Durable Roof System and Solar Array Revitalize Manufacturing Facility

When a 70,000-square-foot print shop and manufacturing facility in Pennsauken Township, New Jersey, needed a new roof, the building owner wanted a cost-effective, durable, and long-lasting replacement that would support a solar array. The building’s 30-year-old existing roof needed to be replaced, as it was completely failing. Because the roof would be replaced in the wintertime, it was important to find a system that could be installed in a wide range of temperatures so the job wouldn’t be delayed by weather.

The roofing contractor, Topline Construction, had an ideal solution to this project’s needs. They recommended a Versico Roofing Systems induction-welded TPO roof attached with RhinoBond plates. By eliminating mechanical fastening in the seam, RhinoBond systems decrease the number of screws and plates required for some assemblies by as much as 50%, resulting in minimized labor and material costs. And because induction-welded systems dry-in faster, the contractor can tackle more square feet each day without the concern of disrupting activities inside the building due to potential inclement weather.

Tear-Off and Installation

Topline Construction began by tearing off the existing 30-year-old built-up roof down to the steel deck and replacing all the bad decking. Next, crews installed two layers of 2.6-inch-thick VersiCore Polyisocyanurate Insulation, which they secured to the deck with RhinoBond Plates and HP-V Fasteners. The next step was installing a 60-mil-thick VersiWeld TPO membrane with APEEL Protective Film and hot-air welding the seams. APEEL guards the TPO membrane’s surface from scuffs and dirt accumulation during installation and eliminates the need to clean the roof once the project is complete. Durable and easy to remove, APEEL Protective Film helps to save time and labor, improve aesthetics, and increase customer satisfaction.

Once the TPO membrane was in place, the Topline Construction crew placed the induction welding tool on the membrane’s surface, directly above each of the RhinoBond plates. The tool activates the special coating, resulting in a bond between the plates and the membrane. Weighted magnets are then placed over the plates to dissipate the heat and ensure intimate contact between the bottom surface of the membrane and the hot-melt adhesive.

The 74,423-square-foot project was completed in three months, including tear-off and decking replacement. “Once we had the roof torn off, the new Versico system was very easy and simple to install,” says Scott Manley of Topline Construction. “The RhinoBond Plates reduce steps and the APEEL keeps us from tracking dirt on the new TPO sheet.”

Now, the building’s durable roof system now includes a complete solar array. The solar installation was completed by Azimuth Renewable Energy. The ballasted rooftop PV system includes 1,344 modules and eight inverters, and it offsets 596,000 kilowatt-hours of electric consumption.

TEAM

Roofing Contractor: Topline Construction, Conshohocken, Pennsylvania

Solar Contractor: Azimuth Renewable Energy, azimuthrenew.com

MATERIALS

Membrane: 60-mil VersiWeld TPO with APEEL Protective Film, Versico, versico.com

Insulation: VersiCore Polyisocyanurate Insulation, Versico