SPRING 2005
VOLUME 5 ISSUE 1
Sarnafil – World Class Roofing & Waterproofing
Eberhard Roofing Wins 2004 Roofing Project of the Year Contest
As visitors and passers-by approach the Veteran’s Sports Complex in Carson, California, their attention is drawn first to the roof. Why? Its steep slope displays 48,000 square feet of patina green Décor.
But the roof, which won the 2004 Sarnafil “Roofing Project of the Year” for Eberhard Roofing, was not always its outstanding characteristic. From assembly in 1988 to renovation in 2004, the building’s metal, standing-seam roof leaked water through the walls and foundation, damaging the venue’s gyms, halls and rooms.
Veteran's Sports Complex, Carson, CA, 2004 Roofing Project of the Year
The project’s construction manager hired Independent Roofing Consultants (IRC) of Santa Ana, CA to provide peer review and manage the renovation project. IRC recommended the Sarnafil roofing system, emphasizing its ability to provide a seamless membrane over the entire roof without the openings of a standingseam metal roof. This would, IRC promised, create a water-tight environment throughout. In September 2003, roofing and general contractor Eberhard Roofing, Van Nuys, Calif., tore off the first section of roof. The team found no felt layer below, as code requires, but only an unevenly-installed lightweight insulating concrete (LWIC). Before the team could continue, the LWIC had to be removed entirely and replaced with a composite board. Eberhard upgraded the insulation to R-19, typical for industrial buildings of this kind. This gave the facility more protection and provided a smooth surface for Sarnafil’s patina green Décor Roof System. This roof provides the appearance of the former metal, standingseam, which the City of Carson wanted, without its leakage problems. “The owners’ highest priority was to have a functional watertight roof assembly that was aesthetically pleasing,” said Rick Boyce, sales manager for Eberhard. “The roof is a major visual focal point of the facility. The Sarnafil Décor Post & Rib assembly meets both requirements.” The appearance is obvious, and the region’s severe weather has documented the performance. “In 2005, Southern California has experienced its third greatest recorded rainfall, and the building envelope is performing as was redesigned,” said Phil Penney, president of IRC. “If we wanted a good water test, we got it.”
2004 “Waterproofing Project of the Year” Awarded to Eagle Cornice
“The British are coming! The British are coming!” That 18th and 19th century war cry no longer sounds an alarm along New England’s Coast, but warnings of hurricanes and winter ice storms do cause concern and drive precautions. Today, historic-preservation advocates are protecting sites that once guarded the nascent United States.
One example of this is the restoration of Fort Adams on Narragansett Bay in Newport, Rhode Island. Eagle Cornice won the 2004 “Waterproofing Project of the Year” award for a waterproofing system designed to withstand whatever Atlantic storms throw against it. Established as a direct response to the War of 1812, the Fort was part of President James Monroe’s defensive Third System of Fortifications. Built in 1857 of shale and granite, with 50-foot walls and a dirt roof, Fort Adams is the largest fort in North America. To revitalize and open the site for public tours, the Fort Adams Trust was formed in 1994. In short order, the Trust secured government grants for renovation, and decided to tackle the officers’ quarters first. Its leaky roof was composed of soil and grass atop masonry
(ramparts) that are up to 20 feet deep, to camouflage the fort. To protect the officers’ quarters from weather damage during its rehabilitation, the team removed just six feet of vertical soil and installed the waterproofing system at that level. Because the Fort was built prior to the Civil War, there were no drawings to reveal its site plans. The team went into the excavations blind. “It was like operating in the dark,” said Larry Brillon, president of Eagle Cornice Co., Cranston, Rhode Island, the project’s contractor. “We found that the back wall was irregular with sharp, jagged rock.” This gave the team their greatest challenge—finding a way to attach a membrane to irregular masonry while maintaining the historic look, an objective that was essential to the Trust. Eagle Cornice installed Sarnafil’s System 1000 atop Fort Adams’ officers’ quarters. The system measures 600 feet long and includes a protection layer, followed by a felt mat and the G476, 80-mil waterproofing membrane. Additional felt and protection layers were laid on top, followed by a drainage mat, and then the ramparts were replaced. The team was able to mask the entire system in historic materials, hiding the waterproofing system from view and exceeding the expectations of the Trust. “The way it is right now looks fantastic,” said Eric Hertfelder, executive director of the Fort Adams Trust. “They did a great job. The high-tech Sarnafil waterproofing is invisible to the naked eye. We wanted it to look like it did in the Civil War, and it does.”
Second Place: Titan Roofing, Inc.
Titan Roofing, Inc. of Chicopee, Massachusetts, earned second place in the 2004 “Waterproofing Project of the Year” competition for waterproofing the plaza deck over the irreplaceable contents of the Beinecke Rare Book and Manuscript Library at Yale University. The project required strict attention to detail by the contractor to ensure the waterproofing system’s integrity. Many water tests confirmed that Titan was successful, and that the project constitutes a high quality installation.
Second Place: American Roofing and Repair Company
American Roofing and Repair Company of West Chicago, Illinois earned second place in the “Roofing Project of the Year” competition for the corporate headquarters of Spiegel, Inc in Downers Grove, Illinois. The circular building, visible from all levels of the 13-floor adjoining tower, required expert installation to achieve the desired results.
Third Place: Capeway Roofing Systems
Third place for the “Roofing Project of the Year” competition was awarded to Capeway Roofing Systems, Inc., Westport, Massachusetts, for outstanding workmanship on the Connecticut College – Luce Field House re-roof project. The unusual roof design of three hyperbolic parabolas joined by a common area presented unique installation challenges.
Fort Adams, Newport, RI, 2004 Waterproofing Project of the Year
Third Place: Apollo Roofing & Sheet Metal
Apollo Roofing & Sheet Metal of Providence, Rhode Island received third place in the “Waterproofing Project of the Year” competition for outstanding workmanship on the Explore the Bay Education Center green roof in Providence, Rhode Island. Apollo’s installation passed all water tests, a critical factor of the installation, as removing the green roof overburden to find a leak after completion would be difficult and expensive.
SPECIAL REPORT
Sarnafil Outperforms the Industry in 2004
2004 was a roller coaster year for the roofing industry. However, Sarnafil closed the year with a record 4th quarter, resulting in a new annual sales record, 14.8% ahead of 2003 levels. Our performance was more than double the overall roofing industry’s growth of 5-7%. Inside the industry’s general numbers, modified bitumen Brian Whelan volume was flat, with a shift Sarnafil President & CEO away from torch-applied products (because of fire risks) to Peel & Stick and cold-applied applications. Built-up roofing continued to lose market share, as the trend towards white, energy efficient, heat weldable roofing continued in 2004. Despite the additional volume in 2004, the overall health of the industry remains elusive. The costs of raw materials, reinforcements, electricity, insurance, labor, and transportation continue to rise. The abundance of many roofing products in North America contributes to a commodity mentality, where price is the driving force. Announcements of additional TPO production plants by Carlisle and Firestone will undoubtedly intensify price pressures for these products into the foreseeable future. Last year we saw polyisocyanurate insulation manufacturers put on allocation as they scrambled after limited supplies. The cost of MDI (methydene diphenyl disocyanuate) reached unparalleled levels, resulting in a spike in prices and availability issues. The only benefit deriving from this difficulty is renewed self-discipline in quoting and pricing throughout the roofing industry.
Shortages Alter Roofing Specifications
Shortages of such roofing products as polyisocyanurate insulation are driving specification writers and owners to consider a variety of options.
A key ingredient in polyisocyanurate, MDI (methylene diphenyl diiocyanate), has been on allocation for most of this year, causing shortages as well as unprecedented cost increases. How dramatic have the prices increases been? In January 2003, two inch polyisocyanurate cost $.38/sf; this January, the cost was $.57/sf—a 50% increase in two years. Industry forecasts call for additional increases of 5% per month for the rest of 2005. While polyisocyanurate has dominated the commercial roof insulation market with an estimated 60% market share, the recent price increases have brought alternatives into play. Sarnafil’s 40 years of experience in providing complete roof system solutions enables us to help our customers consider all options, and we can follow through with a broad list of systems approved by both Factory Mutual and Underwriters Laboratories. Sarnafil has earned Class A (U.L.) and Class 1 (F.M.) fire ratings with various types of Sarnatherm insulation, such as polyisocyanurate, extruded polystyrene, and expanded polystyrene. Installing hard boards, such as Dens-Deck ® by Georgia Pacific, over our Sarnatherm insulation improves system compressive strength, and resistance to puncture, fire, and hail. Sarnafil also offers system options for adhering feltbacked membrane to cellular lightweight concrete, a
Pouring of cellular lightweight concrete.
fast, economical way to build an insulated monolithic substrate to accept the Sarnafil roof membrane. This approach is especially cost-effective in applications involving sloping to drains. The system comes with Factory Mutual wind uplift ratings as high as I-540 (psf), which enabled many Sarnafil cellular lightweight concrete roof systems to survive all three Florida hurricanes in 2004. Sarnafil’s technical sales representatives are prepared to provide owners and spec-writers with alternative roofing solutions to help them determine the most cost-effective solution. In some cases, it may be appropriate to bid a project two ways – one bid specifying polyisocyanurate and an alternate bid specifying another type of insulation system. Jay Thomas, Sarnafil’s director of marketing, said, “This is the kind of flexibility and openness to alternative solutions the industry must consider to ensure competitive pricing with the ability to meet construction deadlines on budget.”
PRODUCT BRIEF
Sarnafil Performance
While 2004 was a challenging year, Sarnafil Inc. positioned itself for continued success for years to come, as the company registered several noteworthy accomplishments: • The U.S. Department of Energy recognized Sarnafil Inc. as a 2004 Premier Partner of the Rebuild America Program, our second such citation. In 2002 we were the sole recipient of the DOE’s Energy Champion Award. • Green Roofs for Healthy Cities recognized two Sarnafil projects with 2004 Green Roof Awards of Excellence. • At the 2004 NRCA (National Roofing Contractors Association) Convention in San Diego, Sarnafil received the 2004 Exhibitor Excellence Award for the most innovative new product, service or program. This award recognized the key role Sarnafil’s EnergySmart Roof ® plays in Solar Integrated Technologies’ solar electric roof system. The Sarnafil Innovation Group also registered important gains. It: • Introduced our new Multi-Purpose Sealant. • Launched the Peel & Stick membrane at the 2005 International Roofing Expo. • Introduced the Décor Batten and created a patented Décor Batten welding kit. • Introduced Alpine Snow Guards designed specifically for Sarnafil roofs. In addition, our Triple A Team (Canton and Switzerland) set the framework for continuous operating efficiencies and improvements. Although the twists and turns of 2004 were challenging, we end the first quarter of 2005 buoyed by strong demand for our products and confident that the advances of 2004 will pay dividends throughout the year.
Peel & Stick: An Owner-Friendly Solution
Sarnafil’s new Peel & Stick membrane provides the building owner with the benefits of an adhered roofing system without the concern of disrupting building operations.
Peel & Stick allows for the roofing of occupied buildings without the concern for odors or volatile organic compounds that can affect building occupants and disrupt building operations. It’s perfect for hospitals, schools or any building where odors and VOC emissions are a concern. And, because the adhesive is applied at the factory, you are assured of consistent coverage. Peel & Stick saves time and improves rooftop productivity allowing the roof to be completed and watertight sooner. After the usual preparation of the roof deck, installation of the 6.5 ft. wide membrane requires just four simple steps: 1. Unroll the Peel & Stick membrane; 2. Cut to fit, laying it in place, and pulling off the release liner; 3. Smooth it out with a broom; and 4. Press it down with a roller.
Removing the Peel & Stick release liner.
Completing a job in half the time required by a traditional, adhered roof is a typical Peel & Stick benefit. Sarnafil’s Peel & Stick membrane is manufactured using the same time proven formulation that has been protecting roofs for over 40 years. That means you can have confidence that Sarnafil’s Peel & Stick membrane will continue to perform for years to come. And, because it is an EnergySmart Roof ® membrane, it has a highly reflective white surface that reduces solar heating of the roof and building envelope, reducing building cooling costs and reducing the urban heat island effect that is a contributor to smog formation.
Learn how your building can benefit from Sarnafil’s new Peel & Stick membrane. Complete and return the enclosed reply card or call 800-576-2358.
SUSTAINABILITY
Sarnafil Green Roofs Save Energy and the Environment
The Sarnafil Green Roof System is proving itself time and again by: 1. Protecting structures from water infiltration that leads to structural deterioration and interior water damage. 2. Minimizing a building’s burden on the environment. The Oaklyn Branch Library, Evansville, Indiana, and Chicago City Hall illustrate both benefits. The current Oaklyn Branch Library replaced a building one-third its size, yet the insulation properties of its green roof enables the building to operate on the same amount of energy for heating and cooling as did the older, smaller facility. The library’s publicly accessible green roof also absorbs storm run-off (80 percent in Oaklyn’s case) to minimize erosion and the burden on sewer systems. Similar benefits are evident in Chicago’s City Hall. When summer temperatures reach 90 degrees, City Hall’s green roof dissipates the heat from the sun while neighboring black asphalt roofs, where temperatures soar above 150° F, strain their air conditioning systems. Sarnafil’s Green Roof System has saved the City of Chicago almost $10,000 annually in energy costs via 30-percent reductions in demand on the City Hall’s heating and air conditioning systems. Additionally, the green roof reduces storm water runoff by absorbing as much as 75 percent of the rainwater, lightening the load on Chicago’s sewer system.
Green roof atop the Oaklyn Branch Library, Evansville, IN.
Company We Keep
We are happy to welcome building owners who selected Sarnafil roofing or waterproofing systems over the past six months. Here is a partial list: RETAIL Aldi, locations across the U.S. Foley’s Stores across the U.S. Westfield Shopping Center, Wheaton, MO Toys R Us across the U.S. Target Stores, Bedford, NH Wendy’s, across the U.S. Walmart, across the U.S. Federated Department Stores, across the U.S. MANUFACTURING/WAREHOUSE Johnson Controls, locations across the U.S. Van Can Company, San Diego, CA Northrop Grumman, El Segndo, CA Boston Scientific, Marlborough, MA OFFICE/HOTEL Pershing Road Development, Kansas City, MO Holiday Inn, St. George, UT Carlsbad Commerce Center, Carlsbad, CA Alaska Sales & Service, Wasilla, AK Rockwell Collins, Melbourne, FL Downey Studios, Downey, CA EDUCATION Pruett Community College, Canton, GA York College Sports Facility, York, PA Oregon State University, Corvallis, OR Enochs School, Modesto, CA Hurricane Intermediate School, Hurricane, UT Wing Luke Elementary School, Seattle, WA San Diego Schools, San Diego, CA OTHER Folsom Prison, Represa, CA Dulles Airport, Washington D.C. Pensacola Port Terminal, Pensacola, FL
it is sufficiently flexibile to allow application over wet or irregular substrates in any temperature. The System 2000 is an adhered waterproofing system, making it ideal for plaza, balcony, and terrace applications — especially in high wind zones where its exceptional wind uplift resistance comes into play. When an application demands absolute system integrity with maximum security, Sarnafil’s System 3000 is the best choice because it combines the installation advantages of Sarnafil’s loose-laid System 1000 with adhered membrane grid strips, or water stops. This system is ideal for such projects as plazas, green roofs, and roofs that protect sensitive or expensive equipment and inventory as the adhered grid strips eliminate any potential spread of water below the waterproofing membrane.
Green Roof Designs
Two types of green roof applications complement Sarnafil’s various waterproofing systems. The extensive roof system is designed for lightweight overburden construction on flat roofs and sloped roofs less than 45 degrees. The intensive roof system is intended for heavier landscape construction for flat roofs, decks, and landscape planters.
To learn more about Sarnafil’s Green Roof Systems, complete and return the enclosed reply card or call 800-576-2358.
Waterproofing Options
Sarnafil membranes provide the waterproofing protection for green roofs, plaza decks, vertical foundation walls, tunnels and a variety of other applications. From the standpoint of total installed cost, System 1000 is the most economical waterproofing solution for plaza decks and green roofs because of ease of installation. The loose-laid system allows for quick installation, and
CASE STUDY
Sarnafil Roofs Stand Up To Ivan
Hurricane Ivan received national coverage when it raged through Florida’s Panhandle early in the morning of Sept. 16, 2004. It battered, and often demolished, coastal homes and businesses with Category 5 fury. What didn’t make the headlines however, were the area roofs that survived Ivan’s onslought. The Pensacola Civic Center is a case in point. Used as a shelter for 1,200 local residents, it was critical that the structure remain intact. Its Sarnafil Engineered Roofing System, installed by Edwards Roofing, withstood Ivan’s 130 mph winds. The Engineered System features metal bars and cover strips installed on top of the membrane for maximum wind uplift protection. While the roof withstood the storm, several of the HVAC units atop the roof were blown off. “The design of the roof on the Civic Center is a testament to Sarnafil’s Engineered Roof System,” said Tom Wiese, Sarnafil technical sales representative for Northwest Florida. “After the storm passed, many of the surrounding buildings were badly damaged or destroyed while the Sarnafil roof protected the building and its occupants.”
Pensacola Civic Center, Pensacola, FL
in March 2004, experienced only minor leaks during the storm as a result of water blown in through rooftop heating and cooling units. Also clad with Sarnafil’s G410 60-mil Feltback membrane, the roof remained intact throughout the storm. In Navarre, 25 miles east of Pensacola, the Fountain Professional Centre, a professional services building, faces the Gulf of Mexico about 2,000 feet from shore. Edwards Roofing had mechanically fastened Sarnafil’s S327 60-mil EnergySmart Roof ® membrane to the 7,000-sq.-ft. roof deck in February 2004, providing a 20-year warranty. Owner and president Greg Fountain says, “the system performed flawlessly during Hurricane Ivan.”
workmanship, and secondly, we’ve taken a lot of care in the design of our systems. “The Engineered System on the Civic Center is head and shoulders above anything out there, and the Adhered Feltback System at the Crowne Plaza — we’ve had great success with that system throughout the Pensacola area as well.” The future of Pensacola’s commercial roofs seems to be sealed. John Crosson, Civic Center operations manager, said he’s optimistic about the Civic Center’s prolonged strength. “Considering what it went through, I’m not worried about the roof,” said Crosson who experienced roof damage in his own Pensacola home. “Let’s just put it this way — I want one for my house.”
Different Roofs—Same Results
Across the street from the Civic Center is the Crowne Plaza Grand Hotel, Pensacola. The Hotel, outfitted with Sarnafil’s G410 60-mil Feltback membrane fully adhered to cellular lightweight concrete, lost the top of its East facade to Ivan. With the walls of the 15th floor blown in, the insulation and structural deck were exposed to the elements, but the roof’s membrane remained completely attached. Less than a mile away is the Pensacola Police Headquarters. Its 25,000-sq.-ft. roof, which was added
Design + Skill = Success
What’s the reason for Sarnafil’s success in Northwest Florida? “Two factors,” says sales representative Wiese. “First, our contractors are industry leaders in terms of
PROJECT SPOTLIGHT
Montreal Olympic Stadium Montreal, Quebec Architect: JLP Architecte Roofing Contractor: Groupe Cirtech Inc. The Problem Soon after the city of Montreal was awarded the 1976 Summer Olympic Games, construction began on a new stadium for the opening and closing ceremonies, men’s and women’s track and field competition, and other events. The focal point of the design was a massive, angled tower rising 556 feet (169.5 m) above the stadium. The tower created major problems for the top of the concrete ring that forms the base of the stadium. Massive icicles formed on the tower, and crashed onto the modified bitumen membrane below. The impact punctured the membrane and severely damaged the insulation below it. Solution Stuck with an inadequate, malfunctioning roof, the Olympic Installations Committee knew that the re-roofing had to solve the icicles problem; they would not have a third chance to get it right. As a result, they conducted extensive research and decided on a Sarnafil roofing system. Third-party testing identified the Sarnafil G410 3.0 mm/120 mil thick membrane as having puncture-resistance superior to that of modified bitumen systems and more than adequate for this installation. System Sarnafil Adhered System in Custom Color Green
Dixie Regional Medical Center St. George, UT Architect: Anshen and Allen Architects Roofing Contractor: Clark's Quality Roofing The Challenge The roof design for the new Dixie Regional Medical Center had to provide a pleasing, soothing atmosphere for patients and employees both inside and outside. This design challenge was complicated by the building’s 23 roof sections on eight levels. Solution Intermountain Health Care, which owns and operates the facility, selected Sarnafil solutions for all roof sections because of its durability and aesthetics. Four different Sarnafil systems and three different membranes were used to help achieve the desired look as well as performance requirements. System Sarnafil EnergySmart Roof® 60-mil adhered and mechanically attached Waterproofing System 3000 with 60-mil G459 membrane
Contact Information
EDITOR
Emily Taft 800-451-2502 x 247 emily.taft@sarnafilus.com
Sarnafil Receives Environmental Merit Award
The New England Office of the U.S. Environmental Protection Agency recently awarded Sarnafil with an Environmental Merit Award in recognition of its exceptional work and commitment to the environment.
In This Issue…
2004 PROJECTS OF THE YEAR
Roofing and Waterproofing Award Winners
SPECIAL REPORT
Get Your News Electronically
Sarnafil will no longer be mailing hard copies of our newsletter. To receive the newsletter by email, please fill out the enclosed business reply card or log onto www.sarnafilus.com/electronic-newsletter and fill out the registration form to subscribe.
Shortages Alter Roofing Specifications
PRODUCT BRIEF
Sarnafil was recognized for its commitment to the principles of the ENERGY STAR ® Roof Products Program by promoting the awareness of the benefits of reflective roofing in helping to reduce building energy usage and urban heat islands.
Peel & Stick: An Owner-Friendly Solution
SUSTAINABILITY
Sarnafil Green Roofs Save Energy and the Environment
CASE STUDY
Sarnafil Roofs Stand Up To Ivan
Sarnafil Inc. 100 Dan Road Canton, MA 02021 TEL: 1-800-576-2358 FAX: 781-828-5365 E-MAIL: webmaster@sarnafilus.com INTERNET: http://www.sarnafilus.com
RETURN SERVICE REQUESTED Prsrt Std US Postage Paid Permit No. 160 Stoughton, MA
Visit us on the web at www.sarnafilus.com or call 1-800-576-2358