per-square rebates for contractors, along with cash bonuses and the chance to earn a brand-new pickup truck for their fleet — which will continue in 2017.

For example, participating contractors have the opportunity to earn up to an $8.00 rebate per square when installed with any three components from the PRO4 Roofing Components System — in addition to up to $22,500 in cash bonuses and a top-tier incentive of a new truck.

Family Success

Located just outside of Boise in Meridian, Idaho, KD Roofing provides a variety of residential and commercial roofing services with a specialty in new construction. Following in the footsteps of their father and KD Roofing’s founder, Kendall Doty, brothers Justin and Jared Doty, office manager and general manager at KD Roofing, helped to drive the company’s success in the promotion.

“We feel blessed to have earned this recognition and are pleased to put the cash bonus and truck back into use for the company,” Justin says.

Additionally, Jared noted that KD Roofing’s Production Manager, David Allen, who has been a long-time employee and friend of the company, also played a role in the success thanks to his continued support in the growth of the company.

“It goes without saying that we have the entire KD Roofing team to thank for this accomplishment,” Jared says.

Distributor and Manufacturer Support

The Doty brothers also noted that support from their distributor, Roofline Supply and Delivery (a division of SRS Distribution), was an element to their success. In fact, the branch manager for Roofline’s Boise location, James Phillips, first introduced the promotion to the KD Roofing team.

“I’ve had a relationship with the KD team almost my entire career in the roofing industry, so when I learned of the PRO4 Plus Promotion, I knew it was a good fit for them,” Phillips says. “But things like this don’t happen overnight; it takes a lot of work and dedication to achieve what the KD Roofing team did. They’ve also built a reputation and trust among their customers by delivering service for more than 20 years.”

IKO Territory Sales Representative, Andrew Buehner, also worked closely with Phillips and the KD Roofing team during the promotion. He helped provide product knowledge and expertise, as well as local service and support to keep the promotion running smoothly for KD Roofing, Phillips added.

“We were onboard with the promotion after discussion with Roofline, but once they introduced us to our IKO rep, Andrew, we knew it was going to be great working with IKO,” Jared says. “IKO is a family-owned business like ours and shares similar valuesplus.”

Coordinating Roofing Components

A roofing components system is engineered to provide more performance than installing just shingles alone.

As such, IKO has developed the PRO4 roofing components system, which includes four multi-layered roofing accessories that protect vulnerable areas of the roof, including eave protection (ice and water protectors), underlayment (for deck protection), roof starters (starter strips to save installation time) and ridge cap shingles (provide protection along a roof’s high-stress areas and accentuate the roof line).

“Our favorite part of working with the PRO4 system is offering our clients a shingle and coordinating components from a single manufacturer,” Jared says. “It’s a benefit for our customers when we assure them it’s one system that’s intended to work together.”

To see a video interview featuring the KD Roofing team and additional details on the IKO PRO4 Plus Promotion, please visit the IKO TV YouTube channel. For more information about IKO’s complete portfolio of residential roofing products and accessories, visit the website.

Polyglass USA Celebrates 25 Years of Roofing, Waterproofing Materials Production

Polyglass USA Inc. is celebrating 25 years of producing roofing and waterproofing materials for the North American roofing industry. Polyglass will commemorate this milestone with its customers throughout 2017.

Polyglass is a manufacturer of modified bitumen roof membranes, elastomeric roof coatings and underlayments. Founded in the early 1950s by roofing contractors in northern Italy, Polyglass established its first manufacturing plant in the 1960s serving roofing contractors across Europe. The company grew and expanded operations into the U.S. in 1992 with its first location in Fernley, Nev. By 2006, Polyglass had grown to three US facilities with the addition of plants in Pennsylvania and Florida.

In 2008, Polyglass was acquired by Mapei, a global manufacturer of adhesives, sealants and construction materials for the building industry. Since the acquistion, Polyglass has added a manufacturing location in Arizona, with an additional facility in Texas slated to be operational at the end of 2017. The Polyglass manufacturing facilities are ISO 9001:2008 certified and strategically located to serve its customers.

“Celebrating 25 years of successfully developing and producing roofing solutions that has helped transform the roofing industry would not be possible without our committed employees,” says CEO Natalino Zanchetta. “With a focus on quality, Polyglass has developed solutions for use in every climate and we continue to innovate to meet the changing needs of our customers.”

Since developing its first compound formula decades ago, Polyglass has added hundreds of products that extend the roof-life cycle, help manage building energy loads and enhance building aesthetics. With the launch of patented ADESO Technology, Polyglass provided a way to install modified bitumen membranes. Polyglass also developed patented CURE Technology, a thin film technology applied to membranes during the manufacturing process to increase reflectivity, durability, stain and UV resistance, granule retention and energy efficiency.

As part of its commitment to customers, Polyglass offers continuing education through Polyschool, a two-day training program that teaches best practices in the installation of Polyglass’ commercial and residential products. Polyglass has also developed a customer loyalty program with its Q Rewards program – rewarding its customers for their Polyglass product purchases.