The community of Winchester, Ind., was in desperate need of a new roof for its aging high school. Teachers and students were coexisting in an interior environment that was wet, humid and had a repulsive smell. The school board met with a number of people, including a conventional roof trade association and an architectural firm that specialized particularly in flat roof work.
In January 2008, they elected to go with another flat roof on the high school.
However, the community was split over whether to use another flat asphalt roof or to use a sloped standing seam metal roof. In March 2008, Metal Roof Consultants attended a school board meeting and presented a sloped metal retrofit roof as an alternative to tearing off the existing roof and replacing it with another flat roof. The retrofit metal roofing system allows the existing roof to stay in place and constructing a new roofing system over the top of it.
The challenge
To provide a long-lasting roof that would permanently fix severe leakage issues associated with the existing flat roof on Winchester High School.
The solution
After the presentation by Metal Roof Consultants, it was decided that a retrofit metal roof system would be the best solution for the existing problem. MBCI, the leading manufacturer of metal roof and wall systems, was approved as the supplier for both the framing system and metal roof system for the 108,000-sf project. Smarrelli Construction was chosen to do the installation. The contract price was approximately $1.6 million, slightly less than the original estimate to remove and replace the existing flat roof.
The MBCI NuRoof Retrofit Roof System was installed over the existing roof’s framing members to create a sloped plane. Six inches of unfaced fiberglass insulation were installed directly over the existing roof. This raised the insulating value of the roof from R-3.5 to R-22.5, which provided significant energy savings. It also allowed the existing roof to release its moisture through the glass insulation into the ventilated air in the new roof cavitty.
Once the framing system was in place, a BattenLok HS standing seam metal roof was installed over it. This option allowed school to stay in session while the new roof was installed. The metal roof was an Energy Star qualified Cool Roof color, which, when properly used considering the environment and the slope of the roof, can reduce energy consumption because of its ability to reflect and emit the sun’s energy, providing significant cost savings.
Additionally, this solution eliminated the need to deposit the existing roof into the local landfill, which recent statics show that 7 to 10% of U.S. landfill space has gone to roofing waste over the last 40 years (ADPSR 1998-2007 Corps of Engineers Study). Metal roofing also allows for little to no maintenance. The contract price was $1.6 million, less than the original estimate to remove and replace the existing flat roof. MBCI also guarantees that the roof will not leak for a minimum of 20 years.
The retrofit system
The NuRoof Retrofit Framing System utilizes light-gauge (16 ga. to 12 ga.) steel framing, which is installed directly over the existing roof’s framing members to create a sloped plane. Regardless of whether your roof substrate is steel, wood or concrete, MBCI’s NuRoof system can be employed to satisfy the building owner’s requirements. MBCI has the experience required to design the retrofit framing system that will comply with the original load requirements of the existing roof.
The existing roof’s physical footprint, framing system and other rooftop conditions will most likely control the new roof’s geometry. A low-slope application (¼:12 to 2:12) is typically driven by economy and designed to discharge rainwater from the roof. High-slope applications (greater than 2:12) are also designed to improve and update the look of an existing building in conjunction with improving the performance of the roof.
Once a NuRoof framing system has been installed, one of MBCI’s standing seam metal roofs is typically installed, creating a ventilated attic space.
Standing seam metal roof systems
MBCI offers two types of standing seam metal roof systems--vertical leg and trapezoidal--which are of the most durable and weathertight roof systems available in the industry. Both systems can be used for new construction or retrofitting an existing building.
The vertical leg standing seam roof panels from MBCI blend the aesthetics of an architectural panel with the strength of a structural panel. These panels have earned several UL uplift ratings, assuring the reliability of performance. They also provide flexibility to meet design challenges. Each of these systems is designed to be installed over open framing. BattenLok HS is a vertical leg system.
Trapezoidal standing seam panels are available as a snap-together system or field-seamed system. They allow for strength, durability and weatherability. The standing seams are three inches above the lowest part of the panel, well above the water level as it flows off the roof. With a recommended minimum slope of ¼:12, the trapezoidal systems can be used on all types of construction, including metal, masonry or wood. +
Related Stories
Urban Planning | Apr 12, 2023
Watch: Trends in urban design for 2023, with James Corner Field Operations
Isabel Castilla, a Principal Designer with the landscape architecture firm James Corner Field Operations, discusses recent changes in clients' priorities about urban design, with a focus on her firm's recent projects.
3D Printing | Apr 11, 2023
University of Michigan’s DART Laboratory unveils Shell Wall—a concrete wall that’s lightweight and freeform 3D printed
The University of Michigan’s DART Laboratory has unveiled a new product called Shell Wall—which the organization describes as the first lightweight, freeform 3D printed and structurally reinforced concrete wall. The innovative product leverages DART Laboratory’s research and development on the use of 3D-printing technology to build structures that require less concrete.
Market Data | Apr 11, 2023
Construction crane count reaches all-time high in Q1 2023
Toronto, Seattle, Los Angeles, and Denver top the list of U.S/Canadian cities with the greatest number of fixed cranes on construction sites, according to Rider Levett Bucknall's RLB Crane Index for North America for Q1 2023.
University Buildings | Apr 11, 2023
Supersizing higher education: Tracking the rise of mega buildings on university campuses
Mega buildings on higher education campuses aren’t unusual. But what has been different lately is the sheer number of supersized projects that have been in the works over the last 12–15 months.
Architects | Apr 10, 2023
Bill Hellmuth, FAIA, Chairman and CEO of HOK, dies at 69
William (Bill) Hellmuth, FAIA, the Chairman and CEO of HOK, passed away on April 6, 2023, after a long illness. Hellmuth designed dozens of award-winning buildings across the globe, including the Abu Dhabi National Oil Company Headquarters and the U.S. Embassy in Nairobi.
Contractors | Apr 10, 2023
What makes prefabrication work? Factors every construction project should consider
There are many factors requiring careful consideration when determining whether a project is a good fit for prefabrication. JE Dunn’s Brian Burkett breaks down the most important considerations.
Mixed-Use | Apr 7, 2023
New Nashville mixed-use high-rise features curved, stepped massing and wellness focus
Construction recently started on 5 City Blvd, a new 15-story office and mixed-use building in Nashville, Tenn. Located on a uniquely shaped site, the 730,000-sf structure features curved, stepped massing and amenities with a focus on wellness.
Smart Buildings | Apr 7, 2023
Carnegie Mellon University's research on advanced building sensors provokes heated controversy
A research project to test next-generation building sensors at Carnegie Mellon University provoked intense debate over the privacy implications of widespread deployment of the devices in a new 90,000-sf building. The light-switch-size devices, capable of measuring 12 types of data including motion and sound, were mounted in more than 300 locations throughout the building.
Affordable Housing | Apr 7, 2023
Florida’s affordable housing law expected to fuel multifamily residential projects
Florida Gov. Ron DeSantis recently signed into law affordable housing legislation that includes $711 million for housing programs and tax breaks for developers. The new law will supersede local governments’ zoning, density, and height requirements.
Energy Efficiency | Apr 7, 2023
Department of Energy makes $1 billion available for states, local governments to upgrade building codes
The U.S. Department of Energy is offering funding to help state and local governments upgrade their building codes to boost energy efficiency. The funding will support improved building codes that reduce carbon emissions and improve energy efficiency, according to DOE.
