flexiblefullpage
billboard
interstitial1
catfish1
Currently Reading

3 Metal Roofing Case Studies Illustrate Benefits

3 Metal Roofing Case Studies Illustrate Benefits

Metal roofing systems offer values such as longevity, favorable life cycle costs, and heightened aesthetic appeal.


By By Susan Bady, Contributing Editor | May 31, 2012
The four-inch-thick Metl-Span insulated roof panels are finished in Cool Forest
The four-inch-thick Metl-Span insulated roof panels are finished in Cool Forest Green on the exterior and Polar White on the int
This article first appeared in the June 2012 issue of BD+C.

Building owners and Building Teams seeking sustainable, aesthetically pleasing roofing solutions are turning to metal for its favorable life cycle benefits, longevity, and resistance to wind uplift, fire, and physical impact.

While metal is typically specified for new construction, it has significant potential for growth in retrofits. “Metal adds insulation, a ventilated cavity, and a reflective coating that makes the [old] roof several hundred percent more energy efficient,” says Chuck Howard, PE, of Metal Roof Consultants, Cary, N.C. “And the roof panels can last well over 60 years.”

Moreover, the installation cost of a metal roof is estimated to be comparable to tearing off and replacing the existing flat roof, says Ken Buchinger, vice president of R&D and business development for Houston-based manufacturer MBCI.

Metal roofing is unquestionably more design-friendly than it was 25 years ago. While steel remains the dominant material, metal roofing can also be fabricated from aluminum, copper, and zinc. Building Teams can dress it up with such features as dormers, Dutch hips, and offset ridges with clerestories. Many panel profiles and paint colors are available, as well as finishes that emulate copper, aluminum, stone, brick, and glass.

Thanks to more advanced manufacturing equipment, metal can be curved, tapered, and perforated in a variety of ways, says Dave Brown, director of new product development for Euramax International’s North American Commercial Division, Lancaster, Pa. Euramax is the parent company of Fabral Metal Roof and Wall Systems.

Brown urges designers to review drawings and specifications with the roofing manufacturer early on in the process. According to architect Mickey Conrad, AIA, “Metal roofs are great, but you can design yourself into a flashing and waterproofing jam if you’re not careful about how different roof forms intersect.”

Six things you should know about using metal roofing

1. If the roof geometry of your project is complicated, request a weather-tightness warranty from the manufacturer.  Such warranties call for multiple roof inspections throughout the installation process.
2. Metal roofing is an especially good substrate for solar installations because it requires no roof penetrations. With proper maintenance, the roof should outlast the solar array.
3. Insulated metal roof panels eliminate the need for highly skilled labor on site and can be installed quickly.
4. In retrofits, if a metal roof is installed over the existing roof, the new framing will create a ventilated cavity that can be insulated to reduce the building’s energy consumption.
5. Architects can get the maximum creativity out of their roof design by working with the manufacturer in the early stages of a project.
6. Consult with the manufacturer for a recommendation on the right installer for the job.

Conrad, principal-in-charge of OCO Architects, San Antonio, Texas, prefers vertical standing-seam metal roofs with concealed fasteners: “They’re going to give our clients the best performance over many years.”

Insulated metal roof panels could become more widespread as Building Teams strive for LEED points. Doug Pickens, vice president of marketing for IMP roofing manufacturer Metl-Span, Lewisville, Texas, says the volume of IMPs sold in the U.S. and Canada has doubled in the last three years, even though IMP systems cost twice as much as single-ply or standing-seam metal roofing.

Because they have insulating foam sandwiched between two layers of metal, he says, IMPs provide an air and vapor barrier with no thermal bridging. “The insulation is continuous across the entire roof,” says Pickens. “The panels go down incredibly fast. A contractor who has a little bit of experience can put down as much as 10,000 sf a day with a five-man crew and a crane.”

Let’s take a look at how metal systems have been used in three different kinds of applications.

1. METAL ROOF MAKES A SPLASH

The new water park at Hope Lake Lodge in Virgil, N.Y., has transformed the resort into a year-round destination. By installing a metal roof, the owners of the water park have been able to maintain its interior temperature at 80-84°F, even during the coldest months.

VIP Structures, Syracuse, N.Y., erected the building and installed 60,000 sf of Metl-Span insulated roof and wall panels. The steep roof, with its 100-foot-long skylight at the ridge line, was something of a challenge, but the crew successfully managed the hips, valleys, and trim, according to Leonard Pogroski, project manager for VIP Structures.

The LEED Silver project was designed by RBA Group, Charlotte, N.C. “By using a steel superstructure with insulated panels, we were able to create the large clear spans necessary for housing the water-park features and provide high thermal efficiency,” says architect Steven E. Finch, LEED AP, Assoc. AIA, RBA’s director of hospitality. IMPs were also chosen because they permitted multiple punched openings where the waterslide chutes exit and reenter the building, according to Finch.

2. RETROFIT HELPS DRY OUT SCHOOL ROOF

During its 42 years of service, the BUR roof of Winchester High School in Richmond, Ind., had been patched numerous times, but continued to leak. Students and teachers regularly complained about the wet, humid environment and unpleasant odor. 

The school board considered a flat-roof retrofit, but parents and students protested so vehemently that the board called in Metal Roof Consultants. MRC proposed installing a sloped metal roof over the existing flat roof. This meant that there would be no interruption of school activities.

Six inches of unfaced fiberglass insulation were installed directly over the existing roof, raising insulating value from R-3.5 to R-22.5. The existing roof was able to release its moisture through the insulation into the new roof cavity, where it was expelled through side vents. “The classroom wing was the wettest, so we worked on that first,” says MRC’s Howard. “It dried out in less than a year.”

Energy Star paint additives create a cool roof that reflects approximately 80% of the solar heat back into the atmosphere. Howard says the roof system is warranted against leaking for 20 years but should provide 50-60 years of service, with no maintenance other than periodic checks for external damage.

Smarrelli General Contractor, Richmond, Ind., used MBCI’s NuRoof system, in which light-gauge steel framing is installed over existing framing members to create a sloped plane. BattenLok HS standing-seam panels were installed over the framing. Steve Shute, Smarrelli’s general manager, says the manufacturer made the project, even with its high load conditions and roof curbs, “work very well.” Most important, there haven’t been any leaks.

3. ROOFTOP SOLAR ADDS  TO SUSTAINABILITY

When the city of Allegan, Mich., had to upgrade its water-treatment plant, it rejected a costly retrofit and decided instead to build a new reverse-osmosis facility. The $10 million project, funded by federal grants and a low-interest loan from the state, includes a half-million-gallon ground storage tank, an on-site mixed-oxidant generation system, and a rooftop solar system.

Architect/engineer Prein & Newhof, Grand Rapids, Mich., specified Fabral’s Solar SSR, which integrates flexible thin-film solar laminates with a standing-seam metal roof. Once the wood-truss framing and sheathing were in place, Erhardt Construction, Ada, Mich., installed the roof and solar array, which generates 29.38 kW of electricity.

Dave Brown of Euramax, Fabral’s parent company, says thin-film laminates are lightweight and flexible and achieve high relative efficiency under high temperatures and low light. “No roof penetrations or additional structural support are needed, and you can walk on the laminates,” says Brown. He says the panel/laminate bond has been proven to withstand 160 mph winds. +

Related Stories

| Aug 11, 2010

Wisconsin becomes the first state to require BIM on public projects

As of July 1, the Wisconsin Division of State Facilities will require all state projects with a total budget of $5 million or more and all new construction with a budget of $2.5 million or more to have their designs begin with a Building Information Model. The new guidelines and standards require A/E services in a design-bid-build project delivery format to use BIM and 3D software from initial ...

| Aug 11, 2010

Opening night close for Kent State performing arts center

The curtain opens on the Tuscarawas Performing Arts Center at Kent State University in early 2010, giving the New Philadelphia, Ohio, school a 1,100-seat multipurpose theater. The team of Legat & Kingscott of Columbus, Ohio, and Schorr Architects of Dublin, Ohio, designed the 50,000-sf facility with a curving metal and glass façade to create a sense of movement and activity.

| Aug 11, 2010

Residence hall designed specifically for freshman

Hardin Construction Company's Austin, Texas, office is serving as GC for the $50 million freshman housing complex at the University of Houston. Designed by HADP Architecture, Austin, the seven-story, 300,000-sf facility will be located on the university's central campus and have 1,172 beds, residential advisor offices, a social lounge, a computer lab, multipurpose rooms, a fitness center, and a...

| Aug 11, 2010

News Briefs: GBCI begins testing for new LEED professional credentials... Architects rank durability over 'green' in product attributes... ABI falls slightly in April, but shows market improvement

News Briefs: GBCI begins testing for new LEED professional credentials... Architects rank durability over 'green' in product attributes... ABI falls slightly in April, but shows market improvement

| Aug 11, 2010

Luxury Hotel required faceted design

Goettsch Partners, Chicago, designed a new five-star, 214-room hotel for the King Abdullah Financial District (KAFD) in Riyadh, Saudi Arabia. The design-build project, with Saudi Oger Ltd. as contractor and Rayadah Investment Co. as developer, has a three-story podium supporting a 17-story glass tower with a nine-story opening that allows light to penetrate the mass of the building.

| Aug 11, 2010

Three Schools checking into L.A.'s Ambassador Hotel site

Pasadena-based Gonzalez Goodale Architects is designing three new schools for Los Angeles Unified School District's Central Wilshire District. The $400 million campus, located on the site of the former Ambassador Hotel, will house a K-5 elementary school, a middle school, a high school, a shared recreation facility (including soccer field, 25-meter swimming pool, two gymnasiums), and a new publ...

| Aug 11, 2010

New Jersey's high-tech landscaping facility

Designed to enhance the use of science and technology in Bergen County Special Services' landscaping programs, the new single-story facility at the technical school's Paramus campus will have 7,950 sf of classroom space, a 1,000-sf greenhouse (able to replicate different environments, such as rainforest, desert, forest, and tundra), and 5,000 sf of outside landscaping and gardening space.

| Aug 11, 2010

U.S. firm designing massive Taiwan project

MulvannyG2 Architecture is designing one of Taipei, Taiwan's largest urban redevelopment projects. The Bellevue, Wash., firm is working with developer The Global Team Group to create Aquapearl, a mixed-use complex that's part of the Taipei government's "Good Looking Taipei 2010" initiative to spur redevelopment of the city's Songjian District.

boombox1
boombox2
native1

More In Category


Urban Planning

Bridging the gap: How early architect involvement can revolutionize a city’s capital improvement plans

Capital Improvement Plans (CIPs) typically span three to five years and outline future city projects and their costs. While they set the stage, the design and construction of these projects often extend beyond the CIP window, leading to a disconnect between the initial budget and evolving project scope. This can result in financial shortfalls, forcing cities to cut back on critical project features.



Libraries

Reasons to reinvent the Midcentury academic library

DLR Group's Interior Design Leader Gretchen Holy, Assoc. IIDA, shares the idea that a designer's responsibility to embrace a library’s history, respect its past, and create an environment that will serve student populations for the next 100 years.

halfpage1

Most Popular Content

  1. 2021 Giants 400 Report
  2. Top 150 Architecture Firms for 2019
  3. 13 projects that represent the future of affordable housing
  4. Sagrada Familia completion date pushed back due to coronavirus
  5. Top 160 Architecture Firms 2021