{"id":13207,"date":"2019-09-20T09:30:16","date_gmt":"2019-09-20T13:30:16","guid":{"rendered":"https:\/\/roofingmagazine.com\/?p=13207"},"modified":"2019-10-30T09:52:48","modified_gmt":"2019-10-30T13:52:48","slug":"roof-re-cover-meets-challenges-of-historic-integrity","status":"publish","type":"post","link":"https:\/\/roofingmagazine.com\/roof-re-cover-meets-challenges-of-historic-integrity\/","title":{"rendered":"Roof Re-Cover Meets Challenges of Historic Integrity"},"content":{"rendered":"\n
\"\"
Austin Hall is a historic landmark on the campus of Sam Houston State University. It was first occupied in October 1851. Photos: McElroy Metal<\/figcaption><\/figure><\/div>\n\n\n\n

Some roofers are simply cut out to do their thing in the spotlight. Empire Roofing<\/a> of Austin, Texas, executed the removal of an existing leaking stainless-steel metal roof and the installation of McElroy Metal\u2019s<\/a> 238T symmetrical copper standing seam roofing system on a historic centerpiece building on the campus of Sam Houston State University.<\/p>\n\n\n\n

Historic Austin\nHall in Huntsville, Texas, was re-roofed less than 10 years ago. It\u2019s the\noldest building west of the Mississippi River to have been used continuously by\nan educational institution. Austin Hall was first occupied in October 1851 and\ncompleted the following year. <\/p>\n\n\n\n

Unfortunately, it\nsoon became evident that there were defects pertaining to the 2009-10 roof\ninstallation and it needed to be replaced. The stainless-steel interlocking panels\nwere not seamed or soldered as specified and in accordance with historically\naccurate methods, resulting in widespread water infiltration beneath the metal\nroof assembly. Armko Industries of Austin was contracted to determine the best\nplan of action for resolving these issues and restoring the Austin Hall roof,\ninternal gutters and cupola back to a watertight condition. During the\nevaluation, portions of the existing roof had to be removed to verify\nconditions. Sam Houston State and Armko requested Empire Roofing assist the\nevaluation.<\/p>\n\n\n\n

\"\"
At the base of the cupola, the specifications called for the installation of through-wall flashing using 20-ounce copper. Photos: McElroy Metal<\/figcaption><\/figure><\/div>\n\n\n\n

\u201cBased on my\ninitial observations, I was hired to come in and actually remove and replace\nsome of the roof near the cupola and internal gutters to assess and verify the\nexact nature of the perceived defects,\u201d says Aaron Todd, who leads the metal\nroofing and sheet metal division at Empire Austin. \u201cI hated to be the bearer of\nbad news, but it was a lot worse than they anticipated. The flat-seam panels\nwere installed using a Pittsburgh seam, which really isn\u2019t designed to be a\nwatertight seam in a low-slope (2:12) roofing application. The underlayment\nthat was installed did a better job of keeping out water than the flat-seamed\npanels.\u201d <\/p>\n\n\n\n

Working together, Empire and Armko put together a plan that required the removal of the stainless-steel flat-seamed panels and the internal gutter liner. The Texas Historical Commission was involved in the renovation to ensure the new roof would be as historically accurate as possible. Plans and specifications issued by Armko Industries<\/a> were to remove the existing stainless steel and to re-roof with the 20-ounce copper 238T standing seam on all roof sections, interior gutters and related sheet metal components. Specifications and details issued siding removed at the cupola walls and a new liquid-applied waterproofing membrane was applied over the new sheathing, with new siding installed to match the original siding. At the base of the cupola, the specifications and details called for the installation of through-wall flashing using 20-ounce copper. Titanium PSU-30 high-temp self-adhering underlayment covered the roofing substrate and was used as a lining in the internal gutters, under the 20-ounce copper.<\/p>\n\n\n\n

\"\"
Empire Roofing removed the building\u2019s existing roof and installed McElroy Metal\u2019s 238T symmetrical copper standing seam roofing system the historic structure. Photos: McElroy Metal<\/figcaption><\/figure><\/div>\n\n\n\n

\u201cWe set up\nscaffolding and worked on the octagonal cupola first,\u201d Todd says. \u201cThe design\nincorporates a convex curvature with all roof sections meeting at the apex.\nTogether with my superintendent, Diego Trevizo, and our lead foreman, Uri\nContreras, we measured everything we needed for the cupola roof and gave the\ncut list to our shop fabricators, who produced the panels and trim for the\ncupola roofing, the design of which was proposed by Empire and approved by the\nTexas Historical Commission and Armko. We also had a 10-foot mechanical brake\nonsite to fabricate and modify any panels as needed during the installation\nprocess. My team and I love working with copper, because aside from the obvious\nqualities inherent in its chemical makeup, it allows for a more thorough\narsenal of seaming and joining techniques due to its unique malleability\nrelative to most other types of commonly used metal components.\u201d<\/p>\n\n\n\n

Todd says standing\nseams were incorporated at each hip of the cupola to avoid the need to solder\nvertical joints. At the apex of the cupola, standing seams were folded down and\nlapped under the finial skirt. The crew sealed\/riveted\/soldered the finial base\nto the copper panels to create a watertight and wind-resistant detail at this\nvery exposed and relatively flat area.<\/p>\n\n\n\n

\"\"
Standing seams were incorporated at each hip of the cupola. At the apex of the cupola, the seams were folded down and lapped under the finial skirt. Photos: McElroy Metal<\/figcaption><\/figure><\/div>\n\n\n\n

Empire Roofing\nowns roll formers with dies to produce McElroy\u2019s 238T and 138T symmetrical\nstanding seam panels. \u201cEmpire\u2019s capabilities with regard to commercial,\nindustrial, and historical roofing projects are far reaching, and we love a\ngood challenge,\u201d Todd says. \u201cIf you\u2019ve got a difficult problem, it\u2019s our job to\nsolve it, and we love working with innovative manufacturers like McElroy in\ndoing so.\u201d<\/p>\n\n\n\n

Symmetrical\nstanding seam systems do not have male and female legs, but are comprised of\npanels with matching left and right legs. The panels are joined with a\nmechanically seamed cap. The panels are non-directional, meaning they can be\ninstalled left to right, right to left, or even from the center out. The seam\ndesign on a symmetrical panel is more watertight than a double lock because\nthere is no interruption of sealant in the seam at the clip locations. Most\nimportantly, a symmetrical panel can be easily replaced if there is ever damage\nor a reason to pull a panel out of the roof at a later date.<\/p>\n\n\n\n

\u201cThrough a\njudicious use of hydrostatic details utilizing butyl tape in lieu of solder at\nkey areas, we were able to achieve a long-term watertight and wind-resistant\nroof assembly that only minimally relies on soldered joints and that can\naccommodate thermal movement much better,\u201d Todd says.<\/p>\n\n\n\n

\"\"
Photos: McElroy Metal<\/figcaption><\/figure><\/div>\n\n\n\n

Austin Hall is\nlocated on a hill among old-growth trees, so there isn\u2019t much room to park a\nroll former to produce panels up to 25 feet long. It\u2019s a relatively small\nproject, about 6,000 square feet. \u201cWe set up our staging area in the road,\nabout a quarter-mile from Austin Hall,\u201d Todd says. \u201cTo minimize disruptions to\ndaily university activities, we decided to run panels in the evening and have\n3-4 guys walk the longer panels up the hill, one at a time. We rented a golf\ncart to transport guys down the hill to the roll former and bring smaller items\nup to the jobsite. We\u2019ve got a great crew and it was \u2018all hands on deck\u2019 for\nthis one. In one night, we produced all the panels and telescoped them to the\nroof on our spreader bar, which we attached to the forks of our onsite SkyTrack.\nWe didn\u2019t damage a single panel \u2026 that\u2019s tough to do with copper.\u201d<\/p>\n\n\n\n

Todd was sure the roofing details would be watertight and wanted to make sure the internal gutters didn\u2019t cause any problems. The Empire crew used sandpaper to etch the flat 20-ounce copper before it was fabricated into gutters. Once fabricated and roof-loaded, the gutter pieces were joined in 40- to 50-foot sections in the interior gutter, then lifted out and placed on sawhorses. All joints and seams were fully soldered on the sawhorses and then placed in their respective areas inside the internal gutter troughs, where the few remaining seams were joined and soldered in place. The gutters then were coated with Kemperol 2K PUR<\/a>, a solvent-free, fleece-reinforced and liquid-applied waterproofing system based in polyurethane resin. Empire used a roller to apply the coating in open areas and brushed on the coating in corners. <\/p>\n\n\n\n

TEAM<\/strong><\/h4>\n\n\n\n

Building Envelope Consultant:<\/strong> Armko Industries, Austin, Texas, www.armko.com<\/a><\/p>\n\n\n\n

Roofing Contractor:<\/strong> Empire Roofing, Austin, Texas, www.empireroofing.com<\/a><\/p>\n\n\n\n

MATERIALS<\/strong><\/h4>\n\n\n\n

Metal Roof System:<\/strong> 238T symmetrical copper standing seam roofing system, McElroy Metal, www.mcelroymetal.com<\/a><\/p>\n\n\n\n

Underlayment: <\/strong>Titanium PSU-30 high-temp self-adhering underlayment, InterWrap, www.interwrap.com<\/a><\/p>\n\n\n\n

Liquid-Applied Waterproofing System:<\/strong> Kemperol 2K PUR, Kemper System, www.kemper-system.com<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"

Austin Hall is a historic landmark on the campus of Sam Houston State University. It was first occupied in October 1851. Photos: McElroy Metal Some…<\/p>\n","protected":false},"author":2,"featured_media":13209,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"jetpack_post_was_ever_published":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_publicize_message":"","jetpack_publicize_feature_enabled":true,"jetpack_social_post_already_shared":true,"jetpack_social_options":{"image_generator_settings":{"template":"highway","enabled":false}}},"categories":[35,4200,34],"tags":[8966,8967,7352,6737,3638,3333,275],"jetpack_publicize_connections":[],"yoast_head":"\nRoof Re-Cover Meets Challenges of Historic Integrity - Roofing<\/title>\n<meta name=\"description\" content=\"Some roofers are simply cut out to do their thing in the spotlight. 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