Mcnfeb Issue Final

February 2012
Roofing Material Handling in Bad Weather
Two Retrofit Metal Roofing Case Studies Success Stories: LaFaves Construction Health Care Projects
www.metalconstructionnews.com
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VOL. 33 NO. 2
Editor's Comments
Modern Trade Communications Inc. 7450 Skokie Blvd., Skokie, IL 60077 Phone: (847) 674-2200 Fax: (847) 674-3676 www.moderntrade.com www.metalconstructionnews.com
The Drive to Compete on Quality

When I talk to contractors in the metal construction industry, I always ask, How do you compete against your quality competition? I find its a good way to get them to articulate the best aspects of their companies, rather than just the mundane. Still, I often hear responses, such as, We have great attention to detail. Or We put the customer first. Those are great platitudes and important accomplishments, but they say nothing about how you accomplish those tasks. And it is in process where performance falls short of expectation. And for companies who want to compete based on the quality of their work, their inability to articulate how they deliver quality means their customers wont believe them. Why does this matter? Because they have become inured to messages of quality. Everybody talks about it, but nobody delivers it. A decade ago, Larry Bossidy, Ram Charan and Charles Burck wrote a great book called, Execution: The Discipline of Getting Things Done. At its publishing in June 2002, it received tremendous attention, and I had the privilege of hearing Charan speak a couple of times about how important executing tasks was to successful companies and how successful companies made sure that proper execution happened. You should know that Im a process kind of guy. I like a regular system that can produce a reliable result and will push hard to make sure that happens. In the editorial field, this is a common occurrence thing, because we have well-proven systems of writing, editing, designing and proofing with specific requirements at every step of the way. In construction, there are a lot more variables, and building reliable systems to execute a project with true attention to detail requires much greater effort. Still, its necessary. If a company wants to compete on quality, especially if its in a field with low-priced alternatives, it has to be able to both execute quality and articulate how its execution of quality is different from quality competitors. There is one, initial step to executing quality that I often see standing in the way of success. Many companies just dont have a sense of urgency. The cultures within those companies are not driven by the necessary and almost genetic need to execute quickly. Sure, deadlines can help drive a process, but a sense of urgency puts real push behind projects and tasks. Does your staff push for change and improvement? Are they restless? Does your management team grow frustrated with the slowness of the work pace? I recently spoke to an exhibitor at a trade show and asked, Whats new with your product? He explained that his product was essentially the same as it had been when he introduced it 30 years ago. Somehow, the advances in building technology, changing demands of designers and building owners, and improvements in construction processes had evaded him. His company did not have the sense of urgency that is imperative to success in todays market. In todays market of greater competition and tighter margins, a sense of urgency is essential to precise execution. And execution is essential to delivering quality. And delivering quality is essential to success. And, finally, an ability to prove quality is essential to gaining market share.
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Circulation audited by METAL CONSTRUCTION NEWS (ISSN-8756-2014) is published monthly and bimonthly in March by Modern Trade Communications Inc., 7450 Skokie Blvd., Skokie, IL 60077. Subscriptions are free for those in the metal construction industry in the United States. For those outside the industry, the subscription price is $45 per year, in the United States; $75, in Canada and Mexico; and $150 per year, in all other countries. Periodicals class postage paid at Skokie, IL, and additional mailing offices. POSTMASTER: Address service requested. METAL CONSTRUCTION NEWS, 7450 Skokie Blvd., Skokie, IL 60077.
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February 2012
METAL CONSTRUCTION NEWS
GET MORE LEADS - SELL MORE PROJECTS
Contents
Features:
18 Roofing Material Handling
Bad weather and roofing can be a bad mix. Ensuring everyone handles materials properly reduces the potential for warranty issues and poor performance.
February 2012 Vol. 33 No.2
18
22
Roundtable: Energy and Metal Construction

The impact of rising energy on metal construction continues to be a huge concern for building owners, designers and contractors. How is the metal construction industry handling the new pressure for increasing energy efficiency? Three industry experts weigh in.
26
Metal on Metal Retrofits

Two case studies examine the role and opportunity for retrofit metal roofing. One looks at metal-over-metal retrofit, while the other looks at metal-over-flat retrofits.
22
28
Devoted to the Long Haul

LaFaves Construction of Landis, N.C., has expanded over the last 30 years due to a devotion to customers and smart decisions about pursuing niches. The decision in 2004 to jump hard into the retrofit metal roof market is paying off today with a stable and sustainable business poised for the future.
Expand Your Business: Lightning Protection for Metal Construction 30 31 32 Lightning Protection Systems:
Separating fact from fiction about metal roofs and construction
26
Threats from Lightning Strikes:

Protecting green buildings from lightning damage
Surge Protection:
Proper electrical grounding increases power quality and decreases potential damage
Departments:
Find out how Simple Saver Synergy Designsm has helped contractors be successful in a down economy and how we can help you get more sales. Thermal Design will provide a Simple Saver Synergy Designsm analysis that includes:
3 8 10 12 34 50 51
Editors Comments Profit Building Retrofit Business: The Project Team Industry News and Events Project Focus: Health Care New Products Product Catalogs: Standing-Seam Metal Roofing; Roof Underlayment; Gutters, Rainware, Ridgecaps and Trim Ad Index Editors Pick: A Unified Campus New U.S. Embassy compound connects with its location
On the cover: LaFave's Construction of Landis, N.C., did this retrofit metal roof on the Ketner Building at Catawba College, Salisbury, N.C. Photo by Mark Bouldin
28
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February 2012 METAL CONSTRUCTION NEWS 5
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Online Contents
Features
February 2012 Vol. 33 No.2
Visit www.MetalConstructionNews.com and see whats happening in the metal design and construction community from the industrys premier news resource.
Discover whats in store for 2012 in our state of the industry report. Find out how to finance metal buildings. Learn about leakproof corners for metal buildings.
Long Tab with Banding

Attractive Efficient Economical
Long Tab wiTh banding
Top Stories
Figure out if you should get into the retrofit roofing game. Read about timely tools to boost your bottom line.
Industry News
Check for the latest updates from the AISC, AISI, the EPA and more.
Social Media
Have you liked us on Facebook? Followed us on Twitter and LinkedIn? Do you read our blogs? We are now updating our social media channels with the latest news and information. You dont want to be left out of the conversation. GUARdEd HoT Box TEsT REsULTs* By CERTIFIEd TEsT LABoRAToRy
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Non-proprietary system Easy installation of electrical, HVAC and sprinkler
Directory
Search our extensive online database for: Metal product suppliers Manufacturers Services that fit your needs
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February 2012
PROFIT BUILDING TIMELY TOOLS TO BOOST YOUR BOTTOM LINE!
Back by Popular Demand

Architects, builders, and suppliers to the metal residential design & construction market have spoken, and weve listened. Metal Home Digest returns in March 2012.
Supplement to Metal Architecture & Metal Construction News Published four times in 2012 Premier issue in March Distribution of over 54,000 Well cover New developments and ideas in single family Multifamily Light-gauge steel framing New and retrofit projects Installation techniques
Tool #2 Focus On Finishing Faster!

By George Hedley
I was visiting one of our construction job sites a few years ago in early August. We were building a large 75,000-square-foot concrete tilt-up warehouse building. The project superintendent, concrete foreman and I were discussing the job schedule and when the tenant was expecting to move in. They werent sure what the exact movein date was nor the contract completion date nor what the city required to get a final inspection and release to get the utilities turned on. Not a comforting thought considering this project team was supposed to be in charge of a $2,500,000 project! will be unhappy; and you will end up in a dispute over delays and damages with your customer and subcontractors. And even more important, your customer will tell everyone that your company finished later than promised. could easily and would surely finish two weeks faster. Not a bad investment for me. A $2,000 investment versus our 20 men crew working for two weeks longer than expected ($40,000 minimum plus on-site costs). The end of the story is they actually tilted-up the walls on October 26. I gave both the superintendent and foreman $1,000 each plus every crew member a day off with pay for their extra efforts.
Spend a little to make a lot!

At our job-site meeting, I next asked the project team leaders when they were planning on tiltingup and erecting the concrete wall panels. Lifting and erecting tilt-up wall panels is a very critical, critical path item when building an industrial building from the ground up. They told me they had scheduled the 100-ton crane to erect the panels in mid-November. I was thinking: Three more months. That seems way too long and wont leave enough time to finish the project and meet our contract completion date! I asked them how they arrived at mid-November. They said they had all decided it was reasonable, doable and makeable in order to make sure they would be ready for the crane. I asked if they had checked the construction contract or budget estimate to see if mid-November would work or fit into the project goals. They hadnt. In fact, both of them didnt know what the contract said about the completion date or the budget for time on the project. I was a little upset, to say the least. Rather than fire them both on the spot, I decided to see if I could coach them to a better result for themselves, the company and our customer. I then asked if they could possibly move the date up a few weeks. They hesitated and shook their heads no in protest. So I tried to encourage them to think about how they could move the job a little faster. No ideas. So I next offered them both a $1,000 incentive bonus if they erected all the walls by October 31. Guess what happened? They both changed their tune in a hurry, agreed, promised and guaranteed they
Offer more to get more!

What games, bonuses and incentives can you offer to entice your crews to work faster and boost your bottom line? Faster jobs equal more money in your pocket. Try different incentives like competitions between crews, games to beat the budget, challenges to finish ahead of schedule, hardware store coupons for no defect or punch-list items, catered barbequed job-site lunches for meeting milestones, dinner gift cards for crews who hit important targets, winter jackets for no job-site accidents, or anything else that will keep work fun, exciting, interesting and competitive. Make it your priority to tell your people how difficult it is to actually make a profit. Explain that these bottom-line boosters can make a big difference. Your job is to make it your priority to focus on the positive factors you can influence instead of complaining about the economy or your competition. Get your team focused on what you need to happen to make money. Post the schedule completion dates for all to see and offer some incentives to beat the schedule. George Hedley owns Hedley Construction & Development Inc. and Hardhat Presentations in Newport Beach, Calif. He is an entrepreneur, best-selling author, popular speaker and business coach. Visit www.hardhatpresentations.com for more information.
Put the dates where all can see them!

Our company bids this type of project often and typically calculates the costs and project requirements based on a six to seven month total completion schedule. Our contracts always specify the start and completion date. And in the first project meeting with our customers, these dates are confirmed and documented to avoid issues at the end of the project when people tend to forget what was said and committed to six months earlier. I recommend the team post these critical dates on the job office wall in bold letters for all to see. I suggest they post the start date; completion milestone target dates including foundations, slab, exterior walls, roof structure, rough framing, drywall taping, floor coverings, final inspection, utilities on, and punch-list completion; and the final contract completion date. With these dates clearly posted and tracks, they will stay focused on the tasks required to not let them slip. A project team without a clear knowledge of the contracted completion date or understanding of whats required to make it happen is a disastrous predicament for a construction company. Finishing a project late means you will surely spend more than the estimated and budgeted costs for field labor, supervision and general conditions; the customer
For advertising information, contact

Jim Morrissey
(847)674-2200 ext. 19 jmorrissey@moderntrade.com
Bob Higgins
(847)674-2200 ext. 22 bobhiggins@moderntrade.com
Art Mazzone
(847)674-2200 ext. 23 artmazzone@moderntrade.com
John Paul Lawrence
(847)674-2200 ext. 21 jplawrence@moderntrade.com
February 2012
RETROFIT BUSINESS
The Retrofit Roofing Game The Project Team

By Mark James
Last month I left you with three things to remember. This month, we
will discuss the first of those, which is the Project Team and how this group is vital to the success of a retrofit project. The members of this team are the building owner, the design professional, the systems manufacturer and the roofing contractor. As mentioned last month, you cant forget that a retrofit roof system is the marriage of the existing roof and its structural support system to
the new metal roof and its structural support system. I know this sounds redundant, but it really is as simple as that. Neglecting what happens to the existing roof when you install a new retrofit roof system can get you in trouble. This is why the design professional is so important to the Project Team. Through design analysis, this player can ensure the existing roof and its structural support systems structural integrity is maintained. To be fair and to recognize our design-build contractor community, there are several of you out there who are legally qualified to do both the design and construction on retrofit projects. Another equally important team player is a systems manufacturer qualified to engineer the new retrofit framing and metal roof systems, as well as provide the materials needed to do the job. The trick here is to find a manufacturer that understands how to minimize the loads being imposed into the existing roof system to maintain that structural integrity I mentioned. Based on the metal construction industrys practices (as defined by the Metal Building Manufacturers Associations Metal Roofing Systems Design Manual) and terminology relating to the design, manufacture and installation of its products, each member of the Project Team has specific roles and responsibilities: Building OwnerThe party who is the owner of the construction project and is the end customer. For a specific construction project, the building owner may act as the general contractor. If the building owner purchases materials only from the roofing contractor, the building owner has the responsibility for the installation of the metal roof system as provided. Design ProfessionalAn architect, engineer or roof consultant (if legally qualified to perform professional design services) retained by the building owner or contractor to assist in the preparation of design specifications for the construction project. The responsibilities and rights of the design professional and the building owner are defined in a separate agreement for professional services between the parties. Systems ManufacturerThe party who designs and fabricates the materials included in the retrofit metal roof system in accordance with the order documents. The systems manufacturers responsibilities include: Design the metal roofing system to meet the design criteria as specified and required, with the direction and advice of the manufacturers engineer.
The systems manufacturers responsibilities do not include: The design of any components or materials not supplied by it or their interface and connection with the metal roofing system. The manufacturer is responsible only for the structural design of the metal roofing system it supplies to the roofing contractor and the manufacturers engineer is not the design professional or engineer of record for the project. Roofing ContractorThe team member that orders and purchases the metal roof system from the systems manufacturer and installs all of the materials for a complete project. The roofing contractor is an independent contractor and is not an agent of the manufacturer.
Design Responsibility
When the building owner hires a design professional for a construction project, design professional is responsible for specifying the design criteria, including all applicable design loads. When the building owner does not retain a design professional, the building owner must specify the design criteria and applicable design loads. In any event, the roofing contractor must interpret all aspects of the building owners specifications and incorporate the appropriate specifications, design criteria and design loads in the order documents submitted to the systems manufacturer. As the Engineer of Record, the design professional is legally responsible for executing the design analysis of the existing roof system and calculating its ability to receive the weight and the newly imposed loads of the retrofit framing and roof system. Please note that most of the Retrofit System Manufacturers do not offer this service under their engineering responsibility or through an independent consulting engineer. The project team is essential to ensuring the existing and the new roof work together to ensure a safe and structurally correct roof assembly. Next month I will dive into this much more with basic roof design and the marriage of old roofs to new roofs. Mark James has more than 40 years experience in the retrofit and metal construction markets, working for leading manufacturers and executing great projects. Currently, he is president of RetroSpec LLC, a consulting company offering direction and deep knowledge of the retrofit business for manufacturers and contractors. James can be reached at mark@retrospecllc.com.
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February 2012
INDUSTRY NEWS
chain can learn practical strategies and affordable measures to run sustainable operations, as well as discover new business opportunities in the green marketplace." Members of the group receive discounts on Products for Windows and Sliding Glass Doors" and AAMA 1102-11, "Voluntary Specification for Side-Hinged Secondary Storm Doors." In previous versions of AAMA 1002, Secondary Storm Products (SSPs) were referred to as combination storm windows and sliding glass doors or insulating storm products for windows and sliding glass doors; however, these products are now included in the scope of AAMA/WDMA/CSA 101/I.S.2/A44011. SSPs covered in this voluntary specification are clarified to be units used in tandem with prime windows and prime sliding glass doors to improve the interior environment. Only those requirements unique to SSPs are detailed in this voluntary specification. The Voluntary Specification for Secondary Storm Products for Windows and Sliding Glass Doors" is available to AAMA members at a cost of $10 for download, $20 for a paper copy and $25 for a CD. Non-members may purchase the document at a cost of $30 to download, $60 for a paper copy and $66 to receive a CD. To order AAMA 1002-11, visit www.aamanet.org. resourcesincluding BIM. Multiple paths to find products. Ability to browse and filter. Find other products users may like. Easy connection to CMC Reps. For more information, visit www.chicagometallic.com.
top stories
Best in industry product finder and
Finished steel import permit tons up 16 percent

Based on the Commerce Department's most recent Steel Import Monitoring and Analysis data, the American Iron and Steel Institute reported that steel import permit applications for the month of December 2011 totaled 2,208,000 net tons. This was a 9 percent increase from the 2,027,000 permit tons recorded in November 2011 and a 5 percent increase from the November preliminary imports total of 2,107,000 NT. Import permit tonnage for finished steel in December was 1,618,000 NT, down 2 percent from the preliminary imports total of 1,646,000 NT in November. Full-year 2011 total and finished steel import permit tons were 28,646,000 NT and 21,871,000 NT, up 20 percent and 16 percent, respectively, vs. the 23,929,000 NT and 18,857,000 NT imported in 2010. The estimated finished steel import market share in 2011 was 22 percent, and was 19 percent in December. Finished steel import permits for products that registered large increases in December vs. the November preliminary include reinforcing bar up 101 percent, sheet and strip all other metallic coated up 45 percent, wire rods up 38 percent and mechanical tubing, up 16 percent For fullyear 2011, products that saw significant increases vs. 2010 include cut length plate up 55 percent, mechanical tubing up 44 percent, plates in coils up 34 percent, line pipe up 33 percent, sheet and strip, all other metallic coated up 32 percent, reinforcing bar up 27 percent, hot rolled bars up 26 percent and oil country goods up 23 percent.
conferences, workshops and webinars; helpful event announcements and topical discussions; as well as access to sustainability resources. The cost to join the Green Manufacturer Network is $150. Members will be able to share knowledge on sustainable manufacturing and promote awareness that going green can increase profitability while forming valuable contacts with other green leaders through volunteer and educational opportunities. For more information, visit www.fmanet.org.
WE JUST IMPROVED ENERGY EFFICIENCY IN METAL BUILDINGS. AGAIN.

NAIMA 202-96 Certified Fiber Glass Metal Building Insulation Standard
AIA and ABC announce contract documents partnership agreement

The American Institute of Architects and Associated Builders and Contractors recently announced a marketing partnership agreement, designed to foster a greater understanding and exchange of ideas between architects and contractors in the construction community. As part of the partnership, AIA will provide a number of benefits to ABC members, including a discount on the purchase of any retail-priced AIA Contract Document software license and access to AIA Contract Documents education programs.
1996
Commercial Energy Calculator
2007
OptiLiner Banded Liner System
2010
GAF sponsors the Certified Green Dealer Program

GAF announced that it has extended its commitment to green building and sustainable building practices by sponsoring the Certified Green Dealer Program at the platinum level. The Certified Green Dealer Program, www.CertifiedGreenDealer.org, is a program for training and certifying building material dealerships in the knowledge of green building products and practices. "GAF has allocated substantial resources to green building, and it's very clear that the company 'talks the talk' and 'walks the walk' when it comes to green building for commercial and residential buildings," says John D. Wagner, partner of the Certified Green Dealer Program. "GAF has demonstrated a clear commitment to green roofing and shingle recycling programs. Through the Certified Green Dealer Program, we hope to make GAF's programs pervasive throughout the industry."
ELAMINATOR Insulation System
1994
Chicago Metallic launches new website
At Owens Corning were always looking for new ways to improve energy efficiency in metal buildings. We started by making roof insulation faster and safer to install with the ELAMINATOR Insulation
R-values. Next we developed a Commercial Energy Calculator to demonstrate the energy cost savings benefits associated with higher levels of insulation. And now, with our OptiLiner Banded Liner System, you can fill the metal building roof and wall cavities to achieve maximum thermal performance. What will we think of next?
Gamco releases new product catalog

Gamco Corp. has released a new product line catalog. The new 20-page full-color brochure represents a major upgrade of the company's existing materials and covers Gamco's full line of storefront systems, glass entranceways, curtainwall, skylights, column covers, railings and metal Chicago Metallics new website features a new landing page with links to all of Chicago Metallic's divisions in North America, Europe, Asia Pacific and Middle East, showcasing the company's global expertise. The landing page formed special products. The catalog includes product and product detail photographs, product features and options lists, and other specific information for each Gamco product line. The new catalog also includes user-friendly product selection tables, an updated corporate profile of Gamco, and many photographs of notable projects where Gamco's custom products have been incorporated. To obtain a copy of the new Gamco catalog or for more information, contact the company at (718) 359-8833, or by e-mail at info@gamcocorp.com.
System. Then we helped drive the development of the NAIMA 202-96 Certified Fiber Glass Metal Building Insulation Standard, ensuring post-lamination
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FMA announces Green Manufacturer Network

The Fabricators & Manufacturers Association International invites manufacturing executives to join its new Green Manufacturer Network, a professional organization of individual members working together to drive the transition toward environmentally friendly manufacturing. "The mission of the Green Manufacturer Network is to be the principal resource to advance sustainable manufacturing," says Edward Youdell, president and CEO of the FMA. "By joining this network, executives throughout the entire supply 12 METAL CONSTRUCTION NEWS February 2012
AAMA announces the release of revised specifications for secondary storm products
The American Architectural Manufacturers Association has revised two specifications related to secondary storm products, AAMA 1002-11, "Voluntary Specification for Secondary Storm
welcomes the design-build industries to their respective geographic home pages to help them quickly find the most pertinent products and information. Features include: In-depth information on a wide range of commercial ceilings. Great photos and case studies showing product in application.
Banding
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THE PINK PANTHER & 19642012 Metro-Goldwyn-Mayer Studios Inc. All Rights Reserved. The color PINK is a registered trademark of Owens Corning. 2012 Owens Corning.
February 2012
13
INDUSTRY NEWS
top stories
Webpage and brochure show benefits of FiberTite simulated roofing project
Seaman Corp. introduces a new brochure and webpage for FiberTite Simulated Metal Roofing. Some of the webpage's features include a link to request the new brochure, project profiles, downloadable PDFs of brochures, data sheets, installation tips, guide specifications and construction details. To visit the page, go to www.fibertite. com/products/simulated-metal-roofing.html.
personnel update
Automatic Stamping is well known in the truss industry and highly regarded as an extremely efficient, high-quality manufacturer of truss plates. We are very excited about this new venture and look forward to being able to offer our customers some of the best truss plate products in the industry, says Mike Bugbee, vice president of the truss and component industry for Simpson Strong-Tie. Bill Black added, Its an honor to be affiliated with a company such as Simpson Strong-Tie who has the same integrity and determination as Automatic Stamping LLC. We look forward to making history in the truss plate industry. In addition to the new truss plate offering, Simpson StrongTie will launch an initial release of its new truss plate software later this year. The company acquired the source code of Keymarks truss software last fall and has been aggressively developing its software and technical support capabilities in order to provide truss and component industry customers with a high-quality, high-performance product offering.
CIW Enterprises acquires assets from Janus International Corp.

Effective immediately, Janus International will cease to produce architectural coiling door products. Their plan is to redirect their energy towards advancing their already leading position in the sheet door business. CIW Enterprises Inc., the owner of The Cookson Co. Inc. and Cornell Iron Works Inc., has entered into an agreement to purchase substantial manufacturing assets from Janus as well as inventory. "I am very excited about the opportunity this agreement affords us," says Andrew Cornell, president of CIWE. "It allows both companies to grow our leadership positions in each of our respective segments. We will continue to use our position to assure an unmatched level of quality to our distributor, architect and contractor customers." Neither Cookson nor Cornell intends to manufacture the Janus rolling service products. While Janus will retain responsibility for any installed product, CIWE and its brands will attempt to handle any issues that may arise. The Cookson and Cornell brands will work to the best of their ability to assist Janus in the processing of any repair needs or warranty claims.
ISIS
AISC launches Spring 2012 Seminar Series

The American Institute of Steel Construction's Louis F. Geschwindner Seminar Series offers structural engineers and other designers opportunities to enhance their professional knowledge while learning from sought after industry experts. Presented by the AISC, the Spring 2012 Seminar Series will be offered in more than 30 cities around the U.S. from February to July. For more information, visit www.aisc.org/seminars.
Simpson Strong-Tie Acquires Automatic Stampin LLC and Automatic Stamping Auxiliary Services LLC
Simpson Strong-Tie has recently acquired the majority of the assets of Automatic Stamping LLC and Automatic Stamping Auxiliary Services LLC to launch its truss plate offering. Automatic Stamping is based in Edenton, N.C., and is a family-owned business with a long history in the truss plate industry. Former owner Bill Black will continue to lead manufacturing and plate innovation operations in Edenton.
A Ceiling Fan That Actually Works.

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Alum-A-Fold Pacific Inc. hires new president

Whittier, Calif.-based Alum-A-Fold Pacific Metal Products announces Raul Casillas has been named president. Casillas comes to AFP with more than 30 years of diverse management and leadership experience in manufacturing, distribution and sales. His previous roles have included COO in the aftermarket industry, vice president of business development in the custom injection molding industry, and global procurement in consumer products and electronics manufacturing industries. Casillas has strong global experience in world-class manufacturing operations.
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Duro-Last Roofing Inc. adds personnel

Saginaw, Mich.-based Duro-Last Roofing announces the addition of Cory L. Gergar as its CFO. Gergar will be responsible for all accounting activities including financial analysis, strategic planning, policy development and implementation, compliance and reporting in support of corporate objectives for Duro-Last and its sister companies: Plastatech Engineering Ltd., EXCEPTIONAL Metals, Creative Impressions, Oscoda Plastics Inc. and TIP-TOP Screw Manufacturing Inc. With extensive experience in financial management, budgeting, coordination between multiple departments, costing systems and continuous improvement processes, Gergar will be a strong contributor to the achievement of the financial goals of all companies. Duro-Last has also hired Bill Carroll as vice president of manufacturing and promoted Jim Chrysler to director of procurement. Carroll is responsible for overseeing the plant operations of all four DuroFebruary 2012
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INDUSTRY NEWS
Last locations, as well as Plastatech Engineering Ltd., Oscoda Plastics Inc., EXCEPTIONAL Metals and TIP-TOP Screw Manufacturing. Carroll's responsibilities include oversight of production, quality, inventory and safety, with the overall objectives of meeting customer delivery requirements and company sales and profitability goals. He has more than 25 years in leadership positions in multi-plant manufacturing environments, most recently as plant manager for Gardner Denver Thomas, a manufacturer of industrial pumps for the medical and environmental industries. Chrysler will be responsible for the supply agreements and activities associated with the procurement of materials for manufacturing operations at Duro-Last and its sister companies. Chrysler was hired in 2001 as the purchasing manager for Plastatech and was promoted to controller in 2004 while continuing his role as purchasing manager for Plastatech and Oscoda Plastics.
personnel update
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Lapolla Industries Inc. hires director of research and development

Houston-based Lapolla Industries Inc. announces Roger Ervast has joined the company as the director of research and development. Ervast will oversee the entire laboratory facility in the Lapolla Corporate Center in Houston. He possesses more than 40 years of experience in the industry focused on urethane technology including spray polyurethane foam and rigid pour systems in both construction and OEM applications.
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Rigid Global Buildings announces two new leadership roles

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16
SPECIAL FEATURE ROOF MATERIAL HANDLING IN BAD WEATHER

The affixed orange warning label explains to contractors what they must do to keep the coil dry. (Photo courtesy of Englert Inc.)
Temperatures on standing seam metal panels can and often do rise above ambient. Steel absorbs heat and the temperature can severely burn roofers. Usually, if temperatures are expected to rise above normal temperatures of 70-80 F, it would be wise to set scheduled work to begin long before sunrise, says Jim Townsend, product manager, EXCEPTIONAL Metals, Saginaw, Mich. Workers will see a peak period in the day, usually around 1 p.m., at which the temperature will rise 60-80 F above ambient. Workers should plan to clean the area, store materials, and leave the job site prior to peak temperatures rising to a point of high risk during handling and installation. Footwear should provide the type of sole that avoids the feet from becoming burned from walking the panels. Summer and spring rain will always cause delays. When you see lightning, you have to be careful and shut down, says Terry Blount, roofing hoist designer at roofinghoist.com, Mobile, Ala. Sometimes you really can get pushed to get a job done. If it is misty or light rain you can just work through it, but not heavy rain. Roofing contractors do not install standing seam in rainstorms and thunderstorms with or without lightning, says Dave Rowe, product manager at Englert Inc., Perth Amboy, N.J. Most standing seam material today has a Kynar coating with properties similar to Teflon designed to shed snow, dirt and debris. Rain makes the material more slippery and not suitable to work on. Working with metal standing seam panels in a thunderstorm is simply not done. Standing seam being cut, carried and installed during a lightning event would be extremely dangerous, like holding a metal golf club in the air. Professional safety experts recommend that any construction involving metal be halted until at least a half hour after thunder and lightning in a storm has stopped.
warmer than the ground when the sun is out, but finding one in the winter is not always easy. A contractor could conceivably shovel the snow off an existing roof, wait until whatever is currently on it to dry and then start installation of a standing seam product, Rowe says. Problem? By the time the roof dries out enough to reroof with metal, the daylight is nearly gone. Contractors never try to install a roof covered with ice. Additionally, panels should be cleaned and free of snow or ice when raising them to the roof to avoid slippage and dropping of the panels as they are lifted and walked on during installation, says Townsend. Ice and snow build up on the metal panels at the roof should be treated with extreme caution due to sliding under normal foot traffic. Clearing the panels and wearing footwear designed to grip the steel panel is strongly recommended for all OSHA safety reasons. In cold weather, installing panel clips and making sure they are positioned correctly gains importance. In cold weather, a metal roofing panel will be shorter than in hot-weather summer, says James R. Kirby, AIA, associate executive director, National Roofing Contractors Association, Rosemont, Ill. If you put the clips on incorrectly, you can actually have some crimping and oil canning. Windy weather can destroy panels by bending them during handling. Debris and dirt can get blown under the roof membrane onto exposed adhesives. High winds make cutting, carrying and installing standing seam roofs dangerous. Because of their light weight and panel widths, standing seam panels can act like a kite, Rowe says. Wind can easily get under uninstalled panel or buffet it when it is carried, making it difficult or impossible to control. In any circumstance of high wind, the panel could be carried away by the wind, making it a dangerous airborne missile. Also, high winds can produce enough uplift forces to cause a complete roof blow-off.
on exposed metal roof panels before installation is quite different from its impact on them once they are installed. One thing that we are concerned with is stagnant water, says Kirby. Ponding water is what we call it on the roof, stagnant water is what we call it when it is on a panel lying on the ground. On low-slope roofs you have ponded water in areas, which will evaporate over a couple of days, versus the water that runs to the drains on a steep-sloped roof. Water comes off of steep-sloped roofs. A roof is not intended to hold water. When exposed to moisture and heat from bad weather, oxidation and paint peeling can occur on metal panels. With galvanized steel, a white powdersometimes called white rustwill form on the zinc coating. To prevent this, once metal panels are delivered to customers, they should be stored indoors in a climate-controlled warehouse. They can be stored outside if necessary, but only for short periods of time. Whether stored in a warehouse or on the ground outside, metal panels must be positioned correctly. Bundles should be placed on wooden skids at least 6 inches off the ground away from high-traffic and flood areas. Raising the panels high enough off the ground creates an airflow beneath the bundle. This inhibits ground moisture from condensing on the bundles underside. Tilting one bundle end higher than the other allows moisture drainage. Pre-formed panels need to be elevated, and they need to be approximately layered and angled to drain so that they dont act like gutters and hold moisture, Kirby explains. Covering them and making sure they dont get wet in bad weather would be the best way to do it. You need materials and packaging that allow for some breathability, you dont want high condensation on stored panels. If you put the panels down on pallets and you use the right tarps, no problem. A loose-fitting waterproof tarp can protect bundles in rain and snow, and allows for air circulation and drying of condensed water. Air should be allowed to move freely around the panels to avoid condensation, Townsend notes. Most people
Take care of your roofing materials before Mother Nature doesnt

In a perfect world, all roofs would be installed on sunny days with temperatures between 35-75 F degrees. This is not always possible. And, as durable as metal and building materials are, they still need protection during storage and handling at construction sites in bad weather. To construct a quality building, you need quality materials, and these materials must be handled and stored correctly in bad weather to retain their quality. ties for metal building construction. Metal roofs can be installed throughout the year provided it is not too rainy, frosty, icy, windy, hot or cold. While it is usually the busiest season for roof construction, summer is not always ideal. Excessive heat can fatigue workers.
Handle with Care

Respect the elements
All four seasons provide challenges and opportuniFebruary 2012
By Mark Robins, Senior Editor
Snow and high winds

Winter months dont necessarily mean a shutdown in roof construction. Many roofing companies offer discounts for roofing jobs during the winter. Often, a snow- and ice-free roof can be 20-30 degrees
Keep metal panels dry

Ironically, one of weathers challenges to metal roof panels quality is moisture. Moistures impact
Communicate about the criteria

Panel manufacturers and their paint suppliers should communicate the performance criteria of their products. Each provider of materials mandates exactly how their materials are to be handled and stored in inclement weather: rain, lightning, snow and ice, says Jim Townsend, product manager, EXCEPTIONAL Metals, Saginaw, Mich. While most recommend the performance, safety and installation steps, each is different in how they recommend that procedure be initiated in the field. An example of this is protective sheeting that comes on metal panels. Depending on how the film is installed on the actual panel, sometimes you have to take the film off right before you crimp the panel seams or after you crimp the panel, says James R. Kirby, AIA, associate executive director, National Roofing Contractors Association, Rosemont, Ill. It depends on the manufacturer. Townsend advises general contractors, architects, construction managers and roofing contractors should get together prior to the start or design of a project to be brought up to date on methods, recommended procedures, storage and handling. When these steps are taken and monitored, the end result is usually the best result.
18
February 2012
19
SPECIAL FEATURE ROOF MATERIAL HANDLING IN BAD WEATHER

Metal building materials frequently arrive at job sites with shrink-wrapped, factory-applied plastic sheeting to protect them from bad weather. (Photo courtesy of Englert Inc.)
Uncoil your vision.
arent aware that panel finishes, like PVDF paint finishes, can dissolve if moisture is allowed to form and remain on the painted finish. Most manufacturers of PVDF paint finish will confirm that they take no liability for the finish if the panels were not stored properly prior to their installation. Metal panels frequently arrive at job sites with shrink-wrapped, factory-applied PVC plastic sheeting to protect them from bad weather, but it should be taken off very quickly after installation. Plasticcoated metal sheets should not be exposed to di-
rect sunlight for prolonged periods of time, Rowe cautions. Direct sunlight can bake the protective plastic to the sheet metal. Frank Albert, owner and operator of Albert's Specialty Roofing, a roofing contractor based in Richmond, Va., says the main thing I've learned about site storage is to keep panels separated from each other. If they're touching, they get wet and stay that way. Rust can form easily if the issue continues. Copper will turn color no matter what you do, not too big a deal if the client is expecting it.
They have to know in advance it will lose its shine and go brown within days anyway. Whenever possible, I try to work at a place that has a garage or other shelter to keep my panels, or raw metal, dry. In the case of 1,000-pound rolls of copper, I sometimes take the metal to the shop for storage every night and weekends if it's on a trailer. Also, 0.045 EPDM makes a good cover instead of plastic or tarps. Regardless of the season or elements, roofers must respect the weather and not haphazardly handle building materials or endanger workers.
Sealants and temperature range

Keep humidity, temperature and moisture in mind when using sealants and caulks. Cold weather delays activation and adhesion of roofing sealants. A common mistake is roofers trying to seal in cold weather, cautions John Pierson, PE, engineering services manager, The Garland Co. Inc., Cleveland. For activation, temperatures should be 40 F and rising. Apply sealants to clean surfaces. They can be cleaned with an alcohol surfactant. Water-based caulks are not recommended for outdoor projects, because these products cannot withstand the hot-to-cold and cold-to-hot weather changes, as well as other harsh weather situations. On job sites where it is below 50 F during sealant application, use a silicone sealant instead of polyurethane, because polyurethane is very difficult to apply at this temperature. In cold weather, store sealants at temperatures of 60-80 F in insulated or heated storage boxes until application. Very few sealants can be applied to wet surfaces, they exist, but they are hard to find. Make sure sealants are rated for exterior use or preferably roofing applications. They must handle the UV rays from the sun and freeze-thaw cycles, which can break down non-rated sealants within a few months causing them to lose their elasticity.
Metal lets you bend your imagination to life. But for all of its flexibility, it will take a tough skin to preserve and protect your greatest accomplishments. Put your trust in the coatings that are engineered to endure the test of time and the elements. And with thousands of colors already formulated, have no doubt we have the right coating for your project. Find out which Valspar product is right for your job. Call 1-888-306-2645 to speak with an expert or visit valsparcoil.com.
2012 Valspar Corporation
20
February 2012
BUSINESS FEATURE ROUNDTABLE

The LEED-platinum certified William J. Clinton Presidential Center in Little Rock, Ark., surpasses existing energy efficiency standards and demonstrates current renewable energy generation technologies. (Photo courtesy of AkzoNobel, AAMA)
Energy Efficiency and Metal Construction

By Mark Robins, Senior Editor
Doug Todd,
market manager, commercial construction Dow Building Solutions, The Dow Chemical Co., Midland, Mich.
Brian Nelson,
general manager, Knight Wall Systems, Deer Park, Wash.
Richard Walker,
president and CEO, American Architectural Manufacturer Association, Schaumburg, Ill.
Metal Construction News asked several industry experts about energy efficiency and its impact on metal construction. MCN:
How has the push towards energy
to focus is on addressing air leakage by detailing effective and efficient air barriers that work with the insulation. For example, Dow Building Solutions THERMAX insulation can meet both continuous insulation requirements with R-6.5 at 1-inch and air barrier requirements in one easy-to-install package. Dow has identified cost effective and field-tested methods to meet the mandatory air sealing of the building envelope using insulation with tapes, PVC joint strips, insulation edge treatments, construction grade sealants and adhesives, and air sealing foamseither singly or in combination as needed. Designers also need to look at addressing heat loss through foundations and slabs.
fluences on overall building design. One of the most common changes has been the increased efficiency of wall assemblies. These improvements generally include increased amounts of insulation; however more recently, stress and emphasis has been placed on the effectiveness of the insulation used. If the push for highly efficient buildings had not come as far as it has, this awareness of insulation effectiveness might not have happened (or happened as quickly as it has). Change within the construction industry is typically a slow and painful process, but todays goals of sustainability and energy conservation have helped speed change right along.
can be beneficial in maintaining structural integrity, while resisting water and air infiltration. This also allows the building to keep its desired appearance. Aluminums versatility has long made it a preferred material in many construction projects. Combined with the fact that it is available in numerous shapes and a spectrum of colors, its structural attributes allow aluminum to be used in nearly every application. These include solar optimization in products like sunshades, light shelves and skylights to adding comfort in the most elite homes in the form of folding walls and sunrooms. Thermal barriers enhance energy efficiency in aluminum fenestration systems. Thermal barriers are made from resins that create a thermal break between the inner and outer surfaces of aluminum fenestrations. These reduce heat loss or heat gain through the aluminum, and improve the U-value characteristics of finished systems. Approximately
70 percent of aluminum fenestration systems produced in North America contains a thermal break. The use of thermal barriers will assist manufacturers aiding building projects that are pursuing LEED performance criteria and to meet stricter government regulations to reduce power usage in buildings.
example, ASHRAEs strategic plan 2010-2015 calls for a 50 percent reduction in annual energy use from the ASHRAE 90.1-2007 standard in all building types; ASHRAE 90.1-2010 version calls for 30 percent more energy-efficient buildings compared to the 2004 version. The codes and design community now recognize the importance of continuous insulation (ci), an uninterrupted blanket of insulation that spans structural members without thermal bridges other than from fasteners and service openings. In most climate zones, buildings designed under ASHRAE 90.1-2007 and IECC 2009 require continuous insulation; it is no longer simply a value-added option. Addressing air leakage through the building envelope is a newer design concept for many. Codes are increasingly mandating air barriers; ASHRAE 90.1-2010 and IECC 2012 mandate a continuous air barrier for all building types. THERMAX insulation
efficiency in buildings influenced the design and construction of metal buildings?
MCN:
What are the codes, standards, laws
or regulations that affect energy efficiency in buildings and what are their impacts?
Doug Todd: The design communityincluding manufacturers and associationshas embraced the need for improving energy efficiency by developing and implementing new and innovative products and solutions. Although one easy way to improve energy efficiency is to add more insulation, adding more insulation is not always enough. If the building envelope leaks air through openings and cracks, the overall impact of the insulation is bypassed. What designers and installers now need
Todd: Model energy codes, such as ASHRAE

90.1 and International Energy Conservation Code (IECC), and other green guidelines, all have similar goals: to reduce energy use by reducing fuel consumption and greenhouse gas emissions. Updates to model codes and green guidelines continue to adopt new building science technologies, such as recognizing the need for mandatory air barriers. For
Richard Walker: For commercial applications, aluminum provides the necessary structural properties with reduced weight and the option for recycled content. The ability of aluminum to deflect from wind loads and still retain its shape
Brian Nelson: With energy efficiency becoming such a strong characteristic in the modern age of buildings, we have seen a wide variety of in-
22
February 2012
February 2012
23
BUSINESS FEATURE ROUNDTABLE

This roof insulation is an R-38 Banded Liner System with an installed U-Value of 0.031. The walls are an R-25 fiberglass system with an installed U-Value of 0.061. (Photo courtesy of Therm-All Inc.) Thermograph of metal building shows heat loss (red) through framing with no continuous insulation. (Photo courtesy of Dow Building Solutions)
materials (by cost or mass) in a qualifying product. Prescriptive energy requirements exceed the IECC by 10 percent. Air leakage requirements are the same as those in IECC, and daylighting is required in 50 percent of occupied floor area.
algorithms. Industry standards-setting organizations, such as AAMA, are working to ensure their specifications and test methods are responsive to the need for accurate characterization of complex and dynamic systems. BMS-controlled mechanical ventilation is employed as a strategy in some ZEBs to provide increased outdoor airflow or reject waste heat, either through louvers, operable vents in the window or curtainwall system, or as part of a rainscreen faade. Lighting accounts for 25 percent of total energy use in a typical U.S. office building, and waste heat generated by artificial lighting contributes significantly to the total cooling load. Both make natural daylight harvest and artificial lighting control imperative in achieving ZEBs.
MCN: What are net-zero metal buildings and

how do they impact energy efficiency? Has their usage increased and are they a success?
Todd: Although there are different definitions

for net-zero buildings, most highlight sustainability concerns such as zero net energy consumption and zero carbon emissions annually. Were seeing different approaches reduce energy consumption of a building and/or generate and use energy sources that produce lower carbon emissions. A cornerstone of any energy neutral or net-zero metal building is designing the building envelope with high R-value insulations and a properly designed and installed air barrier. Fortunately there are fieldtested solutions. Insulation is also ideal in metal buildings when installed in concealed roofs, slabs and foundations. High R-value products directly impact energy efficiency in any building using a systems approach and a compatible product line. Although the net-zero design concept is gaining inroads and we will continue to see innovative products for this market, it is important that the design community remain cognizant of working with products that come with proven field experience and industry leadership. with properly detailed joints has been tested and meets the prescriptive air leakage requirements of <0.004 cfm/ft 2 as required in the model energy codesa solution that addresses both continuous insulation and air barrier. But just meeting code requirements is not enough; the right materials must be used. minimum has increased quite substantially over the last decade, influencing the design of a modern day building. Other standards also exist for those who would like to exceed the minimum and create a high-performance building (ASHRAE 189.1), though it appears that soon enough the high-performance building of today will be the standard for tomorrow given 90.1s evolution to this point.
MCN:
How do metal buildings with energyexisting metal buildings for energy efficiency is critical when considering the size of the older building stock across the country. Just adding insulation is not enough thoughthe insulation must be installed as an air barrier to maximize value. Fortunately there are viable and cost-effective solutions. One example is when ORNL turned to Robert Scichili of RG Scichili & Associates [in Richardson, Texas] to manage a project and put together the construction team. Scichili teamed up with Paramount Metal Systems, a Little Rock, Ark., design-build contractor and Dow Building Solutions to help improve the sustainable performance of their [ORNL] 50-year-old building. cess of the modern envelope has been evident, though time is the greatest test of all.
efficient envelopes affect energy efficiency? Has their usage increased and are they a success?
Todd: Without a doubt, energy-efficient building envelopes directly impact energy efficiency, especially because of the extent of the metal building market penetration. Historically, one challenge for the design community has been finding easy-to-implement solutions to meet energy code requirements. However, at Dow Building Solutions, we are continually developing products that are specifically tailored to this market segment. For example, THERMAX Metal Building Board comes with a high, long-term R-value polyisocyanurate foam core with embossed aluminum foil facers that not only dampens noise but can be installed on the interior without a thermal barrier when allowed by code. Boards are available in lengths up to 30 feet that minimize the number of board joints and potential air leakage locations. Designers are cautioned to look not only at the R-value of the assembly, but also the configuration or how it is put together in the field. Recent hot box testing of metal roofing assemblies by the Metal Building Manufacturers Association (MBMA) and Oak Ridge National Laboratory (ORNL) showed that the overall tested R-value of the assembly can be directly affected by the size of thermal spacers and panel clips. New construction is one thing, but retrofitting
Walker:
The Energy Policy Act of 2005 and
the Energy Independence and Security Act of 2007 seek to reduce building-related energy consumption and our dependence on foreign energy sources. Title IX, Subtitle A, Section 914 of the 2005 Act specifically directs the National Institute of Building Sciences (NIBS) to explore the potential for accelerating and supporting the development of consensus-based voluntary Standards for producing more energy-efficient, less resource-intensive, high-performance buildings. NIBS formed the High-Performance Building Council (HPBC) in April 2007 to work on standards above code. The HPBC adopted the following definition: High-performance buildings which address human, environmental, economic and total societal impact are the result of the application of the highest level design, construction, operation and maintenance principlesa paradigm change for the built environment. The HPBC recognizes that developing highperformance design and construction standards will be a complicated, long-term task, but a task that is necessary for improving energy efficiency, reducing operation and maintenance costs, decreasing property loss, and increasing functionality and productivity.
Walker: Like any building system, windows

and curtain walls in net-zero energy buildings (ZEBs) or other high-performance buildings are subject to inherent trade-offs, specifically between thermal performance, natural daylighting, ventilation, cost and appearance. In a traditional product selection approach, static energy-related parameters such as U-factor, solar heat gain coefficient (SHGC), and visible light transmission (VLT) are used to set performance specifications. These will often not be sufficient when assessing active ZEB system interactions. The use of between-glass blinds, electrochromic dynamic glazing or automatically controlled shading can make VLT and SHGC values a function of building management system (BMS) control
Nelson: The building envelope is one of the

most crucial parts a buildings design. Not only are we concerned with promoting the longevity of the building by adding different barriers within the assembly to reduce condensation and mold risk, but we are also very concerned with how well the assembly keeps the conditioned air where it belongs: inside the building. With a poorly designed or implemented envelope, not only may longevity become an issue, but massive amounts of energy may be potentially lost. Todays modern energy-efficient envelopes generally include means for reducing air leakage (an air barrier) and increased insulation effectiveness to mitigate loss of energy. Thus far, the suc-
Nelson: There are many standards and codes,

but the one that comes to mind first is ASHRAE 90.1. This is often the basis for many states energy codes, as well as the IECC. The impact of this standard is the minimum energy efficiency from many standpoints, including lighting, HVAC equipment and building envelope. Keep in mind that the ASHRAE 90.1 standard is the minimum, and many within the design community would agree that this
Walker: The 2012 International Green Construction Code (IgCC), has not been adopted on a statewide basis, but has been implemented by several local jurisdictions, especially in Arizona and Washington. It is applicable to all construction types, except low-rise residential, and references ASHRAE/IES 189.1. For example, material selection requires 55 percent recycled or recyclable
24
February 2012
February 2012
25
FEATURE PRODUCT INSTALLATION

Photo Credit: Ken Parks
By Mark James
Photo courtesy of I & E Specialties
Retrofit Metal Roof Systems, Is Now the Time for You?

During the last few decades, many contractors have jumped into the retrofit business only to be snake bit. Because of this, several of them elected to not stay in the retrofit market, but others persevered and over the years built their reputations and expertise with successful projects. Today, many of those contractors continue to thrive even in a down construction market. This article introduces two different types of retrofit systems and two very successful and experienced building contractors who have focused on retrofit as an addition to their general construction roots.
26 METAL CONSTRUCTION NEWS February 2012
Case Study No. 1: Metal-over-Metal

The metal-over-metal retrofit represents a tremendous opportunity for any contractors who are considering expanding his or her services and to help themselves become a little more recession proof.
The business is installing a new metal roof system over an existing metal roof. Why install new metal over existing metal? That question comes up frequently, and there are countless reasons why you would want to do this. The existing roof may have reached the end of its service life, or it may be in need of repair due to major storm damage. Also the building owner may just want to upgrade the buildings curb appeal and appreciable value. Some of the drivers of the retrofit market today are projects with the military and our public schools. A metal-over-metal retrofit is a great solution that offers increased energy efficiency and reduces life cycle costs. Plus, the new roof can serve as an ideal platform for adding solar energy technologies. For the contractor, metal-over-metal retrofit is an easy way to get into the retrofit market. It is typically less complex than other types of retrofit. Projects can be started quickly due to fewer upfront requirements, and jobs can be completed faster and often in a safer construction environment. In addition, many projects qualify under building maintenance programs, which makes funding more readily available. One contractor who has capitalized on his metal systems expertise is Donald J. Parks General Contracting and Crane Service, located in Randolph, N.J. Ken Parks and his son, Ken Jr., know how to create retrofit opportunities in both the public and private markets. The company, started in 1952 by Kens father, has always had a metal systems focus having been a Varco Pruden builder since 1986 and having actively pursued retrofit projects since. One of their latest retrofit projects is an 180,000-square-foot metal-over-metal reroof project for a building occupied by Archive Systems of Washington, N.J., which provides records storage for companies in the eastern and western U.S. Needless to say, a waterproof roof was vital to this company's operations and reputation. The project utilized 37,000 lineal feet of factory-notched zee shaped sub-purlins to accommodate an existing 24-inch-wide by 3-inch-high trapezoidal standing seam roof. Roof Hugger Inc. of Lutz, Fla., manufactured the sub-purlins. The Parks have used Roof Hugger on numerous projects in the past because of the ease of installation; the systems ability to accommodate most metal roof profiles, rib height or spacing; and the companys commitment to product and performance testing. Since a metal-over-metal retrofit creates a cavity between the existing and the new roofs, the Parks design team installed 3 inches of unfaced fiberglass, thus reducing heat gain/loss through the new roof assembly. This means major energy savings to Archive Systems for years to come. w w w. m et a l c o n s t r u c t i o nn ew s .c o m
Case Study No. 2: Metal-over-Flat

The metal-over-flat retrofit is a reroofing/roof replacement technology that has been embraced by many design professionals and building owners over the years. You will find projects installed on schools, office buildings and nearly every military base built in the U.S. prior to 1990. Some people believe that metal-over-flat is extremely complex and difficult to execute. It can be but there are jobs that are pretty simple as well. The idea is to install a light-gauge steel framing system over an existing flat roof to create a slope, enabling the building owner to capture the benefits from a new high-performance metal roof. Instead of replacing the existing flat roof with a conventional membrane, building owners opt for a roof that has a service life of a minimum 40 years that is nearly double conventional roofing. Metal-over-flat retrofits typically cost more than conventional roof replacements, but for those building owners and managers who consider the life cycle costs of their buildings, it is a more desirable option. The return on their investment is usually recouped within a few years according to recent case studies. Still, dont be fooled into thinking the metalover-flat retrofit is always more expensive. In many cases it can cost less if the roof design or geometry is less complex. When making the comparison between metal versus conventional, always compare the metal retrofit to a complete tear-off w w w. m et a l c o n s t r u c t i o nn ew s .c o m and full replacement. If your building is temperature controlled and you want to increase the speed of the payback, upgrade the retrofit package with a new insulation package as well. I & E Specialties of Lexington, S.C., has been in business since 1988 and has principally operated in the public bid market. Wayne Fulmer, president, explains the company works in the public construction market because John Q. Public doesnt really understand that you can install a sloped framing system and new metal roof on top of an existing flat roof. When private building owners need a new roof, they call a roofer and not a metal construction contractor. However, the inherent benefits of metal roofing are known at all levels of governmentfrom city to federalwhich continue to specify retrofits for older buildings. I & E typically completes about 10 retrofit projects a year in addition to its new construction business. It is considered one of the premier retrofit contractors in South Carolina, a state that is very familiar with retrofitting existing building roofs. Due to this level of retrofit work, the company has elected to perform its own in-house designs and installation with framing and roofing materials purchased from McElroy Metal, headquartered in Bossier City, La. One I & E projects that sets an example of excellence is a 32,000-square-foot building for York Technical College in Rock Hill, S.C. Completed a few years ago, the building had an existing 4-ply fiberMark James has more than 40 years experience in the retrofit and metal construction markets, working for leading manufacturers and executing great projects. Currently, he is president of RetroSpec LLC, a consulting company offering direction and deep knowledge of the retrofit business for manufacturers and contractors. James can be reached at mark@retrospecllc.com. February 2012 METAL CONSTRUCTION NEWS 27 glass built-up roof over insulation, concrete decking and steel bar joists. The new retrofit framing system created a 3 in 12 pitch (14 degree slope) and included McElroys 24-gauge Maxima 216 standing seam metal roof in a Dark Bronze color. To make the building more energy efficient, I & E specified 6 inches of blown-in fiberglass to be installed at the existing roof level. York Technical College has had an active retrofit program with the goal of converting all of the buildings to metal roofs for aesthetic purposes and for energy savings. Is now the time for you to get into the retrofit roofing market? If you have been thinking about how to subsidize your workflow and keep your people on the job, then maybe you should consider this as a viable alternative. When you are ready, there are a few metal component and retrofit system manufacturers out there that have the expertise, the knowledge, the products and the technical personnel to support your efforts. We suggest you contact one of them to get started out on the right foot.
SUCCESS STORIES
Devoted to the Long Haul By Paul Deffenbaugh, Editorial Director

LaFaves Construction has positioned itself to continue for another 30 years of success
Management Team Joe LaFave, President Ken Cooley, Project Manager Chris Crider, Project Manager Clifton Hollopeter, Project Manager Billy Livengood, Project Manager Jeff Deason, Retrofit Roof Superintendent Sandy Gobble, Administrative Assistant
Company Profile Year Founded: 1982

Photographs courtesy of Alberts Specialty Roofing
Location: Landis, N.C. Markets Served: North Carolina, South Carolina, Virginia and Tennessee 2011 Total Revenue: $8 million Number of Employees: 40 Services Offered: Commercial construction, retrofit metal roofing, industrial maintenance Metal Roofing Square Footage Installed 2009: 166,500 square feet 2010: 137,600 square feet 2011: 544,800 square feet Roofing Manufacturer Affiliation: MBCI, Houston; McElroy Metal, Bossier City, La.; Construction Metal Products Inc., Statesville, N.C. Metal Building Systems Square Footage Installed 2009: 68,000 square feet 2010: 159,600 square feet 2011: 2,400 square feet
Mountain View Elementary School, Jefferson, N.C.
Mabel Elementary School, Zionville, N.C.
Webb Road Flea Market, Salisbury, N.C.
Starting a construction company often seems like an act of faith, especially in a down economy.
But in 1982, when Joe LaFave felt he was led by his faith to find a direction for his life and that direction was to start a construction company, he sought the wisdom of his pastor. As LaFave relates, He said, Young man, you need to make sure this is the Lords leading because there are many construction companies going out of business in this downturned economy. LaFave pressed on, and 30 years later, LaFaves Construction, Landis, N.C., is surviving the current downturn just as he survived the tough times in 1982. Back then, it was LaFave by himself with tools and truck and support from a part-time secretary. Today, LaFaves Construction is a sophisticated operation that employs 40 people, generates $ 8 million in revenue annually and is licensed in four statesNorth Carolina,
South Carolina, Virginia and Tennessee. The company provides design-build and construction management services, as well as maintenance and repair work and retrofit. The company prides itself on having expertise in every facet of commercial construction. However, a significant reason for LaFaves Construction being able to weather the downturn is its increase in metal retrofit work. That is one of the few segments of the metal construction industry and commercial construction that has not been decimated. LaFaves Construction moved into the niche with a bang in 2004 when it earned low-bidder position on a metal retrofit roof project. The company turned to Metal Roof Consultants, Cary, N.C., founded by Chuck Howard, P.E. Howard brought his years of experience in retrofit metal roofing and continues to assist on projects with LaFaves Construction. Says LaFave, We have maintained that independent
We realize our name is only as good as those who partner with us on any given project.
Joe LaFave, LaFaves Construction
consulting relationship with MRC throughout the years and it has been mutually beneficial for us as well as them. For the last eight years, LaFaves Construction has seen strong growth from its retrofit metal roofing push so that now it accounts for about 50 percent of the company revenues. The company self-performs all the work and has invested in its own fully automated metal shop that produces all trim and roof curbs. This has enabled us to maintain higher quality projects as well as being
able to respond to job needs in a more efficient and timely manner, LaFave says. LaFaves Construction also offers services in metal building projects and has constructed a lot of churches and industrial projects. Both of these clients have specific needs that present design opportunities, says LaFave. I consider it a challenge to determine the best application of layout, design, materials and subcontractors to meet the customers needs in the most efficient manner. As every contractor knows, the business can be brutal and cyclical, but LaFaves Construction is devoted to the long haul. That means success is built on relationships. Relationships mean a lot to us, says LaFave. Companies providing high-quality product at competitive prices along with service after the project is completed means everything to us. We realize our name is only as good as those who partner with us on any given project.
The success of that relationship building shows in the high percentage of work that comes from repeat customers. That ability to nurture long-term bonds comes from a management philosophy and company culture that puts the customer first. Quality ethics and principles are what this company was founded on and by Gods grace, we will continue to strive for these things, says LaFave. He credits the success of the company to the best employees in the industry who understand and share the management philosophy. I am very thankful for our employees and their commitment and contributions to the company, he says. And the future? I believe having been able to survive and actually see growth over the past few years during the downturn says a lot about the potential of the company moving forward. We want to continue to grow and provide services to our customer base.
(LaFaves Construction also does wood frame construction.) Building Manufacturer Affiliation: Metallic Building Co., Houston; Varco Pruden Buildings, Memphis, Tenn.
Ketner Building, Catawba College, Salisbury, N.C. Photo Credits - Living Water, Ryan Hoshor. Anco Eaglin, Joe LaFave. All others, Mark Bouldin
Anco-Eaglin World Headquarters, High Point, N.C.
Living Water Church of God, Kannapolis, N.C.
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EXPAND YOUR BUSINESS LIGHTNING AND METAL ROOFS
By Kim Loehr
By Jennifer Morgan
Lightning Protection Systems Separating fact from fiction about metal roofs and construction
Lightning is a frequently experienced weather peril and a known risk for many structures. Yet lightning remains a
misunderstood weather hazard and myths persist about lightning protection; especially where metal construction or roofing is concerned. Here are a few common myths associated with lightning and metal construction: framing and reinforcing rods in concrete walls or flooring. On the outside of the structure, lightning can travel along conductive metal vents, roof drainage elements and external supports as it seeks a path to ground. Once inside the structure, lightning can travel through the electrical, communication, or data wiring, along with plumbing, gas or process piping systems. Most structures have an electrical system ground, communications system ground and a data system ground, which are designed to handle current flow, but are not designed to accommodate grounding for a lightning strike. Lightning can carry a 30,000 amp or larger electrical surgewhich is why a lightning strike to an unprotected structure can be disastrous. While lightning receives little media attention, a recent 9/11 Opinion Survey conducted by disaster safety firm Cote & DAmbrosio revealed that it is a serious concern for U.S. consumers. When asked to rate their concerns about natural disasters, the highest number of consumers were very or somewhat concerned about lightning strikes (62 percent), as compared to other hazards such as: flooding, tornadoes, hurricanes, ice storms, earthquakes, hail storms and wild fires. Consumer concerns about lightning are well-founded, as the Insurance Information Institute (I.I.I.) reported that lightning strikes cost more than $1 billion in insured losses in 2010 with claims up nearly 15 percent from 2009. Unlike threats posed by tornadoes, hurricanes or floods, lightnings incredible electrical power can be controlled on a specified path. The highly conductive materials used in a lightning protection system provide a low resistance path for lightnings harmful electricity. When the protection network is in place, a lightning strike is intercepted and directed to ground without impact to a structure or its contents. Without the presence of the protection system, lightning will fight its way through nonconductive building materials like isolated metal, wood, brick, rubber membranes, glass, plastic, etc., as it seeks its way to earth ground. The resistance it encounters will produce heat, fires and even explosions, as these building materials are not designed to provide a safe path to ground for lightning. Providing a safe path to ground is the objective of the lightning protection system design. The concept behind lightning protection is relatively simple, but requirements for installation are specific and often complex. The best way to ensure proper system design and installation is to specify compliance with nationally recognized safety standards for lightning protection. The LPI-175 Standard of Practice (based on NFPA 780 Standard requirements), is published by the Lightning Protection Institute (LPI), as a quality control resource for installation and materials. A complete lightning protection system includes the following elements: A network of prominent strike termination devices A network of ground terminations (ground electrodes) A network of conductors or qualified structural steel framing members to interconnect strike and ground terminations Interconnections/bonding with other metallic grounded building systems Surge protection devices on all incoming power, data and communication lines Inspection service to verify standard compliance and quality assurance Failure to make proper provisions for any of the elements involved in installation can result in inadequate protection. LPI is a nonprofit, nationwide group founded in 1955 to promote lightning safety, awareness and protection education. A new LPI-IP Inspection program now provides on-site lightning protection inspection services. The LPI-IP provides the most thorough inspection program on the market, explains Tim Harger, program manager for the LPI Inspection Program. Obtaining a Certified Master Installation Certificate will ensure that your metal building meets all national lightning protection safety standards and quality control measures. Kim Loehr is the communications director for the Lighting Protection Institute in Maryville, Mo. LPI conducts certification and educational programs and is a leading resource for lightning protection information and system requirements. Visit www.lightning.org for more information.
Threats from Lightning Strikes Protecting green buildings from lightning damage
Nearly every construction project today incorporates measures for energy conservation and sustainability. Todays
project owners demand state-of-the-art earth friendly products and technologies for both the physical structure and the building systems. When working with earth friendly products and green technology, designers need to consider the unique threats that lightning strikes pose. When the goal is to build a structure with a longer life span and a smaller impact on the environment, the wisdom of protecting that structure from lightning damage should not be underestimated. A lightning fire, which will typically destroy the roof and attic of a structure, is hardly an earth friendly event. Even if there is no direct strike or fire, nearby lightning strikes frequently cause damage to electronic systems. In many cases, surge induced damages are not covered by property insurance policies. Prior to the age of electronics, the threat to structures from lightning strikes was primarily fire related. The low resistance pathways that lightning protection systems provide prevent the energy of a lightning strike from igniting structural fires. The introduction of low voltage wiring and electronically controlled building components presented a new vulnerability to lightning. To address these concerns, lightning protection standards were updated during the 1990s. Additional provisions for grounding and augmented criteria for lightning arrestors and surge protection devices were added to protect building electronics. The green building era presents yet another level of lightning vulnerability. Fire prevention is a green initiative in its own right, since burning structures present a serious hazard to the atmosphere and rebuilding after a preventable fire increases a structures energy footprint substantially. Many eco-friendly building components, such as bamboo flooring, cedar shingles and resin countertops are both flammable and costly to replace. A lightning protection system will prevent a lightning ignited fire from destroying the green structure and contents. Green buildings also use sophisticated energy collection methods that can be damaged or destroyed by direct and nearby lightning strikes. Of particular importance are wind and solar energy collection systems, which present a unique set of considerations for lightning damage. Not only do these systems typically involve elevated structural elements that need to be protected from direct lightning damage, but they also contain costly bearings, gearboxes, electrical systems and electronic controls that are vulnerable to direct and transient lightning damage. growing problem by the National Fire Protection Association (NFPA) and the NFPA 780 Technical Committee on Lightning Protection. The increasing number and height of installed turbines throughout the U.S. has led to a rise in lightningrelated incidents to these structures. Lightning strikes to these towers can explode blades, sending flaming chucks of debris hundreds of feet in the air. While blade damage is the most expensive and disruptive damage caused by lightning, the most common damage reported is to turbine control systems, which can be caused by direct and indirect lightning surges. Although wind turbines present unique challenges due to their height and construction of insulating composite materials (glass fibers, reinforced plastic and other nonconductive materials), it is possible to protect these structures through the installation of a fully integrated lightning protection system. To limit damage from lightning, the tower and blades need to be provided with lightning protection as well as bearings, gearboxes and the electrical and control systems. Like solar energy systems, the equipment used to store and distribute the energy generated by the windmills must be protected from lightning surges. The 2011 Edition of Standard NFPA 780 contains a new annex with provisions for how to protect wind turbine generator systems from lightning. Lightning protection specialty contractors can work with project planners and building owners to make certain that lightning protection system designs take into account the unique hazards that green and sustainable building methods and materials can present. These measures will help make certain that a structures production and storage of electricity is not interrupted when storms roll through. Jennifer Morgan is the director of Winsted, Conn.-based East Coast Lightning Equipment Inc. For more information, visit www.ecle.biz.
Myth: A metal roof will increase the likelihood of

lightning striking a structure.
Fact: The probabilities of lightning striking a

metal-roofed structure are no more or less than lightning striking any other kind of structure. A metal roof does not attract lightning, nor does it protect a structure against lightning.
Myth: A protection system is not needed for a

metal roof since the metal will disperse lightnings energy safely through a structure. Fact: Metal buildings are typically constructed of thin section metal, which is generally considered mechanically continuous, not electrically, and doesnt have sufficient thickness to serve as a capable lightning conductor. A metal roof does not provide an adequate path to take lightnings harmful electricity safely to ground.
Myth: Lightning protection systems are only

needed for wood or masonry structures, not modern day metal construction buildings. Fact: Metal roofing is often thought of as a low risk option that can prevent lightning fires. In reality, lightning does hit and damage unprotected metal construction buildings. The November/ December Firewatch report (NFPA Journal) details a lightning fire to a single-story, wood-frame barn equipped with a metal-covered roof and metal walls. The report described Ohio firefighters arriving at the scene to find the barn completely engulfed in flames with the metal roof collapsing. The barn stored $2.5 million in farm equipment and was not equipped with lightning protection, fire detection or a suppression system.
Solar systems The upfront cost of incorporating active or passive solar energy collection is significant. Measures to protect this expensive equipment from lightning damage should be standard practice when designing these systems. The first consideration should be the protection of any rooftopmounted equipment from direct lightning strikes. A UL-listed lightning protection system can be designed to prevent lightning from arcing to this equipment and damaging it. Solar collection equipment that is mounted remotely from the structure can similarly be protected from direct lightning strikes. Equally important is the need to protect the equipment within the building that is collecting, storing and distributing the solar energy or heat. This equipment is often directly tied to a structures electrical system and provisions must be made to protect it from lightning surges. Code compliant bonding provisions as well as properly selected surge suppression devices are necessary for keeping this equipment safe. Surge suppression, bonding and grounding provisions are equally important whether the solar equipment is situated on or near a structure, since buried lines are particularly vulnerable to traveling lightning currents. Wind systems Damage to wind turbines from lightning has been recognized as a
Myth: Todays metal roofed structures are

grounded and at less risk for lightning.
Fact: Lightning can travel through structural steel
Close-up of a blunt-tipped strike termination device on a metal roof.
Ground rod installation for a lightning protection system.
Rooftop bonding of metal bodies in conjunction with a lightning protection system.
On this active solar roof the lightning protection system was installed during construction leaving the slender rooftop lightning rods as the only portion of the system on the exterior of the structure.
Braided lightning conductor cables are available in aluminum, copper and tin-plated copper and should be matched with the roofing material based on galvanic compatibility as well as aesthetics.
Lightning protection connectors and fittings are used to join the lightning protection system to metal bodies such as piping, support beams, gutters, copings and railings.
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EXPAND YOUR BUSINESS LIGHTNING AND METAL ROOFS
By Ned Brush
Surge Protection Proper electrical grounding increases power quality and decreases potential damage
Thirty years ago, it would have taken an active imagination to believe that there would be a computer at every desk and a cell phone charger in every outlet. With technology booming and our individual
electricity intake rising in correlation, its no surprise that the electrical grounding system of most buildings should be upgraded accordingly to satisfy our appetite for electricity. With all daily operations relying on power quality and reliability, a secure grounding system is the foundation for the consistency of the electricity throughout the structure. For building design purposes, power quality should be defined by the relative frequency and severity of fluctuations in the incoming power voltage supplied to electrical equipment compared to the customary 60 Hz of sinusoidal voltage. A facility with poor power quality experiences many deviations in this voltage and often incurs faulty operations in its computers and other computer-based equipment. Good power quality, on the other hand, means a steady flow of the standard voltage and current and, therefore, fewer breakdowns in connected computers and electronics devices. This power deviation can quietly decrease the life span of a computer and, in extreme cases, compromise the device entirely with one severe deviation (surge). Often times more important than the physical effect on the equipment, is the loss of productivity resulting from computer equipment failure and downtime. In fact, it has been estimated that the total cost to U.S. businesses of this lost productivity is a staggering $15 billion to $30 billion per year. Many business owners do not calculate the cost of their annual losses due to power quality (or even erroneously attribute power quality glitches to software or hardware causes). When determining power quality, the average voltage and therefore current flow rarely takes into account the extreme outliers in power fluctuation, i.e., lightning strikes and surges. A single deviation, such as a well-placed lightning strike, is all it would take to cause irrecoverable damage to a poorly grounded facility. On the other hand, a well-grounded facility can avoid this threat by creating paths of least resistance for strong electrical currents to be guided away from the buildings electrical infrastructure. Broadcast communication towers, data centers, emergency call centers and hospitals are all examples of facilities where power outages simply are not an option and power quality should be a high priority. Constantly providing valuable information and services for countless people, these buildings must have grounding systems that can withstand anything. With important structures like these, a failure in the grounding system could prove much more costly than the equipment at stake, says David Brender, national program manager for the New York Citybased Copper Development Association (CDA). He adds that it is important for contractors and facility managers to realize that it is necessary to surpass minimum grounding system requirements to ensure the publics safety and eliminate potential damage. According to NFPA 780, metal must be 3/16-inch-thick or thicker to take a direct lightning strike and conduct it to a grounding system. Most metal construction will melt through where the lightning makes contact so a metal building or roof area is generally protected in the same way as a non-metallic building. Electrical grounding is often overlooked and not tested for extreme cases such as lightning strikes, says Brender. Outdated systems must be brought up to code or beyond and maintained before its too late. Most facilities meet the bare minimum requirements, but to help ensure protection in extreme cases we recommend that you go above and beyond code minimums. The Motorola R 56 and NFPA 780 standards provide a good foundation for codes regarding communication towers and mandatory lightning protection in facilities, but they still only represent the bare minimum requirements, adds Brender. All facilities should evaluate their current electrical grounding systems and improve them to the point where power quality should not be an issue (or, at least, much less of an issue). In many cases, simply installing enhanced electrical systems and improving existing grounding systems will go a long way in preventing the problem. Copper is the grounding material of choice because of its inherent conductivity properties and high resistance to corrosion. Copper wiring, radials and phase conductors provide superior protection for any grounding system and are simple to protect during installation. CDA offers the following steps that may prevent most power quality problems from occurring: Use double-size neutral conductors or separate neutrals for each phase. Specify a separate, insulated full-size grounding conductor, rather than relying on the conduit alone. Use an isolated grounding conductor for sensitive equipment. Segregate sensitive loads on separate branch circuits, fed from a separate panel board, fed from separate feeders (and even separate transformers if possible). Run a separate branch circuit for every four to six duplex outlets. Use an outside copper ground ring and multiple ground rods as part of the grounding electrode to achieve lowest practical resistance to ground. Measure ground resistance. Use harmonic-rated circuit breakers, panel boards and transformers. Use surge and lightning protection. Oversize phase conductors to minimize voltage drop. (This will save energy too, and may even pay for itself through lower I2R losses.) Choose materials based on superior connectability. Poor quality connections are a major consideration. This is where all-copper wiring excels over other materials. Remember that code minimums can be exceeded, but should not be violated. Ned Brush is an energy efficiency consultant with BBF & Associates, New Harbor, Maine. For more information about copper grounding systems, visit the New York City-based Copper Development Association at www.copper.org.
A florida police station uses a large copper busbar To safely carry increased electrical loads.
A copper bulkhead was installed at a Clarcona, Fla., police station to protect the electrical components from surges.
Insufficient grounding leads to significant structural damage to a lightning prone broadcast tower in Hinton, Iowa. Photography by CDA Project Manager David Brender
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PROJECT FOCUS HEALTH CARE
For more projects, visit
www.metalconstructionnews.com/articles/projects/healthcare.aspx
Cradling Curves
Curved metal framing rounds out new neonatal intensive care unit
Mercy Health Center in Oklahoma City renovated and expanded its neonatal intensive care unit to incorporate the most current technology and care unit design. The unit is one of only three Level III neonatal intensive care units in the greater Oklahoma City metropolitan area. Design for the 21,000-square-foot renovation was provided by Rees Associates Inc. and features prominent curves and complex radiuses in hallways, nurses stations and common areas. Approximately 1,400 linear feet of 3 5/8- and 6-inch Flex-C Trac, Flex-C Angle and Flex-C Arch were utilized to meet design objectives. General contractor United Acoustics Inc. installed the FlexAbility Concepts products. According to President David Penland, United Acoustics has an on-going relationship with Mercy Health Center and is also a frequent user of Flex-C Trac. In this day and age, labor costs are key, Penland says. Advances in the drywall and ceiling industry come along pretty infrequently. Flex-C Trac has made a very positive impact on the industry and what we do. It really increases productivity and ease of installation. We seldom use the track bender we purchased several years ago. Ron Palmer, field superintendent with United Acoustics notes, Architects seem to be designing more curves than ever, particularly in health care applications. This job had radius eyebrows, ellipses, compound curves and just about everything you could imagine. The Flex-C Trac really simplifies the job and its easy to use. I can put any of my guys on it. One newborn of every 10 will require special medical attention. The renovation includes the expansion of special care nursery beds from 28 to 42 and the inclusion of space and amenities for family comfort and convenience. In particular, the NICU includes a family gathering room, 16 private rooms, 13 semiprivate rooms, two lactation rooms and various nurse stations throughout the unit.
Mercy Health Center Neonatal Intensive Care Unit, Oklahoma City

Architect: Rees Associates Inc., Oklahoma City Installer: United Acoustics Inc., Oklahoma City Curved framing: Flex-Ability Concepts, Oklahoma City, www.flexabilityconcepts.com, Circle #41
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Drake Eye Center, Hartselle, Ala. Completed in December 2010, the 5,000-squarefoot optometry center features 900 square feet of MBCIs 24-gauge LokSeam standing seam roof panels coated in MBCIs Signature 300 Tundra finish. Franklin Square Hospital Patient Tower & Emergency Department, Baltimore A new entryway and lobby are the focal points of the new addition to Franklin Square Hospitals Patient Tower and Emergency Department. Quality Metalcrafts worked closely with the contractor, Zephyr Aluminum, to coordinate material releases General contractor/roofing contractor: E-Tech, Hartselle, Ala. Metal roof panels: MBCI, Houston, www.mbci.com, Circle #42 and shipments to accommodate the construction schedule for both the interior and exterior components of the project. Quality Metalcrafts AMERICLAD AC-1000 composite panels with a clear anodized finish, complement the buildings exterior and the entrances canopy. The same panel type was also used for the soffits, cornice panels, and coping and fascia of the exterior, carrying the fresh new look to the entire front of the new addition. In addition to supplying materials for the additions exterior, Quality Metalcrafts also supplied custom AMERICLAD AC-10C composite column covers with a clear anodized finish, for both the buildings interior and exterior. The open canopy and glass entrance allow natural light into the lobby. The end result is a style that creates an open atmosphere in a lobby that spans three stories high.
General contractor: Zephyr Aluminum LLC, Lancaster, Pa. Architect: Wilmot/Santz Inc., Gaithersburg, Md. Metal wall panels and column covers: Quality Metalcrafts LLC, Rogers, Minn., www.qmcrafts.com, Circle #43
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Cheyenne River Health Center, Eagle Butte, S.D. Completed in 2009, the Cheyenne River Health Center is located on the Cheyenne River Sioux Tribe Indian Reservation. The structures standout element is unquestionably its entrance, designed to invoke the resemblance of a tepee. Featuring a column with a beautiful ceramic tile mural on the front, 24-gauge UNA-CLAD Flat-Lock tiles in Classic Copper from Firestone Building Products Co. were installed in a diamond pattern around the remainder of the column. Flat-Lock tiles in Terra Cotta were also mounted on the round-shaped exterior walls surrounding the buildings west entrance. In addition to the UNA-CLAD Flat-Lock tiles, the 138,542-square-foot facility contains multiple roofing systems, wall panel systems and accessories, including various Firestone UNA-CLAD metal products, Firestone UltraPly TPO XR and ISO 95+ GL insulation. Leading up to the main entrance, UNA-CLAD UC-6 Double-Lock Standing Seam roofing panels in Colonial Red, were chosen for the covered walkways and curved side canopies. The roofing and soffit panels were custom tapered to maintain the integrity of the curved design. To create copper-colored awnings over eight separate side entrances, the UC-6 roofing panels were used in conjunction with a UNA-CLAD UC-500 Flush Panel System. The health centers main building was covered with a tan, 60-mil fully adhered Firestone UltraPly TPO XR roofing system over two layers of 2.5-inch ISO 95+ GL Insulation. The roof is covered by a 15-year Firestone Building Products Red Shield Warranty. A row of upper windows overlook the TPO roof, letting natural sunlight in the building. UC-601 UNA-CLAD Exposed Fastener Panels in Sierra Tan were mechanically attached to the exterior walls to encase this window area and UC-6 panels in the same finish covered this section. Installer: SGH, Omaha Metal wall panels: Dri-Design, Holland, Mich., www.dri-design.com, Circle #45 Zinc: Umicore Building Products USA Inc., Raleigh, N.C., www.vmzinc-us.com, Circle #46 Architect: HDR, Omaha Home Instead Center for Successful Aging, University of Nebraska Medical Center, Omaha, Neb. Located at the University of Nebraska Medical Center, the Home Instead Center for Successful Aging is a three-story, 30,000-square-foot facility that provides specialized services aimed at helping seniors age better and live healthier lives. Installed by SGH, the center features 4,300 square feet of VM Quartz Zinc panels from Dri-Design. Umicore Building Products USA Inc. supplied the VM Quartz Zinc utilized in the panels. The center is named for Home Instead Senior Care, the worlds largest, private non-medical senior care program. The center includes geriatric medicine and psychiatric clinics, as well as access to clinical trials involving geriatric-specific disorders.
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Owner: Indian Health Services, Rockville, Md. Architect: Weller Architects, Albuquerque, N.M. Installer: Guarantee Roofing of S.D. Inc., Sioux Falls, S.D. Metal roof and wall panels and insulation: Firestone Building Products Co., Indianapolis, www.firestonebpco.com, Circle #44
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METAL CONSTRUCTION NEWS February 2012
February 2012
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Concentra Healthcare, Nashville, Tenn. Designed by Mark E. Watson Architects, Concentra Healthcare features 95 square feet of two aluminum blade cantilevered, clear anodized canopies from Mapes Architectural Canopies Inc. Formed in 8-inch style J fascia, the first canopy has a 1-foot projection and is 24 1/3 feet wide, while the second canopy has a 2-foot projection and is 34 1/2 feet wide. Rockford Center, Newark, Del. The first private psychiatric facility in Delaware, the Rockford Center features a new expansion and renovation designed by Array Healthcare Facilities Solutions in 2011. The original center was built in 1974 as a 55-bed unit, and over the years has grown into a 118-bed unit with additional inpatient and outpatient services. The center features 1,058 square feet of 0.032-inch aluminum Belvedere (BWK360) wall panels in Classic Architect: Mark E. Watson Architects, Nashville Distributor: The Hannah Co., Nashville Metal canopies: Mapes Architectural Canopies Inc., Lincoln, Neb, www.mapes.com/canopies, Circle #47 Bronze from ATAS International Inc. The panels act as vertical wall accents, producing a subtle yet noticeable, aesthetic effect on the space. According to Jim Bush, vice president of sales for ATAS, This project illustrates how well metal integrates with other building materials. At the same time, it shows how metal can be added to accent a particular design feature. By adding vertical metal wall panels around the windows, the designers created different depths, textures and shadows to the building, which creates an inviting space for the patients.
Architect: Array Healthcare Facilities Solutions Inc., King of Prussia, Pa. Builder: Wohlsen Construction, Lancaster, Pa. Installer: D. Shinn Inc. Co.,
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St. Marys Hospital, Grand Junction, Colo. A major expansion and renovation of St. Marys Hospital is anchored by a new 12-story, 200,000-square-foot tower. The tower adjoins and expands an existing two-level emergency and surgical building and significantly adds 256 current and planned patient rooms. To complement the existing hospital and avoid competing with surrounding mesas and cliffs, architects chose a simple rectangular silhouette for the tower. The design utilizes brick and glass for the base of the tower to echo the scale and exterior of the existing hospital. As the tower clears the height of the original building, the cladding transitions to Citadel panels and glass for a more weightless, contemporary look. The uppermost area of the tower is clad with 11,000 square feet of Citadel Envelope 2000 Rout & Return (RR) System metal composite material panels in Silver Metallic from Citadel Architectural Products. Health Center 4, Riddle Hospital, Media, Pa. Riddle Hospitals new Health Center 4 combines patient-centered design and environmentally friendly features. The $40 million, 80,000-squarefoot medical office building embodies todays best practices for creating new health care facilities. The project features more than 7,000 square feet of 2- and 3-inch Architectural Flat insulated metal wall panels in custom Platinum and Medium Gray from Metl-Span. Additionally, approximately 800 square feet of Metl-Spans CFR 36 standing seam roof panels in Cool Metallic Silver were used on a pedestrian bridge. Panelcraft Inc. installed the panels horizontally in module widths ranging from 21 to 40 inches. It was a complicated, complex job with unique detailing on each elevation, according to Richard Scharr, project manager. Virtually everything was custom and required extremely careful field measurements along with field fabrication as needed. The design called for segmented panels Architect: Perkins + Will, Minneapolis
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at the top of the structure to follow the arc of the building and they turned out great.
Fabricator/installer: Douglass Colony Group, Commerce City, Colo. Metal wall panels: Citadel Architectural Products Inc., Indianapolis, www.citadelap.com, Circle #49
General contractor: John S. McManus Inc., Chester Heights, Pa. Architect: The Sheward Partnership, Philadelphia Installer: Panelcraft Inc., Boothwyn, Pa. Metal wall panels: Metl-Span, Lewisville, Texas, www.metl-span.com, Circle #50
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Fort Belvoir Community Hospital, Fort Belvoir, Va. Designed by the architectural team HDR/Dewberry, the new world-class facility combines technology and data to advance health care services for active duty U.S. military members, retirees and their families. Fort Belvoir Community Hospital includes a nine-story main hospital building, two three-story clinical buildings and two two-story clinical buildings. The project has achieved LEED Silver certification and is striving to attain LEED Gold. The facility was built by Turner Gilbane, a joint venture between Turner Construction and Gilbane Building Co. Opening of the massive $1.03 billion hospital culminated five years of interservice collaboration as one of the largest and most involved medical Base Realignment and Closure projects. The 1.27-million-square-foot facility replaces DeWitt Army Community Hospital and will also absorb some services and patients from the recently closed Walter Reed Army Medical Center. With the normal 10-year procurement cycle needing to be reduced to a five-year process to meet the BRAC timeline, the hospital was designed and constructed using Integrated/Design/ Bid/Build. The facility was constructed in just over three yearshalf the time it normally takes to build a facility of its magnitude. More than 36,000 Dri-Design panels covering 120,000 square feet were utilized. The 1-mm VM Quartz Zinc panels clad five structures in the complex. The Dri-Design panels interface with a terra cotta faade which also utilizes a rainscreen assembly. A limited amount of painted aluminum Dri-Design panels were also used on interior applications including stairwell entry areas. Umicore Building Products USA Inc. supplied the VM Quartz Zinc utilized in the panels.
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Swedish Medical Center Issaquah Campus, Issaquah, Wash. According to Col. Susan Annicelli, commander of Fort Belvoir Community Hospital, This is Americas newest, most extraordinary, most technically advanced facility and we are proud to have it in the military health system. Featuring 16,000 square feet of Metl-Spans 2-inch CF Architectural and CF Striated insulated wall panels in custom Harvest Gold Pearl, the 550,000-squarefoot medical campus was completed in two phases. The initial phase included the medical office building housing primary and specialty care clinics and the General contractor: Turner Gilbane, Arlington, Va. Architects: HDR, Alexandria, Va.; and Dewberry, Fairfax, Va. Metal wall panels: Dri-Design, Holland, Mich., www.dri-design.com, Circle #51 Zinc: Umicore Building Products USA Inc., Raleigh, N.C., www.vmzinc-us.com, Circle #52 Swedish Cancer Center. In addition, the first phase included an emergency room, pharmacy, laboratories and imaging center. The recently concluded second phase added 80 beds for inpatient care, surgical facilities, intensive care units, as well as areas for labor and delivery and pediatric care.
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Shore Memorial Surgical Pavilion, Somers Point, N.J. Located near the seaside, the Shore Medical Center Surgical Pavilion was designed to meet LEED specifications. Upon opening in September 2011, the Shore Memorial Hospital facility was re-branded as Shore Memorial Medical Center. The 138,000-square-foot facility contains more than 25,000 square feet of Wasau Window and Wall Systems SuperWall. The systems aluminum framing contains high recycled content, in varying unit depths of 6.25 inches, 8.25 inches and 10.25 inches, and painted in a durable, three-coat, 70 percent PVDF. Steve Pluger, Wasaus factory supervisor, notes, The strip windows and curtainwall systems aluminum framing was finished by Linetec in Slate Gray and punched windows were painted Bone White. Deep covers were provided for the punched windows and strip windows. The $125 million surgical center also emphasizes daylight, as Lisa May, LEED Green Associate and Wasaus health care market manager, explains: In addition to saving energy and costs by reducing electric lighting, natural light benefits patients and staff. The USGBC reports that patients in settings with natural light and views of nature recover faster, use less pain medication and have shorter stays. Studies also have shown that a naturally-
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illuminated workplace contributes to improved staff health and morale. The facilitys close proximity to the Atlantic Ocean required a curtainwall system that could withstand hurricanes. Wausaus SuperWall systems impact rating testing includes large missile tests for windborne-debris-impact resistance performance and adheres to ASTM E 1886 and ASTM E 1996 for missile level D, Exposure C, wind zone 2. The finish used for Shore Memorial is tested to meet AAMA 2605, a high-performance specification for architectural and heavy commercial applications that includes 4,000 hours salt spray and heat-and-humidity resistance, notes Tammy
Owner: Shore Memorial Medical Center, Somers Point General contractor: Massett Building Co., Somers Point Architect: Ballinger Architects, Philadelphia Glazing contractor: Guthrie Glass & Mirror, Egg Harbor Township, N.J. Curtainwall: Wausau Window and Wall Systems, Wausau, Wis., www.wausauwindow.com, Circle #54 Finisher: Linetec; Wausau,
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www.linetec.com, Circle #55 February 2012 METAL CONSTRUCTION NEWS 47
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Ed McCabe VA Hospital, West Roxbury, Mass. University Hospitals Ahuja Medical Center, Beachwood, Ohio Officially opened March 1, 2011, the new $298 million, 432,000-square-foot medical center includes a seven-story, 144-bed hospital and a three-story medical outpatient building. The medical center was designed to garner attention and incorporate an innovative theory of evidence-based design in which scientific research was incorporated to better serve patients and promote healing in a guest-centered environment. University Hospitals Ahuja Medical Center was awarded a LEED New Construction 1099 (NCv2009) Silver certificationgiving it the distinction of being the first health care facility in the United States to receive certification under this version of higher and more stringent sustainable requirements. Among the many green building methods incorporated in the medical center are the use of bio-swales and bio-retention basins to manage on-site stormwater, a plan to reduce energy through metering and monitoring, installation of photovoltaic panels on the roof, and the selection of sustainable and eco-friendly materials to provide a healthy indoor environment. University Hospitals wanted a unique, modern structure, says Seth Meltzer, AIA, vice president in the Richmond, Va., office of HKS Inc., and project architect. They wanted a Owner: VA Boston Healthcare System, Metal Snow Guards Soldering Application West Roxbury Installer: Capeway Roofing Systems Inc., Westport, Mass. Metal roof panels: The Garland Co. Inc., Cleveland, www.garlandco.com, Circle #56 signature-type project to serve as this communitys hospital. This design also was integral to an overall response to patient needs, including patient flow and sight lines. The hospital features a seven-story curved curtainwall filled with glass and accent bands fabricated from 3A Composite USA Inc.s Alucobond Aluminum Composite Material. Alucobond also clads a large portion of the medical centers exterior walls in combination with rain-screened terra cotta ceramic tile. Both interior and exterior columns and beams are covered in Alucobond ACM as well as the entryway canopies. Royalton Architectural Fabrication Inc. fabricated a total of 95,970 square feet of 4-mm-thick Alucobond PVDF-2 in custom Ahuja Crystal for the medical center. The
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Part of the VA Boston Healthcare system, the Ed McCabe VA hospital needed a new roof that guaranteed long-term, watertight protection. A life cycle costing analysis was conducted and supported the recommendation of replacing the shingled roof with a standing seam metal roof system. The existing roof system was removed down to the
Winkler, president, Royalton Architectural Fabrication. The panels were incorporated into the glazing in the window system and had to fit like a glove. Wall panels were field measured and fabricated by elevation as the buildings were being constructed, according to Winkler. The hospital is expected to expand through the years to 600 beds with the new seven-story tower serving as the first of three planned towers, according to Meltzer.
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wooden deck and replaced with 25,000 square feet of 22-gauge, 16-inch R-Mer Span standing seam roof panels in Natural Patina from The Garland Co. Inc. The 30-foot continuous standing seam panels with no laps were installed to achieve watertight integrity. The functional versatility of R-Mer Span was critical to the success of the project due to the various changes in plane and steep 5:12 slope of the roof. The panels also added aesthetic value to the medical center, originally built in the 1940s. The standing seam metal system was chosen for this project for its industry-leading performance in windstorm and water penetration resistance and guaranteed long-term performance. The high-
Construction manager: Gilbane Building Co., Cleveland Design architect: HKS Inc., Richmond, Va. Corporate architect/interior designer: Array Healthcare Facilities Solutions Inc., King of Prussia, Pa. Metal fabricator: Royalton Architectural Fabrication Inc., North Royalton, Ohio Installer: Carroll Glass Co., Euclid, Ohio Metal wall panels: 3A Composites USA Inc., Mooresville, N.C., www.alucobondusa.com, Circle #57
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Alucobond was installed with Royaltons Royaltech 200A wet-seal panel system by Carroll Glass Co. The sweeping-curve design provides a visually striking exterior and makes the building interior easy to navigate, reducing foot traffic and improving patient sight lines to staff. Additionally, the curved design reduces wind and traffic noise from nearby Interstates 271 and 480 while offering panoramic views of the 53-acre park-like campus setting that includes protected wetlands. This project posed a number of challenges, especially with the hospitals large radius design and its grandiose two-story entrance, notes Stefan
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NEW PRODUCTS Standing Seam Metal Roofing BAMCO launches FABLOGIC I-500 composite wall panels
BAMCO Inc. introduces its I-500 FABLOGIC product line. The panels use internal gaskets to provide a fully weather-sealed system combined with the visual aesthetics of an open joint or rainscreen system. No caulk or exterior gaskets are required. The I-500 is offered in a full range of colors and can be used in complex shapes and sloping angles. www.fablogic.com Circle #60
PRODUCT CATALOG
Varco Pruden Buildings Inc.

Varco Prudens High Wind Roof system can provide performance and protection against winds above 130 mph. When incorporated as part of a total Varco Pruden building system, the HWR actually can withstand wind conditions in excess of 180 miles per hour.
The Garland Co. Inc.

Standing Seam Solutions, a brochure providing architects, building owners and specifiers with valuable information to help them meet the widest possible range of functional and aesthetic requirements using strong metal systems and accessories, is now available from The Garland Co. Inc. www.garlandco.com. Circle #63
American Buildings Co.

American Buildings Co. is proud to offer standing seam insulated roof panels as an ideal solution where energy-efficient standing seam roof panels are required. This self-aligning panel arrives in one piece requiring simple, one-step installation. The unique design allows for 26-gauge exterior and interior skins, saving money and weight. www.americanbuildings.com Circle #65
The HWR system combines sturdy steel roof panels with a patented clip and 180-degree fieldformed seams to create a single roof membrane. The unique clip assembly allows the HWR to maintain normal thermal expansion and contraction of the roof while still offering the high-wind protection. Panels are offered in 14 cool paint finishes as well as acrylic-coated unpainted Galvalume. www.vp.com Circle #68
Valspar announces release of Flurothane Coastal coating system

Valspar Corp. introduces its Flurothane Coastal coating system, a PVDF system. The Flurothane Coastal coating system provides excellent resistance to ultraviolet rays and exceptional color retention. The system can be applied to Hot-Dip Galvanized, Galvalume and Aluminum substrates. www.valsparcoil.com Circle #61
Architectural Building Components

The new 138Ts lower profile makes it an aesthetically appealing option for steep-slope new construction. By expanding ABC's symmetrical product line the opportunities for standing seam metal roofing multiply. The 138T comes in a standing seam height of 1 3/8 inches with an optimum width of 16 inches, a minimum 2:12 slope and 8-inch fixed or multispan clips. The most measurable benefit of the symmetrical panel design is individual panel replaceability and repairability. The profiles satisfy the structural and weathertightness standards while providing the ability to be removed, modified or reinstalled as necessary. This results in a lower total cost of ownership and ensures a longer lasting roof. www.archmetalroof.com Circle # 66 w w w. m et a l c o n s t r u c t i o nn ew s .c o m
MBCI
MBCI offers two types of standing seam metal roof systems: vertical leg structural standing seam and trapezoidal structural standing seam. The vertical leg SSR systems consist of MBCIs LokSeam, BattenLok HS, SuperLok and curved BattenLok offerings. These panels have earned several UL uplift ratings, assuring the reliability of performance. The trapezoidal systems include the snap-together Ultra-Dek system and the fieldseamed Double-Lok system. The standing seams are 3 inches above the lowest part of the panel, well above the water level as it flows off the roof. www.mbci.com Circle #67
Palram unveils containment and bullet-resistant glazing

Palram Americas has unveiled its PALSHIELD product line of containment and bullet-resistant polycarbonate glazing. PALSHIELD is engineered to meet various levels of ballistics and forced entry test standards. Its layered structure and no spall design will withstand both physical attack and multi-shot assault while the abrasion resistant coating ensures long-term clarity. www.palramamericas.com Circle #62
Englert Inc.
Englerts metal and aluminum roofing materials, fasteners and clips meet or exceed durability test requirements set by the 2003 Florida Building Code. During independent lab tests to meet Florida code requirements, Englerts Series 2000 and 1300 standing seam panels performed perfectly, while the test apparatus gave out at stress levels well in excess of requirements. www.englertinc.com Circle #64
Firestone Building Products

Firestone Building Products UNA-CLAD UC-4 Roofing Panel is a patented self-locking, architectural standing seam metal roof panel that completely eliminates the need for clips. The UC-4 Roofing Panel's unique integral fastening flange accommodates thermal movement, and its easy snap-together seam saves installation time and money. It may be eligible for Firestones 25year Millennium Warranty. www.firestonebpco.com Circle #69 February 2012 METAL CONSTRUCTION NEWS 51
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February 2012
PRODUCT CATALOG Underlayment The Garland Co. Inc.

The Garland Co.s HPR Aqua Shield self-adhering underlayment is a lightweight, reinforced base sheet designed for a variety of steep- and low-slope roofing applications. Formulated using a high-quality Styrene-Butadiene-Rubber modified bitumen; the underlayment is reinforced with high-strength fiberglass. Its self-adhering technology uses an advanced adhesive surface. www.garlandco.com Circle #74
PRODUCT CATALOG Gutters, Rainware, Ridge Caps, Trim
Grace Construction Products

Grace Ice & Water Shield HT is made with innovative and proprietary rubberized asphalt that will not flow, even at temperatures as high as 240 degrees. It provides 120 days of exposure time to provide peace of mind during long, unpredictable construction cycles and, because the membrane bonds firmly to the deck, there is no need for heat or special adhesives. www.graceconstruction.com Circle #70
Englert Inc.
Englert offers both 5- and 6-inch K-style, seamless aluminum gutters in a wide variety of colors. Standard gutters come with the Castle Clad 20-year, pro-rated paint finish warranty. All Englert gutter systems come with a wide variety of accessories, including downspouts, elbows and end caps. Englert also offers a 7-inch box gutter that can be produced on the Englert 770 Gutter Rollforming Machine. www.englertinc.com Circle #77
Firestone Building Products

New to the line of Firestone CLAD-GARD metal roofing underlayments is CLAD-GARD
InterWrap
InterWraps Titanium UDL line of roofing underlayment products are made with a minimum 20 percent pre-consumer recycled content and can contribute to M.R. 4 for the LEED program. In addition, InterWrap recycles 99 percent of all scrap generated from its plants. www.interwrap.com Circle #71
R, an economical choice in Firestones self adhered underlayment offering with a distinctively textured, skid resistant surface for greater walkability during installation and maintenance. Available in an unboxed, twosquare roll, this underlayment has a split-release backer for easy installation and can be directly applied to Firestone HailGard Composite, OSB and plywood substrates. Since CLAD-GARD R is waterproof, it can be exposed for up to two months during construction without the need for tarping. www.firestonebpco.com Circle #73
Englert Inc.
Englerts HT Underlayment features black, non-woven polyester topside designed for use as a metal underlayment. The new self-adhering, slip resistant product is 100 percent UV protected, heat reflective and slip resistant, and good for 90 days of exposure to accommodate construction scheduling and weather delays. Englert HT Underlayment provides an excellent defense against costly ice dams and wind driven rains, sleet and snow, particularly in the cold winter months. The new Englert membrane is designed for use in high temperature environments where the in-service temperature can reach as high as 250 F. The selfsealing, high tensile strength underlayment comes in two configurations, each designed to provide waterproof protection before, during and after the installation of metal roofing. www.englertinc.com Circle #72 52 METAL CONSTRUCTION NEWS February 2012
European Copper
European Copper chimney pots bring a new
Lyon Metal Roofing Inc.

A few years ago, Lyon Metal Roofing had the goal of developing a premium, breathable synthetic roofing underlayment and delivering it at a price comparable to #30 felt. Lyon Metal Roofing achieves this goal with the introduction of the HydroBlock Synthetic Roofing Underlayment. The HydroBlock offers excellent traction, weatherability and ease of installation. www.wesellmetalroofing.com Circle #75
level of style and safety to the chimney. Compatible with all major fireplace brandsboth wood burning and gasthey keep out pests and water while enhancing the fireplace draft. European Copper chimney pots compliment a wide range of home styles including Mediterranean, Country French, English, Craftsman and Cape Cod. European Copper chimney pots are available in three styles, seven sizes and two finishes. They are easy to install, 100 percent recyclable and building code compliant. www.europeancopperchimneypots.com
ADVANCED Architectural Sheet Metal

ADVANCED Architectural Sheet Metal roll forms commercial strength seamless 6-inch K-style and 7-inch Box gutters that are manufactured in 35- to 40-foot lengths (with or without a roof flange). Gutters can be rollformed in 24-gauge, 0.032-aluminum in Kynar 500 colors, and 24-gauge Galvalume Plus. Shipping arrangements and other length sizes can be made when placing your order. Miters can be fabricated for the gutters. Also available are accessories such as 6and 7-inch gutter hangers and end caps. www.advarchsm.com Circle #78 February 2012 METAL CONSTRUCTION NEWS 53
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Circle #76
CLASSIFIEDS
Company Name Page 43 44 15 41 36 37 47 16 46 44 33 42 49 47 6 14 42 BC IFC 45 38 40 13 1 11 2 17 41 IBC 45 46 48 7 48 8 a-p 4 39 43 21 Phone (877)756-4890 (866)454-1800 (877)BIG-FANS (620)345-6394 (770)692-7230 (732)367-6333 (800)868-9910 (800)821-5448 (888)680-9462 (906)774-6678 (281)807-7400 (800)288-9489 (800)443-6536 (515)993-4251 (800)852-6832 (877)285-2607 (800)284-1412 (877)713-6224 (800)562-3576 (888)284-6794 (800)247-6455 (256)255-0190 (800)GET-PINK (800)999-9459 (800)PAC-CLAD (888)PPG-IDEA (770)487-7300 (800)771-1711 (800)825-3432 (800)446-7325 (800)352-4864 (888)766-4367 (800)SNOJAX1 (800)951-SAWS (888)2-INSUL-8 (800)255-0776 (800)867-7177 (800)486-1832 (888)306-2645 www.gsplc.com www.gssisealants.com www.hi-fold.com www.inlandcoatings.com www.lamtec.com www.litesteelbeam.com www.lmcurbs.com www.mbci.com www.mcelroymetal.com www.mrsrollform.com www.millsteel.com www.ornametals.com www.bandedliner.com www.palramamericas.com www.pac-clad.com www.ppgideascapes.com www.RAS-systems.com www.roofhugger.com www.s-5.com www.sealeze.com www.sealtite.com www.snogem.com www.snoblox-snojax.com www.tenryu.com www.therm-all.com www.thermaldesign.com www.toppsproducts.com www.trianglefastener.com www.valsparcoil.com Website www.advarchsm.com www.rmsteel.com www.bigassfans.com www.bradburygroup.com www.cidanmachinery.com www.cbssheetmetal.com www.designcomponents.com www.dynamicfastener.com www.icebrakes.com
AD INDEX
Circle 26 27 11 22 16 17 33 12 32 28 15 24 37 34 5 10 23 39 1 29 18 20 9 2 8 3 13 21 38 30 31 35 6 36
Steel Mfg. Equipment for Sale

NAC Plasma Cutter S/N 9831. Nutech Engineering Automatic Frame Welder S/N 99-137. Piranha Iron Worker S/N 9081. MRS Double Deck Roll Former 26 & 29 Ga. Like new with Decoiler. 3 1/2 ton Jib Crane. 21 CNC Bradbury Folder 18 Ga. Like new. 80 ENF 8 Enforcer TS 48 Slitter, five knives. Like new. Portable Hydraulic Punch
Advanced Architectural Sheet Metal R&M Steel Co. Big Ass Fans
At Rapidset Buildings we design, engineer, detail and ship prefabricated steel buildings anywhere in the US or export worldwide. We serve professional builders, steel erectors, and metal building resellers 800.793.8555
Bradbury Group Cidan Machinery Creative Building Supply Design Components Inc. Dynamic Fastener
See details and pictures on our website www.mfgequipment4sale.com
BC Steel Building, a full line pre-engineered metal building manufacturer, has an immediate opening for a sales person in the DFW and north TX area. PEMB experience is a must. Excellent salary and benefits. For confidential consideration email or fax resume to: Jon Wensman, V.P. of Sales, fax 405-324-5093 or e-mail jwensman@bcsteel.com
REGIONAL SALES MANAGER
Metal Building Manufacturer is seeking experienced District Managers for several territories in the southeast region of the U.S. This is a career opportunity with a growing I.A.S. certified building manufacturer. Please send resume to lbichuck@cox.net
Simple
& STRONG
East Coast Lightning FLS Canopy LLC Green Span Profiles
Your Online Source for Metal Building Components
INTERNATIONAL BUSINESS DESIGN ENGINEER

Consolidated Systems, Inc is a progressive multi-location manufacturer of Commercial and Residential Roof, Floor, and Form Deck Systems headquartered in Columbia, SC. Some of the responsibilities include: Design support for products in all business units; analysis and design for roof and floor deck systems Ensure jobs conform to the drawings, specifications or special requirements Design assistance in support of CSi building systems Redesign structural systems to include those manufactured by CSi Assist internal personnel and CSi customers worldwide with interpretation of design drawings and specifications Produce and check shop drawings using CSi Engineering standards Position requires candidate to be fluent in English and Japanese. Must possess good organizational and communication skills, and have strong computer skills with knowledge of Revit, AutoCAD, Excel and Mathcad preferred. Must be fluent in structural engineering principals and understand and have knowledge of building codes. Minimum of BS degree in Civil Engineering or related discipline and Fundamentals of Engineering (FE) Certification. Excellent compensation and benefit package including medical/dental/vision insurance, life insurance and 401K.
ese are words to live by. For over 30 years, we have been producing quality steel buildings, while providing our customers with exceptional products, knowledge and service. Were building strong for you, call us today.
GSSI Sealants Hi-Fold Door Corp. Inland Coatings Corp. Lamtec Corp. LiteSteel Beam LMCurbs MBCI McElroy Metal Inc. Metal Rollforming Systems Mill Steel Ornametals Manufacturing
Trim Accessories Structural Roof Panels Wall Panels Doors & Windows
www.mbpcomponents.com
Qualified candidates should submit resume, cover letter, and salary history with position title to debra.patton@csisteel.com or fax resume to (803) 744-6123. EOE/AA
54 METAL CONSTRUCTION NEWS February 2012
www.moderntrade.com www.metalconnect.net www.themetaldirectory.com
Visit, Advertising Bookmark, Rates Search, Learn

Closing date is the 3rd of the month preceding publication.
1.800.643.5555 HeritageBuildings.com
Owens Corning Palram Americas Inc. Petersen Aluminum Corp. PPG Industries Inc. RAS Systems LLC Roof Hugger Inc. S-5! Sealeze SEALTITE Building Fasteners Sno-Gem SnoBlox/SnoJax Tenryu America Inc. Therm-All Inc. Thermal Design Topps Products Inc. Triangle Fasteners Inc. Valspar Coil
$145 for color, up to a total of 5 column inches per page. Use display advertising rates for ads over 5 column inches.
Call (847) 674-2200.
4 19 25 14
February 2012
55
EDITOR'S PICK
A Unified Campus
By Marcy Marro, Managing Editor
sunlight to the interior spaces while complimenting the local Maltese limestone faade. The building design incorporates vertical and horizontal sunshades at windows for light protection. The Chancerys interior gallery connects two separate office masses, and feature stainless steel railings and stringers from Hegarty and Sons, Easton, Pa., ascend the stairwell to the second level and draw upon a contemporary aesthetic in line with the Sahara Beige marble from Egypt and Rojo Alicante marble from Spain. The 6,800-square-foot warehouse is made up of a pre-engineered steel building with 10,602 square feet of formed insulated metal panels for the walls and roof, all from Oklahoma City-based Star Building Systems. The structure purlins were sized to accommodate future photovoltaic panels on the roof. The warehouse features high bay storage for the embassy supplies and maintenance shops. The LEED-certified project features drainage systems that collect rainwater in underground storage tanks used for irrigation and other non-potable uses, along with selected plant specimens that help minimize water consumption. The $125 million design-build project took place over 24 months and generated jobs in both the United States and Malta, and at times, involved more than 800 workers in its construction.
Dont let anyone tell you it doesnt hurt!

Every hole you put in your standing seam metal roof voids your manufacturers warranty and risks leaks. Only S-5! utility attachment clamps, with their patented round-point setscrews, provide maximum strength without piercing or damaging the paneling. They install quickly and easily! The right way to attach almost anything to metal roofs!
To learn more about the entire S-5! line of attachment solutions and snow retention systems, visit us at:
U.S. Embassy Compound, Valletta, Malta

Owner: U.S. Department of State, Bureau of Overseas Building Operations, Washington, D.C. Contractor: American International Contractors Inc., Arlington, Va.
www.S-5-Clamp.com/mcn or call us at 888-825-3432
New U.S. Embassy compound connects with its location

Occupying a 4.05-hectare site, the new United States Embassy Compound in Vallatta, Malta, is made up of eight buildingsthe Chancery, three compound access control facilities, main residence, utility building, warehouse and recreation buildingfor a total of 98,274 square feet. Completed in May 2011, a primary goal of the project was to create a unified complex, which provides a state-of-the-art workspace for more than 125 American and Maltese U.S embassy employees. The space also features a collection of contemporary Maltese, American and Maltese-American art curated by the Office of Art in Embassies. Designed by Washington, D.C.-based architectural firm Karn Charuhas Chapman & Twohey, the site plan was organized around Bronze Age and Roman archeological remains that were dis56 METAL CONSTRUCTION NEWS February 2012 covered during the excavation, and are featured in the central stone garden. Welcoming visitors to the U.S. Embassy, a 1,000-pound bronze seal marks the entrance to the Chancery building, which is the largest single casting of the Great Seal in Bronze to date. The seal was designed by the U.S. Department of State, Bureau of Overseas Building Operations, Washington, D.C., and fabricated by APCO Architectural Signs, Lanham, Md. While the original design called for the seal to be suspended from the entrance canopy, its final weight was determined to be too heavy to be suspended from the steel canopy, resulting in the seal being secured to a Maltese limestone plinth in front of the canopy. Adorning the exterior of the Chancery are 68 aluminum sunshades from Shofield, Wis.-based Airolite, which serve a dual purpose of filtering
Architect: Karn Charuhas Chapman & Twohey, Washington, D.C. Bronze seal: APCO Architectural Signs, Lanham, Md., www.apcosigns.com, Circle #79 Fence: Hegarty and Sons, Easton, Pa., www.hegartyandsons.com, Circle #80 Metal building, roof and wall panels: Star Building Systems, Oklahoma City, www.starbuildings.com, Circle #81 Sunshades: Airolite, Shofield, Wis., www.airolite.com, Circle #82
Visit us in February at IRE Booth
DYNAMIC FASTENER DYNAMIC FASTENER

Dynamic Fastener has seven locations to serve you. For more information: Call 800-821-5448 or visit www.DynamicFastener.com
#225

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February 2012

Roofing Material Handling in Bad Weather

Custom profiles just became a breeze with SunSky.

No High Volume Commitment.

Introducing MetalMatch Technology Custom profiles delivered fast.

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The Drive to Compete on Quality

BUILDING ENVELOPE PROTECTED BY

Editorial & Production

Business & Sales

To serve and protect, choose Duranar coatings and a certied partner.

Editorial Director pdeffenbaugh@moderntrade.com

All trademarks are marks of PPG Industries Ohio, Inc.

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METAL CONSTRUCTION NEWS

GET MORE LEADS - SELL MORE PROJECTS

February 2012 Vol. 33 No.2

Roundtable: Energy and Metal Construction

Metal on Metal Retrofits

Devoted to the Long Haul

Threats from Lightning Strikes:

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Use Lamtec Facing for High-R Insulation

February 2012 Vol. 33 No.2

Long Tab with Banding

Long Tab wiTh banding

Long Tab with Banding

U ValUe U=.037 U=.029

InsUlatIon R-19/R-11 R-25/R-19

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METAL CONSTRUCTION NEWS

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PROFIT BUILDING TIMELY TOOLS TO BOOST YOUR BOTTOM LINE!

Back by Popular Demand

Tool #2 Focus On Finishing Faster!

Spend a little to make a lot!

Offer more to get more!

Put the dates where all can see them!

For advertising information, contact

(847)674-2200 ext. 22 bobhiggins@moderntrade.com

(847)674-2200 ext. 23 artmazzone@moderntrade.com

John Paul Lawrence

(847)674-2200 ext. 21 jplawrence@moderntrade.com

METAL CONSTRUCTION NEWS

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The Retrofit Roofing Game The Project Team

See us at the IRE! Booth 835

METAL CONSTRUCTION NEWS

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Finished steel import permit tons up 16 percent

WE JUST IMPROVED ENERGY EFFICIENCY IN METAL BUILDINGS. AGAIN.

AIA and ABC announce contract documents partnership agreement

Commercial Energy Calculator

OptiLiner Banded Liner System

GAF sponsors the Certified Green Dealer Program

ELAMINATOR Insulation System

Chicago Metallic launches new website

Gamco releases new product catalog

FMA announces Green Manufacturer Network

METAL CONSTRUCTION NEWS

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