After a tornado damaged the three roofs at Bale Chevrolet in Little Rock, Arkansas, Riley Hays Roofing and Construction did more than fix them. The contractor ensured the longstanding local business could remain open while the work was being done. Even better, it delivered TPO retrofit roofs that perform better than the originals did before the storm struck.
On March 31, 2023, a massive and deadly storm tore through 15 states from the Great Lakes to the Deep South. Multiple tornadoes were confirmed in the Little Rock area, including one rated as an EF3 with estimated peak winds of 165 miles per hour.
“It missed our offices by a quarter mile,” says Riley Hays, owner of Riley Hays Roofing and Construction, of the twister.
Bale Chevrolet, located just five blocks away, was not so fortunate. The dealership’s three metal buildings — one housing the main showroom and service center, one home to the body shop and one containing the commercial sales center — were all hit. Service bay doors and interior and exterior lighting fixtures were damaged. Flying debris left numerous cars on the lot with broken windows and body damage. Rooftop HVAC units were moved by the wind. The Bale Chevrolet sign was torn off its pole.
The tornado also left its mark on the buildings’ combined 1,500 squares of 20-year-old low-slope standing seam metal roofing.
“Several panels were peeled back like the pop tops on Coke cans,” Hays says. “Coping caps were peeled off. Debris thrown by the wind had cut the roof. There were large voids throughout.”
A review by Bale Chevrolet’s insurance provider, and its direction on how to proceed, would take time. Temporary fixes, including using Seal-Fast Repair Hero fiber-reinforced sealant from Mule-Hide Products Co. to patch several large cuts in the metal panels, kept the weather out and the business running in the meantime.
The insurance company ultimately determined that repairing the roofs was not a viable option. Recovering them with a new single-ply system was, however. It would be much faster and cost far less than replacing the roofs. The business could operate with minimal disruption while the work was completed. The roofs would come with fresh warranties. And it would help reduce the dealership’s air-conditioning costs.
Tough, Energy-Efficient TPO
Hays recommended Mule-Hide Products’ 60-mil Standard TPO in white for its toughness and energy efficiency. Because the roof’s metal panels would be flute-filled, mechanical attachment was required.
The three roofs have more than 50 HVAC units, all of which require regular service. TPO will stand up to that foot traffic, according to Hays. To further protect the new roofs, the crew used TPO Walkway Roll from Mule-Hide Products to create paths around and leading to each unit. Made of reinforced TPO material and featuring a non-slip tread pattern and safety yellow trim, it delivers excellent tear and puncture resistance and clearly defines walkways that service providers can use to access the units without damaging the roofs.
Average high temperatures in Little Rock are 90 degrees and higher all summer, so energy efficiency and helping manage cooling costs were key priorities for Bale Chevrolet. The white membrane will reflect much of the sun’s energy away from the roof and expel much of the heat that does enter the building back into the atmosphere. The rooftop and the building’s interior will remain cooler and the HVAC units will operate more efficiently, lowering the dealership’s air-conditioning costs while keeping customers and employees comfortable.
While the roof deck did not need to be replaced, repairs were essential before installing the TPO system. Where sheets had torn or otherwise been damaged, the crew overlapped the seams with 20-gauge metal and then mechanically re-seamed them to ensure they were level. Several panels were re-secured to purlins.
Additional layers of insulation roughly doubled the roofing system’s R-Value to approximately R-30. The existing insulation beneath the roof deck was retained. Custom EPS flute filler with 2.5 inches of EPS insulation on top was laid over the existing metal panels. That was then covered with 2 inches of Mule-Hide Poly ISO Flat insulation.
“Adding R-Value without disturbing the roofs was key,” Hays says. “This was the least invasive and most cost-effective way to get the necessary R-Value and the swiftest way to get the roofs operational so the customer didn’t have to worry about them.”
Business as Usual
The crew of 10 completed the job in six weeks, wrapping up the project less than four months after the tornado struck. And all the while, Bale Chevrolet operated with little disruption.
Communication between contractor and client was essential. “They were in constant communication with us, giving us status updates,” notes Logan Amsler, chief of staff at Bale Chevrolet. “They were great at being proactive about letting us know when materials would be delivered so we could identify where they should go. When they would need to get a forklift into an area that would require us to move inventory, they’d let us know the day prior so we could move the cars before the crew started work at 6:30 a.m.”
Hays adds, “I had direct access to the owner. That helped immensely. I’d tell him our thoughts on the work we’d do the next day. If he was concerned, he’d tell us to load in first thing so we didn’t interrupt traffic during the day; we’d bring in the crane, load the materials onto the roof and be out before they opened for the day.”
One crew member was always stationed on the ground to direct traffic and collect any debris, keeping the business operating smoothly and safely. Regular use of magnets and blowers kept the parking lot clean.
“The number one thing you want to avoid is having a pile of nails so every car driving by gets a flat,” Hays says.
Most rewarding for Hays, however, was the opportunity to work with Bale Chevrolet.
“They’re a fourth-generation business that has been around since 1912,” he says. “They showed loyalty to someone local who also is a customer of theirs. They trusted me with a lot of money and a lot of issues. We needed to hit a home run.”
And they did.
“It was a great project for us,” Hays says. “Everyone ended up happy. The client is so busy, they’re just happy not to have to deal with it anymore. I’m a roofer, and I’ll tell you that these are good-looking roofs. Our attention to detail was very tight with these roofs. They’re laid out perfectly, with no wrinkles. They’re aesthetically pleasing as well as watertight. They look sharp. You can’t question anything on these roofs.”
TEAM
Roofing Contractor: Riley Hays Roofing and Construction, Little Rock, Arkansas, rileyhays.com
MATERIALS
Membrane: 60-mil Standard TPO, Mule-Hide Products Co., mulehide.com
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